T4ej e 00

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
ADDITIONAL REFERENCES
• Please refer to the other materials (operator’s

manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.
MANUAL COMPOSITION
• This manual consists the Technical Manual and the • Information included in the Workshop Manual:
Workshop Manual. technical information needed for maintenance
and repair of the machine, tools and devices
• Information included in the Technical Manual: needed for maintenance and repair, maintenance
technical information needed for redelivery and standards, and removal/installation and assem-
delivery, operation and activation of all devices ble/disassemble procedures.
and systems, operational performance tests, and
troubleshooting procedures.
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001
SA-688
UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
• Some safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a SA-1223
situation which, if not avoided, could result in damage to
the machine.
• NOTE indicates an additional explanation for an element

of information.
002-E01A-1223
SA-
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the machine and
all safety messages in this manual.
• Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
• Learn how to operate the machine and its controls correctly
and safely.
• Allow only trained, qualified, authorized personnel to
SA-003
operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization. Failure
to do so may deteriorate the part safety, function, and/or service
life. In addition, personal accident, machine trouble, and/or
damage to material caused by unauthorized modifications will
void Hitachi Warranty Policy.
• Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/or
your authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the fire-extinguisher
at the recommended intervals as specified in the fire-
extinguisher manual.
• Establish emergency procedure guidelines to cope with
fires and accidents.
• Keep emergency numbers for doctors, ambulance
SA-437
service, hospital, and fire department posted near your
telephone.
004-E01A-0437
SA-
SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
SA-438
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435 SA-435
SA-
SAFETY
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
• Do not leave parts and/or tools lying around the operator’s
seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-
SAFETY
USE HANDRAILS AND STEPS

• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
SA-439
008-E01A-0439
ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the
operator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear SA-462
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR

LEAVING OPERATOR’S SEAT
• Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the load handling lever lock to the LOCK position. Failure to
do so may allow the machine to unexpectedly move when
a body part unintentionally comes in contact with a control
lever, possibly resulting in serious personal injury or death.
• Before leaving the machine, be sure to first lower the
front attachment to the ground and then move the load
handling lever lock to the LOCK position. Turn the key
switch OFF to stop the engine.
• Before leaving the machine, close all windows, doors, and
access covers and lock them up.
SA-
SAFETY
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident. SA-237
• We recommend that the seat belt be replaced every four

years regardless of its apparent condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or operating
SA-4EK-001
the machine in congested areas. Coordinate hand signals
before starting the machine.
• Use appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location. SA-293
• Do not incinerate or puncture a starting fluid container.
036-E01A-0293-3
SA-
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• NEVER start the engine while standing on the track or on
ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers
are in neutral.
SA-4EK-002
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine. SA-032
S013-E01A-0032
SA-
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the work
and job site.
• Reinforce ground, edges, and road shoulders as SA-4EK-003
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
015-E01B-0447
SA-
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
Any modification of the ROPS structure will modify its
performances and its certification will be lost.
ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure
SA-521
PROVIDE SIGNALS FOR JOBS INVOLVING

MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines, provide
signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s directions.
018-E01A-0481
SA-481
SA-
SAFETY
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
014-E01B-0427
SA-4EK-004
DRIVE SAFELY
• Beware of the possibility of slipping and/or turning over the
machine when driving on a slope.
• When driving on level ground, hold the bucket at mark
(A) 250 to 350 mm above the ground as illustrated.
• Avoid traveling over any obstacles.
• Drive the machine slowly when driving on rough terrain.
• Avoid quick direction changes. Failure to do so may cause
the machine to turn over.
• If the engine stops while driving, the steering function
becomes inoperative. Immediately stop the machine by
applying the bake to prevent personal accident. SA-4EK-005
• Even though the machine is equipped with the emergency

steering system, if the steering function becomes
inoperable during drive operation, press the emergency
steering check switch on the right console to activate the
emergency steering system. Then, immediately park and
stop the machine in a safe location.
019-E07A-0448
SA-10
SAFETY
DRIVE MACHINE SAFELY (WORK SITE)

• Before driving the machine, always confirm that the
steering wheel and Forward/Reverse lever direction
corresponds to the direction you wish to drive.
• Be sure to detour around any obstructions.
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death. SA-4EK-006
• When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 250 to 350 mm
(approximately 10 to 14 in) (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
• Driving across the face of a slope or steering on a slope

may cause the machine to skid or overturn. If the direction
must be changed, move the machine to level ground, then,
change the direction to ensure safe operation.
SA-4EK-007
019-E05B-0515
SA-4EK-008
DRIVE SAFELY WITH BUCKET LOADED

• If the machine is incorrectly operated while driving with the
bucket loaded, turning over of the machine may result. Be
sure to follow all the instructions indicated below.
• When driving the machine on a job site with the bucket
loaded, hold the bucket as low as possible to keep the
machine balanced and to have good visibility.
• Do not exceed the rated load capacity. Always operate
the machine within the rated load capacity.
• Avoid fast starts, stops, and quick turns. Failure to do so
may result in personal injury and/or death.
SA-4EK-009
• Avoid rapid drive direction changes which could possibly
cause personal injury and/or death.
051-E02A-0400
SA-11
SAFETY
DRIVE ON SNOW SAFELY

• Beware of the possibility of slipping or turning over the
machine when driving on frozen snow surfaces.
• The machine may slip more easily than expected on
frozen snow surfaces even if the inclination is small.
Reduce speed when driving. Avoid fast starts, stops and
quick turns.
• Road shoulder and/or set-up utilities covered with snow
are difficult to locate. Be sure where they are before
removing snow.
SA-4EK-011
• Be sure to use tire chains when driving on snow.
• Avoid applying the brake for quick stops on snow. If a
quick stop is required, lower the bucket to the ground.
052-E02A-0452
TRAVEL ON PUBLIC ROADS SAFELY

• This machine is not allowed to drive on public loads with
the bucket loaded.
• Be sure to empty the bucket.
• Hold the bucket at mark (A) 250 to 350 mm above the
road surface as illustrated.
• Even though the machine is equipped with the emergency

steering system, if the steering function becomes
inoperable during drive operation, press the emergency
steering check switch on the right console to activate the
emergency steering system. Then, immediately park and SA-4EK-010
stop the machine in a safe location.
053-E02A-0453
SA-12
SAFETY
AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket to the ground.
• Place the Forward/Reverse lever in neutral, and put the
SA-4EK-012
park brake switch in the ON (parking brake) position.
• Run the engine at low idle speed without load for 5
minutes to cool down the engine.
• Stop the engine and remove the key from the key switch.
• Pull the lock lever to LOCK position.
• Block both tires and lower the bucket to the ground.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-4EK-013
020-E02A-0516
SA-13
SAFETY
AVOID ACCIDENTS FROM BACKING UP AND

TURNING
• Make sure no one is working under or close to the machine
before backing up or turning the machine to avoid personal
injury and/or death by being run over or entangled in the
machine.
• Keep all personnel away from the machine by sounding
the horn and/or using hand signals. Use extra care to be
sure no one is in from the articulation area before turning
the machine.
• Keep windows, mirrors, and lights in good condition.
SA-383
• Reduce travel speed when dust, heavy rain, fog, etc.,
reduce the visibility.
• In case good visibility is not obtained, use a signal person
to guide you.
021-E02A-0517
SA-312
SA-14
SAFETY
AVOID POSITIONING BUCKET OVER ANYONE

• Never allow the bucket to pass over co-workers and/or the
dump truck operator’s cab. Falling soil from the bucket or
contact with bucket may cause serious personal accidents
and/or damage to the machine.
• Avoid carrying the bucket over the co-workers to ensure

safe operation.
SA-4EK-014
023-E02A-0518
AVOID TIPPING
Do not attempt to jump clear of tipping
machine. Machine will tip over faster than you
can jump free, possibly resulting in serious
personal injury or death. If tipping over of
the machine is predicted, securely hold the
steering wheel to prevent your body from
being thrown out of the machine.
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
SA-4EK-015
• The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than 5
degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging loads.
• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become
soft and make ground travel unstable.
SA-15
SAFETY
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing
026-E01A-0519
SA-4EK-016
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
• Before digging check the location of cables, gas lines, and
water lines.
• Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
• If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
• Contact your local “diggers hot line” if available in your
SA-4EK-017
area , and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382
PERFORM TRUCK LOADING SAFELY

• Do not operate the machine involuntarily. Unexpected
machine movement may cause personal injury and/or
death.
• Do not lower the bucket with the loader control lever
in the FLOAT position. The bucket may free fall, possibly
causing personal injury and/or death.
• Always select a level surface for truck loading.
SA-4EK-018
028-E01A-397
SA-16
SAFETY
AVOID POWER LINES

Serious injury or death can result from contact with electric
lines.
Never move any part of the machine or load closer to any

electric line than 3 m (10 ft) plus twice the line insulator
length.
029-E01A-0455
SA-4EK-019
PRECAUTIONS FOR OPERATION

• If the front attachment or any part of the machine comes in
contact with an overhead obstacle, both the machine and
the overhead obstacle may become damaged, and personal
injury may result.
• Take care to avoid coming in contact with overhead
obstacles with the bucket or arm during operation.
PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.
SA-4EK-020
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.
• When using the machine for craning operations, be sure
to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the
position of the bucket support located on the chassis at
the front.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head. SA-132
• Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
032-E01A-0132
SA-17
SAFETY
PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body, serious
injury may result.
• Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place the Forward/Reverse lever in neutral, and put the
park brake switch in the ON (parking brake) position.
• Run engine at low idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
SA-4EK-013
• Lower the lock lever to the LOCK position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E07B-0456
SA-18
SAFETY
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
• Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
504-E01A-0034
SA-034
TRANSPORT SAFELY
• Take care the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe
transportation.
• Select an appropriate truck or trailer for the machine to Less than 15˚
be transported.
SA-4EK-021
• Be sure to use a signal person.
• Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight.
3. Use the low speed gear.
4. Never steer the machine while on the ramp. If the
traveling direction must be changed while the ramp,
unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
5. After loading, install the lock bar to securely hold the
articulation mechanism.
6. Wedge the front and rear of tires. Securely hold the
machine to the truck or trailer deck with wire ropes.
Be sure to further follow the details described in the

TRANSPORTING section.
035-E07A-0454
SA-19
SAFETY
HANDLE FLUIDS SAFELY−AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
• Do not refuel the machine while smoking or when near
open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are flammable.

• Store flammable fluids well away from fire hazards.
SA-018
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
SA-019
034-E01A-0496
SA-20
SAFETY
PRACTICE SAFE MAINTENANCE

To avoid accidents:
• Understand service procedures before starting work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is moving.
• Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine:

1. Park the machine on a level surface. SA-028
2. Lower the bucket to the ground.
3. Run the engine at low idle speed without load for 5
minutes.
4. Turn the key switch to OFF to stop engine.
5. Relieve the pressure in the hydraulic system by moving
the control levers several times.
6. Remove the key from the switch.
7. Attach a “Do Not Operate” tag on the control lever.
8. Lower the lock lever to the LOCK position.
9. Lock bar connects the front and rear frames. SA-312
10. Allow the engine to cool.
• If a maintenance procedure must be performed with the

engine running, do not leave machine unattended.
• Never work under a machine raised by the lift arm.
• Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris. SA-134
• When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02C-0520
SA-527
SA-21
SAFETY
• Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
• Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
SS2045102
SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing
the machine first.
• Always lower the attachment to the ground before you
work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
519-E01A-0527
STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
502-E01A-0026
SA-026
SA-22
SAFETY
SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can cause
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
• When inflating tires, use a chip-on chuck and extension
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
it available.
• Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
SA-249
• Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and
may result in tire explosion.
521-E02A-0249
PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
503-E03A-0344
SA-344
SA-23
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
• The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
• Wait for the oil and components to cool before starting

any maintenance or inspection work.
505-E01B-0498
SA-225
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of

“Periodic replacement of parts” in the operator’s manual.)
• Failure to periodically replace rubber hoses may cause a fire, SA-019

fluid injection into skin, or the front attachment to fall on a
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
S506-E01A-0019
SA-24
SAFETY
AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
• Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this SA-031
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.
507-E03A-0499
SA-292
SA-044
SA-25
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
SA-019
• Never install bent or damaged lines, pipes, or hoses.
Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
• Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine
daily and by removing spilled or accumulated flammables
immediately.
Check Key Switch:

• If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at low idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.
508-E02B-0019
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393
SA-26
SAFETY
EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the following
way:
• Stop the engine by turning the key switch to the OFF
position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
• After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded SA-818
area still smoldering.
523-E01A-0818
SA-27
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID

LINES
• Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
• Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
• Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc.
SA-030
AVOID APPLYING HEAT TO LINES CONTAINING

FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain
flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
SA-28
SAFETY
BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer.
• Depending on the wok site conditions, the risk of inhaling
asbestos fiber may exist. Spray water to prevent asbestos
from becoming airborne. Do not use compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated to
prevent the inhalation of asbestos.
SA-029
• Keep bystanders out of the work site during operation.
• Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.
PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.
• Keep sparks, lighted matches, and flame away from the
top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm the
battery to 16 °C (60 °F) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the SA-032
battery may result.
• Loose terminals may produce sparks. Securely tighten all
terminals.
• Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
• Be sure to wear eye protection when checking electrolyte
specific gravity.
512-E01B-0032
SERVICE AIR CONDITIONING SYSTEM SAFELY

• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the instructions described on the container for
proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
SA-405
513-E01A-0405
SA-29
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
• A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment. SA-309
• See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.
515-E01A-0309
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source.
SA-226
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
516-E01A-0226
SA-30
SAFETY
BEFORE RETURNING THE MACHINE TO THE
CUSTOMER
• After maintenance or repair work is complete, confirm

that:
• The machine is functioning properly, especially the

safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435
SA-435
SA-31
SAFETY
(Blank)
SA-32
SECTION AND GROUP SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Specifications
Group 3 Component Layout
SECTION 2 SYSTEM
Group 1 Fuel System
TECHNICAL MANUAL Group 2 Hydraulic System
Group 2 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 HST Pump
Group 2 HST Motor
Group 3 Axle
Group 4 Brake
Group 5 Orbitroll
Group 6 Control Valve
Group 7 Main Pump
SECTION 4 OPERATIONAL PER-
FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
All information, illustrations and speci-
Group 4 Wheel Loader Test
fications in this manual are based on
the latest product information available
SECTION 5 TROUBLESHOOTING
at the time of publication. The right is Group 1 Diagnosing Procedure
reserved to make changes at any time
without notice. Group 2 Failure List
Group 3 Engine
COPYRIGHT(C)2008
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 1
GENERAL
―CONTENTS―
Group 1 Specification
Specifications ........................................... T1-1-1
Group 2 Component Specifications

Engine ...................................................... T1-2-1
HST Pump ................................................ T1-2-2
Gear Pump ............................................... T1-2-2
Orbitroll..................................................... T1-2-3

Main Component (Overview) .................... T1-3-1
Main Component (Power Line) ................. T1-3-3
Hydraulic System (Overview) ................... T1-3-4
Electrical System (Overview).................... T1-3-5
Electrical System (Monitor Panel)............. T1-3-7
Engine ...................................................... T1-3-8
HST Pump ................................................ T1-3-9
HST Motor ................................................ T1-3-9
Reduction ............................................... T1-3-10
Control Valve ...........................................T1-3-11
4EJT-1-1
(Blank)
4EJT-1-2
GENERAL / Specification
SPECIFICATIONS
45°
H
C
B E L
R1 D
R2 A
T4EJ-01-01-001
Standard Bucket Capacity (with edge) m3 (yd3) 0.3 (0.39)

Canopy spec. kg (lb) 1840 (4060)
Operating Weight
Cab spec. kg (lb) 2015 (4450)
Rated Machine Weight kg (lb) 500 (1110)
KUBOTA D1105-K2A
Engine 16.2 kW/2500 min-1
22 PS/2500 rpm
A: Overall Length mm (ft⋅in) 3440 (11′ 3″)
B: Overall Width (Bucket) mm (ft⋅in) 1350 (4′ 5″)
Canopy spec. mm (ft⋅in) 2350 (7′ 9″)
C: Overall Height
Cab spec. mm (ft⋅in) 2395 (7′ 10″)
D: Wheel Base mm (ft⋅in) 1500 (4′ 11″)
E: Tread mm (ft⋅in) 1065 (3′ 6″)
F: Minimum Ground Clearance mm (ft⋅in) 215 (0′ 9″)
G: Dumping Clearance mm (ft⋅in) 1850 (6′ 1″)
H: Dumping Reach mm (ft⋅in) 570 (1′ 10″)
R1: Minimum Rotation Radius Center of Outside Tire mm (ft⋅in) 2545 (8′ 4″)
R2: Minimum Rotation Radius Bucket Outside Edge mm (ft⋅in) 2970 (9′ 9″)
Travel Speed Forward/Reverse km/h (mph) 15/15 (9.3/9.3)
Transmission Speeds Forward/Reverse − 2/2
Maximum Gradeability % (deg.) 58 (30)
Articulation Angle (Left/Right) deg. 42
Tire Size − 10-16.5-4PR
T1-1-1
GENERAL / Specification
(Blank)
T1-1-2
GENERAL / Component Specification
ENGINE
Item Unit Specification

Engine Model KUBOTA D1105-K2A
Engine Type Four-Cycle Diesel Engine, Water-Cooled
Cylinder No.-Bore x Stroke mm (in) 3-78×78.4 (3.07×3.09)
Piston Displacement L (US gal) 1.123 (0.3)
Combustion Chamber Type E-TVCS (Swirl Chamber)
Rated Output kW (PS)/rpm 16.2 (22) ±2.5%/2500±50
kW (PS)/
Gross Output/Torque 17.0 (23.1)/70.6 (7.2, 52)
N⋅m (kgf⋅m, lbf⋅ft)
No Load Maximum Idle Speed/Idle Speed rpm 2650+85-50/1100+100-50
Maximum Output Torque/Engine Speed N⋅m (kgf⋅m, lbf⋅ft)/rpm 68.6 (7.0, 51)/1500 to 1700
Injection Order 1-2-3
Direction of Rotation CCW (Viewed from Flywheel End Side)
Injection Nozzle DN-OPD mini-nozzle
Injection Pump Bosch MD type mini-pump
2
Injection Pressure MPa (kgf/cm , psi) 13.7 (140, 1990)
Injection Timing TC -17° to -19°
Compression Ratio 23
Fuel Diesel Fuel
Fuel Consumption Ratio g/kW⋅h (g/ps⋅h) 258 (190) (Minimum Fuel Consumption)
Pressurized Radiator (Forced Circulation
Cooling System
with Cooling Pump)
Lubrication System Forced Lubrication with Trochoid Pump
Lubricant Oil CC class and above10W-30
Lubricant Oil Capacities L (US gal) 3.8 (1.0)
Lubricant Oil Effective Dose L (US gal) 1.2 (0.3)
Coolant Capacities L (US gal) 1.7 (0.4) (Engine Only)
Air Cleaner Cyclone Separator Type Filter
Regulator IC Type (Built-in Alternator)
Dimension: Length×Width×Height mm (in) 532.8×398.8×580 (21×16×23)
Weight (Dry) kg (lb) 113.5 (250)
Starting Method Starter (with Glow Plug)
Starter Motor V-kW 12 V-1.4 kW
Alternator V-kW 12 V-0.48 kW
12 V-52 Ah (Genial Climate)
Battery Capacity V-Ah
12 V-64 Ah (Cold Climate)
T1-2-1
HST PUMP
Part Name A4VG28DA

Type Variable Piston Pump
Driving Method Engine-Crankshaft Direct Coupling
Delivery Flow Rate 0 to 28 CC rev
High Pressure Relief Valve Set Pressure 39 MPa (398 kgf/cm2, 5670 psi)
Low Pressure Relief Valve Set Pressure 2.5 MPa (26 kgf/cm2, 360 psi)
Control System DA Control
Weight 35 kg (77 lb)
HST Charging Pump Gear Type
GEAR PUMP
Part Name 2-Unit Gear Pump

Type S621-3994C
Driving Method Gear Type
1st Pump: 9.50 cm3
Displacement
2nd Pump: 6.68 cm3
Weight 5.8 kg (13 lb)
1st Pump: For Steering/Implement
Function
2nd Pump: For HST Charging
T1-2-2
ORBITROLL
Part Name Orbitroll

Type PGC1R175YA3D
Load Sensing/with Non Load Reaction Pri-
Valve System
ority Valve (Dynamic Signal Type)
17.9 to 17.2 (MPa) /40 (L/min) (183 to 175
Relief Valve Set Pressure
kbf/cm2, 2600 to 2500 psi/11 US gal)
Maximum Pressure 20.6 MPa (210 kgf/cm2, 2990 psi)
System Control Pressure 0.53 MPa (5.4 kgf/cm2, 77 psi)
Rated Flow Rate 80.0 L/min (21 US gal)
Displacement 96 cm3/rev
T1-2-3
(Blank)
T1-2-4
GENERAL / Component Layout
MAIN COMPONENT (OVERVIEW)
6
5
10
11
1
T4EJ-01-03-001
1 - Bucket 4 - Bucket Cylinder 7 - Back Mirror 10 - Lift Cylinder

2 - Bucket Link 5 - Combination Lamp 8 - Canopy 11 - Lift Arm
(Turn Signal Light and Clearance Light)
3 - Bell Crank 6 - Head Lamp 9 - Fuel Feed Port
T1-3-1
4
9
5
T4EJ-01-02-001
6 7 8
1 - Operator Seat 4 - Counterweight 6 - Backlight 8 - Combination Lamp

(Turn Signal, Tail Light, and Stop Light)
2 - Engine Hood 5 - Towing Pin 7 - Reflector 9 - Hydraulic Oil Tank
3 - Radiator/Oil Cooler
T1-3-2
MAIN COMPONENT (POWER LINE)
9 8
10
T4EJ-01-02-002
4 5 6
1 - Front Axle 4 - Reduction 7 - Engine 9 - Main Pump

2 - Propeller Shaft (Front) 5 - Propeller Shaft (Rear) 8 - HST Pump 10 - Charging Pump
3 - HST Motor 6 - Rear Axle
T1-3-3
HYDRAULIC SYSTEM (OVERVIEW)
1 2 3 4
10
T4EJ-01-02-003
7 6 5
1 - Bucket Cylinder 4 - Hydraulic Oil Tank 7 - HST Oil Filter 9 - Steering Cylinder
2 - Lift Cylinder 5 - Oil Cooler 8 - Inching Valve 10 - Control Valve
3 - Orbit Motor 6 - Hydraulic Oil Return Filter
T1-3-4
ELECTRICAL SYSTEM (OVERVIEW)
1 2 3 4 5 6 7
16
9
15
10
14
13
12 11
T4EJ-01-02-004
1- Bucket Proximity Switch 5- Shift Lever 9- Rear Combination Lamp 13 - Parking Brake Solenoid
2- Horn 6- Horn Switch 10 - Backlight 14 - Fuel Gauge Sending Unit
3- Head Light 7- Combination Lamp Switch 11 - Back Buzzer 15 - Brake Lamp Switch
4- Front Combination Lamp 8- Battery 12 - Fuel Pump 16 - Brake Oil Level Switch
T1-3-5
5 6 7
1 2
8 10
9
11
12 14
13
15 16 17
18
T4EJ-01-02-005
1 - Monitor Panel 6 - Relay 2 (For Monitor Lamp 11 - Glow Lamp Timer 15 - Solenoid (Forward)
Check)
2 - Key Switch 7 - Relay 3 (For Parking 12 - Glow Relay 16 - Solenoid (Reverse)
Brake)
3 - Parking Brake Switch 8 - Relay 4 (For Parking 13 - Starter Relay 17 - Temperature Gauge
Brake) Sender Unit
4 - Travel Mode Switch 9 - Flasher Unit 14 - Slow Blow Fuse (65A) 18 - Solenoid (Fixed for Mid
Speed)
5 - Relay 1 (For Monitor Lamp 10 - Fuse Box
Check)
T1-3-6
ELECTRICAL SYSTEM (MONITOR PANEL)
1 2 3 4 5 6 4 2 7
T4EJ-01-02-006
10 9 8
1 - Brake Oil Low Level Indicator 4 - FNR Indicator 7 - Parking Brake Indicator 9 - Fuel Gauge
2 - Left Turn Signal Indicator 5 - Engine Oil Pressure Indicator 8 - Hour Meter 10 - Temperature Gauge
3 - Charging Lamp 6 - Glow Signal
T1-3-7
ENGINE
2 3
T4EJ-01-02-007
10 9
1 - Engine Stop Solenoid 4 - Temperature Gauge 7 - Water Drain Plug 9 - Engine Oil Filter
Sender Unit
2 - Glow Plug 5 - Alternator 8 - Engine Oil Pressure Switch 10 - Drive Belt
3 - Engine Oil Level Gauge 6 - Starter Motor
T1-3-8
HST PUMP
4
1 3
5
5
T4EJ-01-02-008
1 - Main Pump 3 - Solenoid Valve A (Forward) 5 - High Pressure Relief Valve 7 - DA Valve
2 - Charging Pump 4 - Solenoid Valve B (Reverse) 6 - Low Pressure Relief Valve
HST MOTOR
T4EJ-01-02-009
1 - Solenoid (Fixed for Mid Speed)
T1-3-9
REDUCTION
8
3
4
6
5
T4EJ-01-02-010
1 - Reduction Gear Case 4 - Cover 6 - Plug (Oil Level) 8 - Bleader

2 - Plug (Oil Feed Port) 5 - Plug (Oil Drain) 7 - Plug 9 - Bolt (For Parking Brake
Forcibly Release)
3 - Flange
T1-3-10
CONTROL VALVE
1
5
2
3
4
6
7
8
T4EJ-01-02-011
1 - Outlet Section 3 - Tilt Section 5 - Overload Relief Valve 7 - Inlet Section

2 - Lift Section 4 - Main Relief Valve 6 - Antivoid Valve 8 - Electromagnetic Detent
T1-3-11
(Blank)
T1-3-12
SECTION 2
SYSTEM
—CONTENTS—
Group 1 Fuel System
Outline ...................................................... T2-1-1
Group 2 Hydraulic System

Outline ...................................................... T2-2-1
HST Circuit ............................................... T2-2-2
HST Oil Filter ............................................ T2-2-4
Brake Circuit............................................. T2-2-5
Steering Circuit ......................................... T2-2-6
Main Circuit Diagram ................................ T2-2-8
Group 3 Electrical System

Outline ...................................................... T2-3-1
Electrical Circuit Diagram ......................... T2-3-2
Power Circuit ............................................ T2-3-4
Electric Power Circuit
(Key Switch: OFF) .................................. T2-3-4
Preheat Circuit (Key Switch: HEAT).......... T2-3-5
Preheat Circuit (Key Switch: START)........ T2-3-6
Charging Circuit........................................ T2-3-7
Starting Circuit .......................................... T2-3-8
Stop Circuit ............................................... T2-3-8
Monitor Indicator Circuit ........................... T2-3-9
Gauge Circuit ......................................... T2-3-10
Travel Circuit ...........................................T2-3-11
Parking Brake Circuit.............................. T2-3-15
Light Circuit ............................................ T2-3-18
Horn Circuit ............................................ T2-3-19
Auto Leveler Circuit ................................ T2-3-19
4EJT-2-1
(Blank)
4EJT-2-2
SYSTEM / Fuel System
OUTLINE
Fuel circuit consists of the fuel tank, the fuel filter and
piping.
FUEL TANK FUEL PIPING
Fuel tank (1) is installed to the rear frame left side with Fuel (diesel oil, JIS K2204-compliant) is suctioned
the bolts. The fuel hose (Feed, Return) is connected to from fuel tank (1) by fuel pump (2) and filtrated by fuel
the engine. filter (3).
In addition, fuel sensor (6) is installed in fuel tank (1). The filtered fuel is supplied to injection pump (4).
The remaining amount of fuel is indicated on fuel Fuel is compressed and delivered to injection nozzle
gauge (7). (5) by using injection pump (4) corresponding to the
injection timing of each cylinder in the engine, and in-
jected to the combustion chamber.
In case of the trapping air, turn the starter switch to the
ON position, and the air bleeding can be performed
through the returning circuit.
(Automatic air bleeding mechanism)
2 3 4
1
T4EJ-02-01-001
1 - Fuel Tank 3 - Fuel Filter 5 - Injection Nozzle 7 - Fuel Gauge

2 - Fuel Pump 4 - Injection Pump 6 - Fuel Sensor
T2-1-1
SYSTEM / Fuel System
FUEL FILTER
The fuel filter has the drain function to separate foreign

particle contained in fuel and precipitated water.
Float (4) is built in filter cartridge (7). When water ac-
cumulates, float (4) is floated.
T4EJ-02-01-002
8 3
7 4
T4EJ-02-01-003
1 - Filter Head 3 - Element 5 - Float 7 - Filter Cartridge

2 - O-Ring 4 - Spring 6 - Retaining Ring 8 - O-Ring
T2-1-2
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system consists of HST circuit, the brake
circuit, the steering circuit and the main hydraulic cir-
cuit.
<Hydraulic circuit diagram>
T4EJ-02-02-001
T2-2-1
HST CIRCUIT
HST hydraulic circuit consists of main hydraulic suc-
tion circuit (A), charging pump circuit (B), HST close
circuit (C), system pressure control pilot circuit (D) and
lubrication and cooling (drain) circuit (E),
Pressure oil by charging pump (2) is discharged and
filled up in both casing of HST pump (1) and HST
motor (4). Pressure oil cools each part and flows to oil
cooler (6).
Hydraulic oil is cooled by oil cooler (6) and retuned to
hydraulic oil tank (5).
5 D 2 1
B E
T4EJ-02-02-002
A 4 E
1 - HST Pump 3 - HST Oil Filter 5 - Hydraulic Oil Tank 7 - Inching Valve
2 - Charging Pump 4 - HST Motor 6 - Radiator (Oil Cooler)
T2-2-2
HST Circuit
Line Filter
Direction Switch Valve DA Valve
Charging
Pump
T4EJ-02-02-003
High Relief Valve Low Relief Valve
HST circuit diagram High Relief Pressure : 39 MPa (400 kgf/cm2, 5670 psi)
Low Relief Pressure : 2.5 MPa (26 kgf/cm2, 360 psi)
Main Pump Flow Rate : 9.5 cc/rev (0.6 in3/rev)
Charging Pump Flow Rate : 6.68 cc/rev (0.4 in3/rev)
Charging Pump
It is 2-spool gear pump combined the main pump and
the charging pump.
The charging pump is installed to HST pump through
the coupling and rotates together with the engine.
Pressure oil from HST charging pump is used for the
charge to add hydraulic oil into HST closed circuit,
the pilot of displacement angle control and the park-
ing brake relief.
Pressure oil from the charging pump is sent to the
inching valve assembly through HST oil filter.
T2-2-3
HST OIL FILTER
Pressure oil from the charging pump assembly flows
into cartridge assembly (1) through the inlet port and is
filtered in element (2).
Pressure oil from the outlet port is sent to the inching
valve assembly.
In case the element clogs, when inlet port pressure
increases and outlet port pressure difference is 0.34
MPa or more, bypass valve (3) is opened and pressure
oil does not flow through element (2), but to the outlet
port directly.
IN OUT
T4EJ-02-02-004
1 - Cartridge Assembly 2 - Element 3 - Bypass Valve
T2-2-4
BRAKE CIRCUIT
Service Brake Inching Mechanism
Service brake uses the wet type disc brake installed Brake pedal (1) and the inching valve lever are con-
to the input shaft in the reduction gear. nected with the link.
Service brake is the hydraulic type and consists of When depressing brake pedal (1) (either right or left),
brake pedal (1), brake oil tank (2), master cylinder (3) the HST pump inching function (HST brake function)
and the piping. operates and the wet type disc brake brakes the
This master cylinder (3) is single type and the brake machine.
hydraulic line is one system.
1 2 5 8 6
T4EJ-02-02-005
1 - Brake Pedal 4 - Brake Light Switch 6 - Brake Oil Level Indicator 8 - Inching Valve
2 - Brake Oil Tank 5 - Brake Oil Level Switch 7 - Bleeder (Air Bleeding) 9 - Reduction Gear Assembly
3 - Master Cylinder
T2-2-5
STEERING CIRCUIT
The steering system mainly consists of the steering When operating (rotating by hand) the steering wheel,
wheel, the power steering (orbitroll), the steering cyl- the orbitroll (power steering) directly installed to the
inder and the piping. steering shaft of the steering column assembly oper-
ates. Pressure oil is sent to the steering cylinder and
the machine direction is changed.
R
4
T
3
T4EJ-02-02-006
1 - Steering Wheel 3 - Power Steering (Orbitroll) 4 - Return Filter 5 - Steering Cylinder

2 - Steering Column Assembly
T2-2-6
Steering Circuit Diagram
Hydraulic oil suctioned from the hydraulic oil tank by The steering hydraulic circuit returns redundant hy-
using the main pump is delivered to the power draulic oil to the main circuit. As for the power steer-
steering (orbitroll). Hydraulic oil is divided into the ing (orbitroll), hydraulic oil is delivered to the steering
main hydraulic circuit and the steering hydraulic cir- cylinder and the machine direction is changed ac-
cuit. cording to the steering wheel operation.
As the steering hydraulic circuit is adopted the load Hydraulic oil delivered from the steering cylinder
sensing system, the steering hydraulic circuit sends flows back to the power steering (orbitroll). Hydraulic
hydraulic oil required for changing the machine di- oil is filtrated in the return filter and returns to the hy-
rection to the power steering (orbitroll) preferentially. draulic oil tank.
Power Steering
(Orbitroll)
96 cc/rev
Steering Cylinder
Pressure Port
17.2 MPa
T P EF
0.15 MPa
Control Valve
(To Port P）
Main Pump
10 μ
Return Filter
Hydraulic
Oil Tank
T4EJ-02-02-007
T2-2-7
MAIN CIRCUIT DIAGRAM
The main hydraulic device consists of the main pump,
the control valve, the hydraulic oil tank, the return filter,
the lift arm cylinder, the bucket cylinder and the hy-
draulic piping.
When the main pump (connected to the charging
pump) is used as the power source by operating the
shovel control lever, change the pressure oil flow by
the control valve and load the work device.
5
3
2
6
8 7
T4EJ-02-02-008
1 - Lift Arm Cylinder (Right) 3 - Orbitroll 5 - Return Filter 7 - Lift Arm Cylinder (Left)
2 - Bucket Cylinder 4 - Hydraulic Oil Tank 6 - HST Pump (Main Pump) 8 - Control Valve
T2-2-8
Main Hydraulic Circuit Diagram
Hydraulic oil suctioned from the hydraulic oil tank by When the spool in the control valve moves by oper-
using the main pump is delivered to VP (priority) ating the control valve, the hydraulic oil flows the se-
valve in the orbitroll. Hydraulic oil is divided into the lected oil passage in the valve to the lift arm cylinder
main hydraulic circuit and the steering hydraulic cir- and the bucket cylinder. Each cylinder is activated.
cuit. Hydraulic oil delivered from the cylinder flows back to
Pressure oil in the main hydraulic circuit is delivered the control valve. Hydraulic oil returns to the hydraulic
to the control valve. When the control valve is in oil tank through the return filter.
neutral, pressure oil flows in the valve and returns to
the hydraulic oil tank through the return filter.
Lift Arm Cylinder 2-φ55-φ30-385
Control Valve
B2
A2
D.C.12V
B1
A1
Hydraulic
Metering Port (DET)
22.6 MPa 22.6 MPa
20.6 MPa
P T
Bucket Cylinder
φ60-φ35-262
0.15 MPa
From Port EF
of Orbitroll
10 μ
Return Filter
Hydraulic Oil Tank T4EJ-02-02-009
T2-2-9
(Blank)
T2-2-10
SYSTEM / Electrical System
OUTLINE
The electrical system consists of the main circuit, the
monitor circuit and the travel circuit.
• Main circuit
• Electric power circuit: It is an electrical power
source for all electrical systems on the machine.
• Preheating circuit: It assists engine start in cold
weather.
• Charging circuit: It charges the batteries and
complements power consumption.
• Starting/Stop circuit: It starts and stops the engine
by the engine stop motor.
• Monitor circuit
• Monitor indicator circuit: It indicates the machine
operation status in the meter panel.
• Gauge circuit: It indicates the engine coolant
temperature and the remaining amount of fuel in
the meter panel.
• Travel system circuit

• Travel system circuit: It changes forward/reverse
selector by the shift lever and controls the parking
brake by the parking brake switch.
• Other circuits
• Light circuit: It turns each light (head light, turn
signal light, rear combination light, reverse light)
ON and OFF.
• Horn circuit: It sounds the horn (alarming horn).
• Auto leveler circuit: It turns the proximity switch of
the auto leveler device (bucket horizontal
mechanism) ON and OFF.
T2-3-1
Code Color
B Black In case of two colors are indicated
W White for one wire, the left initial stands for
R Red the base color, while the right initial
G Green stands for the marking color.
L Blue
Preheat
Y Yellow Relay Relay Relay Relay Flasher Indicator
Key S.W. Connecting Chart (1) (2) (3) (4) Unit Timer
Br Brown
O Orange
Key
P Pink S.W.
Slow Slow
Momently Blow Blow
Fuse Fuse
Parking Blake S.W.

Connecting Chart
Diode Diode
Main Harness Rear Harness
Parking Brake S.W.
(OP)
S.W.
Fuel
Heater
Hour
Gauge
Meter
ELECTRICAL CIRCUIT DIAGRAM
Battery
Turn Signal
Light (R)
(21W)
Tail Light
Meter Panel
(5W)
Stop Light
Illumination Light License (21W)
Light (OP)
Glow Plug Diode

Starter
Relay Relay
T2-3-2
S.W.
Medium
Gauge
Coolant
Speed Lock
Temperature
S.W.
Coolant Reverse
Engine Oil Alter-
Lighting
Starter Tem-
Motor Pressure nator Light (21W)
S.W. perature
Light .S.W.
Sensor
Combination
Stop
Solenoid
Steering
Colum
S.W
Dimmer
Glow
HST Pump
Clearance Light Plug Engine Back
Horn S.W. Buzzer
Turn Signal Light (R)
Shift Lever
Head Light (55W) No. Capacity Connected to
Turn Signal
HST (F) and (R) Solenoid, HST First Speed Light (L)
1 15 A Lock S.W. Solenoid, Parking Blake Solenoid (21W)
Auto Leveler
Tail Light
Proximity S.W. Relay (3) and (4), Back Light, Back Buzzer. (5W)
Head Light, Meter Panel Illumination Indicator, Stop Light
(21W)
2 30 A Turn Signal Light, Flusher Unit, Clearance
Diode
Light, Tail Light. Fuel Pump
Head Light (55W) Meter Panel Monitor Indicator, Coolant Tem-

C/V Tilt Detent Head Light 3 10 A perature Gauge, Fuel Gauge, Hour Meter, Re-
Upper Beam
Turn Signal Light (L) (21W)
lay (1) and (2).
Fuel Sensor 4 15 A Stop Light, Horn
5 10 A Alto Lever Proximity S.W. C/V Tilt Detent.
Clearance Light (55W) 6 10 A Fuel Pump, Engine Stop Solenoid.
7 (10 A) Heater (OP)
8∼20 − Optional Power
T4EJ-02-03-001
(Blank)
T2-3-3
POWER CIRCUIT
The battery negative terminal is grounded to the vehi- Current from the battery plus terminal flows as illus-
cle frame. trated below when the key switch is in OFF position.
Key Switch Connecting Chart
Fuse Box Slow Blow Fuse
Optional Power Source

Automatic Battery
Power Source
Power Source
for the Cab
Starter Motor
Engine
T4EJ-02-03-002
ELECTRIC POWER CIRCUIT (KEY SWITCH: OFF)

Fuse Box Slow Blow Fuse
Optional Power Source

Automatic Battery
Power Source
Power Source
for the Cab
Starter Motor
Engine
T4EJ-02-03-003
T2-3-4
PREHEAT CIRCUIT (KEY SWITCH: HEAT)
When the key switch is turned to the HEAT position, The preheat indicator notices the preheating comple-
current excites the glow plug relay and flows to the tion by going off for 5 seconds by the preheat indicator
glow plug. timer
The other current flows through the preheat indicator

timer and lights the preheat indicator.
Key Switch Connecting Chart Preheat Indicator Glow Plug Slow Blow Slow Blow
Timer Relay Fuse Fuse
Meter Panel
Shift Lever
Diode
Battery
Starter Motor Alternator

Glow Plug
T4EJ-02-03-004
T2-3-5
PREHEAT CIRCUIT (KEY SWITCH: START)
When the key switch is turned to the START position, When the key switch is returned to the ON position
current flows from key switch terminal C to the preheat after the engine starts, current exciting the glow plug
indicator timer through the shift lever. Current excites relay is blocked, and current to the glow plug is
the glow plug relay and flows to the glow plug. blocked.
The other current flows through the preheat indicator

timer and lights the preheat indicator.

Preheat Indicator Glow Plug Slow Blow Slow Blow
Timer Relay Fuse Fuse
Meter Panel
Shift Lever
Diode
Battery

Glow Plug
T4EJ-02-03-005
T2-3-6
CHARGING CIRCUIT
After the engine starts and the key switch is released, At the same time, current flows through the fuse box
the switch turns moves to the ON position. and powers the head light and others.
When the key switch is in the ON position, terminal B In addition, current from terminal L of the alternator
is connected to terminal BR and terminal ACC in the flows to relay [1]. When the battery charge is normal,
key switch. the alternator indicator goes off.
When the engine starts, the alternator starts rotating

and generating electricity.
Current from alternator terminal B flows to the batter-

ies and charges the batteries.
Relay [1]
(For Monitor Indicator
Meter Panel Check and Parking Blake) Diode Slow Blow Fuse
Fuse Box
Engine
T4EJ-02-03-006
T2-3-7
STARTING CIRCUIT STOP CIRCUIT
Key switch ON → START operation: Key switch is ON:
The starter relay coil is excited from key switch termi- Positive current from the fuse box excites the stop
nal C through the neutral switch of the shift lever and solenoid coil and is operated.
the relay is closed.
Therefore, positive current flows through the starter Key switch is OFF:
relay to the starter motor and the starter motor is op- The engine stops as current does not flow to stop so-
erated. lenoid coil.
Key switch ON → START operation on the engine op-

erating condition:
Current does not flow to the starter relay coil as ter-
minal L in the alternator is not grounded (the monitor
indicator goes off) in the engine operating condition.
The relay is opened and the starter motor is not oper-
ated.
Slow Blow Slow Blow

Fuse Box
Diode Fuse (2) Fuse (1)
Key
Switch
Shift Lever
Starter Relay

Battery
Stop Solenoid
Engine
T4EJ-02-03-007
T2-3-8
MONITOR INDICATOR CIRCUIT
Relay (1) Relay (2)
Fuse Box Diode
Monitor Panel
Blake Oil
Level Monitor
Indicator
Engine Oil
Pressure Monitor
Indicator
Engine Oil
Pressure
Blake Alternator
Switch
Oil Level
Switch Engine
T4EJ-02-03-008
T2-3-9
GAUGE CIRCUIT
Fuse Box
Hour Meter
Fuel Gauge
Fuel Sensor
Coolant
Temperature
Gauge
Monitor Panel
Coolant
Battery
Temperature
Sensor
T4EJ-02-03-009
T2-3-10
TRAVEL CIRCUIT Relay [1]
(For Monitor In-
dicator Check Relay [3] Relay [4]
and Parking (For Parking (For Parking Momentary
Fuse Box
Brake) Brake) Brake)
Parking Brake Switch
Connecting Chart
Battery
Monitor Panel
Parking Brake Monitor

Indicator
Diode
[F] Solenoid
[R] Solenoid
HST Pump
(Medium Speed Lock) Solenoid
Shift Lever
HST Motor
Speed Change Solenoid Valve
Parking Brake
Solenoid
Medium Speed
Lock Switch
Diode
Parking Brake
Solenoid Valve
T4EJ-02-03-010
T2-3-11
Shift lever “N” → “F”:

In case parking brake is released, relay [4] is closed
(refer to Parking Brake Circuit) and current from the
fuse flows to the parking brake solenoid and the shift
lever.
Current flows to solenoid F of HST pump by operating
the shift lever from “N” to “F” and lights FNR indicator
(1).
1
Monitor Panel
Battery
Diode
Shift Lever
[F] Solenoid
[R] Solenoid
HST Pump
Parking Brake
Solenoid
Parking Brake
Solenoid Valve
T4EJ-02-03-011
T2-3-12
Shift lever “N” → “R”:
In case parking brake is released, relay [4] is closed
(refer to Parking Brake Circuit) and current from the
fuse flows to the parking brake solenoid and the shift
lever.
Current flows to solenoid R of HST pump by operating
the shift lever N → R and lights FNR indicator (2).
Monitor Panel
2
Battery
Diode
Shit Lever
[F] Solenoid
[R] Solenoid
HST Pump
Parking Brake
Solenoid
Parking Brake
Solenoid Valve
T4EJ-02-03-011
T2-3-13
Travel mode selector switch: AUTO
The power from fuse does not flow to the medium
speed lock solenoid of HST motor and keeps on the
automatic speed shift circuit.
Fuse Box
Medium Speed (Medium Speed Lock)

Lock Switch Solenoid
HST Motor
Speed Change
Solenoid Valve
Diode
T4EJ-02-03-012
Travel mode selector switch: LOW

Pilot lamp (1) of selector switch lights and the power
from fuse flows to the medium speed lock solenoid of
HST motor. The power operates the medium speed
lock solenoid and becomes the medium speed lock
circuit.
Fuse Box
Medium Speed (Medium Speed Lock)

Lock Switch Solenoid
HST Motor
Speed Change
Solenoid Valve
Diode
T4EJ-02-03-013
T2-3-14
PARKING BRAKE CIRCUIT
Before Starting the Engine (Key Switch is ON):
Current from the fuse to relay [1] excites the relay coil Current from other fuse flows through relay [4] and
and the relay is opened. Then, current does not flow lights the parking brake monitor indicator.
to the parking brake switch and the parking brake is
locked.
Parking Blake
Monitor Indicator
Parking Blake Relay (3)
Switch
Parking Blake
Solenoid
Relay (4)
Forward/Reverse
Shift Lever Solenoid
(HST Pump)
Fuse
Relay (1)
Alternator
T4EJ-02-03-014
After Starting the Engine (Parking brake switch is

ON):
Current from the fuse to relay [1] flows to terminal [6] However, relay [4] is not operated, current keeps the
of the parking brake switch as the relay is closed. parking brake lock conditions and lighting the monitor
indicator.
Parking Blake
Monitor Indicator
Switch
Parking Blake
Solenoid
Relay (4)
Forward/Reverse
(HST Pump)
Fuse
Relay (1)
Alternator
T4EJ-02-03-015
T2-3-15
Parking Brake Switch is in Neutral:
Current from the fuse to relay [1] flows to terminal [6] As relay [4] is not operated, current keeps the parking
of the parking brake switch as the relay is closed. brake lock conditions and lighting the monitor indi-
cator. (Rapid starting prevention circuit)
Parking Blake
Monitor Indicator
Switch
Parking Blake
Solenoid
Relay (4)
Forward/Reverse
(HST Pump)
Fuse
Relay (1)
Alternator
T4EJ-02-03-016
Parking brake switch is operated OFF (Auto

Restoration):
Current from the fuse to relay [1] flows to terminal [6] On the other hand, current to relay [4] excites the
of the parking brake switch and flows from terminal relay [4] coil and the contact is opened.
[4] and terminal [1] to relay [3] and relay [4]. The circuit to the monitor indicator is blocked and the
Current to relay [3] flows to the parking brake sole- monitor indicator goes off.
noid and the parking brake is unlocked. Parking Blake
Monitor Indicator
Switch
Parking Blake
Solenoid
Relay (4)
Forward/Reverse
(HST Pump)
Fuse
Relay (1)
Alternator
T4EJ-02-03-017
T2-3-16
After Operating the Parking Brake Switch to OFF
(Auto Restoration):
Once the parking brake switch is OFF (Auto Restora- Current to the parking brake solenoid is blocked and
tion), relay [4] is kept opened. the parking brake is locked.
At the same time, the monitor indicator lights.
When the parking brake switch is turned ON, terminal
[1] and terminal [2] of the parking brake switch are
connected. Current excites the relay [3] coil and the
relay is opened. Parking Blake
Monitor Indicator
Switch
Parking Blake
Solenoid
Relay (4)
Forward/Reverse
Shift Lever
Solenoid
(HST Pump)
Fuse
Relay (1)
Alternator
T4EJ-02-03-018
Parking Brake Switch is ON → Neutral:

Current from terminal [2] of the parking brake switch released. At the same time, the monitor indicator
is blocked and relay [3] is closed. Current is sent to goes off.
the parking brake solenoid and the parking brake is
Parking Blake
Monitor Indicator
Switch
Parking Blake
Solenoid
Relay (4)
Forward/Reverse
Shift Lever
Solenoid
(HST Pump)
Fuse
Relay (1)
Alternator
T4EJ-02-03-019
T2-3-17
LIGHT CIRCUIT
Flasher
Fuse Box Unit
Battery
Meter Panel
Fuel Gauge
Turn Signal Light R/H
(21W)
Indicator (Cab Light) Tail Light (5W)
Stop Light (21W)
(Cab Light) License Light

(OP)
Coolant
Temperature
Gauge
Reverse Light
(21W)
Turn Signal
Switch
Hazard Switch Lighting Switch
Turn Signal Light R.H
(21W)
Combination Stop Light Switch
Tail Light (5W)
Light Switch Stop Light (21W)
Dimmer
Switch
Shift Lever
Clearance Light (5W)
Turn Signal Light R.H

(21W)
Head Light (55W)
Head Light (55W)

Head Light
Upper Beam
Turn Signal Light L.H (OP)
(21W)
Clearance Light (5W)

T4EJ-02-03-020
T2-3-18
HORN CIRCUIT
Combination
Light Switch Fuse Box
Steering Column
Horn Switch
Horn
T4EJ-02-03-021
AUTO LEVELER CIRCUIT

Fuse Box
Auto Leveler
Proximity Switch
Diode
C/V Tilt Detent T4EJ-02-03-022
T2-3-19
(Blank)
T2-3-20
SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 HST Pump Group 6 Control Valve
HST Circuit ............................................... T3-1-1 Control Valve ............................................ T3-6-1
HST Pump ................................................ T3-1-2 Operation .................................................. T3-6-2
High-Pressure Relief Valve....................... T3-1-4 Operation of Tilt Section ........................... T3-6-3
Low-Pressure Relief Valve........................ T3-1-6 Operation of Lift Section and Spool........... T3-6-6
HST Pump Characteristic Curve ............... T3-1-6 Detent Operation .................................... T3-6-10
DA Control ................................................ T3-1-7 Relief Valve............................................. T3-6-12
Displacement Angle Return Force Anti-Void Valve........................................ T3-6-14
and Advance ......................................... T3-1-16
Group 7 Main Pump
Inching Valve .......................................... T3-1-17
Main Pump................................................ T3-7-1
Automatic Transmission Function ........... T3-1-18
Return Filter .............................................. T3-7-2
Torque Control Function ......................... T3-1-18
Group 2 HST Motor

HST Motor ................................................ T3-2-1
Constand Control (HA Control) ................. T3-2-2
Group 3 Axle
Axle .......................................................... T3-3-1
Differential Assembly ................................ T3-3-2
Final Drive Assembly ................................ T3-3-3
Group 4 Brake
Service Brake ........................................... T3-4-1
Parking Brake ........................................... T3-4-4
Towing Machine Method
(In Emergency) ....................................... T3-4-6
Wet Type Brake Assembly in
Reduction Gear ...................................... T3-4-7
Master Cylinder ........................................ T3-4-8
Group 5 Orbitroll
Power Steering (Orbitroll) ......................... T3-5-1
Operation in Neutral ................................. T3-5-4
At Right Swing Operation ......................... T3-5-5
At Relief Valve Operation.......................... T3-5-6
4EJT-3-1
(Blank)
4EJT-3-2
COMPONENT OPERATION / HST Pump
HST CIRCUIT
HST is the hydraulic drive device to transfers the driv- There are three elements to control HST.
ing force to the wheels by using oil. HST of this ma- By controlling these three elements, the machine can
chine is equipped with the variable displacement type travel smoothly.
axial piston pump and the variable displacement type
motor. Oil Delivery Flow Rate → Vehicle Speed
The mechanical power from the engine is converted to Oil Flow Direction → Forward and Reverse
hydraulic pressure by the pump. Travel (FNR)
This hydraulic pressure is converted the mechanical Oil Pressure → Driving Force
power by the motor again. The mechanical power is
transmitted to the wheels.
HST provides both functions of the clutch and trans-
mission. The variable conversion can be performed by
the hydraulic control.
HST uses basically slow and high-pressure oil. HST is
the oil circulation type of the closed circuit composed
of the pump and the motor.
From Engine
Pump To Wheel
Motor
(Forward)
Swash Plate Piston Cylinder Block
Piston
(Stop)
(Reverse)
Slow Speed
Torque is Large
As the input shaft rotational direction of the pump is
Cylinder block tilt angle
always the same direction and the delivery pressure oil is large
direction from the pump is changed according to tilting
the swash plate, the output shaft rotational direction of
the motor is changed. Fast
Therefore, FNR control is performed according to tilt-
ing the swash plate.
In addition, the fast-slow selection is performed by Torque is Small
Cylinder block tilt angle
changing the cylinder block tilt angle. is small T4EJ-03-01-001
T3-1-1
HST PUMP
The cylinder block is connected to the drive shaft and In addition, the gear pump is installed to the drive shaft
rotates. and used for charging oil in the closed circuit and for
At that time, as the piston installed in the cylinder block the pilot of displacement angle control.
reciprocate according to the swash plate, the volumet-
ric change occurs. The pumping action such as suc-
tion / delivery is performed.
The suction / delivery is continuously performed by
rotating the drive shaft as each nine piston performs
one stroke of suction / delivery on every one revolu-
tion.
Suction
Drive Shaft
Swash Plate Piston Cylinder Block
Delivery T4EJ-03-01-002
DA Controller High-Pressure DA Valve

Relief Valve
Charge Pump
Low-Pressure
Relief Valve
T4EJ-03-01-003
T3-1-2
Port of HST Pump
Drain Port
High-Pressure Gauge Port
T2 (G1/2 O-Ring Port)
Ma (G1/4 O-Ring Port)
DA Valve
Charge Pressure Port

G (G1/4 O-Ring Port)
Low-Pressure Relief Valve
High-Pressure Gauge Port Pilot Pressure Port

(Reverse) Ps (G1/4 O-Ring Port)
Mb (G1/4 O-Ring Port)
Solenoid b
Pilot Pressure Measuring

Port (Forward)
X2 (G1/4 O-Ring Port)
Pilot Pressure Measuring

Solenoid a Port (Reverse)
X1 (G1/4 O-Ring Port)
High-Pressure Relief Valve
Drain Port
T1 (G1/2 O-Ring Port)
High-Pressure Main Port
(Reverse)
B (SAE Flange High-Pressure 3/4)
HST Lubrication Pump and

Main Pump Mounting Part
High-Pressure Main Port (Forward)

A (SAE Flange High-Pressure 3/4)
High-Pressure Relief Valve Filter Port

Fa (G3/8 O-Ring Port)
T4EJ-03-01-004
T3-1-3
HIGH-PRESSURE RELIEF VALVE
It regulates the circuit maximum pressure and protects In addition, the high-pressure relief valve has built-in
the circuit on the high-pressure side. the check valve function for charge. When the flow
rate to the suction circuit is insufficient, charge pres-
sure is routed to the suction circuit.
5
6
A 7
B T4EJ-03-01-005
1 - Rod 4 - Hexagon socket screw 7 - Poppet A- HST High-Pressure (Low-Pressure) Circuit

2 - O-Ring 5 - O-Ring 8 - Valve Seat B- Charging Circuit
3 - Spring 6 - Adjust Spring
<At Relief Operation>

As hydraulic pressure in high-pressure circuit [A] is
larger than the spring force by spring 6, poppet 7 is
pushed down (as illustrated position) and
high-pressure circuit [A] is routed to charging circuit
[B].
T4EJ-03-01-006
T3-1-4
<At Bypass Operation>
When hydraulic pressure in low-pressure circuit [A]
and the spring force by spring 1 are smaller than hy-
draulic pressure of charging circuit [B], the valve seat
2 is pushed upward (as illustrated position) and
charging circuit [B] is routed to low-pressure circuit
[A].
T4EJ-03-01-007
<At Towing Operation (Engine stops.)>

By tightening rod 1, poppet 7 is pushed down (as il-
lustrated position) and high-pressure circuit [A] is
routed to charging circuit [B].
T4EJ-03-01-008
T3-1-5
LOW-PRESSURE RELIEF VALVE
It regulates charge pressure.
The low-pressure relief valve always operates during
operation. The relieved oil returns to the tank through
the pump housing for lubrication and cooling.
HST PUMP CHARACTERISTIC CURVE
Engine Speed – HST Control Pressure
T4EJ-03-01-009
NOTE: 1 kgf/cm2 = 14.2 psi
T3-1-6
DA CONTROL
Advantages
1. The delivery direction of pressure oil can be
changed by the selector solenoid.
FNR selector can be performed by just one
switch.
2. The delivery flow rate is controlled according to
the engine speed. The vehicle speed can be con-
tinuously controlled by only accelerator control.
3. The torque constant control is adopted. When the
load increases, the torque constant control limits
the delivery flow rate to prevent the engine over-
load.
DA Valve
The gear pump is coaxially connected to HST pump
for the charge and pilot.
The gear pump flow rate is changed in proportion to
the engine speed.
All of flow rate flows to the charge circuit through the
orifice of DA valve.
DA valve decreases charge pressure to generate
control pressure by using the signal based on the
pressure difference caused by the flow rate change
between the front and rear of orifice.
Therefore, the pump displacement angle is controlled
by pressure almost in proportion to the engine speed.
The charging pump delivery flow rate in proportion to
the engine speed flows to charging circuit [C] through
port [A].
DA valve decreases charging circuit [C] pressure to
generate control pressure in control circuit [B] by us-
ing the signals based on the spring force by spring (4)
and the pressure difference caused by the flow rate 3
change between the front and rear of orifice (6).
1- Control Cartridge 1
2- O-Ring
3- Set Screw
4
4- Adjust Spring
5- Differential Piston
6- Orifice C
2
A- DA Valve Primary side (From Charging Pump)
B- DA Valve Secondary side (To Control Circuit)
C- DA Valve Secondary side (To Charging Circuit) Charging Circuit
D- DA Valve Drain
5
D
Control Circuit
Drain
B
6
A
Pump Circuit T4EJ-03-01-010
T3-1-7
DA valve
Main Circuit Pressure PH
Engine
Displacement Angle
Return Force
Control
Pressure
Spring
(DA Valve)
To Charge Circuit
Low-Pressure
Relief Valve
T4EJ-03-01-011
T3-1-8
<At Idle Operation>
As the charging pump delivery flow rate is low, the
pressure difference between the front and rear of ori-
fice (6) is small. Differential piston (5) is located on
the illustrated position
Consequently, as the flow passage between charging
circuit [C] and control circuit [B] is narrow, low control
pressure is routed to control circuit [B]
T4EJ-03-01-012
<At High Idle Operation>

As the charging pump delivery flow rate is high, the
pressure difference between the front and rear of ori-
fice (6) is large. Differential piston (5) is pushed up-
ward (as illustrated position).
Consequently, as the flow passage between charging
circuit [C] and control circuit [B] widens, high control
pressure is routed to control circuit [B]
T4EJ-03-01-013
T3-1-9
DA Control
5 To Inching valve
To Parking Brake 12
17
6 To Motor X F
1 9
G C PS X2
2 15
11
16
13
7 18 14
D 19
B
16
8
A 11
15
X1
10
17
12
T4EJ-03-01-014
1- Low-Pressure Relief Valve 8- Orifice 14 - Displacement Angle Piston A- DA Valve Primary side (From
2- O-Ring 9- Solenoid Valve [b] 15 - Guide Ring Charging Pump)
3- DA Valve 10 - Solenoid Valve [a] 16 - Turcon Glyd Ring B- DA Valve Secondary side (To
4- Set Screw 11 - O-Ring 17 - O-Ring Control Circuit)
5- Adjust Spring 12 - O-Ring 18 - Swash Plate C- DA Valve Secondary side (To
6- O-Ring 13 - Control Piston 19 - Slide Ring Charging Circuit)
7- Differential Piston D- DA Valve Drain
E- Displacement Angle Piston (x1)
F- Displacement Angle Piston (x2)
T3-1-10
<At Neutral Operation>
T4EJ-03-01-015
T3-1-11
<At Forward Travel Operation>
When the shift lever is set to [F], solenoid valve [a]
(10) is excited and control piston 13 connected to the
solenoid valve is pushed upward (as illustrated posi-
tion). Control circuit [B] generated from DA valve (3)
is routed to right chamber [F] of the displacement
angle piston.
Consequently, hydraulic pressure in proportion to
control circuit [B] pressure acts on displacement an-
gle piston 14. Displacement angle piston 14 moves
downward (as illustrated position).
Swash plate 18 is connected to displacement angle
piston 14 through slid ring 19. HST pump delivers to
the forward direction travel circuit by rotating swash
plate 18 in clockwise direction (as illustrated posi-
tion).
T4EJ-03-01-016
T3-1-12
<At Reverse Travel Operation>
When the shift lever is set to [R], solenoid valve [a]
(9) is excited and control piston 13 connected to the
solenoid valve is pushed downward (as illustrated
position). Control circuit [B] generated from DA valve
(3) is routed to left chamber [E] of the displacement
angle piston.
Consequently, hydraulic pressure in proportion to
control circuit [B] pressure acts on displacement an-
gle piston 14. Displacement angle piston 14 moves
upward (as illustrated position).
Swash plate 18 is connected to displacement angle
piston 14 through slid ring 19. HST pump delivers to
the reverse direction travel circuit by rotating swash
plate 18 in counterclockwise direction (as illustrated
position).
T4EJ-03-01-017
T3-1-13
Displacement Angle Mechanism
The displacement angle piston is connected to the
swash plate pin.
The displacement angle piston has the built-in spring.
The built-in spring force acts on the direction of re-
turning the displacement angle piston to neutral (the
delivery flow rate is zero.).
The displacement angle piston position, namely the
pump flow rate is determined by the control pressure
change routed to the displacement angle cylinder.
The exciting solenoid and the pump delivery direction
of the direction selector valve are:
<Pressure Generating Port When Applying Current to Solenoid>

Exciting Solenoid Delivery Port Pilot Port
Solenoid (a) A (Forward Direction) x2
Solenoid (b) B (Reverse Direction) x1
T3-1-14
Control Pressure P3
sol.a sol.b
X2 X1
Pin
Spring
Displacement
Angle Piston
Swash Plate
Pin
sol.a sol.b
θ; Displacement S
Angle
q
Displacement
Drawing Delivery
P3 Control Pressure
T4EJ-03-01-018
T3-1-15
DISPLACEMENT ANGLE RETURN FORCE
AND ADVANCE
The hydraulic pressure acts on the swash plate The eccentric pin on the adjusting screw end is con-
through the piston. nected to the groove on control plate.
As the high/low-pressure shifting point of the control The advance adjustment of the control plate can be
plate is installed to the rotation direction with advanced performed according to this amount of eccentricity by
angle, the point of action on high-pressure part acting turning the adjusting screw.
on the piston is displaced from the pivot of swash
plate.
Force F acts to return the displacement angle accord-
ing to displacement ε between this pivot and the point
of action. (Displacement Angle Return Force, known
as Self Recovery Force)
θ = 2° P Advance is Small
θ = 4°
Advance is
Advance Adjusting Screw Large
θ = 6° (Adjusting Range 4±2°)
q
Swash Plate Piston
Control Plate
θ
Piston
Pivot Swash Plate Pivot
F
ε
High-Pressure Part
Swash Plate Swash Plate T4EJ-03-01-019

(Viewed from Drive Shaft)
T3-1-16
INCHING VALVE
The inching valve is the separated type to HST pump As port (P) is connected to DA pilot pressure, the pilot
and connected through the link and rod of brake. pressure becomes low by draining to the hydraulic oil
When depressing the brake pedal, the lever rotates tank. The pump displacement angle is decreased.
according to the brake pedal. By rotating the spool with
the lever, the oil passage on the spool is connected to
the oil passages of port (P) and port (T).
Brake Pedal (Right)
View A
Inching Valve
Lever
P Section BB
Use it when the vehicle speed is required to control

slowly or the machine is required to stop while in-
creasing the engine speed and the operation speed.
P3 (Control Pressure) P3 (Control Pressure)
Inching Lever Angle

is large
N (Engine Speed) N (Engine Speed)

T4EJ-03-01-020
T3-1-17
AUTOMATIC TRANSMISSION FUNCTION
The direction selector valve selects the displacement The control pressure increases and bends the spring
angle cylinder direction. The control pressure in pro- according to increasing the engine speed and changes
portion to the engine speed from DA valve is con- the pump displacement angle.
nected to the displacement angle cylinder. Therefore, as the pump delivery flow rate is changed
The control pressure is smaller than the spring force of according to the engine speed, the vehicle speed
the displacement angle piston at engine idling. The control can be performed continuously by operating
pump stops in neutral. the accelerator.
q P3 V
qmax
P3 N N
T4EJ-03-01-021
q: Pump Displacement
P3: Control Pressure
N: Engine Speed
V: Vehicle Speed
TORQUE CONTROL FUNCTION

When increasing pressure, the displacement angle When the engine speed decreases, the pump driving
return force increases and the pump displacement torque is reduced. The pump displacement angle is
angle is decreased. The approximate torque constant balanced at the point depending on the engine torque.
control is adopted.
As the setting torque is determined by the balance Namely, with engine speed slightly decreased corre-
between the control pressure and the spring force and sponding to the load increase, HST pump performs the
displacement angle return force, the setting torque is displacement angle control automatically and can use
changed according to the engine speed. the engine torque efficiently without engine stall.
When the excessive load to exceed the engine torque
is applied on the engine, the engine speed decreases
from N1 ⇒ N2.
P P P, T
N = N1
N Large
Q
N = N2
T = Const
N Small T Engine Torque
q q Q
Flow Rate
T4EJ-03-01-022
T3-1-18
COMPONENT OPERATION / HST Motor
HST MOTOR
Motor Operation
The rotation direction of drive shaft is determined by As the component force of hydraulic pressure be-
whether pressure oil is connected to port A or port B. comes the rotational force, larger the displacement
Seven pistons are installed to the cylinder block in a angle, stronger the rotational force.
circle under running HST motor. When pressure oil In addition, as larger the displacement angle, the
flows to the cylinder block, the piston pushes the more suction increases, and the speed decrease.
drive shaft to rotate. The control plate is connected to the control piston
A piston moves one stroke for one revolution to suck through the connecting rod. The displacement angle
and drain oil. is determined according to the control piston position.
The drive shaft can perform the smooth rotational
movement by operating seven pistons continuously.
FP F; Component Force of
Hydraulic Pressure FP
F θ
Drive Shaft Cylinder Block

θ; Displacement
Angle
Piston
Control Piston
qmin
Drive Shaft qmax

Connecting Rod
Cylinder Block
Control Plate
T4EJ-03-02-001
T3-2-1
CONSTANT CONTROL (HA CONTROL)
Pressure oil from each high-pressure side (A or B) Therefore, the control piston moves to the maximum
flows to the small diameter side of control piston (cyclic displacement angle (qmax). As the displacement be-
area) through the check valve. comes large, torque is large and the speed is low.
Therefore, the rotary group is pushed to the minimum When the high-pressure oil in the main circuit de-
displacement angle position. creases, the adjust spring force overcomes, the pilot
In addition, pressure oil from each high-pressure side piston is moved backward. The secondary side of
(A or B) flows to the primary side of control bushing. control bushing is routed to the hydraulic oil tank and
The secondary side of control bushing is connected to pressure oil in the large diameter side of control piston
the large diameter side of control piston. returns to the hydraulic oil tank.
When the high-pressure routed to the primary side of Thus, the displacement angle moves to the small side
control bushing overcomes the initial load of the adjust by pressure oil in the small diameter side of control
spring set by the adjusting screw, the pilot piston piston.
moves to the spring side. The oil passages of the pri-
mary side and the secondary side of control bushing
are opened. The high-pressure oil in the main circuit
flows into the large diameter side of control piston.
U B X M1
A G T T4EJ-03-02-002
T3-2-2
HA Control
4
Movement of Control Piston
(Hydraulic Pressure in Large Di- 5
ameter Side > Hydraulic Pressure
in Small Diameter Side)
A B
(Forward) (Reverse)
7
3
Movement of Pilot Piston

(Hydraulic Pressure > Spring Force) 8
B 9
A 2 10
T4EJ-03-02-003
1- Pilot Piston 5 - O-Ring 8 - O-Ring A- Control Bushing Primary Side

2- Set Screw 6 - Restriction Valve 9 - Backup Ring B- Control Bushing Secondary Side
3- Adjust Spring 7 - Check Valve 10 - O-Ring C- Control Piston Small Diameter (Cyclic) Side
4- Control Piston D- Control Piston Large Diameter Side
T3-2-3
HA Control (When Machine Stops (At Idle Opera-
tion))
As hydraulic pressure in the primary side [A] of con- Consequently, hydraulic pressure according to pres-
trol bushing is smaller than spring (3) force, pilot sure in the small diameter side [C] of control piston
piston (1) is located on the illustrated position. Pres- acts on control piston (4). Control piston (4) is held on
sure oil in the large diameter side [D] of control piston the small displacement angle side (as illustrated po-
is released to the hydraulic oil tank. sition).
T4EJ-03-02-004
T3-2-4
HA Control (At Primary Travel)
When exciting 1st-speed lock solenoid, as pilot piston Consequently, hydraulic pressure according to pres-
(1) is pushed upward forcibly, pilot piston (1) is lo- sure in the large diameter side [D] of control piston
cated on the illustrated position. Pressure in the pri- acts on control piston (4). Control piston (4) moves to
mary side [A] of control bushing is routed to the large the large displacement angle side (as illustrated po-
diameter side [D] of control piston. sition).
T4EJ-03-02-005
T3-2-5
HA Control (At Automatic Travel)
trol bushing is smaller than spring (3) force, pilot sure in the small diameter side [C] of control piston
piston (1) is located on the illustrated position. Pres- acts on control piston (4). Control piston (4) moves to
sure oil in the large diameter side [D] of control piston the small displacement angle side (as illustrated po-
is released to the hydraulic oil tank. sition).
T4EJ-03-02-006
T3-2-6
HA Control (At Maximum Traction Power)
trol bushing is larger than spring (3) force, pilot piston sure in the large diameter side [D] of control piston
(1) is located on the illustrated position. Pressure in acts on control piston (4). Control piston (4) moves to
the primary side [A] of control bushing is routed to the the large displacement angle side (as illustrated po-
large diameter side [D] of control piston. sition).
T4EJ-03-02-007
T3-2-7
(Blank)
T3-2-8
COMPONENT OPERATION / Axle
AXLE
The axle consists of the axle tube, the differential as-
sembly, the final drive assembly (final reduction gear)
and the drive shaft. The wheels are installed to the
drive shaft.
Power from the reduction gear is transmitted to the
front axle and the rear axle via the propeller shaft.
Inside the axle, power is transmitted to the differential
assembly, divided into right and left, and transmitted to
the final drive assembly (final reduction gear) through
the drive shaft to drive the axle shaft and the wheels.
The front axle is directly secured to the front frame with
the bolts.
The rear axle adopts the cradle pin support type, which
supports the front and rear of the rear axle to the rear
frame by the axle support.
Therefore, the rear axle oscillates around the front and
rear cradle pins according to unevenness on the road.
Rear Axle
Front Axle
T4EJ-03-03-001
T3-3-1
DIFFERENTIAL ASSEMBLY
The differential assembly consists of the reduction
gear device and the actuator as one unit.
The differential assembly changes the direction of

power through the propeller shaft at right angle by us-
ing the drive pinion and the ring gear. In addition, the
differential assembly reduces the gear speed and
transmits to the drive shaft.
Operation of Differential
When traveling straight, the pinion gear in the differ-
ential case does not rotate and the ring gear, the dif-
ferential case and the side gear solidly rotate. The
same speed powers from the right and left gears are
transmitted to the wheels through the axle shaft re-
spectively.
When changing the machine direction (turning ma-
chine) and traveling on the unevenness road, as the
right and left wheels speed are different, the pinion
gear in the differential case rotates according to the
difference between the right and left side gears
speed in order to travel smoothly.
2 1
Speed is High Speed is Low
5
7
6
T4EJ-03-03-002
When Traveling Straight When Traveling On Curve
1 - Pinion Gear 3 - Drive Shaft 5 - Spider 7 - Ring Gear

2 - Side Gear 4 - Differential Case 6 - Drive Pinion
T3-3-2
FINAL DRIVE ASSEMBLY
The final drive assembly (final reduction gear) is the
device finally to reduce the speed in the power trans-
mitted from the differential assembly, and adopts a
planetary gear type.
Operation of Planetary Gear Device

As for power transmission, power from the differential
assembly, is transmitted from the shaft, rotates three
planetary gears in the ring gear, and transmits rota-
tion of the planetary gear to the axle shaft through the
planet carrier with the drive power increased.
A
8 7 6 5 4 3 2
To Wheel 3 4
6 A
1
Flow of Power
5
10
5
Section AA 10
(Operation of Planetary Gear)
T4EJ-03-03-003
1 - Drive Pinion 4 - Planet Shaft 7 - Planet Carrier 9 - Ball

2 - Differential 5 - Planet Gear 8 - Drive Shaft 10 - Needle Bearing
3 - Gear and Shaft 6 - Ring Gear (Stationary)
T3-3-3
(Blank)
T3-3-4
COMPONENT OPERATION / Brake
SERVICE BRAKE
When Brake is Applied
1. When depressing brake pedal (1) (either right or 3. Therefore, service brake piston (6) moves and
left), HST pump inching valve (2) operates at first. pushes brake disk (7) to generate the brake force.
The braking force is generated as well as the 4. In addition, brake light switch (8) is turned ON and
drive force stops in order to stop the oil feed from the stop light lights.
HST pump.(HST Brake Function)
2. In addition, push rod (3) operates and the piston
in master cylinder (4) is pushed. Pressure oil
generated from the piston is sent to service brake
cylinder chamber (5) in the reduction gear.
Depressing
Brake Oil ON
Tank
Reduction Gear
Parking Brake
Solenoid Valve
7 6 5 Parking Brake Piston T4EJ-03-04-001
T3-4-1
In Release of Brake
1. When releasing brake pedal (1) (either right or
left), push rod (3) in master cylinder (4) is pulled
out in initial conditions. Brake oil in service brake
cylinder chamber (5) in the reduction gear is re-
turned to the master cylinder.
2. Service brake piston (6) is free and brake disk (7)
is released.
3. In addition, HST pump inching valve (2) lever is
returned to the original position. The inching (HST
brake function) is released.
4. Brake light switch (8) is turned OFF and the stop
light goes off.
Release
1
Brake Oil ON
Tank
Reduction Gear
Parking Brake
Solenoid Valve
7 6 5 Parking Brake Piston

T4EJ-03-04-002
T3-4-2
(Blank)
T3-4-3
PARKING BRAKE
The parking brake uses the wet type disc brake of the Operation of Parking Brake
service brake combinedly and consists of the HST 1. When pushing parking brake switch (9) by hand
charge hydraulic circuit as hydraulic source and the to turn ON, hydraulic oil in parking brake cylinder
electrical circuit such as the parking brake switch and chamber (11) is drained by parking brake solenoid
the parking brake solenoid valves. valve (10).
In order to operate the parking brake, operate the 2. Parking brake piston (12) moves to the left by
parking brake switch on the right side of the meter spring force (13). Service brake piston (6) is
panel. pushed and wet type disc brake (7) operates.
HST Charge Hydraulic Pressure
Parking Brake Operation
Reduction Gear
T4EJ-03-04-003
7 6 12 11 13 10
T3-4-4
Unlock
1. When pushing parking brake switch (9) by hand
to turn OFF, HST charge hydraulic pressure in
parking brake cylinder chamber (11) acts on
parking brake piston (12).
2. Parking brake piston (12) overcomes spring force
(13) and moves to the right. Service brake piston
(6) is free and wet type disc brake (7) is released.
HST Charge Hydraulic

Pressure
Parking Brake Release
OFF
Reduction Gear 9
T4EJ-03-04-004
7 6 11 12 13 10
T3-4-5
TOWING MACHINE METHOD
(IN EMERGENCY)
Manual Release Method of Parking Brake
As the parking brake release is performed with hy-
draulic pressure, even if the parking brake switch is
turned to the OFF position, the parking brake is not
released.
When towing the machine with the engine stopped,

forcibly release (manual) the parking brake.
CAUTION: Do not tow with the parking brake

forcibly released (manual) except for emer-
gency.
A
1. Remove bolt (1) (releasing bolt M10×L55)
2. Remove plug (2).
3. Tighten bolt (1) into the port A removed plug (2).
1 2
The parking brake piston is pulled back and parking Parking Brake Piston
brake is released in order to move the machine.
• Discontinuity of HST Pump Hydraulic Circuit

Loosen the relief valves (2 places) three times.
Short the circuit between high-pressure side and
low-pressure side.
CAUTION: Do not loosen the relief valves (2

places) three times or more in order to pre- T4EJ-03-04-005
vent oil leaks. Relief Valve
T3-4-6
WET TYPE BRAKE ASSEMBLY IN RE-
DUCTION GEAR
Reduction gear provides the wet type disc brake in-
stalled to the input shaft and uses the service brake
and the parking brake combinedly.
Pressure oil passes into seal retainer (7) with natural

lubrication mechanism in the wet type brake through
oil hole (A). This mechanism is to lubricate pressure oil
in the reduction gear to the brake part by using splash
lubrication.
Air Bleeder
(For Bleeding Brake Air)
B
From Parking Brake

From Master Cylinder Solenoid
12 8 7 6 5 4 3 9 10 2 13 11 1
T4EJ-03-04-006
1- Cap 5 - Brake Plate 8 - End Plate 11 - Spring

2- Piston Housing 6 - Brake Housing 9 - Service Brake Piston 12 - Input Shaft
3- Wave Spring 7 - Seal Retainer 10 - Disc Hub 13 - Parking Brake Piston
4- Brake Disc
T3-4-7
MASTER CYLINDER
The master cylinder is operated by operating the brake
pedal and supplies the pressurized brake oil to the wet
type disc brake in the reduction gear.
WARNING: Use the specified mineral brake

oil for the brake oil tank in the master cylinder.
Do not use non-mineral (plant system) oil for
automobiles.
Brake in Reduction Gear
From Brake Pedal
T4EJ-03-04-007
7 5 3 2 4 1
1 - Cylinder 3 - S Cup 5 - Snap Spring 7 - Rod

2 - Piston Assembly 4 - P Cup 6 - Bleeder Valve
T3-4-8
COMPONENT OPERATION / Orbitroll
POWER STEERING (ORBITROLL)
The selection of the oil passage is performed with the The orbitroll consists of the control valve and the rotor
orbitroll by operating (rotating by hand) the steering set. The control valve uses the rotary type valve to
wheel. This hydraulic pressure allows the steering perform the selection of the oil passage by rotation.
operation easily. The control valve performs the selection of the oil
passage to the steering cylinder.
The rotor set is installed under the control valve and
performs the metering function as an oil motor at
normal operation. The machine can be manually
steered as the hand pump in emergency.
P Port 8 To LS Check EF Port

A
R Port C
C
T Port
L Port
A 7
6 5 4 3 2 1 10
9 Section A-A
Section C-C
Main Relief Part
1 3 LS Check Part
10
9 8
T4EJ-03-05-001
1 - Rotor 4 - Spool 7 - Center Ring Spring 9 - Relief Valve

2 - Drive 5 - Pin 8 - Spool 10 - LS Check Valve
3 - Sleeve 6 - Housing
T3-5-1
When rotating the steering wheel, spool (4) is turned
through the steering shaft. The relative displacement
angle between spool (4) and sleeve (3) arises and the
selection of the oil passage is performed.
Pressure oil is sent to the steering cylinder through
rotor (1). Sleeve (3) is turned by rotor (1) rotation
through drive (2) and pin (5).
When sleeve (3) rotates according to spool (4) rotation,
sleeve (3) closes the oil passage and stops.
When the steering wheel (spool) rotates, then sleeve
(3) rotates in equal amount of rotation. By performing
this operation continuously, the steering operation is
performed.
Emergency Operation
When pressure oil is not supplied due to the faulty
pump or the engine stop, the orbitroll provides the
emergency steering functions in order to operate the
steering.
NOTE: Unlike normal operation, the steering wheel
operation becomes considerably heavy in
emergency operation.
• VP (Priority) Valve
VP valve is the priority valve built in the orbitroll and
composes the load sensing system combining with
the orbitroll. VP valve divides hydraulic oil delivered
from main pump into the steering device and the
shovel device. In addition, VP valve provides the
relief valve in steering hydraulic circuit.
Section F-F
Check Valve F
To LS Check
EF Port
F
P Port To Main Relief To LS Check
T4EJ-03-05-002
• Load Sensing System • Dynamic Signal System

When the steering wheel is in neutral or in relief, This load sensing system uses the dynamic signal
almost all of total delivery flow from main pump is system built in LS line check system and CF line
sent to the shovel device. check valve in order to prevent the handle kick
When the steering wheel is turned, the flow rate phenomenon.
according to the steering wheel rotation is sent to
the steering device. The redundant oil is sent to the
work device.
T3-5-2
(Blank)
T3-5-3
OPERATION IN NEUTRAL
Delivery pressure oil from the main pump is sent to At this time, the priority valve spool moves to the right
port P. according to the balanced force between the orifice
Pressure oil flows from spool (8) via spool (4) through force and the control spring. Almost all of pump
the check valve and returns from tank port T to the delivery flow rate flows to port EF.
hydraulic oil tank through the return filter.
Power Steering
(Orbitroll)
Steering
Cylinder
17.2 MPa
2
(174.5 kgf/cm , R
2500 psi)
Pressure Port
T Orifice P EF
Control Spring
Main Pump
2
0.15 MPa (1.5 kgf/cm , 22 psi)
To Control Valve
Port P
10 μ
0.05 MPa
2
(0.5 kgf/cm , 7.3 psi)
Return Filter
Hydraulic
Oil Tank
T4EJ-03-05-003
T3-5-4
AT RIGHT SWING OPERATION
When turning the steering wheel to the right, the oil At this time, the priority valve spool moves to the left
passage of the orbitroll is shifted as illustrated. according to the balanced force between the orifice
Delivery pressure oil flow from the main pump is force and the control spring. As for the movement of
divided into the passage from spool (8) to spool (4) spool (4), only flow rate according to the rotation of the
and the passage from LS check valve to spool (4). steering wheel is sent to the steering cylinder and
Then, the divided flows are combined and send to the other oil amount is sent to the control valve.
steering cylinder through rotor (1).
Steering
Cylinder
17.2 MPa
2
(174.5 kgf/cm , R
2500 psi)
Pressure Port
T Power Steering P EF
(Orbitroll)
Main Pump
2
0.15 MPa (1.5 kgf/cm , 22 psi)
To Control Valve
Port P
10 μ
Return Filter
Hydraulic
Oil Tank
T4EJ-03-05-004
T3-5-5
AT RELIEF VALVE OPERATION
When the steering cylinder reaches the stroke end or
relief valve (9) set pressure, in addition, trying the
steering wheel to turn, relief valve (9) operates.
Delivery pressure oil from the main pump flows from
the orifice in sleeve (8) to the hydraulic oil tank through
relief valve (9).
Steering Cylinder
(Orbitroll)
Steering
Cylinder
17.2 MPa
2
(174.5 kgf/cm , R
2500 psi)
Pressure Port
T P EF
Orifice
Main Pump
2
0.15 MPa (1.5 kgf/cm , 22 psi)
To Control Valve
Port P
0.05 MPa
2
(0.5 kgf/cm , 7.3 psi)
10 μ
Return Filter
Hydraulic
Oil Tank
T4EJ-03-05-005
T3-5-6
COMPONENT OPERATION / Control Valve
CONTROL VALVE
The control valve consists of inlet section (7), lift sec-
tion (2), tilt section (3), and outlet section (1). The
control valve is 2-spool valve to operate the work de-
vice by controlling the direction and pressure of pres-
sure oil delivered from the main pump.
Relief Valve Detent Mechanism

The main relief valve is installed to this control valve. The valve detent mechanism is electromagnetic type
The main relief valve controls operation pressure and detent (auto leveler device) installed to the tilt sec-
protects the total hydraulic circuit mechanism of the tion.
work device.
In addition, the overload relief valve is installed to
both cylinder ports connected to the tilt cylinder.
When the abnormal load is applied on the cylinder
and cylinder port pressure is the adjusted pressure or
more, pressure oil is released in order to protect the
cylinder and piping.
Port A2 Port B2 Port B1 Port T
1
5
2
3
6 4
8
7
Port A1 Port P
T4EJ-03-06-001
1 - Outlet Section 5 - Overload Relief Valve (22.6±0.5 MPa) A1- Tilt Cylinder Rod Side P- Pump
2
(230±5.1 kgf/cm , 3285±72.7 psi) A2- Lift Cylinder Rod Side T- Oil Tank
2 - Lift Section 6 - Anti-Void Valve B1- Tilt Cylinder Bottom Side
3 - Tilt Section 7 - Inlet Section B2- Lilt Cylinder Bottom Side
4 - Main Relief Valve (20.6±0.5 MPa) 8 - Electromagnetic Detent
2
(210±5.1 kgf/cm , 2995±72.7 psi)
T3-6-1
OPERATION
Slide each spool and select the oil passage by oper- The electromagnetic detent mechanism is installed to
ating the control lever. Select and deliver pressure oil the tilt spool, when operating the control lever from the
from VP valve in the orbitroll to the tilt cylinder or the lift bucket dump position to the Declined Backward posi-
cylinder. tion, that position is held electrically. Even if the lever is
The detent mechanism is installed to the lift spool, released, the spool is not returned to the neutral posi-
when operating the control lever to the Float position, tion until the bucket auto leveler is operated.
that position is held mechanically. Even if the lever is In other position, when the lever is released, the spool
released, the spool is not returned to the neutral posi- is returned to the neutral position automatically.
tion.
B2
A2
D.C.12V
B1
A1
5
(DET)
22.6 MPa 22.6 MPa
2 2
(230 kgf/cm , (230 kgf/cm ,
20.6 MPa 3285 psi) 3285 psi)
2
(210 kgf/cm ,
2995 psi)
P T T4EJ-03-06-002
4 3 8 5
T3-6-2
OPERATION OF TILT SECTION
In Neutral
1. As the tilt section spool is in the neutral position,
the cylinder ports of A (rod side) and B (bottom
side) are completely closed by the spool.
2. Pressure oil to the control valve flows from the
inlet section to the tilt section and the neutral flow
passage of the lift section. Pressure oil is routed
to the low-pressure flow passage in the outlet
section and flows out from the inlet section.
1 2
B1 A1
T4EJ-03-06-003
2 3 4 2
1 - Check Valve 2 - Delivery Oil from Pump 3 - Neutral (Return) Flow Pas- 4 - Drain (Low-Pressure Re-
sage opened to Lift Section turn) Flow Passage opened
to Tank Port
T3-6-3
Declined Backward
1. When the control lever is set to the Declined
Backward position, the tilt spool moves as illus-
trated.
2. The neutral circuit is closed by the spool accord-
ing to this operation. The pressure oil pushes to
open the load check valve. The pressure oil is de-
livered to cylinder port (B 1) and sent to the tilt
cylinder bottom side.
3. In addition, hydraulic oil delivered from the tilt cyl-
inder rod side flows from cylinder port (A 1) to the
low-pressure flow passage and returns to the hy-
draulic oil tank.
1 2
B1 A1
T4EJ-03-06-004
2 3 4 2
1 - Check Valve 2 - Delivery Oil from Pump 3 - Neutral (Return) Flow 4 - Drain (Low-Pressure Re-
Passage opened to Lift turn) Flow Passage opened
Section to Tank Port
T3-6-4
Declined Forward
1. When the control lever is set to the Declined
Forward position, the tilt spool moves as illus-
trated.
2. The neutral flow passage is closed by the spool
according to this operation. The pressure oil
pushes to open the load check valve. The pres-
sure oil is delivered to cylinder port (A 1) and sent
to the tilt cylinder rod side.
3. In addition, hydraulic oil delivered from the tilt
cylinder bottom side flows from cylinder port (B 1)
to the low-pressure flow passage.
1 2
B1 A1
T4EJ-03-06-005
2 3 4 2
1 - Check Valve 2 - Delivery Oil from Pump 3 - Neutral (Return) Flow 4 - Drain (Low-Pressure Re-
Passage opened to Lift turn) Flow Passage opened
Section to Tank Port
T3-6-5
OPERATION OF LIFT SECTION AND
SPOOL
In Neutral
1. As the lift section spool is in the neutral position,
the cylinder ports of A (rod side) and B (bottom
side) are completely closed by the spool.
2. Pressure oil to the control valve flows from the
inlet section to the neutral flow passage of the lift
section. Pressure oil is routed to the low-pressure
flow passage in the outlet section and flows out
from the inlet section.
B2 1 2 A2
T4EJ-03-06-006
2 4 3 2
1 - Check Valve 2 - Delivery Oil from Pump 3 - Neutral Flow Passage 10 - Drain (Low-Pressure Re-
opened to Outlet Section turn) Flow Passage opened
to Tank Port
T3-6-6
Increase
1. When the control lever is set to the Lift position,
the lift spool moves as illustrated.
2. The neutral circuit is closed by the spool accord-
ing to this operation. The pressure oil pushes to
open the load check valve. The pressure oil is de-
livered to cylinder port (B 2) and sent to the lift
cylinder bottom side.
3. In addition, hydraulic oil delivered from the lift cyl-
inder rod side flows from cylinder port (A 2) to the
low-pressure flow passage and returns to the hy-
draulic oil tank.
1 2
B2 A2
T4EJ-03-06-007
2 4 3 2
to Tank Port
T3-6-7
Lower
1. When the control lever is set to the Lower position,
the lift spool moves as illustrated.
2. The neutral flow passage is closed by the spool
according to this operation. The pressure oil
pushes to open the load check valve. The pres-
sure oil is delivered to cylinder port (A 2) and sent
to the lift cylinder rod side.
3. In addition, hydraulic oil delivered from the lift cyl-
inder bottom side flows from cylinder port (B 2) to
the low-pressure flow passage.
1 2
B2 A2
T4EJ-03-06-008
2 4 3 2
to Tank Port
T3-6-8
Float
1. When the control lever is moved downward from
the Lower position more and set to the Float posi-
tion, the lift spool moves as illustrated.
2. The neutral circuit is opened by this operation.
Pressure oil flows similar to the neutral condition.
In addition, both cylinder ports (A 2) and (B 2) are
connected to the low-pressure flow passage.
Therefore, the lift arm operates up and down
freely according to unevenness on the road.
Pressure oil from the lift cylinder rod side freely
flows to the bottom side and pressure oil from the
lift cylinder bottom side freely flows to the rod side
respectively through the low-pressure flow pas-
sage in the control valve.
1 2
B2 A2
T4EJ-03-06-009
2 3 4 2
to Tank Port
T3-6-9
DETENT OPERATION
Lift Side
1. When pushing the control lever forward and set to 3. In order to deactivate the detent operation, pull
the Float position, lift spool (1) is pulled out fully. the control lever and detent ball (3) is removed to
In addition, detent pin (2) installed to the spool deactivate.
end moves. Detent ball (3) is dropped in the
groove on detent sleeve (4).
2. As detent ball (3) is pushed by spring (5), lift spool
(1) keeps the position and the detent operates.
1 5 2 3 4
Float
Operation of Lift Side Detent T4EJ-03-06-010
Tilt Side
1. The tilt side detent uses the electromagnetic type 3. When operating the control lever fully to the De-
detent. The electrical circuit is connected from the clined Backward position, tilt spool (1) is pushed
battery to the proximity switch of the auto leveler fully. In addition, detent pin (2) installed to the
through coil assembly (4) of the tilt section. spool end is pushed. Plate (3) makes contact with
2. When the bucket position is declined forward coil (4). The position of tilt spool (1) is held and
compared to horizontal position, the proximity the detent operates.
switch is Closed and excites coil assembly (4). 4. When deactivating the detent, set the proximity
switch to Open and degauss the coil assembly or
operate the control lever by hand in order to de-
activate.
Proximity Switch
Battery
1 2 3 4
Fuse
Declined Backward
Contact
T4EJ-03-06-011
Operation of Tilt Side Detent
T3-6-10
(Blank)
T3-6-11
RELIEF VALVE
The main relief valve (1 used) and the overload relief
valves (2 used) are used for this control valve.
The main relief valve is installed between the neutral
flow passage and the low-pressure flow passage (re-
turn flow passage). The overload relief valve is in-
stalled between both cylinder ports of overload relief
valve and tilt section and the low-pressure flow pas-
sage (return flow passage).
Main Relief Valve

The main relief valve is located on the circuit between
port P (pump side port) and port T (tank side port) in
order to prevent the loader circuit pressure from ris-
ing over the set pressure.
Pressure oil in port P acts on pilot poppet (8) through
orifice (2) in main poppet (1) and orifice (7) in sleeve
(6).
If loader circuit pressure increases over the set pres-
sure of spring (9), pilot poppet (8) is opened and a
small amount of pressure oil flows to port T through
the outer circumference of sleeve (3).
At this time, the differential pressure is developed
between port P and spring chamber (5) due to orifice
(2).When the differential pressure increases and the
force pushing main poppet (1) to the right overcomes
spring (4) force, main poppet (1) is opened so that
pressure oil in port P flows directly to port T.
When pressure in port P decreases, main poppet (1)
is closed again by spring (4) force.
1 2 3 4 6 7
5 8 9
T4EJ-03-06-012
1 - Main Poppet 4 - Spring 6 - Sleeve 8 - Pilot Poppet

2 - Orifice 5 - Spring Chamber 7 - Orifice 9 - Spring
3 - Sleeve
T3-6-12
Overload Relief Valve
The overload relief valve is located on the circuit
between the cylinder and port T (tank side port). The
overload relief valve controls pressure in the circuit in
order not to rise abnormally if the cylinder is moved
by external force and so on. Pressure in the cylinder
side acts on pilot poppet (5) through the internal
passage of poppet valve (1).
If circuit pressure increases over the set pressure of
spring (6), pilot poppet (5) is opened and a small
amount of pressure oil flows to port T through the
outer circumference of sleeve (3).When pilot poppet
opens, pressure in the chamber decreases and the
pressure difference between the cylinder side and
chamber (4) occurs.
When poppet valve (1) moves to the right due to this
pressure difference, poppet valve (2) is opened so
that pressure oil in the cylinder side flows directly to
port T.
When pressure in the cylinder side circuit becomes
negative, this overload relief valve draws the pres-
sure oil from port T (hydraulic oil tank side) and pro-
vides the cavitation prevention function (Make-up).
1 2 3 4 5 6
T4EJ-03-06-013
1 - Poppet Valve 3 - Sleeve 5 - Pilot Poppet 6 - Spring

2 - Main Poppet 4 - Chamber
T3-6-13
ANTI-VOID VALVE
When pressure in the lift cylinder rod side becomes
negative, the anti-void valve provides the function to
deliver pressure oil from the tank port to the lift cylinder
rod side directly.
LP
Operation
1. Pressure oil from cylinder port (HP) is sent into B
A
anti-void valve through the hole on poppet (1).
Poppet (1) is located on the illustrated position
due to the difference in the pressure receiving HP
area between (A) and (B).
LP
1
LP
2. When cylinder port (HP) pressure becomes lower
than tank port (LP) pressure, poppet (1) moves to B
A
the right due to the difference in the pressure re-
ceiving area between (A) and (B).
At this time, enough pressure oil flows from tank HP
port (LP) to cylinder port (HP) and prevents cavi-
tation in the cylinder.
LP T4EJ-03-06-014
1
T3-6-14
COMPONENT OPERATION / Main Pump
MAIN PUMP
Main pump is 2-spool gear pump combined the main As for the operation of the main charging pump, hy-
pump and the charging pump. draulic oil from the hydraulic oil tank is filled the space,
The charging pump is installed to HST pump through which composed of the gear teeth bottom and the
the coupling and rotates together with the engine. housing inner surface due to the suction force when
The main pump doubles as the steering pump. The the drive gear and the driven gear are meshed and
main pumps draw hydraulic oil through the hydraulic rotate together. Hydraulic oil is delivered to the outlet
oil tank and deliver to the orbitroll (VP valve). port at the restart point to mesh.
Hydraulic oil is divided into the main hydraulic circuit In addition, the main pump uses the bushing to pre-
and the steering hydraulic circuit in the orbitroll (VP vent oil leaks from the gap between the gear and the
valve). side plate. In order to increase the pump efficiency
(volumetric efficiency), route delivery pressure to this
bushing surface to balance pressure and reduce the
gap.
Driven Gear Main Pump Driven Gear

Charging Pump Bushing Bushing HST Pump
Bushing
Housing
Driven Gear Bushing Housing

Driven Gear
Bushing Driven Gear
Outlet Port Inlet Port
Bushing
T4EJ-03-07-001
Driven Gear Housing
T3-7-1
COMPONENT OPERATION / Main Pump
RETURN FILTER
Head Assembly
The return filter is provided in the return circuit of the
main hydraulic circuit, pressure oil flows through the
inlet port and is filtered in the element. Pressure oil
from the outlet port is sent to the hydraulic oil tank. IN OUT
In case the element of the return filter clogs, when inlet

port side pressure increases and the difference be-
tween inlet port side pressure and outlet port side
pressure is 0.14 MPa (1.4 kgf/cm2, 20 psi) or more, the
bypass valve is opened and pressure oil does not flow
through the element, but from the inlet port to the out-
let port directly.
As this return filter uses the cartridge type, replace the

filter cartridge assembly when replacing the element.
Filter Cartridge
T4EJ-03-07-002
T3-7-2
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Operational Performance Tests ................... T4-1-1
Preparation for Performance Tests .............. T4-1-2
Group 2 Standard
Standard....................................................... T4-2-1
Group 3 Engine Test

ACT. Eng Speed........................................... T4-3-1
Engine Compression Pressure .................... T4-3-2
Valve Clearance ........................................... T4-3-4
Nozzle .......................................................... T4-3-6
Group 4 Wheel Loader Test

Travel Speed ................................................ T4-4-1
Service Brake Control Function ................... T4-4-3
Parking Brake Control Function................... T4-4-4
Hydraulic Cylinder Cycle Time ..................... T4-4-6
Hydraulic Cylinder Drift Check ..................... T4-4-8
Control Lever Operating Force .................... T4-4-9
Control Lever Stroke .................................. T4-4-10
Main Relief Set Pressure ........................... T4-4-11
Steering Relief Pressure ............................ T4-4-12
DA Control Pressure in HST Pump............ T4-4-13
Low Relief Pressure in HST Pump ............ T4-4-13
High Relief Pressure in HST Pump ........... T4-4-14
4EJT-4-1
(Blank)
4EJT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 50 m (164 ft), and to oper-
ate steering.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. T105-06-01-003
Pay special attention to this when removing hy-

draulic pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
The performance standard values are listed in the table below.
PERFORMANCE TEST DESIGNATION Unit Performance Standard Remark
ACT. ENG SPEED
Slow Idle Speed (No-load) min-1 1050 to 1200
-1
Fast Idle Speed (No-load) min 2600 to 2735
Engine Compression Pressure MPa 2.8 to 3.2
(after the engine warming-up) (kgf/cm2, psi) (29 to 33, 407 to 465)
Valve Clearance (IN, EX) mm 0.145 to 0.185 With Engine Cold
13.7 to 14.7
MPa
Nozzle Injection Pressure (140 to 150,
(kgf/cm2, psi)
1990 to 2140)
TRAVEL SPEED
Fast Speed km/h 15 to 16
Slow Speed km/h 8.2±0.5
Service Brake Control Function m 1.5
Parking Brake Control Function mm/5 min 0
Hydraulic Cylinder Cycle Time
Lift Arm Raise sec 4.6±0.5
Lift Arm Lower sec 3.2±0.3
Lift Arm Float sec 3.2
Bucket Roll-In sec 1.3±0.3
Bucket Roll-Out sec 1.0±0.3
Right Steering
sec 3.6/1.1 or less
(Engine Slow Speed/Engine Fast Speed)
Left Steering
sec 2.7/0.9 or less
(Engine Slow Speed/Engine Fast Speed)
DIG FUNCTION DRIFT CHECK
Lift Arm Cylinder mm 6 or less Rod Retraction
Bucket Cylinder mm 11 or less Rod Retraction
CONTROL LEVER OPERATING FORCE
Lift Arm Lever (Raise) N (kgf, lbf) 24.5 (2.5, 5.5) or less
Lift Arm Lever (Lower) N (kgf, lbf) 24.5 (2.5, 5.5) or less
44.1/17.7
Lift Arm Lever (Lower Float/Float Release) N (kgf, lbf)
(4.5, 9.9/1.8, 4) or less
Bucket Lever (Roll-In) N (kgf, lbf) 24.5 (2.5, 5.5) or less
Bucket Lever (Roll-Out) N (kgf, lbf) 24.5 (2.5, 5.5) or less
FNR lever N (kgf, lbf) 9.8 (1, 22) or less
Accelerator Pedal N (kgf, lbf) 98 (10, 22) or less
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
PERFORMANCE TEST DESIGNATION Unit Performance Standard Remark

CONTROL LEVER STROKE
Lift Arm Lever mm 70
Lift Arm Lever (Float) mm 110
Bucket Lever mm 60
FNR Lever mm 40
Accelerator Pedal deg 51 to 37
Service Brake Pedal deg 55 or less
Steering Wheel (Right Speed/ENG_MAX) rev 4.5 End to End
Steering Wheel (Left Speed/ENG_MAX) rev 3.4 End to End
MAIN RELIEF SET PRESSURE
At Lift Arm Relief Operation MPa (kgf/cm2) 20.6±1.0 (210±10)
2
Relief Operation for Bucket MPa (kgf/cm ) 20.6±1.0 (210±10)
2
Steering Relief Pressure MPa (kgf/cm ) 17.2±1.0 (175±10)
HST PUMP RELIEF PRESSURE
High Relief Pressure MPa (kgf/cm2) 39±2.1 (398±21)
2
Low Relief Pressure MPa (kgf/cm ) 2.5 (25.5)
T4-2-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ACT. ENG SPEED
Summary 1 2
1. Measure the engine speed.
NOTE: If the engine speed is out of specification,

all other measured performance data will
also be out of specification. Therefore,
measure the engine speed before per-
forming all other tests in order to check that
the engine speed meets specification.
Preparations
1. Install rotary pickup (1) to injection pipe (2).
2. Warm up the machine until coolant temperature
reaches 50 °C (122 °F) or more, and hydraulic oil
temperature is 50±5 °C (122±9 °F) or more.
NOTE: When the slow idle speed (low idle) is set, 3 5

confirm that governor lever (4) touches
slow idle stopper bolt (3). When the fast
idle speed (high idle) is set, confirm that
governor lever (4) touches slow idle stop-
per bolt (5).
Measurement 4 T4EJ-04-03-001
1. Measure the slow idle speed and the fast idle

speed at no load.
2. Start the engine, set the parking brake switch to
the ON position and FNR lever to the Neutral po-
sition.
3. Measure the engine speeds while operating the
accelerator pedal.
4. Repeat the measurement three times. Calculate
the average values.
FNR Lever
Evaluation Parking Brake

Refer to OPERATIONAL PERFORMANCE TEST / Switch
Standard.
T4EJ-04-03-002
Remedy
Refer to Troubleshooting.
T4-3-1
ENGINE COMPRESSION PRESSURE
Summary
1. Measure compression pressure in each cylinder
to check for a decline in engine power.
2. Check the exhaust gas color. Keep track of en-
gine oil consumption.
3. Check for any abnormalities in the intake system
including the air filter.
Preparations
1. Check that the valve clearances are correct.
2. Charge the battery.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Remove all the glow plugs of each cylinder.
5. Securely install pressure gauge the glow plug
mounting part in order to prevent air leakage.
Measurement T4EJ-04-03-003
1. Turn the starter and measure compression pres-

sure for each cylinder.
2. Repeat the measurement three times and calcu-
late the mean values.
Evaluation
Refer to OPERATIONAL PERFORMANCE TEST /
Standard.
Remedy
T4-3-2
(Blank)
T4-3-3
VALVE CLEARANCE
Summary
1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparations
1. Locate the top dead center (TDC).
2. Align 1TC Mark on the flywheel with Punch Mark
on the rear end plate. The piston No.1 is located
at the TDC. Housing
3. Remove the head cover.
4. When both intake and exhaust valve are closed,
the piston No.1 is positioned at TDC in the com-
pression stroke. Start measurement from the cyl-
inder No.1 positioned at TDC in the compression
stroke.
1TC Mark and
Punch Mark
Flywheel
T4EJ-04-03-004
Measurement
1. Insert a thickness gauge into the clearance be-
tween rocker arm and valve stem and measure
the valve clearance.
Adjusting Screw
NOTE: The cylinders are aligned from No.1 to Lock Nut

No.3 in that order, as viewed from the fan
side. Rocker Arm
Thickness Gauge
2. When measurement is started from cylinder No.1,
perform the same measurement for all the valves
marked with "z" in the following table. When
starting measurement from cylinder No.3, perform
Valve Stem
measurement in the valves marked with "|" in
T4EJ-04-03-005
the table below.
T4-3-4
Cylinder No. No.1 No.2 No.3

Valve locations In. Ex. In. Ex. In. Ex.
Cylinder No.1 at TDC z z z z
Cylinder No.1 at Overlap | |
Injection order: 1-2-3
3. Rotate the crankshaft 360°. Align the TC mark

with the pointer. Continue measurement of other
valves in the same way.
Evaluation
Standard.
Adjustment
Adjusting Screw
If the measurement results are out of specification,
adjust the valve clearance in the same order of the Lock Nut
measurement.
Rocker Arm
1. Loosen the lock nut of the adjusting screw on the
Thickness Gauge
rocker arm. Adjust adjusting screw (A) with the
specified thickness gauge inserted.
2. After adjustment, tighten the lock nut. Check the
valve clearance after the lock nuts are tightened.
Valve Stem
T4EJ-04-03-005
T4-3-5
NOZZLE
Summary
1. Check the injection pressure and the spray
pat-tern by using a nozzle tester.
2. Before starting any work, clean the mounting part
for nozzle holder in order to avoid contamination
in the engine.
Preparations
1. Removal of the nozzle holder.
Remove all nozzle holders and fuel injection pip-
ings.
2. Installation to the nozzle tester.
Install the nozzle holder, which was removed from
the engine, to the nozzle tester.
CAUTION: The fuel spray from the nozzle

may penetrate the skin and results in serious
injury. If fuel penetrates into the blood stream,
it may cause blood toxication. Do not touch
spray directly.
1. Injection starting pressure

After installing a nozzle to the nozzle tester,
strongly inject fuel several strokes. Operate the
tester at approx. 60 time strokes a minute and
read the fuel injection pressure at this time. As for
the adjustment, loosen the lock nut and perform
with the adjusting screw. When turning to the right,
pressure increases. Contrary when turning to the
left, pressure decreases.
2. Spray pattern
After installing a nozzle to the nozzle tester,
strongly inject fuel several strokes and check the
fuel spray pattern. For this test, do not operate the
pressure gauge in principle.
IMPORTANT: Use clean diesel oil.
T4-3-6
Evaluation
1. Standard injection starting pressure.
Refer to OPERATIONAL PERFORMANCE TEST
/ Standard
Normal
2. Spray pattern
• No relatively rough and large flying pieces in vis-
ual.
• No flying pieces laterally.
• Initial injection shall exhibit the fine intermittent
injection.
• No after-dripping after injection.
• Injection angle shall be normal.
T4EJ-04-03-007
Incorrect
T4EJ-04-03-008
Adjustment
• As for the adjustment of injection starting
pres-sure, loosen the lock nut and perform with
the adjusting screw. When turning to the right,
pres-sure increases. Contrary when turning to the
left, pressure decreases.
• Tighten the lock nut after adjustment.
T4EJ-04-03-009
T4-3-7
(Blank)
T4-3-8
OPERATIONAL PERFORMANCE TEST / Wheel Loader Test
TRAVEL SPEED
Summary
In order to check the performance of travel device
systems (from HST pump to HST motor), measure
the time required for the excavator to travel a test
track.
Preparations
1. Adjust pressure of all tires equally.
Standard air pressure: 200 kPa (2.0 kgf/cm2, 29

psi)
2. Prepare a flat and solid test track 20 m (66 ft) long

or more, with extra length on both ends of the test
track for machine acceleration and deceleration. T4EJ-04-04-001
3. Empty the bucket, and hold the lift arm where the 40 cm (16 in)
bucket is floated at 0.4 m (16 in) above the
ground.
4. Keep hydraulic oil temperature at 50±5 °C
(122±9 °F).
5. Warm the axle oil and the reduction oil suffi-
ciently.
Acceleration Zone Travel Test Distance Acceleration Zone
End Start
T4EJ-04-04-002
T4-4-1
Measurement
CAUTION: Do not measure travel speed
when traveling in reverse.
1. Measure travel time at both fast and slow travel

speeds.
2. Shift the FNR lever to forward, depress the ac-
celerator pedal to full stroke and travel the ma-
chine from the acceleration zone.
3. Measure the time (second) necessary for travel-
ing 20 m (66 ft) in each mode.
the average values.
5. Convert the measured values to km/h.
Measured value (second) = S (sec)
Converted value (km per hour) = A (km/h)
A = (20 × 3600)/(S × 1000)
Evaluation
Standard.
Remedy
T4-4-2
SERVICE BRAKE CONTROL FUNCTION
Summary Measurement
1. The overall performance of the service brake is
CAUTION: Do not measure travel speed
judged.
2. Carry out the performance test of brake certainly. when traveling in reverse.
1. Measure travel speed in fast idle.

Preparations 2. Shift the FNR lever to forward, depress the ac-
1. Adjust pressure of all tires equally. celerator pedal to full stroke and travel the ma-
chine at 15 km/h from the acceleration zone.
Standard air pressure: 200 kPa (2.0 kgf/cm2 29 3. Depress the right (service) brake pedal at the
psi) brake start position and stop the machine com-
pletely.
2. Prepare a dry and paved test track 50 m (164 ft) 4. Measure the distance from the brake start posi-
long. Determine the brake start position. tion to the tread of a front tire.
3. Empty the bucket, and hold the bucket floated at 5. Repeat the measurement three times. Calculate
0.4 m (16 in) above the ground. the average values.
(122±9 °F).
Evaluation
Standard.
Remedy
Stop Position
Stop Distance Brake Start Position

T4EJ-04-04-002
T4-4-3
PARKING BRAKE CONTROL FUNCTION
Summary
1. Measure the parking brake function on a specified
slope (11.31 °).
2. Carry out the performance test of brake certainly.
Measurement
1. Climb the slope and turn the parking brake switch
ON.
2. Stop the engine.
3. After the machine has stopped, put a mark (white
line) on the tire and the ground surface respec-
tively.
4. After 5 minutes, measure the distance between
marks (white line) on the tire and slope.
40 cm
(16 in)
Evaluation
Standard.
T4EJ-04-04-003
T4-4-4
(Blank)
T4-4-5
HYDRAULIC CYLINDER CYCLE TIME
Summary
1. The overall performance of the cylinders drive
system (between the loader٠steering pump and
each cylinder) is judged by measuring the oper-
ating time of the cylinders for the lift, tilt and
steering.
2. The bucket must be empty.
Preparations
1. Measurement is made for the following positions.
1-1. Measurement of the lift cylinder
Lift the lift arm to the highest position.
T4EJ-04-04-004
Lift Cylinder
1-2. Measurement of the tilt cylinder

Lower the lift arm until the bucket bottom sur-
face touches the ground horizontally.
T4EJ-04-04-005
Tilt Cylinder
1-3. Measurement of the steering cylinder

Empty the bucket and set the front attachment
at the travel forward position.

(122±9 °F).
T4-4-6
Measurement
1. Measure the engine speed at fast idle (full stroke),
with the FNR lever set in the neutral “N” and the
parking brake switch turned “ON”.
2. Perform measurement operation as follows. (Cyl-
inder full stroke includes cylinder cushioning
zone.)
2-1. Measurement of the lift cylinder
Boom cylinder: Operate the lift arm lever to full
stroke. Measure the time to raise and lower the
lift arm.
In addition, set the lift arm to the highest posi-
tion. Operate the lift arm lever at the float posi-
tion. Measure the time to lower the lift arm.
2-2. Measurement of the tilt cylinder
Bucket cylinder: Operate the bucket control
lever to full stroke. Measure the time to roll in
and roll out the bucket.
3-3. Measurement of the steering cylinder
Operate the steering wheel full stroke and
measure the movement time of the steering
wheel from the right to the left end, and from the
left to the right end.

the average values.
Evaluation
Standard.
Remedy
T4-4-7
HYDRAULIC CYLINDER DRIFT CHECK
Summary
1. Measurement is made in the standard front at-
tachment configuration (standard bucket).
2. When testing the dig function drift just after cyl-
inder replacement, slowly operate each cylinder
to its stroke end in order to bleed air prior to test-
ing.
Preparations
Keep hydraulic oil temperature at 50±5°C (122±9 °F).
Measurement
1. Stop the engine.
2. After 5 minutes, measure the shrinkage of the lift
cylinder, shrinkage of the tilt cylinder, and the set-
A1→A2
tlement of the bucket bottom respectively.
the average values.
Evaluation
Standard.
A1 – A2 = Lift Cylinder Retraction T4EJ-04-04-006
Remedy
A1→A2
A1 – A2 = Tilt Cylinder Retraction T4EJ-04-04-007
T4-4-8
CONTROL LEVER OPERATING FORCE
Summary
1. Check a play and operating condition and meas-
ure the operating force of control lever.
2. Measure the operating force at the grip center of
control lever.
Preparations
Keep hydraulic oil temperature at 50±5°C (122±9 °F).
1. Stop the engine.

2. Attach a spring balance scale at the measure-
ment position of pedal. Operate the control lever
to full stroke and measure the maximum operat-
ing force.
the average values.
Evaluation
Standard.
T4-4-9
CONTROL LEVER STROKE
Summary
1. Plays and operating conditions of operating levers,
pedals and steering wheel are confirmed, and
their strokes are measured.
2. Measure the operating force at the grip center of
each control lever. As for each pedal, measure
the stroke from the center position to stopper.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparations
Keep hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement
1. Stop the engine.
2. Measure the stroke from the neutral position to
the stroke end of each lift arm, bucket and FNR
lever at the top center of the grip.
3. Measure the stroke from the neutral position to
the stroke end of the pedal at the top of the pedal.
4. Measure the number of rotations while rotating
the steering wheel from the left stroke end to the
right.
5. Measure the straight dimension.
the average values.
Evaluation
Standard.
T4-4-10
MAIN RELIEF SET PRESSURE
Summary Oil Pressure Drop
Measure the main relief pressure (the main relief (Counterclock-
valve set pressure in the control valve) in loader cir- wise)
cuit.
Oil Pressure
Rise
(Clockwise)
Preparations
1. Stop the engine.
2. Bleed air in the hydraulic oil tank. Main Relief Valve
3. Install the oil pressure gauge to the tilt cylinder
hydraulic oil outlet port.
4. Start the engine. Confirm that no oil leakage is
observed at the oil pressure gauge connection.
5. Keep hydraulic oil temperature at 50±5°C T4EJ-04-04-009
(122±9 °F).
Measurement
parking brake switch turned “ON”.
2. Slowly operate the lift arm and bucket control
levers. Operate each cylinder to the stroke end
and relieve each function. Measure the pressure
at this time.
the average values.
Evaluation
Standard.
NOTE: If the measured pressures for all functions
are lower than the specified range, the
probable cause is a decrease of main relief
valve setting pressure. If relief pressure of
a particular function is lower, the probable
cause is other than main relief valve.
Adjustment Lock Nut

Loosen a lock nut and adjust the pressure by using
an adjusting screw.
1. Loosen the lock nut.
2. Turn the adjusting screw and adjust the main re-
lief set pressure.
Tightening (clockwise): Oil pressure increases.
Loosening (counterclockwise): Oil pressure de-
creases. Adjusting
Screw
3. Tighten the lock nut.
4. After adjustment, check the set pressure by using T4EJ-04-04-010
an oil pressure gauge.
T4-4-11
STEERING RELIEF PRESSURE
Summary
Measure relief pressure in the steering circuit.
Preparations
1. Stop the engine.
2. Bleed air in the hydraulic oil tank.
3. Install the oil pressure gauge to the steering cyl-
inder hydraulic oil outlet port.
5. Keep hydraulic oil temperature at 50±5°C
(122±9 °F).
Measurement
parking brake switch turned “OFF”.
2. Turn the steering wheel to either the right or left Steering Cylinder Hydraulic
direction to the steering end. Oil Outlet Port
the average values. T4EJ-04-04-011
Evaluation
Standard.
T4-4-12
DA CONTROL PRESSURE IN HST PUMP
A
Summary
Measure DA control pressure in HST pump.
Preparations
1. Stop the engine.
2. Install the oil pressure gauge to PS port of HST
PS Port
pump. (G 1/4)
3. Install the engine tachometer to the engine.
5. Keep hydraulic oil temperature at 50±5°C
(122±9 °F).
Measurement
Measure DA control pressure according to the engine
speed.
View A T4EJ-04-04-012
Evaluation
Refer to the HST pump characteristic curve.
LOW RELIEF PRESSURE IN HST PUMP

B
Summary
Measure hydraulic pressure in the low-pressure
(charging) circuit.
Preparations
1. Stop the engine.
2. Install the oil pressure gauge to G port of HST G Port
pump. (G 1/4)
Measurement
parking brake switch turned “OFF”.
View B T4EJ-04-04-012
the average values.
Evaluation
Standard.
T4-4-13
HIGH RELIEF PRESSURE IN HST PUMP
Summary
Measure hydraulic pressure in the high-pressure cir-
cuit.
Preparations A
1. Stop the engine.
2. Install the oil pressure gauge to the HST pump
port.
Gauge Port MA: Forward
Gauge Port MB: Reverse
3. Secure the bucket against a solid wall such as
concrete in order not to move the vehicle abso-
lutely.
4. Start the engine. Confirm that no oil leakage is “Reverse” Gauge Port
observed at the oil pressure gauge connection. (MB) (G 1/4)
(122±9 °F).
Measurement
1. Set the shift lever in forward.
“Forward” Gauge Port
2. Increase the engine speed gradually to the fast View A (MA) (G 1/4)
idle (full stroke) and measure the engine speed.
3. As for the reverse, measure the engine speed in T4EJ-04-04-012
the same way.
Evaluation
Standard.
T4-4-14
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure
Introduction .............................................. T5-1-1
Diagnosing Procedure .............................. T5-1-2
Group 2 Failure List

Trouble Symptoms Regarding
the Engine .............................................. T5-2-1
Trouble Symptoms Regarding
the Vehicle Performance......................... T5-2-2
Group 3 Engine
Group 4 Vehicle Performance
4EJT-5-1
(Blank)
4EJT-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Refer to the inspection and troubleshooting proce-
dures after any machine trouble has occurred. The
inspection and troubleshooting procedures are pre-
sented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution.
The troubleshooting section in this manual consists of

5 groups; Diagnosing Procedure, Engine, Trouble-
shooting 1 (base machine diagnosis starting with in-
spection of abnormal operational status), Trouble-
shooting 2 (monitor diagnosis) and Electrical System
Inspection.
• Engine (engine diagnosis starting with inspection

of abnormal operational status)
Refer to these procedures when engine opera-
tional malfunctioning.
• Troubleshooting 1 (base machine diagnosis start-

ing with inspection of abnormal operational
status)
Refer to these procedures when machine opera-
tional malfunctioning.
• Troubleshooting 2 (monitor diagnosis)

Refer to these procedures when gauges and/or
indicators are malfunctioning.
• Electrical System Inspection

Refer to this group when required to obtain pre-
cautions and/or information for the electrical sys-
tem inspection.
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator

Before inspecting, get the full story of T4GB-05-01-001
malfunctions from the operator below.
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what

types of work the machine doing at that
time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear
suddenly for the first time?
(d) Did the machine have any other troubles

previously? If so, which parts were repaired
before?
3. Inspect the machine

Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as T4GB-05-01-002
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system
such as low battery voltage, loose connections
and blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.
T5-1-2
4. Operate the machine yourself

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed (this states
are repeated that the trouble is resolved later
altough the trouble sometimes occurs), stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of
the wire harnesses correponding to the trouble.
NOTE: It should take time to required to find the

malfunction according to the trouble during
the troubleshooting. The malfunction may
occur due to up and down of hydraulic
temperature, weather and under the
special condition including expansion by
heat and shorted harness by moisture. The
informations of weather when the
mulfunction occurs, time from the engine
start to the trouble occurrence are also
important.
5. Perform troubleshooting
CAUTION: Do not disconnect harnesses or

hydraulic lines while the engine is running.
The machine may malfunction or pressurized
oil may spout, possibly resulting in personal
injury. Stop the engine before disconnecting
harnesses or hydraulic lines.
Check operating condition of each component by

referring to this section.
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T5-1-3
(Blank)
T5-1-4
TROUBLESHOOTING / Failure List
Trouble symptoms regarding the engine
1. Starter motor is not operated.
2. Hard to start engine
3. Idle speed is unstable.
4. Engine power decreases at high loaded.
5. Dark smoke is so much in the exhaust gas.
6. Engine overheats.
7. Unusual noise is generated from engine.
8. Engine oil consumption is so much.
9. Fuel consumption is so much.
T5-2-1
TROUBLESHOOTING / Failure List
Trouble symptoms regarding the vehicle performance
A: Travel performance
1. The vehicle does not travel at all (traveling is impossible forward and reverse).
2. Traveling is impossible either forward or reverse.
3. Travel speed decreases.
4. When the work mode is normal and the travel mode is in (AUTO), the speed
cannot reach to the fast idle.
5. Travel force and towing force decrease.
6. Travel at engine low idle operation.
7. HST oil (hydraulic oil) decreases.
8. Leakage from the axle and the reduction gear.
9. Abnormal noise is generated or the traveling is impossible.
B: Brake performance
1. Brake control force decreases.
2. Parking brake is not applied.
3. Dragging of parking brake occurs.
C: Steering performance
1. Steering operation is impossible or heavy.
2. Machine mistracks.
D: Work performance
1. Lift arm is not raised or the raising time is long.
2. Cylinder drift of lift arm is large at the neutral position of control lever.
3. It is impossible to raise the front wheel by the lift cylinder.
4. The cylinder drift speed of lift arm becomes fast at the specified position.
5. When raising the lift arm, lower the lift arm before rising.
6. Bucket operation (tilt back) time is long or operation force is insufficient.
7. Normal declined forward of bucket is large when the control lever is in neutral.
8. Normal roll-out speed of bucket becomes fast at the specified position.
9. Bucket wobble occurs in traveling.
10. The operation of control lever is heavy.
T5-2-2
TROUBLESHOOTING / Engine
Trouble symptoms 1. Starter motor is not operated.
Faulty battery
Battery
Faulty battery charge
Open circuit or poor contact
Looseness or corrosion of terminal
Wirings Faulty starter switch
Faulty starter relay 2.
Faulty battery ground line
Trouble symptoms 2. Trouble symptom hard to start engine
Stuck plunger
Fuel system
Delivery valve malfunction
Injection pump Faulty control rack operation
Control pinion looseness
Faulty feed pump operation
Lack of injection
No fuel in the fuel tank
amount
Air suction in the fuel system
Water intrusion in fuel
Clogged fuel filter

Others
Fuel pipe connection looseness
Clogged fuel hose
Crack or looseness of injection pipe
Clogged breather hose in fuel tank
T5-3-1
Trouble symptoms 2. Hard to start engine
Fuel system
Incorrect of injection timing Wear of tappet, roller and cam
Injection starting pressure Faulty nozzle and nozzle holder

is too low.
Seizure in needle valve

Faulty spray pattern
Aging damage or breakage of nozzle
spring
Valve burnout
Engine unit
Seizure or wear in valve stem
Valve spring breakage

Compression pressure de- Faulty valve clearance
crease
Wear of cylinder, piston and piston ring
Sticking or breakage of piston ring
Blow-by of head gasket
Faulty engine control mechanism

Others
Faulty preheat system
T5-3-2
Trouble symptoms 3. Idle speed is unstable
Fuel system
Plunger spring breakage
Faulty control rack operation

Injection pump
Faulty governor operation
Faulty adjustment of idling spring

Injection amount
unevenness

Others
Incorrect of injection timing
Faulty spray pattern Aging damage of nozzle spring
Carbon build-up at injection tip
Injection starting pressure unevenness Faulty nozzle and nozzle holder
Compression pressure decrease

Engine Unit (Refer to the Hard to start engine)
Others Faulty engine control mechanism
T5-3-3
Trouble symptoms 4. Engine power decreases at high loaded
Fuel system
Wear or seizure in plunger

Injection pump
Faulty governor operation
Injection amount
unevenness

Others
Incorrect of injection timing Wear of tappet, roller and cam

Others
Lack of intake-air amount Clogged air cleaner
Faulty exhauster Clogged muffler
T5-3-4
Trouble symptoms 5. Dark smoke is so much in the exhaust gas
Fuel system

Unevenness or excess of injection
amount Delivery valve malfunction
Wear of tappet, roller and cam

Looseness of tappet adjust bolt
Injection starting pressure is too low. Looseness of nozzle adjust screw

Others
T5-3-5
Trouble symptoms 6. Engine overheats
Cooling system
Wear of water pump seal

Water leak
Crack of hose and piping or looseness
of clamp
Head gasket damage
Faulty water pump operation
Clogged radiator
Faulty radiator cap

Part malfunction
Faulty Thermostat
Looseness or damage of fan belt
Adhered deposit on coolant path
Excessive injection amount

Combustion system
Injection starting pressure drop
Faulty engine oil circulation

Lubrication system
Oil cooler malfunction
Carbon build-up in combustion chamber
Others Clogged muffler
Overload
T5-3-6
Trouble symptoms 7. Unusual noise is generated from engine
Injection amount unevenness
Injection starting pressure is too high.

Knocking noise
Faulty fuel ignition
Compression pressure decrease (Refer to the Hard to start engine)
Wear of cylinder and piston
Seizure or breakage of piston and piston ring
Wear of connecting rod small end bushing and piston pin
Wear or breakage of crank pin and connecting rod bearing
Hammering sound Wear or breakage of crankshaft journal and journal bearing
Excessive axial play of crankshaft and camshaft
Looseness of flywheel and crank pulley installation
Wear of tappet and cam
Excessive valve clearance
Wear or breakage of bearings of alternator and water pump
Continuously sounds Wear of timing gear or faulty contact
Looseness or damage of fan belt
T5-3-7
Trouble symptoms 8. Engine oil consumption is so much
Lubrication System
Looseness of oil filter installation or faulty O-ring
Lubrication System Looseness of oil pan installation or faulty gasket
Looseness of oil pipe connection or pipe crack
Engine Unit
Wear of cylinder liner and piston
Breakage or sticking of piston ring

Oil up
Clogged oil holes of piston and oil ring
Clogged breather pipe
Wear of valve stem and valve guide

Oil down
Faulty valve stem oil seal
Oil leaks Faulty gasket and oil seal
T5-3-8
Trouble symptoms 9. Fuel consumption is so much
Fuel system

Unevenness or excess of injection
amount Delivery valve malfunction
Wear of tappet, roller and cam

Looseness of tappet adjust bolt
Injection starting pressure is too low. Looseness of nozzle adjust screw

Others
Overheat (Refer to the Engine overheats.)
T5-3-9
(Blank)
T5-3-10
TROUBLESHOOTING / Vehicle Performance
Trouble symptoms A-1. The vehicle does not travel at all (traveling is impossible forward and reverse)
(1) Oil shortage in the hydraulic oil tank
Check for the hydraulic oil level.

1. Keep the machine horizontally.
2. Lower the bucket or the attachment onto the
ground horizontally.
3. Check that the oil level of dipstick is between the
upper limit mark and the lower limit mark.
Dipstick
Hydraulic oil Hydraulic oil amount

amount is short. is normal. Upper Limit
Repair oil leak area

and add oil.
Lower Limit
T4EJ-05-04-001
(2) Clogged suction strainer
Remove suction strainer (1) in the hydraulic oil tank.

Check for restrictions.
With restriction No restriction 1
Check HST filter element (2)

and hydraulic oil filter element 2
(3). Check for the foreign parti-
cles, which cause suction
strainer (1) restrictions.
3
Cleaning of suc- Repair of hydraulic Repair of hydraulic

tion strainer cylinders and hose pump
(Metal fragments (Nylon and rubber pieces)
included copper
powder)
T4EJ-05-04-002
T5-4-1
(3) Degradation and milk white of hydraulic oil, or

use of improper hydraulic oil.
Perform the check of hydraulic oil.

1. Check if oil is degraded and discolored to brown.
2. Check if water intrudes in oil and oil is discolored
to white.
3. Check if bubbles (air) are mixed in oil and oil is
discolored to white.
(Air is sucked from air inlet system)
4. Check if the specified hydraulic oil (especially T4EJ-05-04-003
pay attention to viscosity) is used.
(Refer to the Operator's Manual.)
Oil: Faulty Oil: Normal
Oil: Change
(4) Wear of the spline of HST pump, damage of

coupling. Check if the shovel operation and the
steering operation are operated properly.
Check for the abnormality of front attachment and

steering operation.
Not operable Operable 2
Wear of the spline of

HST pump drive shaft 1
(1), damage of coupling
(2)
Replacement of drive
shaft and coupling
T4EJ-05-04-004
T5-4-2
(5) Faulty operation and adjustment of brake (inch-

ing) pedal linkage
Confirm that the inching valve lever is in the

Close position.
Stop the engine, adjust stopper (3) so that dimension
A is 200±5 mm (7.9±0.2 in) without brake (inching)
pedal (1) operated (without depressing the pedal).
NOTE: When the pedal is not depressed, confirm

that the inching lever always returns to
the Close position.
Pedal (Metal Plate) Bottom End
Lever is not at the Lever is at the Close 1

Close position. position. A
Repair and adjustment

of linkage
90 °
“Open” “Close”
2 T4EJ-05-04-005
T5-4-3
(6) Faulty parking brake solenoid and parking brake switch (with the ma-
chine dragged)
Measure the terminal voltage of parking brake solenoid.

1. After starting the engine, operate the parking switch to RESET.
2. Check that the shift lever is locked in neutral.
3. Disconnect the connector of parking brake solenoid.
4. Operate the parking brake switch from ON to OFF and measure volt-
age.
(Machine side connector and parking brake monitor lamps go off.)
Specification: Voltage 10.95 to 14.4 V
Out of specification Within Specification
1. Faulty parking brake switch Faulty parking brake solenoid

2. Faulty relay 3
3. Poor contact of connector and
ground line
Replacement of faulty parts
Parking Brake
Monitor Lamp
Parking Brake Switch Relay (3)
Relay (4)
Forward and Reverse
(HST Pump)
Fuse Parking Brake Solenoid

Relay (1)
Alternator
B GR
Travel System Circuit (Parking Brake Switch from ON to OFF). Connector
(Machine Harness End)
T4EJ-05-04-006
T5-4-4
(7) DA control pressure drop
Measure DA control pressure in HST pump.

1. Install the oil pressure gauge to PS port (G1/4)
of HST pump.
2. Install the engine tachometer to the engine.
3. Measure DA control pressure according to Op-
erational Performance Test.
4. Refer to Specification → Characteristic curve
Out of Specification Normal.
A-1. (8) A-2. (3) PS Port (G 1/4)

Hydraulic pressure Measurement of hy-
drop of low-pressure draulic pressure in
relief valve high-pressure circuit
T4EJ-05-04-007
View
Engine Speed – HST Control Pressure

25 2.45
20 1.96
15 1.47
[kgf/cm ]
[MPa]
2
10 0.98
5 0.49
0 0.00
500 1000 1500 2000 2500 3000
-1
[min ]
T5-4-5
(8) Hydraulic pressure drop of low-pressure relief

valve
Measure hydraulic pressure in the low-pressure

(charging) circuit.
1. Install the oil pressure gauge to port G. (G 1/4)
2. Measure hydraulic pressure in the low-pressure
circuit according to Operational Performance
Test.
3. Specification
2. 5 MPa (25.5 kgf/cm2, 362.6 psi)
NOTE: Measure hydraulic oil temperature at op-

erating temperature (40 to 60 °C (104 to
140 °F)).
Out of specification Within Specification
Remove low-pressure
relief valve. Check for
the foreign object over-
lapped, damage and
sticking on the seat sur-
face.
G Port (G 1/4)
Replacement of faulty
parts
T4EJ-05-04-007
View
T5-4-6
Trouble symptoms A-2. Traveling is impossible either forward or reverse
(1) Faulty shift lever or electrical wiring.

Solenoid Valve Solenoid Valve
(Forward) (Reverse)
Measure the terminal voltage of FNR solenoid.
1. After starting the engine, operate the parking switch to RESET. Connector
2. Disconnect the connector of FNR solenoid. (Four Polarities)
3. Set the shift lever in Neutral and turn the parking brake switch OFF.
(Measure with machine side connector and parking brake monitor
lamp goes off.)
4. Operate the shift lever to the Forward position and measure voltage.
5. Operate the shift lever to the Reverse position and measure voltage.
SOL: R
Out of specification Within Specification SOL: F

Connector (HST Pump Side)
B L
Faulty solenoid on measured 1. Faulty shift lever
side 2. Faulty relay 3
B LW
3. Faulty parking brake switch
Connector
(Machine Harness End)
T4EJ-05-04-008
Parking Brake
Monitor Lamp
Parking Brake Switch Relay (3)
Parking Brake
Solenoid
Relay (4) Forward and Reverse

(HST Pump)
Fuse
Relay (1)
Alternator
Travel System Circuit (Parking Brake Switch from ON to OFF). T4EJ-05-04-009
T5-4-7
(2) Measurement of hydraulic pressure in

high-pressure circuit
Measure high-pressure circuit in HST pump.

1. Install the oil pressure gauge to gauge port MA
(Forward).
2. Measure hydraulic pressure in the high-pressure
circuit according to Operational Performance
Test.
3. As for specification, refer to Operational Per-
formance Standard.
Hydraulic pressure drop Within Specification
Faulty high-pressure HST motor check

relief valve
“Reverse” Gauge Port (MB)

(G 1/4)
View “Forward” Gauge Port (MB)

(G 1/4)
T4EJ-05-04-010
T5-4-8
(3) Faulty high-pressure relief valve
Remove and check the high-pressure relief valve.

1. Check for the abnormality (looseness and so on)
of high-pressure relief valve installation.
(If the installation is loosened, the circuit be-
tween high-pressure and low-pressure is
shorted and pressure decreases.)
2. If there is no abnormality for the installation,
remove the high-pressure relief valve. Check for
the foreign object overlapped on valve seat sur-
face (1) and valve seat surface (2).
3. Switch the forward high-pressure relief valve
and the reverse high-pressure relief valve.
Check for the change of trouble symptoms.
4. Replace the high-pressure relief valve with a
new one and check the new high-pressure relief
valve.
Abnormal Normal
Repair or replacement HST motor assembly

of high-pressure relief check
valve

(Forward) High-Pressure Circuit
Low-Pressure Circuit
2 1

High-Pressure Relief Valve T4EJ-05-04-011
(Reverse)
T5-4-9
Trouble symptoms A-3. Travel speed decreases.
Confirm travel speed

When some complaints about “No speed” are received, measure the travel speed at FNR each work mode (kept
at speed 1) first and the travel mode (AUTO). Check whether the speed is felt slow regardless of normal or the
speed is slow due to the malfunction.
Measure the travel speed according to Operational Performance Test.
Travel speeds de- Work mode: Specification Specification

crease in each mode. Travel mode: The speed
cannot reach to the fast idle.
Engine power is low Dragging of brake (service, parking) Normal
(1) Engine power shortage (poor speed)
Measure the engine fast idle speed under no load.

Measure the engine fast idle speed under no load according to Engine Performance Test / Engine speed.
Out of Specification Within Specification
Investigate the reason why the engine speed de- Measurement of shovel stroke speed
creases under no load.
1. Place the lift arm to the highest position.
1. The adjustment of control is faulty. Even if the 2. In addition, set the lever to the “Raise” position.
accelerator pedal is fully depressed, the pedal Operate the main relief valve and measure the
does not get in contact with the fast idle stopper. engine speed.
2. Clogged fuel filter and air filter 3. As for specification, refer to Operational Per-
3. Faulty fuel pump and injection nozzle formance Standard.
4. Other engine trouble
Maximum Speed Position
T4EJ-05-04-012
Dragging of brake
Engine repair (service, parking)
T5-4-10
A-4. Although the work mode is normal, the speed cannot reach to the fast idle in
Trouble symptoms
the travel mode (AUTO).
(1) Faulty mode selector switch or electrical wiring.
When changing the mode selector switch from Work

Mode to Travel Mode, confirm that the monitor lamp
is turned OFF and the Rabbit monitor lamp is turned
ON in the meter panel.
Abnormal Normal
Check or replacement Measure the terminal voltage of mode selector solenoid.

of selector switch 1. Remove connector (1) of mode selector solenoid valve.
2. Measure voltage between the terminals of connector (1) ma-
chine harness ends when setting the starter switch to the ON
position and operating the mode selector switch to Travel Mode.
3. Specification: 0 V
When the mode selector switch is normal, current flows in Work
Mode and does not flow in Travel Mode.
Energized Within Specification
Mode selection switch to Mode Faulty operation of mode selection

Faulty wiring between selection solenoid valve
solenoids
GW B
1
Machine Side Connector T4EJ-05-04-013
T5-4-11
Trouble symptoms A-5. Travel force and towing force decrease
(1) Internal leakage and stuck in HST motor system pressure control part
When there is no fault and some towing force shortage is felt after performing the preceding countermea-
sures, the motor displacement angle may not have returned from small displacement (small torque, fast
speed) to large displacement (large torque, slow speed).
Faulty HST Motor
Trouble symptoms A-6. Travel at engine low idle operation.
(1) Engine low idling speed is too high.
Measure the engine low idling speed.

Measure the engine low idling speed according to Engine Performance Test / Engine speed.
As for specification, refer to Operational Performance Standard.
1. The adjustment of accelerator linkage is faulty. Faulty bleeding air from HST circuit
Even if the accelerator pedal is returned, the and damage of AU controller
pedal does not get in contact with the slow idle
stopper in the governor.
2. Foreign objects get caught in the accelerator
pedal and the accelerator pedal is not returned
completely.
3. Rust and stuck of accelerator linkage.
Slow Idle Stopper
T4EJ-05-04-014
T5-4-12
Trouble symptoms A-6. Travel at engine low idle operation.
(2) Faulty bleeding air from HST circuit and damage of AU controller
1. When the machine travels with the shift lever set in the Neutral position, perform the check of hydraulic
oil. (Especially pay attention to viscosity)
2. After the engine starts, when the machine travels with the shift lever set in the Neutral position for a
moment, bleed air from HST circuit.
Cause of trapping air is replacement of hydraulic oil filter or element, repair of motor or residual air
when replacing HST piping or hose. If any cause cannot be found, as air may be sucked from the
loosened part of HST piping and hose, check and retighten the hose and piping
3. When the machine travels with the shift lever set in the Neutral position regardless of bleeding air, it can
be presumed that this trouble occurs due to damage of AU controller and faulty neutral controller.→
Faulty HST pump
Trouble symptoms A-7. HST oil (hydraulic oil) decreases.
(1) Faulty rear oil seal of HST motor or internal leakage in parking brake
When oil in the hydraulic oil tank decreases, oil in the reduction gear increases and oil blowoff from the
breather is found, hydraulic oil may flow in the reduction gear due to faulty oil seal of HST motor or the in-
ternal leak of hydraulic oil through the parking brake control system may occur due to the damage of parking
brake piston in the reduction gear.
CAUTION: If operating with hydraulic oil shorted, immediately repair it as a serious accident
may occur to HST pump or motor such as seizure or stuck.
T5-4-13
Trouble symptoms A-8. Leakage from the axle and the reduction gear
(1) Oil leaks from tightening nut (2) on drive pinion (1) of the front axle
Looseness between drive pinion (1) and the Faulty O-ring (4) on the spline part.
spline part of input flange (3). Faulty O-ring (4) in
the spline part
Remove tightening nut (2) and turn input flange (3) by hand. Check for looseness of the spline part
With looseness No looseness
Replacement of drive pinion Replacement of O-ring (4)

(1) or input flange (3)
2
4
3
T4EJ-05-04-015
T5-4-14
(2) Oil leaks from the oil seal of front axle / input flange (3)
Faulty oil seal (5) or wear of the seal sliding sur- Wear and damage of bearings (6), (7)
face of input flange (3)
Turn input flange (3) by hand. Check for looseness of the flange
Replacement of bearings (6), Replacement of oil seal (5) or

(7) input flange (3)
5
6
T4EJ-05-04-016
7
T5-4-15
(3) Oil leaks from oil seal (1) of wheel hub
Faulty oil seal (1) Wear and damage of bearings (3), (4)
Remove the wheel and move the flange of driveshaft (2) by hand. Check for looseness of axial direction and
periphery direction
Replacement of bearings (3), Replacement of oil seal (1)

(4)
3
1
T4EJ-05-04-017
T5-4-16
(4) Oil leaks from output flange (1) tightening nut (2) of the reduction gear box
Looseness between shaft (3) and the spline part Faulty O-ring (4) in the spline part
of output flange (1).
Remove tightening nut (2) and turn output flange (1) by hand. Check for looseness of the spline part
Replacement of shaft (3) or Replacement of O-ring (4)

output flange (1)
1 2 4 3
T4EJ-05-04-018
T5-4-17
(5) Oil leaks from oil seals (6), (7) of output flanges (1), (5)
Faulty oil seal (6), (7) or wear of the seal sliding Wear and damage of bearings (3), (4)
surface of input flange (1), (5)
Turn output flange (1) or (5) by hand. Check for looseness of the spline part.
Replacement of bearings (8), Replacement of oil seals (6),

(9) (7) or output flanges (1), (5)
1 6 8 9 7 5
T4EJ-05-04-018
T5-4-18
Trouble symptoms A-9. Abnormal noise is generated or the traveling is impossible
(1) Shortage or degradation and deterioration of oil in the axle housing
Remove level plug (1) in the axle housing. Check oil amount. In addition, remove drain plug (2). Check for
any abnormality such as oil dirt, milk white (water intrusion) or viscosity of sample oil.
Abnormal Normal
Add oil to the specified level or change oil

(As for the specified oil, refer to Operator's Manual)
1 2 T4EJ-05-04-019
T5-4-19
(2) Shortage or degradation and deterioration of oil in the reduction gear box
Remove level plug (1) in the reduction gear. Check oil amount. In addition, remove drain plug (2). Check for
any abnormality such as oil dirt, milk white (water intrusion) or viscosity of sample oil.
Shortage of oil amount Excess of oil amount Normal

Degradation and deterioration
Add oil to the specified level or Check oil amount. When oil
change oil amount is excessive, remove
(As for the specified oil, refer to drain plug (2) and drain oil to
Operator's Manual) the specified level.
Then, operate the machine
and check oil amount.
Excess of oil amount

1 2 T4EJ-05-04-020
Hydraulic oil gets mixed in with oil in the reduction gear box due to faulty
rear oil seal (3) of HST motor or faulty O-ring (4) of the brake piston.
When operating with the rear oil seal of HST motor faulted, immediately repair it as a serious accident may
occur, such as seizure or stuck of HST pump or HST motor, dragging of brake, seizure of brake disc and
wear-out at early stage of brake disc due to hydraulic oil shortage.
3 4
T4EJ-05-04-021
T5-4-20
Faulty mounting angle of propeller shaft Looseness of spline part (2) of the propeller
shaft is wear and damage of universal joint (1).
Check that the mounting angle of universal Remove the propeller shaft assembly. Check
joint (1) is normal in visual. for looseness of spline part (2) or wear and
damage of universal joint (1).
Faulty mounting angle
Repair of mounting angle Replacement of faulty parts
Front Axle to Reduction
Reduction to Rear Axle T4EJ-05-04-022
T5-4-21
Wear and damage of axle inner parts Wear and damage of reduction gear box inner
parts
Drain and recover oil. Check for foreign objects (fragments and metal powder from gear and bearings).
With foreign object
Replacement of defect parts
When the generating area (front, rear axle or reduction gear box) of unusual noise is unplaceable, identify the
generating area by using the following methods.
1. Raise the machine and hold the machine by using a stand.

2. Remove propeller shaft (1) (reduction gear box to front axle) and operate only the rear wheels.
If unusual noise stops, it can be determined that trouble occurs in the front axle.
3. If unusual noise does not stop in paragraph 2, install propeller shaft (1). Remove propeller shaft (2) (reduc-
tion gear box to rear axle) and operate only the front wheels
If unusual noise stops, it can be determined that trouble occurs in the rear axle.
Rear Axle
Front Axle
Reduction Gear Box
T4EJ-05-04-023
T5-4-22
Trouble symptoms B-1. Brake control force decreases
(1) Leakage from the brake piping
Check oil amount in the brake oil tank. If oil level is low, check for oil leaks from the master cylinder and
brake piping.
Brake oil shortage Normal
Oil leaks to the exterior is Oil leaks to the exterior is not

found. found.
Repair of oil leaks Add brake oil to specification. Mixing air in brake system
Add brake oil
Operate the service brake. Check oil amount in the brake oil tank.
Oil decrease Oil amount is normal.
Oil leaks in the reduction.
2 1 3
When there is no brake oil leaks to the exterior
completely and brake oil decreases at short
times, oil leaks may occur in the reduction.
1. Wear and damage of O-ring (1) of the brake
piston and O-ring (2), (3) of the parking brake
piston.
2. Wear and damage of piston sliding surface
Replacement of O-ring and faulty parts
T4EJ-05-04-024
T5-4-23
(2) Mixing air in brake system
Depress brake pedal and check for Sponge State.
With Sponge State No Sponge State
Bleeding Air
(3) Faulty master cylinder
Check if the pedal can be stopped with the brake pedal depressed.
When oil leaks occurs in the master cylinder, the brake pedal does not stop and get into the endmost al-
though the brake pedal is firmly depressed.
Causes of oil leaks in the master cylinder are:
1. Wear and damage of cup (1)
2. Wear and damage of cylinder inner surface
CAUTION: In case of faulty cup (2), oil leaks to the exterior may occur.
T4EJ-05-04-025
With internal oil leaks No internal oil leaks
Repair or replacement of master cylinder
T5-4-24
(4) Unusual noise is generated when brake is applied.
Degradation of brake oil and reduction oil and use of improper hydraulic oil
Check for brake oil and reduction oil.
As the brake of this machine is built-in wet type, when using degraded oil or other than the specified (dif-
ferent viscosity) oil for the brake circuit and reduction, possibly causing decrease of brake control force,
unusual noise generation and abnormal wear.
Degradation oil, water intrusion There is a burned smell from Normal

and use other than specified oil reduction oil.
Change oil
(5) Wear and damage of brake disc and brake plate
Wear and damage of brake disc (1), brake plate (2), damage of brake piston sliding part, and the allowable
limit of brake disc (1) and brake piston (2)
2 1
T4EJ-05-04-026
No. Item Specification Allowable limit

1 Brake Disc 2.25 mm (0.09 in) 1.9 mm (0.08)
2 Brake Plate 1.6 mm (0.06 in) 1.4 mm (0.06)
NOTE: When abnormality and wear-out at early stage of brake disc (1) and brake plate (2), the dragging of
brake may occur.
T5-4-25
Trouble symptoms B-2. Parking brake is not applied
(1) Parking brake is not applied in both cases the engine stops and the engine operates.
Wear and damage of brake disc (1) and brake plate (2)
Refer to paragraph (5) on B-1.
(2) Parking brake is applied in case the engine stops, but it is not applied in case the engine operates and
the parking switch is set in the ON position.
Faulty parking brake solenoid valve, parking switch and relay

The parking brake is not applied at all when the parking switch is set in the ON position, the following trouble
may occur.
1. The parking solenoid is energized → Faulty switch, relay and harness
2. The parking brake solenoid valve is stuck in the released condition.
NOTE: In case the parking brake is

normal after performing para-
graph (1) and paragraph (2),
Parking Brake Oil Pressure
measure the parking brake oil Measuring Points
pressure at the right measuring
points.
Specification: 0 kgf/cm²
Parking Brake
Solenoid Valve
T4EJ-05-04-027
Repair or replacement of faulty parts
T5-4-26
Trouble symptoms B-3. Dragging of parking brake occurs
(1) Faulty electrical system of parking brake control
Measure the terminal voltage of parking brake solenoid.

1. After starting the engine, operate the parking switch to RESET.
2. Check that the shift lever is locked in neutral.
3. Disconnect the connector of parking brake solenoid.
4. Operate the parking brake switch from ON to OFF and measure the voltage.
(Machine side connector and parking brake monitor lamps go off.)
B GR
Connector
Parking Brake
Solenoid Valve T4EJ-05-04-028
0 V or operating voltage or less Normal.
1. Faulty parking brake switch Faulty parking brake solenoid

2. Faulty relay
3. Poor contact of connector and ground
line
T5-4-27
(2) Faulty hydraulic system of parking brake control
Measure parking brake oil pressure (charging pressure).

1. Hose (1) under HST pump (under the inching valve)
Remove adapter (2) and install the oil pressure gauge.
2. Start the engine and read the needle of oil pressure gauge.
3. Measure hydraulic oil temperature at operating temperature (40 to 60 °C (104 to 140 °F)).
Parking brake release oil pressure

Specification: 1.57 MPa (16 kgf/cm², 227.5 psi)
2 (Rc1/4)
T4EJ-05-04-027
Release oil pressure or less Release oil pressure or more
Faulty parking brake solenoid Faulty parking brake solenoid
T5-4-28
Measure parking brake oil pressure on the parking brake solenoid side.
1. Remove hose (1) of the parking solenoid valve and 90°elbow (4). Install the oil pressure gauge.
2. Start the engine and operate the parking switch to RESET. Read the needle of oil pressure gauge.
3. Measure hydraulic oil temperature at operating temperature (40 to 60 °C (104 to 140 °F)).
Parking brake release oil pressure

Specification: 1.57 MPa (16 kgf/cm², 227.5 psi)
2 (Rc1/4)
T4EJ-05-04-027
Release oil pressure or less
Stuck parking brake solenoid
Replacement of parking brake

solenoid
T5-4-29
(4) Seizure in brake disc and brake plate
Disassemble the parking brake. Check for seizure and damage (bending) of brake disc (1)
and brake plate (2).
Allowable limit of brake disc (1) and brake piston (2)
2 1
T4EJ-05-04-026
No. Item Specification Allowable limit

1 Brake Disc 2.25 mm (0.09 in) 1.9 mm (0.08)
2 Brake Plate 1.6 mm (0.06 in) 1.4 mm (0.06)
T5-4-30
Trouble symptoms C-1. Steering operation is impossible or heavy
Measurement of steering time

When some complaints about “Steering operation is heavy.” are received, measure the steering time first.
Check whether the steering is felt heavy (slow) regardless of normal or the steering is heavy (slow) due to
the malfunction.
Measure the hydraulic cylinder cycle time according to Operational Performance Test.
1. Park the machine on a level paved road with traveling position. Release the parking brake.
2. Hydraulic oil temperature is kept at operating temperature (about 40 to 60 °C (104 to 140 °F)).
4. Check the tire air pressure. Standard air pressure: 200 kPa (2.0 kgf/cm2, 28.4 psi)
5. Measure the steering time from the left end to the right end (right swing) and from the right end to the
left end (left swing) at fast idle speed.
Normal.
A-1 (1) Oil shortage in the hydraulic oil tank
A-2 (2) Clogged suction strainer
T5-4-31
(2) Hydraulic pressure drop of steering main relief

valve
Measure steering oil pressure.
Measure the steering relief pressure according to

Operational Performance Test.
As for specification, refer to Operational Performance

Standard.
Repair or replacement Normal.

of main pump 1
T4EJ-04-04-011
(3) Damage of piston seals in steering cylinder
Perform the internal oil leak check of steering cylinder.

1. Turn the steering wheel to the right and get in 1
contact with the frame stopper completely. Stop
2
the engine.
2. Remove cylinder rod side hose (1) of steering 3
cylinder. Install plug (2) to hose (1).
3. Start the engine and set engine speed at fast idle.
Supply pressure oil to the cylinder bottom side
while turning the steering wheel to the right.
4. If pressure oil flows out from cylinder port (3), the
piston seals in cylinder may be damaged.
T4EJ-05-04-027
With oil leaks No oil leaks
Repair of steering cylinder Normal.
T5-4-32
(4) Faulty orbitroll (sticking and wear of spool and sleeve)
Measure the operating force of steering wheel.

1. Park the machine on a level paved road with traveling position. Release the parking brake.
2. Hydraulic oil temperature is kept at operating temperature (40 to 60 °C (104 to 140 °F)).
4. Measure the operating (rotational) force of steering wheel at engine low idle speed and fast idle speed
in this condition. At the same time, check for the unevenness (sticking) of operating (rotational) force.
Measure the slip amount of steering wheel.

1. Turn the steering wheel to the right or left and get in contact with the frame stopper completely (stroke
end).
2. In addition, turning the steering wheel from this condition, the wheels rotate while slipping due to the
internal leaks of orbitroll.
Measure the revolutions of steering wheel per 1 minute.
Specification
Specification on a new machine: 3.5 rev/min
When the slip amount of steering wheel reaches to 1.5 times or more, repair is required as the internal
leaks becomes excessive.
Out of Specification Spring Balance
Repair or replacement of orbitroll
T4EJ-05-04-030
T5-4-33
(5) Faulty priority valve operation
Perform the disassembly and check of priority valve.

The causes of faulty priority valve operation are
shown below. 1 2 3
1. Stuck spool (1)

2. clogged orifice (2)
3. Permanent deformation of spring (3)
T4EJ-05-04-031
Repair or replacement of priority valve
T5-4-34
Trouble symptoms C-2. Machine mistracks
(1) Faulty orbitroll (sticking and wear of spool and sleeve)
(2) Damage of piston seals in steering cylinder
Refer to paragraph (3) and paragraph

(4) on C-1.
(3) Looseness of the steering cylinder mounting pin part and center pin
Check of looseness
Replacement of pin and bushing
(4) Wear and air pressure of tire is nonuniform.
Check for abnormal wear, pressure

drop (blowout) of the specified tire,
use of other than the specified size
tires and so on.
Repair, replacement or air charge of tire
T5-4-35
Trouble symptoms D-1. Lift arm is not raised or the raising time is long.
Measure the raising time of lift arm.

When some complaints about “Lift arm rising time is slow.” are received, measure the lift arm raising time
first. Check whether the lift arm raising speed is slow regardless of normal or the lift arm raising speed is
slow due to the malfunction.
1. Measure the time required for raising the lift arm from the ground to the maximum height according to
Operational Performance Test.
4.6 Sec
T4EJ-05-04-032
NOTE: The above value is specification on a new machine. The machine becomes slightly slow after
operation for a certain period.
The lift arm raising speed is consid- Within Specification

erably slower than specification.
(1) Oil shortage in the hydraulic oil tank Normal.
T5-4-36

Upper Limit
Check for the oil level (hydraulic oil) in the hydraulic

oil tank.
1. Park the machine on level ground.
2. Lower the bucket or the attachment onto the Lower Limit
ground horizontally.
3. Stop the engine. Check that the oil level is be-
tween the upper limit mark of dipstick and the
lower limit mark of dipstick.
Hydraulic oil amount Hydraulic oil amount

is normal. is short
1 T4EJ-05-04-033
3
Cavitation is generated Repair oil leak area
from the pump. and add hydraulic oil.
Remove suction strainer (1) in the hydraulic oil tank.

Check for restrictions Floor Plate Lower / Right Side of Machine
2
With restriction No restriction
Near The Rear

Frame Center Pin
At the same time, check HST filter element (2) and T4EJ-05-04-034
hydraulic oil filter element (3). Check for the foreign

particles, which cause suction strainer (1) restrictions
Aluminum or metal fragments Nylon and rubber pieces
Cleaning of suction strainer Repair of hydraulic pump Repair of hydraulic

cylinders and hose
T5-4-37
(3) Faulty adjustment of control link

Float
5.6 mm
Dump (0.2 in)
Lower
7.2 mm 7.2 mm
Measure the stroke amount of control lever. (0.3 in) (0.3 in)
In Neutral In Neutral
7.2 mm 7.2 mm
Remove nut (1). Operate the lever to each position Tilt
(0.3 in)
Raise (0.3 in)
and check if rod end (2) and (3) are moved more
than the specification of spool.
Specification or less Specification or more

Tilt Spool Lift Spool
T4EJ-05-04-035
Adjustment or repair of Repair of control valve

control link
Control Lever
Lift Spool 1 2
Control Cable
1 3
Tilt Spool T4EJ-05-04-036
T5-4-38
(4) Hydraulic pressure drop of shovel main relief

valve or faulty main pump
Measure the main hydraulic pressure of shovel

control valve.
Measure the main relief pressure according to Op-
erational Performance Test.
Specification: 20.6 MPa (210 kgf/cm², 2986 psi)
Hydraulic pressure drop
Adjustment or replacement of relief valve hydraulic

pressure
(Perform the adjustment according to Operational
Performance Test.) Hydraulic Oil Outlet
Pressure does not increase Tilt Cylinder T4EJ-05-04-037

even after adjustment.
Adjustment of overload relief valve, or repair and

replacement of main pump
Hydraulic Pressure Down

(Counterclockwise)
Hydraulic
Pressure Rise
(Clockwise)
Lock Nut
Main Relief Valve
Adjusting Screw T4EJ-05-04-038
T5-4-39
Disassemble and check the priority valve built in the orbitroll.

1. Check for stuck spool (1) and clogged orifice (2).
With sticking and restriction Normal
Cleaning and replacement of defect parts
2 1
T4EJ-05-04-039
P1 Port
T5-4-40
(6) Damage of piston seals in lift cylinder
Perform the internal oil leak check of lift cylinder.

1. Tilt (Decline backward) the bucket and lower the lift arm to the lowest position.
2. Remove hose (1) of cylinder bottom side. Install plug (2) in order to prevent the oil spout from hose (1).
3. Start the engine. Set the control lever to the Lower position and apply hydraulic pressure on the piston
rod (cylinder head) side.
NOTE: Do not shift the control lever from the Lower position to the Float position at this time.
4. If pressure oil flows out from cylinder port (3), the piston seals in cylinder may be damaged.
Repair of lift cylinder
3 2 1
T4EJ-05-04-040
T5-4-41
(7) Breakage of the coupling of HST pump and main pump, wear of spline.
When the lift arm does not move at all even if the shovel and the steering are operated, start the engine and
check if the travel (HST device) is normal.
Faulty travel Normal.
Coupling (1) spline of main pump

Wear or breakage of coupling (2) of HST
pump and wear of the spline
Repair or replacement of defect parts
1 2
T4EJ-05-04-041
T5-4-42
Trouble symptoms D-2. Cylinder drift of lift arm is large at the neutral position of control lever.
Measure the cylinder drift of lift arm.

When some complaints about “Lift arm is lowered at the Hold (Neutral) position of control valve” are re-
ceived, check if the lift arm drift amount is specification (normal) first.
1. Measure the hydraulic cylinder drift amount according to Operational Performance Test.
2. As for specification, refer to Operational Performance Standard.
The hydraulic cylinder drift amount is Within specification

considerably larger than specification.
Normal.
P1 Port
T4EJ-05-04-042
T5-4-43
(1) Damage of piston seals in lift cylinder

1. Tilt (Decline backward) the bucket and lower the lift arm to the lowest position.
2. Remove hose (1) of cylinder bottom side. Install plug (2) in order to prevent the oil spout from hose (1).
3. Start the engine. Set the control lever to the Lower position and apply hydraulic pressure on the piston
rod (cylinder head) side.
NOTE: Do not shift the control lever from the Lower position to the Float position at this time.
4. If pressure oil flows out from cylinder port 3, the piston seals in cylinder may be damaged.
Repair of lift cylinder
3 2 1
T4EJ-05-04-040
T5-4-44
(2) Faulty lift spool oil tight in control valve
Perform the disassembly and check of control valve.

1. When there is any dent, scratch, rust development or corrosions on spool (1) or housing (2), repair by
using a sandpaper #2000 or oil stones.
2. If the repair is impossible, replace the plunger section as an assembly.
Repair of control valve or replacement of plunger section assembly
T4EJ-05-04-043
1 2
T5-4-45
Trouble symptoms D-3. It is impossible to raise the front wheel by the lift cylinder.
(1) Faulty anti-void valve operation
Cylinder drift of lift arm is normal. Raise the front wheel by the lift cylinder. If it is impossible to hold the front
wheel, remove and check the anti-void valve.
1. When the poppet seal surface (2) contact of anti-void valve (1) is poor, as pressure oil of piston rod side
directly relieve to the drain circuit through anti-void valve, it is impossible to hold the front wheel raised
by the lift cylinder
Cleaning or replacement of anti-void valve
2 1
T4EJ-05-04-044
T5-4-46
Trouble symptoms D-4. The cylinder drift speed of lift arm becomes fast at the specified position.
(1) Expansion or scratch of cylinder tube
Measure the cylinder tube inner diameter. Check the expansion. In addition, check for a dent or scratch on
the sliding surface.
Standard diameter: inner diameter 55 mm (2.2 in)
Repair or replacement of cylinder tube
Cylinder Gauge
(Inner Diameter
Measurement)
T4EJ-05-04-045
T5-4-47
Trouble symptoms D-5. When raising the lift arm, lower the lift arm before raise.
(1) Faulty load check valve operation
When the cylinder drift of lift arm is normal and the lift lever shift to the Raise position while loading the
bucket, in case the lift arm starts rising after lowering the lift arm for a moment, remove and check the load
check valve on the lift position.
1. When the load check is normal, pressure oil

flows from the control valve to the bottom side of
lift cylinder. However pressure oil cannot flow
from the cylinder to the control valve.
2. Therefore, even if a load is applied on the bucket
and lift cylinder piston side pressure P1 is larger
than pressure P2 (at low speed and low pres-
sure), the lift arm does not is lowered.
3. When arising the damage of poppet seat surface P1
(1), foreign object overlapped, stuck poppet or
damage of spring (2), pressure oil flows from P1
to P2 and the lift arm is lowered for a moment.
Load Check
Valve
Main Relief Valve P2 Pump

2
210 kgf/cm
(2986 psi)
2 T4EJ-05-04-046
Cleaning or replacement of load check valve
T5-4-48
D-6. Bucket operation (declined backward) time is long or operation force is insuf-
Trouble symptoms
ficient.
Measure the operating (tilt back) time of the bucket.

When some complaints about “Bucket operation is slow.” are received, measure the bucket operating time
first. Check whether the bucket operation is slow regardless of normal or the bucket operation is slow due to
the malfunction.
1. Measure the time for operating the bucket from the maximum dumping (declined forward) position to
the maximum tilt back (declined backward) at the highest position of lift arm according to Operational
Performance Test.
1.8 Sec
T4EJ-05-04-047
NOTE: The above value is specification on a new machine. The machine becomes slightly slow after
operation for a certain period.
The operating speed is considerably Within Specification

slower than specification.
Normal.
(3) Looseness and faulty adjustment of control link
(4) Hydraulic pressure drop of shovel main relief valve or

faulty main pump
T5-4-49
Trouble symptoms
ficient.
(1) Damage of piston seals in tilt cylinder

1. Lower the lift arm to the lowest position and tilt back (decline backward) the bucket
2. Remove hose (1) of piston rod (cylinder head) side. Install plug (2) in order to prevent the oil spout from
hose (1).
3. Start the engine. Set the control lever to the Tilt Back (Decline Backward) position and apply hydraulic
pressure on the cylinder bottom side.
Repair of tilt cylinder
3 2 1
Tilt Back
T4EJ-05-04-048
T5-4-50
Trouble symptoms D-6. Bucket operation (declined backward) time is long or operation force is insufficient.
(2) Hydraulic pressure drop of overload relief valve
Measurement of overload relief valve hydraulic pressure

1. Install the oil pressure gauge to tilt cylinder hy-
draulic oil outlet port (1).
Measure and adjust the main relief valve set
pressure.
Main hydraulic pressure specification: 20.6 MPa Hydraulic Oil Outlet

(210 kgf/cm², 2986 psi)
2. Increase the set pressure of main relief valve (1).

Even if tightening the adjusting screw, in case Tilt Cylinder
hydraulic pressure does not increase, the needle T4EJ-05-04-037
of oil pressure gauge is the set pressure of piston (Rod Side) 4

rod side overload relief (2). After measuring and
adjusting the overload relief valve set pressure,
return the main relief valve (1) set pressure to
specification.
3. Lower the bucket onto the ground horizontally. 5
Remove and replace tilt cylinder hoses (4) and (5) (Bottom Side)
on the cylinder side.
(In sert hose (4) to the cylinder bottom side and
insert hose (5) to the rod side.)
(Rod Side)
NOTE: Setting in this condition, the bucket tilts
5
back when operating the control lever to
the Dump side, on the other hand, the
bucket is dumped when operating the con-
trol lever to the Tilt Back side.
4
Increase the set pressure of main relief valve (1) (Bottom Side)
in this condition. Operate the control lever to the
tilt back side continuously. (The bucket is
dumped.)
Even if tightening the adjusting sc rew, in case Hydraulic Pressure Down
T4EJ-05-04-049
hydraulic pressure does not increase, the needle (Counterclockwise)

Overload Relief Valve 3
of oil pressure gauge is the set pressure of cyl- (Cylinder Bottom Side)
inder bottom side overload relief valve (3). 2
22.5 MPa (230 kgf/cm ,
After measuring and adjusting the overload relief 3270 psi)
valve set pressure, return the main relief valve (1)
se t pressure to specification. Replace tilt cylinder Hydraulic
Hydraulic Pressure Rise
hoses (4) and (5), and return to the original con- Pressure Rise (Clockwise)
dition. (Clockwise)
1
4. Set pressure specifications of overload relief
Main Relief Valve
valves (2) and (3) 2
20.6 MPa (210 kgf/cm ,
2 2986 psi)
Specification: 22.5 MPa (230 kgf/cm², 3270 psi) Hydraulic Pressure Down Overload Relief Valve T4EJ-05-04-056
(Counterclockwise) (Cylinder bottom side)

2
22.5 MPa (230 kgf/cm , 3270 psi)
T5-4-51
Trouble symptoms
ficient.
D-1. Lift arm is not raised or the raising time is long.
5. All of measurement values in paragraph 1 to paragraph 3 of Measurement of Overload Relief Valve

Hydraulic Pressure are the same and lower than the main relief valve specification.
Faulty main relief valve. Faulty main pump. Faulty or faulty adjustment of both
overload relief valves (2) and (3)
6. Measurement values in paragraph 1 to paragraph 2 of Measurement of Overload Relief Valve Hydraulic

Pressure are the same and lower than the main relief valve specification. In addition, measurement
value in paragraph 3 is specification.
Faulty or faulty adjustment of overload relief valve (2)
<Adjustment Methods>
(1) According to paragraph 2 of Measurement of Overload Relief Valve Hydraulic Pressure, hydraulic pres-
sure of overload relief valve (2) can be measured by using an oil pressure gauge.
(2) Loosen lock nut (6) of overload relief valve (2)
(3) While reading the needle of oil pressure gauge, turn adjusting screw (7) by using a hexagonal wrench so
that the needle indicates specification.
Tightening (clockwise) → Oil pressure increases
Loosening (counterclockwise) → Oil pressure decreases
Specification: 22. 5 MPa (230 kgf/cm², 3270 psi)
NOTE: As the relief sensitivity is exceedingly sensitive, do not loosen quickly.

٠ Hold adjusting screw (7) by using a hexagonal wrench and secure by using lock nut (6).
٠ Measure the overload relief pressure again and confirm that set pressure is specification.
٠ Adjust the main relief valve set pressure to specification.
3
6
2
Overload Relief Valves (2) and (3)

T4EJ-05-04-050
T5-4-52
Trouble symptoms
ficient.
7. All of measurement values in paragraph 1 to paragraph 3 of Measurement of Overload Relief Valve

Hydraulic Pressure are the same and lower than the main relief valve specification. In addition, meas-
urement value in paragraph 2 is specification.
Faulty or faulty adjustment of overload valve (3)
<Adjustment Methods>
(1) According to paragraph 3 of Measurement of Overload Relief Valve Hydraulic Pressure, hydraulic pres-
sure of overload relief valve (3) can be measured by using an oil pressure gauge.
(2) Loosen lock nut (6) of overload relief valve (3)
(3) While reading the needle of oil pressure gauge, turn adjusting screw * by using a hexagonal wrench so
that the needle indicates specification.
Tightening (clockwise) → Oil pressure increases
Loosening (counterclockwise) → Oil pressure decreases
Specification: 22.5 MPa (230 kgf/cm². 3276 psi)
NOTE: As the relief sensitivity is exceedingly sensitive, do not loosen quickly.

٠ Hold adjusting screw (7) by using a hexagonal wrench and secure by using lock nut (6)
٠ Measure the overload relief pressure again and confirm that set pressure is specification.
٠ Adjust the main relief valve set pressure to specification.
3
6
2
Overload Relief (2) and (3)

T4EJ-05-04-050
(4) In order to measure hydraulic pressure, return the replaced tilt cylinder hoses (4) and (5) to the original
position.
8. When measurement values in paragraph 2 of Measurement of Overload Relief Valve Hydraulic Pres-
sure is higher than specification, refer to paragraph 6 and adjust overload relief valve (2)
9. When measurement values in paragraph 3 of Measurement of Overload Relief Valve Hydraulic Pres-
sure is higher than specification, refer to paragraph 7 and adjust overload relief valve (3)
T5-4-53
Trouble symptoms D-7. Normal declined forward of bucket is large when the control lever is in neutral.
Measure the normal roll-out amount of bucket.

When some complaints about “Bucket is declined forward at the Hold (Neutral) position of control valve” are
received, check if the declined forward amount is specification (normal) first.
Measure the hydraulic cylinder drift amount according to Operational Performance Test.
The hydraulic cylinder drift is con- Within Specification

siderably slower than specification.
Internal oil leak check of tilt cylinder Normal.
A1 → A2
T4EJ-05-04-051
T5-4-54
(1) Internal oil leak check of tilt cylinder

1. Lower the lift arm to the lowest position and tilt back (decline backward) the bucket
2. Remove hose (1) of piston rod (cylinder head) side. Install plug (2) in order to prevent the oil spout from
hose (1).
3. Start the engine. Set the control lever to the Tilt Back (Decline Backward) position and apply hydraulic
pressure on the cylinder bottom side.
Repair of tilt cylinder 1

2
2
(2) Faulty overload relief valve oil tight
T4EJ-05-04-052
Perform the oil tight check of overload relief valve.

1. Check if the front wheel can be raised and held by using a tilt cylinder.
2. When foreign objects are overlapped on overload relief valve and the seat surface contact is poor, as
pressure oil of piston rod side directly relieve to the hydraulic oil tank circuit through overload relief
valve, it is impossible to hold the front wheel as the tilt cylinder rod is extended. (The front wheel is
lowered gradually.)
3. As the piston rod side parts and the cylinder bottom side parts consist of the same parts, it is possible to
check for the function of both valves by replacing parts.
4. In case faulty overload relief valve (cylinder bottom side) oil tight, the declined forward bucket occurs.
In case faulty overload relief valve (piston rod side) oil tight, it is impossible to raise and hold the front
wheel.
Cylinder Bottom Side

Piston Rod Side
T4EJ-05-04-053
Faulty overload relief valve oil tight Overload relief valve oil tight is normal.
Cleaning or replacement of overload relief valve
T5-4-55
(3) Faulty tilt spool oil tight in control valve
Perform the disassembly and check of control valve.

1. When there is any dent, scratch, rust development or corrosions on spool (1) or housing (2), repair by
using a sandpaper #2000 or oil stones.
2. If the repair is impossible, replace the plunger section as an assembly.
Repair of control valve or replacement of section assembly
T4EJ-05-04-054
1 2
T5-4-56
Trouble symptoms D-8. Normal roll-out speed of bucket becomes fast at the specified position.
(1) Expansion or scratch of cylinder tube
Measure the cylinder tube inner diameter. Check the expansion. In addition, check for a dent or scratch on
the sliding surface.
Standard diameter: inner diameter 60 mm (2.4 in)
Cylinder Gauge
(Inner Diameter
Measurement)
T4EJ-05-04-045
Repair or replacement of cylinder tube
Trouble symptoms D-9. Bucket wobble occurs in traveling.
(1) Damage of piston seals in tilt cylinder Refer to paragraph (1) on D-6.
(2) Hydraulic pressure drop of overload relief valve Refer to paragraph (2) on D-6.
(3) Faulty overload relief valve oil tight Refer to paragraph (2) on D-7.
(4) Faulty tilt spool oil tight in control valve Refer to paragraph (3) on D-7.
(5) Wear of pin and bushing in shovel linkage Replacement of pin and bushing
T5-4-57
Trouble symptoms D-10. The control lever operation is heavy.
Measure the operating force of control lever.

When some complaints about “Control lever operation is heavy” are received, check for the operating force
of control lever first.
Measure the Lever Stroke according to Operational Performance Test.

Dump Hold Tilt Lower Hold Raise
Within specification Float

The operating force of
control lever is consid-
erably larger than
specification.
Normal.
T4EJ-05-04-055
(1) The operating resistance of control lever is large.
Separate the cable and the control valve at nut (1) and operate the control lever.
The operating force is The light operation

very heavy. can be done.
Control Lever
Repair or replacement of
control cable
Lift Spool 1 2
Control Cable
1 3
Tilt Spool T4EJ-05-04-036
T5-4-58
Trouble symptoms D-10. The control lever operation is heavy.
(2) Stuck control valve spool
Measure the operating force of spool.
Measure the operating force of spool by using a push-pull gauge.
1. The operating force when the tilt spool is in the Hold or Neutral position.
2. The operating force when the tilt spool is at full stroke in the Tilt or Dump position.
3. The operating force when the lift spool is in the Hold or Neutral position.
4. The operating force when the lift spool is at full stroke in the Raise or Lower position.
5. Float release (detent release) operating force
The operating force of control lever is Within specification

considerably larger than specification.
Disassembly and check of control valve Normal.
T5-4-59
(Blank)
T5-4-60
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

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INTRODUCTION

• Please refer to the other materials (operator’s

• Each page has a number, located on the center

Consecutive Page Number for Each Group

RECOGNIZE SAFETY INFORMATION

UNDERSTAND SIGNAL WORDS

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an element

FOLLOW SAFETY INSTRUCTIONS

PREPARE FOR EMERGENCIES

WEAR PROTECTIVE CLOTHING

You may need:

• Avoid wearing loose clothing, jewelry, or other items that

PROTECT AGAINST NOISE

GENERAL PRECAUTIONS FOR CAB

USE HANDRAILS AND STEPS

ADJUST THE OPERATOR'S SEAT

ENSURE SAFETY BEFORE RISING FROM OR

FASTEN YOUR SEAT BELT

• We recommend that the seat belt be replaced every four

MOVE AND OPERATE MACHINE SAFELY

HANDLE STARTING AIDS SAFELY

• Starting fluid is highly flammable.

OPERATE ONLY FROM OPERATOR'S SEAT

INVESTIGATE JOB SITE BEFOREHAND

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

ROPS: Roll-Over Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLVING

KEEP RIDERS OFF MACHINE

• Even though the machine is equipped with the emergency

DRIVE MACHINE SAFELY (WORK SITE)

• Driving on a slope may cause the machine to slip or

• Driving across the face of a slope or steering on a slope

DRIVE SAFELY WITH BUCKET LOADED

DRIVE ON SNOW SAFELY

TRAVEL ON PUBLIC ROADS SAFELY

• Even though the machine is equipped with the emergency

AVOID INJURY FROM ROLLAWAY ACCIDENTS

AVOID ACCIDENTS FROM BACKING UP AND

AVOID POSITIONING BUCKET OVER ANYONE

• Avoid carrying the bucket over the co-workers to ensure

• Be careful when working on frozen ground.

NEVER UNDERCUT A HIGH BANK

DIG WITH CAUTION

PERFORM TRUCK LOADING SAFELY

AVOID POWER LINES

Never move any part of the machine or load closer to any

PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR LIGHTENING

PROTECT AGAINST FLYING DEBRIS

PARK MACHINE SAFELY

STORE ATTACHMENTS SAFELY

Be sure to further follow the details described in the

HANDLE FLUIDS SAFELY−AVOID FIRES

• All fuels, most lubricants, and some coolants are flammable.

PRACTICE SAFE MAINTENANCE

Before servicing the machine:

10. Allow the engine to cool.

• If a maintenance procedure must be performed with the

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.

SUPPORT MACHINE PROPERLY

STAY CLEAR OF MOVING PARTS