CX460 Tier3 en

Copyright ©
CX460 TIER 3 CRAWLER EXCAVATOR

SERVICE MANUAL
TABLE OF CONTENTS
DIVISION/SECTION SECTION N° REFERENCE N°
1 GENERAL INFORMATION
Safety, general information and standard torque data ..................................... 1001 7-27691EN
General specifications and special torque setting ........................................... 1002 SC4601002-0EN
2 ENGINE
Radiator and oil-cooler .................................................................................... 2001 SM4602001-0EN
Engine specifications ..............................................................................................*
Disassembly and assembly of the engine ..............................................................*
3 FUEL SYSTEM
Fuel tank .......................................................................................................... 3001 SM4603001-0EN
Fuel engine system ................................................................................................*
4 ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting ............................ 4001 SC4604001-0EN
Main and engine electronic control boxes ....................................................... 4003 SM4604003-0EN
5 UNDERCARRIAGE
Removal and installation of tracks ................................................................... 5001 SM160B5001-0EN
Rollers ............................................................................................................ 5003 SM4605003-0EN
Sprocket........................................................................................................... 5004 SM160B5004-0EN
Idler wheel and tension shock absorber .......................................................... 5005 SM4605005-0EN
6 DRIVE TRAIN
Drive motor and final drive transmission removal and installation ................... 6001 SM4606001-0EN
Swing reduction gear, removal and installation ............................................... 6003 SM4606003-0EN
Swing reduction gear, disassembly and assembly .......................................... 6004 SM4606004-0EN
Travel reduction gear disassembly and assembly .......................................... 6005 SM4606005-0EN
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components.............................................. 8000 SM4608000-0EN
Specifications, troubleshooting, checks and hydraulic pressure settings ........ 8001 SC4608001-0EN
Hydraulic reservoir removal and installation ................................................... 8002 SM4608002-0EN
Main and hydraulic pilot pumps, removal and installation .............................. 8003 SM4608003-0EN
Main hydraulic control valve, removal and installation .................................... 8004 SM4608004-0EN
Attachment cylinders, removal and installation ............................................... 8005 SM4608005-0EN
Hydraulic swivel, removal and installation ...................................................... 8006 SM4608006-0EN
Pilot blocs, removal and installation................................................................. 8007 SM4608007-0EN
Swing motor, removal and installation ............................................................. 8008 SM4608008-0EN
Main hydraulic pump, disassembly and assembly ........................................... 8010 SM4608010-0EN
Main hydraulic control valve, disassembly and assembly................................ 8011 SM4608011-0EN
Attachment cylinders, disassembly and assembly .......................................... 8012 SM4608012-0EN
Hand control levers, disassembly and assembly ............................................. 8013 SM4608013-0EN
Foot control levers, disassembly and assembly............................................... 8014 SM4608014-0EN
Six-solenoid valves, disassembly and assembly ............................................. 8015 SM4608015-0EN
Caution valve, disassembly and assembly ...................................................... 8016 SM4608016-0EN
Safety valves.................................................................................................... 8017 SM4608017-0EN
Hydraulic swivel, disassembly and assembly .................................................. 8018 SM4608018-0EN
Swing motor, disassembly and assembly ........................................................ 8019 SM4608019-0EN
Hydraulic functions .......................................................................................... 8020 SC4608020-0EN
Travel hydraulic motor, disassembly and assembly ......................................... 8021 SM4608021-0EN
Fan motor, removal and installation ................................................................. 8022 SM4608022-0EN
Fan motor, disassembly and assembly............................................................ 8023 SM4608023-0EN
Fan pump, removal, disassembly, assembly and installation........................... 8024 SM4608024-0EN
Hydraulic component functions........................................................................ 8030 SC4608030-0EN
Copyright © 2007 CNH France S.A.

Printed in France
CNH Lep SM460TOC-0EN September 2007
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Copyright ©
DIVISION/SECTION SECTION N° REFERENCE N°

9 UPPERSTRUCTURE
Upperstructure, turntable and counterweight..................................................... 9002 SM4609002-0EN
Boom, dipper and bucket ................................................................................... 9003 SM4609003-0EN
Seat, removal and installation............................................................................ 9004 SM4609004-0EN
Cab and cab equipment..................................................................................... 9005 SM4609005-0EN
Air conditioning unit disassembly and assembly................................................ 9007 SM4609007-0EN
Large size hydraulic schematics ......................................................................Pocket 87574463A
Large size electrical schematics ......................................................................Pocket 87574470A
* Consult the Engine Service Manual
NOTE: CNH Company reserves the right to make changes in the specification
and design of the machine without prior notice and without incurring any obliga-
tion to modify units previously sold.
The description of the models shown in this manual has been made in accord-
ance with the technical specifications known as of the date of design of this
document.
Lep SM460TOC-0EN Issued 09-07

Copyright ©
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

Printed in France
CNH Lep 7-27691EN February 2006
Copyright ©
1001-2
TABLE OF CONTENTS
GENERAL INFORMATION .......................................................................................................................................3
SAFETY..................................................................................................................................................................... 4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep 7-27691EN Issued 02-06

Copyright ©
1001-3
GENERAL INFORMATION
Cleanning Gears
Clean all metal parts except bearings, in a suitable Check all gears for wear and damage. Replace gears
cleaning solvent or by steam cleaning. Do not use that have wear or damage.
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with Oil seals, O-rings and gaskets
compressed air. Clean bearings in a suitable cleaning
Always install new oil seals, O-rings and gaskets. Put
solvent, dry the bearings completely and put oil on
petroleum jelly on seals and O-rings.
the bearings.
Inspection Shafts
Check all shafts that have wear or damage. Check
Check all parts when the parts are disassembled.
the bearing and oil seal surfaces of the shafts for
Replace all parts that have wear or damage. Small
damage.
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for Service parts
indications of wear, pitting and the replacement of
parts necessary to prevent early failures. Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
Bearings number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
Check bearings for easy action. If bearings have a
replacement parts are not covered by warranty.
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit Lubrication
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR. Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
Needle bearings use of non-specified oils and lubricants are not
covered by warranty.
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.

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1001-4
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
! symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
To prevent injury always follow the Warning, Caution

and Danger notes in this section and throughout the
manual. WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
Put the warning tag shown below on the key for the all safety signs on machine. Clear the area of
keyswitch when servicing or repairing the machine. other persons. Learn and practice safe use
One warning tag is supplied with each machine. of controls before operating.
Additional tags Part Number 331-4614 are available It is your responsibility to understand and
from your service parts supplier
! f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
. machine operation, service and to observe
pertinent laws and regulations. Operator’s
WARNING: Read the operator’s manual to and Service Manuals may be obtained from
familiarize yourself with the correct control your Case dealer.
! functions.
WARNING: If you wear clothing that is too

WARNING: Operate the machine and loose or do not use the correct safety
equipment controls from the seat position equipment for your job, you can be injured.
! only. Any other method could result in Always wear clothing that will not catch on
serious injury. ! objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
WARNING: This is a one man machine, no gloves and reflector clothing.
! riders allowed.
WARNING: When working in the area of the

! fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
WARNING: When doing checks and tests

on the equipment hydraulics, follow the
! procedures as they are written. DO NOT
change the procedure.
WARNING: When putting the hydraulic

cylinders on this machine through the
! necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.

Copyright ©
1001-5
WARNING: Use insulated gloves or mittens WARNING: When servicing or repairing the
! when working with hot parts. machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
! grease, tools, etc. Use an oil absorbing
WARNING: Lower all attachments to the material and/or shop cloths as required. Use
ground or use stands to safely support the safe practices at all times.
! attachments before you do any maintenance
or service.
WARNING: Some components of this
machine are very heavy. Use suitable lifting
WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in
of hydraulic oil under pressure can penetrate this Service Manual.
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
WARNING: Engine exhaust fumes can
immediately. Maintain all hoses and tubes in
! cause death. If it is necessary to start the
good condition. Make sure all connections
engine in a closed place, remove the exhaust
are tight. Make a replacement of any tube or ! fumes from the area with an exhaust pipe
hose that is damaged or thought to be
extension. Open the doors and get outside
damaged. DO NOT use your hand to check
air into the area.
for leaks, use a piece of cardboard or wood.
WARNING: When the battery electrolyte is

WARNING: When removing hardened pins frozen, the battery can explode if (1), you try
such as a pivot pin, or a hardened shaft, use to charge the battery, or (2), you try to jump
a soft head (brass or bronze) hammer or use start and run the engine. To prevent the
! a driver made from brass or bronze and a
! battery electrolyte from freezing, try to keep
steel head hammer. the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
! grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
WARNING: Use suitable floor (service)

jacks or chain hoist to raise wheels or tracks
! off the floor. Always block machine in place
with suitable safety stands.

Copyright ©
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
[mm] 10 13 17 19 22 24 27 30
Spanner
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Cap Screw
Tightening [Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
torque
[lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217
[mm] 5 6 8 10 12 14 14 17
Spanner
Socket [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Head Cap
Screw [Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
Tightening
torque
[lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2

Copyright ©
1002
Section
1002
SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

Printed in France
CNH Lep SC4601002-0EN March 2007
Copyright ©
1002-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5
Machine ....................................................................................................................................................................... 5
Engine .......................................................................................................................................................................... 5
Serial numbers of the components .............................................................................................................................. 5
FLUIDS AND LUBRICANTS ............................................................................................................................................ 6

Hydraulic fluid .............................................................................................................................................................. 6
Transmission component oil ........................................................................................................................................ 6
Grease ......................................................................................................................................................................... 6
Engine Oil .................................................................................................................................................................... 7
Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8
Anti-freeze/Anti-corrosion........................................................................................................................................... 10
Environment ............................................................................................................................................................... 10
Plastic and resin parts................................................................................................................................................ 10
SPECIFICATIONS ......................................................................................................................................................... 11
Main data ................................................................................................................................................................... 11
Performance .............................................................................................................................................................. 11
Complete machine dimensions .................................................................................................................................. 11
Main body dimensions ............................................................................................................................................... 11
Engine ........................................................................................................................................................................ 12
Cooling system .......................................................................................................................................................... 12
Capacity of coolant and lubricants ............................................................................................................................. 12
Hydraulic oil filter........................................................................................................................................................ 12
Fuel filter .................................................................................................................................................................... 12
Operating devices ...................................................................................................................................................... 13
Hydraulic system........................................................................................................................................................ 14
Swing unit .................................................................................................................................................................. 16
Travel lower body....................................................................................................................................................... 16
Work Unit ................................................................................................................................................................... 17
Digging force (ISO 6015) ........................................................................................................................................... 18
COMPONENT WEIGHT................................................................................................................................................. 19
Major component weight ............................................................................................................................................ 19
Bucket weight............................................................................................................................................................. 20
Other component weight ............................................................................................................................................ 21
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 22

Sprocket ..................................................................................................................................................................... 22
Idler wheel.................................................................................................................................................................. 23
Lep SC4601002-0EN Issued 03-07
Copyright ©
1002-3
Upper roller .................................................................................................................................................................24
Lower roller .................................................................................................................................................................25
Track...........................................................................................................................................................................26
DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................27

1. Boom foot/Frame ....................................................................................................................................................27
2. Boom cylinder foot/Frame.......................................................................................................................................28
3. Boom cylinder head/Boom......................................................................................................................................28
4. Arm cylinder foot/Boom ..........................................................................................................................................29
5. Boom/Arm...............................................................................................................................................................29
6. Arm cylinder head/Arm ...........................................................................................................................................29
7. Bucket cylinder foot/Arm.........................................................................................................................................30
8. Connecting rod/Arm................................................................................................................................................30
9. Compensator/Bucket ..............................................................................................................................................30
10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................31
11. Arm/Bucket ...........................................................................................................................................................31
SHIMS FOR ADJUSTING ATTACHMENT GAPS ..........................................................................................................32

For boom foot .............................................................................................................................................................32
SPECIAL TORQUE SETTINGS......................................................................................................................................33
MACHINE OVERALL DIMENSIONS ..............................................................................................................................36

Copyright ©
1002-4

Copyright ©
1002-5
TYPE, SERIAL NUMBER
AND YEAR OF MANUFACTURE OF THE MACHINE
For all part orders, request for information or assistance, always specify the type and the serial number of the machine
to your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the
serial numbers of the hydraulic and mechanical components.
Machine
CT04A171A
(1) Type .......................................................................................................................................................................

(2) Serial number ........................................................................................................................................................
(3) Year of manufacture...............................................................................................................................................
Engine
Make and type.............................................................................................................................................................
Serial number..............................................................................................................................................................
Serial numbers of the components

Hydraulic pump ...........................................................................................................................................................
Swing reduction gear ..................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Control valve ...............................................................................................................................................................

Copyright ©
1002-6
FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application.
WARNING: The conditions of use for individual fluids and lubricants must be respected.
!
Hydraulic fluid
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
Temperate climates: -20°C to +40°C (-4° to 104° F)
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Hot climates: 0°C to +50°C (32° to 122° F)
CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)
Cold climates: -25°C to +20°C (-13° to 68° F)
CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2)
Biodegradable fluid: -30°C to +40°C (-22° to 104° F)
This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit
completely before refilling with this fluid.
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Transmission component oil

Extreme pressure oil used for enclosed transmission components.
CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and calcium.
CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

Copyright ©
1002-7
Engine Oil
THE CASE/AKCELA No. 1 engine oil is recommended
for your engine. This oil ensures proper lubrication of
your engine for all operating conditions.
If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL"
cannot be obtained, use the oil corresponding to one of
the following categories: ACEA E7. API CI-4.
CP02N001
Oil viscosity / Oil range
1
2
2
3
3
CT02M001
1) With mineral base

(2) With semi-synthetic base
(3) With synthetic base

Copyright ©
1002-8
Engine fuel, maintenance of fuel filters and fuel storage
In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and
they are to be used under high-pressure conditions.
Therefore, the specified fuel must be used for the engine.
As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it
may invite a serious breakdown.
In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the gen-
uine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel
and the fuel elements.
Fuel to be applied
Selection of fuel
Following conditions must be met for the diesel engines, that is the one;
1 In which no dust even fine one is mixed,
2 With proper viscosity,
3 With high cetane rating,
4 With good flow properties in lower temperature,
5 With not much sulfur content, and
6 With less content of carbon residue
Applicable standards for diesel fuel
Applicable Standard Recommendation
JIS (Japanese Industrial Standard) NO.2
DIN (Deutsche Industrie Normen) DIN 51601
SAE (Society of Automotive Engineers)
Based on SAE-J-313C NO. 2-D
BS (British Standard)
Based on BS/2869-197 Class A-1
EN590
If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.
Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big
influence on its service durability and service life.
Be sure to observe the following requirements for selecting fuel.
Sulfur content............................................................................... 2500 ppm or less
HFRR*.......................................................................................... 460 mm or less
Water content............................................................................... 0.05 wt% or less
* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.
Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be
worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components may result if such a
fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.

Copyright ©
1002-9
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in accelera-
tion of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of conden-
sation.
This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice
allowing the fuel line to be clogged.
IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the crite-
ria described above.
IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and
performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine
or an accident may be invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not
meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control.
IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the
items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns
caused by not to follow these items.
1 Selection of engine oil
Use API grade CF-4 or JASO grade DH-1.
2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operator’s
Manual.
3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use.
* EGR: Exhaust Gas Recircultion
Maintenance of fuel filters
Be sure to use the genuine fuel filters.
The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional fil-
ters to improve protection of machine equipment.
If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine
equipment can wear out in a short period of time.
IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the
use of a wrong filter.
Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Man-
ual.
IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float
reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine.
Time to replace filters may be advanced according to properties of the fuel being supplied.
• Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel.
• When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply
clean fuel standing above a precipitate.
• If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel
tank of the machine to supply clean fuel.
Water drain cock is provided on the bottom side of the fuel tank.
• Drain water before starting the engine every morning.
• In addition, remove the cover under the tank once a year to clean up inside of the tank.

Copyright ©
1002-10
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the
system.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of dis-
posing of these lubricants.
Plastic and resin parts

When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint
solvents etc... Use only water, soap and a soft cloth.
The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.

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1002-11
SPECIFICATIONS
Main data
Model name ............................................................................................................................CX460 Hydraulic Excavator
Operating weight ............................................................................................................................. 46600 kg (102735 lbs)
Engine output ....................................................................................................................................... 270 kW / 1950 rpm
Performance
Swing speed....................................................................................................................................................... 9.0 Tr/min.
Travel speed
Low Speed.................................................................................................................................... 3.1 km/h (1.93 mph)
High Speed ................................................................................................................................... 5.3 km/h (3.30 mph)
Maximum drawbar pull ..........................................................................................................................341 kN (76659.85)
Grade ability ........................................................................................................................................................70% (35°)
Ground pressure ............................................................................................... 80 kPa (600 mm (23.62 in) grouser shoe)
Complete machine dimensions

Standard Short
arm arm
(3.40 m) (2.55 m)
(11 ft 1.85 in) (8 ft 4.39 in)
Length 11940 mm 11990 mm
(470.07 in) (472.04 in)
Width 3350 mm 3350 mm
(131.88 in) (131.88 in)
Height 3600 mm 3670 mm
(141.73 in) (144.48 in)
Main body dimensions

Main body width .............................................................................................................. See machine overall dimensions
Main body length............................................................................................................. See machine overall dimensions
Upper side swing body width ................................................................................................................. 3040 mm (120 in)
Cab width ............................................................................................................................................ 1000 mm (39.37 in)
Main body height............................................................................................................................... 3270 mm (128.73 in)
Tail swing radius ................................................................................................................................ 3620 mm (142.51 in)
Distance of rear swing body.............................................................................................................. 3600 mm (171.73 in)
Ground clearance for upperstructure ...................................................................................................... 1330 mm (52.36)
Center-to-center of wheels.................................................................................................................... 4400 mm (173.22)
Overall track length ............................................................................................................................... 5450 mm (214.56)
Maximum track width ........................................................................................................................ 3350 mm (131.88 in)
Center-to-center for track ...................................................................................................................... 2750 mm (108.26)
Width of track shoe .................................................................................600 mm (23.62 in) (Optional: 750 mm (29.52 in)
Minimum ground clearance (To bottom of lower frame) ............................................................................ 540 mm (21.25)

Copyright ©
1002-12
Engine
Name.............................................................................................................................................................ISUZU, 6UZ1
Type: ................................................................................ Water-cooled, 4-cycle diesel, 6-cylinder in line, direct injection
.............................................................(electronic control), turbocharger with air cooled intercooler, without cooling fan.
No. of cylinders - bore x stroke....................................................................................................6-dia. 120 mm x 145 mm
Displacement........................................................................................................................................ 9.839 L (2.599 gal)
Compression ratio ....................................................................................................................................................... 17.5
Rated output.......................................................................................................................................270 kW / 1950 min-1
Maximum torque................................................................................................................. 1435 Nm / apprex. 1500 min-1
Dry weight ........................................................................................................................................Approximately 840 kg
Engine dimensions (LxWxH) ........................................................................ 1235x953x1272 mm (48.62x37.51x50.07 in)
Oil pan ...................................................................................................................................... All direction 35°, inclinable
Cooling fan ................................................... Remote (diameter 1016 mm (39.99 in) suction type-6 blades resin & steel)
Oil pan capacity.................................................. Maximum: 36 L (9.51 gal) Minimum: 25 L (6.60 gal) (excluding oil filter)
Direction of rotation ...................................................................................................................... Right (as seen from fan)
Starter, reduction type ................................................................................................................................... .24 V, 5.5 kW
Alternator, AC type ............................................................................................................................................. 24 V, 50 A
Battery ............................................................................................................................................... 2 x 12V, 128 Ah/5 Hr
Cooling system
Fan drive system .........................................................................................................................................Hydraulic drive
Fan type........................................................................................................... Ø 1016 mm (39.99 in), 6 blades, air intake
Radiator
Fin type .................................................................................................................................................................. wavy
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Oil cooler
Fin type .................................................................................................................................................................. wavy
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Inter-cooler
Fin type ...............................................................................................................................................triangular straight
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Fuel cooler
Fin type .................................................................................................................................................................. wavy
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Capacity of coolant and lubricants

Coolant ...................................................................................................................................................... 38 L (10.03 gal)
Fuel ....................................................................................................................................................... 611 L (161.41 gal)
Lubricant for engine..................................................................................................................................... 36 L (9.51 gal)
Lubricant for travel reduction gear (per side)............................................................................................... 15 L (3.96 gal)
Lubricant for swing reduction gear (per side) ........................................................................................... 10.5 L (2.77 gal)
Hydraulic oil........................................................................................................................................... 460 L (121.51 gal)
Capacity of hydraulic oil tank................................................................................................................... 230 L (60.76 gal)
Hydraulic oil filter

Suction filter (inside tank) ....................................................................................................................................150 mesh
Return filter (inside tank) .......................................................................................................................................... 10 µm
Nephron filter (inside housing) ................................................................................................................................... 1 µm
Pilot line filter (inside housing).................................................................................................................................. 10 µm
Fuel filter
Main filter.................................................................................................................................................................... 4 µm
Pre-filter.................................................................................................................................................................... 10 µm

Copyright ©
1002-13
Operating devices
Operator's seat
Location: left side
Structure: KAB 555: Low frequency air suspension with helical springs and double acting hydraulic damper.
Cab
Smooth and round shape design cab, fabricated by press work Safety glass for all window.
Levers and pedals
For travel use: Levers and pedals (hydraulic pilot type) (x2)
For operating machine use: Levers (hydraulic pilot type) (x2)
Instruments and switches
Work mode switchover: 4 modes (heavy digging, standard, finishing and auto)
Travel speed switchover: Low-speed / high-speed switch
One-touch idle: Knob switch type
Monitor device
Machine status display (full-dot liquid crystal)
Travel speed selection status: Low Speed / High Speed
Work mode selection status: H/S/L/A
Auto idle selection status: ON/OFF
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge: bar graph indicator
Engine coolant temperature gauge: bar graph indicator
Hydraulic oil temperature gauge: bar graph indicator
Hour meter: digital type
Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm
Over heat* Battery charge* Faulty electrical system*
Refill fuel* Engine oil pressure* Refill coolant*
Engine preheat Auto warm-up Air cleaner
Idling Service interval Digging power up
Lighting
Working light House: 24V, 70W (x1)
Boom: 24V, 70W (x1)
Cab: 24V, 70W (x2)
Interior light 24V, 10W (x1)
Horn: electric horn (x2)

Other:
Wiper with intermittent function.
Window washer fluid.
Air conditioner.
Rear view mirror (left and right side).
DC-DC converter.

Copyright ©
1002-14
Hydraulic system
Hydraulic pump drive system, directly coupled to the engine (no transmission)
Main pump
Manufacturer............................................................................................................................................... Kawasaki
Pump type .............................................................................................. double variable displacement piston pump
Displacement volume ................................................................................................. 182 cm3 (11.11 cu in) x 2 /rev
Rated operating pressure .......................................................................................................... 31.4 MPa (4554 psi)
Maximum operating pressure .................................................................................................... 34.3 MPa (4975 psi)
Input revolution speed......................................................................................................1980 min-1 (at 1980 rpm-1)
Maximum discharge flow .................................................. 360 L/min (95.10 gpm) x 2 at 1980 min-1 (at 1980 rpm-1)
Input horsepower ........................................................................................................................................ 221.6 kW
Shaft input horsepower ................................................................................224.7 kW at 1980 min-1 (at 1980 rpm-1)
Shaft input torque .............................................................................................. 1072.8 Nm (791 lb-ft) at 1980 min-1
Pilot pump
Pump type ............................................................................................................................................... Gear pump
Displacement volume ............................................................................................................ 15 cm3 (0.91 cu in)/rev
Operating pressure ........................................................................................................................ 3.9 MPa (566 psi)
Maximum flow ....................................................................... 29.7 L/min (7.84 gpm) (at 1980 min-1) (at 1980 rpm-1)
Input horsepower ............................................................................................................................................ 3.1 kW
Control characteristics
Simultaneous output control of overall.
Negative control.
Electric horse power control.
Control Valve
Model; 4-spool section: integrated (1) or 5-spool section: integrated (1)
Operation method: hydraulic pilot method: travel, swing and operating machine
Maximum flow .......................................................................................................................... 360 L / min (95.10 gpm)
Main relief set pressure.......................................................standard; 31.4 MPa (4554 psi) (at 340 L/min (89.81 gpm))
...................................................................................... power boost; 34.3 MPa (4975 psi) (at 315 L/min (83.21 gpm))
Overload set pressure.............................................. when boom down; 24.5 MPa (3553 psi) (at 20 L/min (5.28 gpm))
..................................................................................................... other: 36.3 MPa (5265 psi) (at 20 L/min (5.28 gpm))
Foot relief set pressure ......................................................................3.38 MPa (490.22 psi) (at 61 L/min (16.11 gpm))
Functions
Straight travel circuit
Boom up / 2-speed internal confluence for arm
Boom/Arm load holding circuit
Boom down regenerative circuit
Arm in forced regenerative circuit
Boom up override variable throttle valve
Swing priority variable throttle valve
Backup 2-speed confluence
Hydraulic Cylinders
Boom cylinder (x2)
Cylinder bore .............................................................................................................................Ø170 mm (Ø6.69 in)
Rod diametre .............................................................................................................................Ø115 mm (Ø4.52 in)
Maximum retracted length .......................................................................................................... 2230 mm (87.79 in)
Stroke ......................................................................................................................................... 1550 mm (61.02 in)
Arm (dipper) cylinder
Maximum retracted length ........................................................................................................ 2588 mm (101.88 in)
Stroke ......................................................................................................................................... 1820 mm (71.65 in)
Bucket cylinder
Maximum retracted length .......................................................................................................... 1972 mm (77.63 in)
Stroke ......................................................................................................................................... 1285 mm (50.59 in)

Copyright ©
1002-15
Rotating Joint
Operating pressure
High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi)
Drain port (T) ................................................................................................................................. 1.0 MPa (145 psi)
Pilot port (P) .................................................................................................................................. 3.9 MPa (566 psi)
Hydrostatic test pressure
High pressure passage (ABCD) ................................................................................................ 51.5 MPa (7469 psi)
Drain port (T) ................................................................................................................................. 2.0 MPa (290 psi)
Pilot port (P) .................................................................................................................................. 5.9 MPa (856 psi)
Flow
High pressure passage (ABCD) .......................................................................................... 360 L / min (95.10 gpm)
Drain port (T) ......................................................................................................................... 40 L / min (10.56 gpm)
Pilot port (P) ............................................................................................................................ 31 L / min (8.18 gpm)
Number of revolutions...................................................................................................................... 15 min-1 (15 rpm-1)
Torque; when pressurizing 2 ports..................................................................................................196 Nm (144.5 lb-ft)
Port A; forward right ...................................................................................................................................................G1
Port B; forward left .....................................................................................................................................................G1
Port C; backward right ...............................................................................................................................................G1
Port D; backward left..................................................................................................................................................G1
Port E; drain port ....................................................................................................................................................G1/2
Port F; pilot port ..................................................................................................................................................... G1/4
Solenoid Valve
Valve specifications
Maximum flow...................................................................... P -> B: 20 L/min (5.28 gpm) Other: 5 L/min (1.32 gpm)
Rated pressure ......................................................................................................................... 4.5 MPa (652.67 psi)
Solenoid specifications
Operating voltage ................................................................................................................................ DC 20 to 32 V
Power consumption .................................................................................................................................. 17 W max.
Hand control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi)
Operating angle
Ports 1, 3 .............................................................................................................................................................. 19°
Ports 2, 4 .............................................................................................................................................................. 25°
Operating torque
Port 1 ...................................................................................................................0.58 to 2.03 Nm (0.42 to 1.49 lb-ft)
Port 3 ...................................................................................................................0.47 to 1.92 Nm (0.34 to 1.41 lb-ft)
Ports 2, 4 .............................................................................................................0.71.to 2.30 Nm (0.52 to 1.69 lb-ft)
Foot control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi)
Operating angle ..................................................................................................................................................... 12.4°
Operating torque
Valve................................................................................................................. 4.16 to 9.03 Nm (3.068 to 6.660 psi)
Damper.........................................................................................4.90 Nm (at 0.0275 m/s) (3.614 psi (at 0.090 f/s))

Copyright ©
1002-16
Swing unit
Swing circle ......................................................................................................... Swing bearing type (with internal gears)
Swing parking brake ................................................................................ Mechanical lock (operational lever linkage type)
Swing lock .............................................................................................. Mechanical lock (swing lock switch linkage type)
Swing hydraulic motor .....................................................................................................Fixed displacement piston motor
Displacement ......................................................................................................................... 250 cm3 (15.26 cu in)/rev
Operating pressure ........................................................................................................................ 29.4 MPa (4264 psi)
Operating flow ............................................................................................................................. 360 L/min(95.10 gpm)
Mechanical brake torque.....................................................................................................1288 Nm (949.97 lb-ft) min.
Brake off pressure................................................................................................................ 2.9 MPa (420.60 psi) max.
Relief valve set pressure....................................................................................................... 29.3 MPa (4249 psi) max.
Reduction gear .................................................................................................. Planetary gear 2-stage reduction System
Reduction ratio ........................................................................................................................................................ 27.143
Travel lower body

Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake
Displacement .............................................................................................. 290.7/170.1 cm3 (17.74/10.38 cu in)/rev
Operating pressure .................................................................................................................... 34.3 MPa (5192 psi)
Operating flow..................................................................................................................... 360.4 L/min (95.20 gpm)
Brake torque................................................................................ 71 KNm (52366 Ib-ft) min. (including reduction gear)
Relief valve set pressure ............................................35.8 to 38.8 MPa (at 50L/min) (5192 to 5627 psi (at 13.20 gpm)
Automatic 2-speed switch-over pressure ....................................................................................... 26.5 MPa (3843 psi)
Reduction gear ...................................................................................................Planetary gear 3-stage reduction system
Reduction ratio .................................................................................................................................................... 60.652
Travel brake .................................................................................................................................................. Hydraulic lock
Parking brake ................................................................................................... Mechanical lock (travel lever linkage type)
Track shoe
Model ....................................................................................................................... Assembly-type triple grouser shoe
Number of shoes (per side)........................................................................................................................................ 50
Shoe width
Standard ....................................................................................................................................... 600 mm (23.62 in)
Optional ....................................................................................................................................... 750 mm (29.52 in)
Grouser height ...................................................................................................................................... 36 mm (1.41 in)
Link pitch .......................................................................................................................................... 228.6 mm (8.99 in)
Roller
Number of upper rollers (per side) ............................................................................................................................... 2
Number of lower rollers (per side)................................................................................................................................ 9
Track belt tension adjuster............................................................................... Grease cylinder type (with cushion spring)

Copyright ©
1002-17
Work Unit
Model ................................................................................................................................................. Backhoe attachment
Capacity / dimensions / working dimensions
Bucket width.................................................................................................... 1400 mm (55.11 in) (without side cutter)
Width of bucket with side cutter ....................................................................................................... 1510 mm (5944 in)
Weight of bucket with side cutter ......................................................................................................1830 kg (4034 lbs)
Boom
6980 mm
(274.80 in)
Standard arm Short arm
3380 mm 2530 mm
Arm (dipper) length
(133.07 in) (99.60 in)
1840 mm
Bucket radius
72.44 in
Bucket wrist angle 176°
12000 mm 11230 mm
Maximum digging radius
472.43 in 442.12 in
11770 mm 10990 mm
Maximum digging radius at ground line
463.38 in 432.67 in
7720 mm 6870 mm
Maximum digging depth
303.93 in 270.47 in
6570 mm 5670 mm
Maximum vertical straight wall digging depth
258.66 in 223.22 in
11140 mm 10820 mm
Maximum reach height
438.58 in 425.98 in
7740 mm 7420 mm
Maximum dump height
304.72 in 292.12 in
4990 mm 5140 mm
Minimum swing radius at front
196.45 in 202.36 in
9250 mm 9320 mm
Overall height with minimum swing radius at front
364.17 in 366.92 in

Copyright ©
1002-18
Digging force (ISO 6015)
Arm (dipper)
3380 mm 2530 mm
(133.07 in) (99.60 in)
247 kN 247 kN
Bucket digging force (standard)
(55527.8 lbf) (55527.8 lbf)
270 kN 270 KN
Bucket digging force (power boost)
(60698.4 lbf) (60698.4 lbf)
209 kN 257 kN
Arm (dipper) digging force (standard)
(46985 lbf) (57775.9 lbf)
229 kN 281 kN
Arm (dipper) digging force (power boost)
(51481.2 lbf) (63171.3 lbf)

Copyright ©
1002-19
COMPONENT WEIGHT
Major component weight
B
A
C
F
G
H
330.3.01.00.51A
Weight information is approximate
A) Operating weight .................................................................................................................... 46600 kg (102735 lbs)
B) Upper mechanism (including counterweight and turntable bearing) ........................................ 19700 kg (43431 lbs)
C) Counterweight............................................................................................................................ 9200 kg (20282 lbs)
D) Lower mechanism (with standard grouser shoe) .....................................................................16700 kg (36817 lbs)
E) Main Unit Weighty ....................................................................................................................36400 kg (80248 lbs)
F) Attachments .............................................................................................................................10000 kg (22046 lbs)
G) Boom (including cylinders)......................................................................................................... 5540 kg (12213 lbs)
H) Arm (dipper) (including cylinders and linkage).............................................................................2670 kg (5886 lbs)

Copyright ©
1002-20
Bucket weight
Bucket capacity (m3) Weight kg (lbs) L1 mm (in) L2 mm (in)
1 1.8 1430 (3153) 1384 (54.48) 1515 (59.64)
2 1.8 HD 1810 (3990) 1400 (55.11) 1508 (59.36)
3 2.0 1500 (3307) 1514 (59.60) 1645 (64.76)
4 2.0 HD 1910 (4211) 1530 (60.23) 1638 (64.48)
5 2.2 1510 (3329) 1825 (71.85) 1956 (77.00)
L1
L2
330.3.01.00.51BA

Copyright ©
1002-21
Other component weight
Engine .....................................................................................................................................................840 kg (1852 lbs)
Air cleaner ...............................................................................................................................................17.6 kg (38.8 lbs)
Hydraulic pump ......................................................................................................................................... 245 kg (540 lbs)
Attachment control valve ........................................................................................................................... 424 kg (935 lbs)
Swing motor (excluding pinion) ...............................................................................................................565 kg (1245 lbs)
Travel motor and reduction gear assembly .............................................................................................613 kg (1351 lbs)
Rotary joint..................................................................................................................................................56 kg (123 lbs)
Solenoid valve bank .................................................................................................................................. 7.0 kg (15.4 lbs)
Hand control valve ......................................................................................................................................1.9 kg (4.2 lbs)
Foot control valve ...................................................................................................................................... 7.8 kg (17.2 lbs)
Standard boom......................................................................................................................................3540 kg (7804 lbs)
Standard arm (dipper)...........................................................................................................................1690 kg (3726 lbs)
Short arm (dipper).................................................................................................................................1490 kg (3285 lbs)
Boom cylinder (one) .................................................................................................................................. 400 kg (882 lbs)
Arm (dipper) cylinder...............................................................................................................................695 kg (1532 lbs)
Bucket cylinder .......................................................................................................................................... 390 kg (860 lbs)
Fuel tank ................................................................................................................................................... 243 kg (536 lbs)
Hydraulic oil tank....................................................................................................................................... 229 kg (505 lbs)
Turntable bearing ....................................................................................................................................656 kg (1446 lbs)
Muffler ........................................................................................................................................................... 20 kg (44 lbs)
Radiator total weight ................................................................................................................................. 208 kg (458 lbs)
Oil cooler................................................................................................................................................... 34 kg (75 lbs)
Radiator ..............................................................................................................................................23.3 kg (51.3 lbs)
Air cooler................................................................................................................................................ 28.8 kg (63 lbs)
Fuel cooler ............................................................................................................................................ 1.2 kg (2.64 lbs)
Idler wheel................................................................................................................................................. 251 kg (553 lbs)
Upper roller ................................................................................................................................................... 44 kg (97 lbs)
Lower roller .................................................................................................................................................82 kg (181 lbs)
Recoil spring ............................................................................................................................................. 343 kg (756 lbs)
Recoil spring ...................................................................................................................................... 141 kg (310.8 lbs)
Grease cylinder assembly ................................................................................................................ 62.3 kg (137.3 lbs)
Threaded ..........................................................................................................................................68.8 kg (151.6 lbs)
Yoke ..................................................................................................................................................66.8 kg (147.2 lbs)
Track chains (per side)
600 mm (23.62 in).............................................................................................................................2580 kg (5688 lbs)
750 mm (29.52 in).............................................................................................................................2930 kg (6459 lbs)

Copyright ©
1002-22
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY
Sprocket
Dimensions
a P
Ød
Øb Øc
800.6.10.00.11A1
Dimension
Mark
mm in
Standard 90 3.54
a
Limit 78 3.07
Standard 773.6 30.45
Øb
Limit 761.6 29.98
Øc
Limit 854.5 33.64
Ød
Limit - -
Standard 43.5 1.71
e
Limit 48.5 1.90
Standard 229 9.01
P
Limit - -
Gauge
Unit in mm
300
228.6
44.8
5.4
87.6
40.2
°
.7
90°
50
37.9
24.5
99.6
.6
117.8
3∼
R
95
R
.9 R
36
3 .1
R
°
R4
R4
23.
33
.8
CI01N501

Copyright ©
1002-23
Idler wheel
Dimensions
c Dimension
Mark
mm in
b Standard 676 26.61
Øa
Limit 665 26.18
Standard 22.5 0.88
b
Limit - 1.00
Standard 102 4.01
c
Limit 92 3.62
Standard 95 3.74
Ø d (shaft)
Limit 94 3.70
Standard 95 3.74
Ø d (bushing)
Limit 96 3.77
a
Standard 100 3.93

e (bushing)
Limit 99 3.89
e f Standard 15 0.59
f
Limit - -
d
330.6.10.00.12B
Gauge
Unit in mm
250
204
102
42.5
°
10
80
22.5
R5
R50
R3
15
R3
0.2
CI01N502

Copyright ©
1002-24
Upper roller
Dimensions
c Dimension
Mark
b
mm in
Standard 150 5.90
Øa
Limit 140 5.51
Standard 15 0.59
b
d
a
Limit - -
Standard 104 4.09
c
Limit - -
Standard 65 2.55
Ø d shaft
Limit 64 2.51
g e Standard 65 2.55
f Ø d bushing
Limit 66 2.59
000.6.10.00.8C Standard 150 5.90
e bushing
Limit 149 5.86
Standard 9 0.35
f
Limit 8.5 0.33
Standard 30 1.18
g
Limit - -
Gauge
Unit in mm
5 210
104
97
°
.1
13
35
65
15
R3
R3
R3
R3
15
R3
125 120
245
CI01N503

Copyright ©
1002-25
Lower roller
Dimensions
f g
a
e
b
000.6.10.00.08D
Dimension Dimension
Mark Mark
mm in mm in
Standard 200 7.87 Standard 85 3.34
Øa Ø e (bushing)
Limit 188 7.40 Limit 86 3.38
Standard 25 0.98 Standard 93 3.66
b Øf
Limit 20 0.78 Limit 92 3.62
Standard 223 8.77 Standard 24.5 0.96
d g
Limit 233 9.17 Limit 23.9 0.94
Standard 85 3.34
Ø e (Shaft)
Limit 84 3.30
Gauge
Unit in mm
KTA1107X-C02

Copyright ©
1002-26
Track
c’ c
d
d’
e’ e
f f
f’ (4 pieces)
800-6-10-00-11E-1
Dimension Dimension
Mark Mark
mm in mm in
a Ø c’ (bushing)
Limit 32 1.25 Limit 68.23 2.68
b Ø d’ (bushing)
Limit 121 4.76 Limit 51.7 2.03
Standard 73.33 2.88 Standard 48.8 1.92
Ø c (bushing) Ø e’ (Pin)
Limit 68.23 2.68 Limit 44.9 1.76
Standard 49.2 1.93 Standard 914.4 35.99
Ø d (bushing) f’ (4 pieces)
Limit 51.7 2.03 Limit - -
Standard 48.6 1.91
Ø e (Pin)
Limit 45.1 1.77
Standard 228.6 8.99
f
Limit - -

Copyright ©
1002-27
DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS
4
6
7
1
10
9
3
5
2
8
11
CRIL06C002F
1. Boom foot/Frame
a
b c
d e
330.6.10.00.12C1
Dimension
Mark
mm in
Standard 874 34.40
a (frame)
Limit 882 34.72
Standard 871 34.29
b (boom)
Limit 868 34.17
Standard 3.5 to 5.5 0.13 to 0.21
c (clearance)
Limit Shim adjustment
Standard 120 4.72
Ø d (shaft)
Limit 119 4.68
Standard 120 4.72
Ø e (bushing)
Limit 121.5 4.78

Copyright ©
1002-28
2. Boom cylinder foot/Frame
b
c
e d
330.6.10.00.1.12C2
Dimension
Mark
mm in
Standard 126 4.96
a (boom)
Limit 132 5.19
Standard 125 4.92
b (cylinder)
Limit 122 4.80
Standard 1.5 to 3.5 0.05 to 0.13
c (clearance)
Standard 120 4.72
Ø d (shaft)
Limit 119 4.68
Standard 120 4.72
Ø e (bushing)
Limit 121.5 4.78
3. Boom cylinder head/Boom
a
c
330.6.10.00.12D1
Dimension
Mark
mm in
Standard 140 5.51
a (boom)
Limit 137 5.39
Standard 679 26.73
a (cylinder)
Limit 675 26.57
Standard 1.5 to 3.0 0.05 to 0.11
c (clearance)
Standard 120 4.72
Ø d (shaft)
Limit 119 4.68
Standard 120 4.72
Ø d (bushing)
Limit 121.5 4.78

Copyright ©
1002-29
4. Arm cylinder foot/Boom
a Dimension
Mark
mm in
b c Standard 156 6.14
a (boom)
Limit 162 6.37
Standard 155 6.10
b (cylinder)
Limit 153 6.02
Standard 1.0 to 3.0 0.03 to 0.11
e d c (clearance)
Standard 120 4.72
Ø d (shaft)
Limit 119 4.68
Standard 120 4.72
Ø e (bushing)
Limit 121.5 4.78
330.6.10.00.12D2
5. Boom/Arm
g g Dimension
a Mark
mm in
b c Standard 437 17.20
a (boom)
Limit 440 17.32
b (arm)
Limit 429.7 16.91
e d c (clearance)
Standard 4.5 to 5.5 0.17 to 0.21
Standard 120 4.72
Ø d (shaft)
Limit 119 4.68
Standard 120 4.72
Ø e (bushing)
330.6.10.00.12E1 Limit 121.5 4.78
Standard 98 3.85
g
Limit 96 3.77
6. Arm cylinder head/Arm

a Dimension
Mark
mm in
b c a (arm)
Standard 156 6.14
Limit 161 6.33
Standard 155 6.10
b (cylinder)
Limit 153 6.02
Standard 1.0 to 3.0 0.039 to 0.11
e d c (clearance)
Standard 120 4.72
Ø d (shaft)
Limit 119 4.68
Standard 120 4.72
Ø e (bushing)
Limit 121.5 4.78
330.6.10.00.12F1

Copyright ©
1002-30
7. Bucket cylinder foot/Arm
a Mark
Dimension
mm in
b Standard 141 5.55
a (arm)
c Limit 146 5.74
Standard 140 5.51
b (cylinder)
Limit 138 5.43
Standard 1.0 to 3.0 0.039 to 0.11
e d c (clearance)
Standard 110 4.33
Ø d (shaft)
Limit 109 4.29
Standard 110 4.33
Ø e (bushing)
330.6.10.00.12F2
Limit 111.5 4.38
8. Connecting rod/Arm
c Dimension
Mark
a mm in
Standard 50 1.96
a
Limit 47 1.85
Standard 441 17.36
b b
Limit 437 17.20
e Standard 1.5 to 2.0 0.059 to 0.078
c (clearance)
a Standard 95 3.74
Ø d (shaft)
Limit 94 3.70
Standard 95 3.74
d Ø e (bushing)
Limit 96.5 3.79
330.6.10.00.12G1
9. Compensator/Bucket
c Dimension
Mark
mm in
Standard 480 18.89
a (bucket)
Limit 485 19.09
Standard 479 18.85
b a b (link)
Limit 476 18.74
e c (clearance)
Standard 1.5 to 3.5 0.059 to 0.13
Standard 100 3.93
Ø d (shaft)
Limit 99 3.89
Standard 100 3.93
Ø e (bushing)
d Limit 101.5 3.99
330.6.10.00.12G2

Copyright ©
1002-31
10. Connecting rod/Compensator/Bucket cylinder head
c Mark
Dimension
mm in
Standard 50 1.96
a a
Limit 48 1.88
f Standard 441 17.36
b
Limit 436 17.16
Standard 1.5 to 2.5 0.059 to 0.098
i d e b c (clearance)
h d (link)
Standard 141 5.55
Limit 143 5.62
Standard 140 5.51
a e (cylinder)
Limit 138 5.43
Standard 1.5 to 2.0 0.059 to 0.078
f (clearance)
g Standard 110 4.33
Ø g (shaft)
330.6.10.00.12H1 Limit 109 4.29
Standard 110 4.33
Ø h (bushing)
Limit 111.5 4.38
Standard 110 4.33
Ø i (bushing)
Limit 111.5 4.38
11. Arm/Bucket
c Dimension
Mark
g mm in
d Standard 480 18.89
a (bucket)
f Limit - -
Standard 479 18.85
b (arm)
Limit 476 18.74
a b Standard 1.5 to 4.0 0.059 to 0.15
c (clearance)
Standard 16 0.62
d
Limit 10 0.39
Standard 100 3.93
Ø e (shaft)
Limit 99 3.89
Standard 100 3.93
Ø f (bushing)
Limit 101.5 3.99
Standard 100 3.93
e Ø g (bushing)
Limit 101.5 3.99
330.6.10.00.12I1

Copyright ©
1002-32
SHIMS FOR ADJUSTING ATTACHMENT GAPS
For boom foot
R
O.D I.D H
000-6-10-02-02A
Part No. I.D. O.D. R H Shim Material

Thickness
KNV1132 76 160 100 30 1.2 SPHC
KRV2390 91 190 115 30 1.2 SPHC
KBV1441 101 220 130 30 1.2 SPHC
KBV1748 101 230 135 30 1.2 SPHC
KSV1805 111 240 140 30 1.2 SPHC
R
O.D I.D H
000-6-10-02-02B
Part No. I.D. O.D. R H Shim Material

Thickness
KSV1930 111 240 140 30 1.0 Urethone
KSV11380 111 240 140 30 2.0 Urethone
KSV1931 116 240 140 30 1.0 Urethone
KSV11390 116 240 140 30 2.0 Urethone
KTV10730 121 245 150 50 2.0 Urethone
KTV10740 121 245 150 50 1.0 Urethone
KTV10750 121 260 150 50 2.0 Urethone
KTV10760 121 260 150 50 1.0 Urethone
KWV0097 141 280 160 50 1.0 Urethone
KWV10510 141 280 160 50 2.0 Urethone
KWV0096 141 300 180 50 1.0 Urethone
KWV10500 141 300 180 50 2.0 Urethone
KUV10150 141 300 170 30 1.0 Urethone
KUV10160 141 300 170 30 2.0 Urethone
KUV10130 151 300 170 30 1.0 Urethone
KUV10140 151 300 170 30 2.0 Urethone

Copyright ©
1002-33
SPECIAL TORQUE SETTINGS
No. Component Screw Wrench (mm) Torque setting
1* Travel motor and reduction gear assembly M24 36 900-1052 Nm (664-776 lb-ft)
2* Drive sprocket M24 36 900-1052 Nm (664-776 lb-ft)
3* Take-up Roller M16 24 267-312 Nm (197-230 lb-ft)
4* Upper roller M24 36 521-608 Nm (385-448 lb-ft)
5* Lower roller M24 36 902-1049 Nm (665-774 lb-ft)
6* Track guard M24 36 902-1049 Nm (665-774 lb-ft)
7 Shoe bolt M24 32 1236-1510 Nm (912-1114 lb-ft)
8 Counterweight M30 46 1765-2010 Nm (1302-1482 lb-ft)
9* Turntable bearing M24 36 952-1050 Nm (702-774 lb-ft)
10 * Swing equipement M24 36 900-1050 Nm (664-774 lb-ft)
11 * Mount M20 30 324-373 Nm (239-275 lb-ft)
12 * Engine Front bracket M10 17 64-73 Nm (47-54 lb-ft)
13 * Rear bracket M16 24 147-176 Nm (108-130 lb-ft)
14 * Radiator M16 24 147-176 Nm (108-130 lb-ft)
15 * Frange M12 19 88-108 Nm (65-79 lb-ft)
Hydraulic pump
16 * Pump M20 17 367-496 Nm (271-366 lb-ft)
17 * Hydraulic reservoir M16 24 226-265 Nm (167-195 lb-ft)
18 * Fuel reservoir M16 24 226-265 Nm (167-195 lb-ft)
19 * Control valve M20 30 333-392 Nm (245-289 lb-ft)
20 * Lock bar M16 24 267-312 Nm (197-230 lb-ft)
Rotating joint
21 * Joint M12 19 54-64 Nm (40-47 lb-ft)
22 Floor M16 24 78-80 Nm (57-59 lb-ft)
Cab
23 * Mount M10 17 35-42 Nm (26-31 lb-ft)
24 Battery M10 17 20-29 Nm (15-21 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Copyright ©
1002-34
19 15, 16
17 11, 12, 13
10
18 8
14
24
20, 21 7
1, 2
9 5
22, 23 6
4
3
2 6
4
6
5
3
TORQUE_1

Copyright ©
1002-35
10
16
15
9 9
14 12 11 13
19
17 18
20
22
24
23
21
TORQUE_2

Copyright ©
1002-36
MACHINE OVERALL DIMENSIONS
NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (36 mm (1.41 in))
Standard arm (3380 mm (133.07 in))

* : with catwalks - (option)
*
BKTU6001_338M
Short arm (2530 mm (99.60 in))

* : with catwalks - (option)
BKTU6001_253M

Copyright ©
2001
Section
2001
FUEL-COOLER, ENGINE INTER-COOLER,

RADIATOR AND OIL-COOLER

Printed in France
CNH Lep SM4602001-0EN September 2007
Copyright ©
2001-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER ............................................................................. 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 3
ENGINE .......................................................................................................................................................................... 4
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 4
ENGINE AND RADIATOR - FIGURE 1 .......................................................................................................................... 6
SPECIFICATIONS
See Section 1002
Lep SM4602001-0EN Issued 09-07

Copyright ©
2001-3
RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER
Before carrying out any operation on the machine, perform the following operations in the order shown:
- Park the machine on hard, flat ground.
- Lower the attachment to the ground.
- Shut down the engine.
- Remove the starter switch key.
- Make sure that pressure in the hydraulic system has been completely released (see Operator’s Manual).
WARNING: When the machine is working, the engine components and the hydraulic pump reach a high temper-
! ature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the machine to cool
down before starting any servicing operation.
Removal Installation
NOTE: For the removal refer to the figure 1, page 6. NOTE: For the installation refer to the figure 1, page 6,
proceed in the reverse order from that of removal.
STEP 1
1) Coat the thread of reference (37) and (13) with loctite
Drain the cooling system (see Operator’s Manual). or equivalent after removing any oil film and fasten by
STEP 2 tightening torque .
Release pressure in the hydraulic reservoir to allow the 2) Apply packing liquid (69) to the connection of radia-
vacuum pump to be mounted (see Section 8000). tor hose after removing any oil film and fasten by tight-
ening torque.
3) Tighten up the hose band from the direction schown
on the D.W.G.
Before operating the machine:
- Check the oil level in the hydraulic reservoir. Top up if
necessary.
- Check the hydraulic fluid cooling circuit for leaks.
- Fill and bleed the engine cooling system (see Opera-
tor’s Manual).
- Check the engine cooling system for leaks.

Copyright ©
2001-4
ENGINE
Removal STEP 7
NOTE: For the removal refer to the figure 1, page 6. Remove the engine retaining hardware.
NOTE: When installing, make a visual inspection of the
STEP 1
condition of the rubber flexible mountings and change
them if necessary. Tighten the engine retaining screws
to the torque specified in Section 1002.
STEP 8
When there is nothing interfering with the removal of
the engine, raise the engine carefully and install it on a
suitable repair bench.
STEP 9
Refer to Section 8003 and remove the hydraulic pump.
Installation
JS00163A
NOTE: For the installation refer to the figure 1, page 6,
Park the machine on hard, flat ground. Lower the
attachment to the ground.
1) Coat the thread of reference (11), (35), (37), (41),
STEP 2 (43) and (49) with loctite or equivalent after removing
Release pressure in the hydraulic system and in the any oil film and fasten by tightening torque .
hydraulic reservoir (see Section 8000).
2) The elastic rubbers of reference (46) and (74) should
STEP 3 be assembled after confirming the discrimination color.
Before operating the machine, carry out the following
operations:
- Bleed and prime the fuel system (see Operator’s
Manual).
1 - Fill and bleed the engine cooling system (see Opera-
tor’s Manual).
- Check the hydraulic, fuel and cooling systems for
leaks.
necessary.
CT07A009
Disconnect the earth cable (-) (1) from the battery.
STEP 4
Label and disconnect all the electrical connections from
the engine.
STEP 5
NOTE: For the removal refer to the figure 1, page 6.
Remove all the clips, etc. which attach the electrical
harnesses to the engine and move out of the way.
STEP 6
Install a suitable lifting device on the engine lifting rings
(for the weight of the engine, see Section 1002).

Copyright ©
2001-5
NOTES
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Copyright ©
2001-6
ENGINE AND RADIATOR - FIGURE 1
330-5-02-02-24

Copyright ©
2001-7
1 - SPL BOLT 57 - ELBOW
2 - BUCKET 58 - SPL JOINT
3 - ELBOW 59 - HIGH STRENGTH NUT
4 - HYDRAULIC HOSE 60 - RUBBER HOSE
5 - HYDRAULIC HOSE 61 - ELBOW
6 - ELBOW 62 - JUBILEE CLIP
7 - GEAR PUMP 63 - JUBILEE CLIP
8 - HIGH STRENGTH BOLT 64 - AIR-INLET HOSE
9 - HIGH STRENGTH WASHER 65 - ELBOW
10 - BRACKET; MUFFLER 66 - CLAMP
11 - HIGH STRENGTH BOLT 67 - SPL BOLT
12 - HIGH STRENGTH WASHER 68 - HOSE CLAMP
13 - BOND 69 - LIQUID PACKING
14 - NUT; FLANGED 70 - RADIATOR HOSE
15 - BOLT; U 71 - CLAMP
16 - MUFFLER 72 - BRACKET
20 - SEAL CLAMP 73 - ENGINE SUPPORT FRONT
22 - EXHAUST PIPE 74 - ELASTIC RUBBER
24 - PLUG 75 - HYDRAULIC HOSE
25 - HOSE ADAPTER 76 - HYDRAULIC HOSE
26 - HOSE CLAMP 77 - HYDRAULIC HOSE
27 - AIR HOSE 78 - ENGINE SUPPORT FRONT
28 - HOSE CLAMP 79 - BRACKET
30 - BRACKET 80 - HOSE BAND
31 - AIR-INLET PIPE 81 - BRACKET
32 - BRACKET 82 - RADIATOR (STD) ASSY
33 - AIR HOSE 83 - SPL LABEL
34 - AIR-INLET PIPE 84 - AIR CLEANER
35 - HIGH STRENGTH BOLT 85 - AIR HOSE
36 - HIGH STRENGTH WASHER 86 - HARNESS BAND
37 - SEMS BOLT 87 - JUBILEE CLIP
38 - RADIATOR STAY 88 - CLAMP
39 - HOSE BAND 89 - ELBOW
40 - TUBE 90 - DIESEL ENGINE
41 - SEMS BOLT 91 - BRACKET
42 - ENGINE SUPPORT REAR 92 - HIGH STRENGTH BOLT
43 - HIGH STRENGTH BOLT 93 - HOSE CLAMP
44 - HIGH STRENGTH WASHER 94 - AIR HOSE
45 - PLATE 95 - HOSE CLAMP
46 - ELASTIC RUBBER 96 - RADIATOR HOSE (IN)
47 - SPL NUT 97 - AIR-INLET PIPE
48 - SEMS BOLT 98 - RADIATOR STAY REAR
49 - ENGINE SUPPORT REAR 99 - HIGH STRENGTH BOLT
50 - HOSE BAND 100 - HIGH STRENGTH BOLT
51 - VINYL HOSE 102 - BRACKET
52 - HOLDER 103 - HOSE CLAMP
53 - SEMS BOLT 104 - CLAMP
54 - RESERVE TANK 105 - LIQUID PACKING
55 - BRACKET 106 - BRACKET
56 - VACUUM SENSOR 107 - SEMS BOLT
108 - ENGINE; DIESEL
109 - SEMS BOLT
110 - HOSE CLAMP
111 - HIGH STRENGTH BOLT

Copyright ©
2001-8
NOTES
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Copyright ©
3001
Section
3001
REMOVAL AND INSTALLATION

OF THE FUEL TANK

Printed in France
Copyright ©
3001-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
FUEL TANK .................................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
Description ................................................................................................................................................................. 5
SPECIFICATIONS
See Section 1002.

Copyright ©
3001-3
FUEL TANK
Removal
STEP 1 STEP 9
Remove the screws (8) and the protective plate (9).
STEP 10
Remove the screws (21) and the protective plate
(22).
STEP 11
Loosen the two screws (10) located under the
machine. Open the side portion of the machine and
remove the two screws (11) located on the RH side of
the fuel reservoir (1). Remove the protective plate
(12) of the reservoir.
JS00163A1
Park the machine on hard, flat ground. Lower the STEP 12
attachment to the ground. Attach labels on the hoses. Remove the hoses and
STEP 2 the retaining clips.
Reduce the engine speed to idle for 30 seconds, then STEP 13

shut down the engine. Shift the plastic protection (13) from the fuel sensor
STEP 3 (14). Remove the retaining screws (15) then the fuel
sensor (14) as well as the seal (16).
Turn the ignition key to "ON" without starting the
engine. STEP 14
STEP 4 Remove the screws (17) and (20) from the fuel tank
(1), and the shims (18).
Attach a "DO NOT OPERATE" tag to the ignition key
in the cab. STEP 15
STEP 5 Remove the fuel tank (1) using a hoist.
NOTE: The numbers within brackets refer to the fig-

ures on pages 5 and 6.
Remove the access panel under the fuel reservoir (1).
STEP 6
Open the filling plug (2) of the tank (1). Bleed the
remaining fuel using the valve (3) then remove the
latter. Remove the filter (19) and the fuel gauge.
STEP 7
Lift the hood of the front boot. Remove the retaining
screw (4) of the access ramp (5). Remove the access
ramp (5).
STEP 8
Remove the screws (6) on top and then inside the
front boot, then remove the protective housing (7).

Copyright ©
3001-4
Installation
NOTE: The numbers within brackets refer to the fig- STEP 8
ures on pages 5 and 6.
Install the protective housing (7) on top of the front
STEP 1 boot using the screws (6) then put back the screw
mask.
Using a hoist, position the fuel reservoir (1) on the
machine. STEP 9
STEP 2 Install the access ramp (5) using screws (4). Close
the front boot.
Install the shims (18) as well as the screws (17) and
(20), tighten the screws (17) to a torque of 225.6 to STEP 10
264.8 Nm (166.39 to 195.31 lbf-ft). Install the valve
(3) and tighten the valve (3) to a torque of 14.7 Nm Fill the fuel reservoir (see the operator's manual) and
(10.80 lbf-ft). make sure that there are no leaks.
STEP 3 STEP 11
Install a new seal (16), then the fuel probe (14) using Reinstall the protective plate on top of the machine.
the five screws (15), reposition the plastic protection
correctly (13).
STEP 4
Install the hoses by taking help of the labels attached
during removal. Tighten using retaining clips.
STEP 5
Install the reservoir protection (12) using screws (10)
and (11). Tighten the screws (10) and (11).
STEP 6
Install the protective plate (9). Tighten the screws (8).
STEP 7
Install the protective plate (22). Tighten the screws
(21).

Copyright ©
3001-5
Description
Location
7 6 9
11
6 8
5 12 21
11 10
22
20
4 SCREW
5 ACCESS RAMP
6 SCREW
7 PROTECTIVE HOUSING
8 SCREW
9 SKID PLATE
10 SCREW
11 SCREW
12 SKID PLATE
20 SCREW
21 SCREW
22 SKID PLATE

Copyright ©
3001-6
Fuel tank
19
1
14
13
16
15
18
17
1 FUEL RESERVOIR 15 SCREW

2 PLUG 16 SEAL
3 VALVE 17 SCREW
13 PLASTIC PROTECTION 18 SHIM
14 FUEL PROBE 19 FILTER

Copyright ©
4001
Section
4001
ELECTRICAL AND ELECTRONIC

CIRCUIT AND TROUBLESHOOTING

Printed in France
Copyright ©
4001-2
TABLE OF CONTENTS
ELECTRIC CIRCUITS OPERATION EXPLANATION ................................................................................................... 4
System Chart of Function .......................................................................................................................................... 4
ENGINE CONTROL ....................................................................................................................................................... 7

Fuel Injection Control (Common rail type) ................................................................................................................. 7
GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)........................................................................ 12
RELAYS AND MAIN FUSES (battery compartment) ................................................................................................... 13
FUSE BOX ................................................................................................................................................................... 14
WORK MODE SELECTION ......................................................................................................................................... 15
THROTTLE CONTROL................................................................................................................................................ 22
IDLING CONTROL (AUTO/ONE-TOUCH)................................................................................................................... 25
BREAKER MODE ........................................................................................................................................................ 27
AUTO PREHEAD (GLOW CONTROL) ........................................................................................................................ 28
AUTO WARM UP ......................................................................................................................................................... 31
OVERHEAT PROTECTION ......................................................................................................................................... 32
ATMOSPHERIC PRESSURE COMPENSATION ........................................................................................................ 33
CONTROL WHEN STARTING ENGINE...................................................................................................................... 34
CONTROL WHEN STOPPING ENGINE ..................................................................................................................... 35
EMERGENCY STOP OF THE ENGINE ...................................................................................................................... 35
ENGINE PROTECTION FUNCTION (EPF) ................................................................................................................. 36
FUNCTION LOCKING.................................................................................................................................................. 38
POWER BOOST .......................................................................................................................................................... 39
SWING BRAKE ............................................................................................................................................................ 40
TRAVEL MODE............................................................................................................................................................ 42
TRAVEL ALARM .......................................................................................................................................................... 43
POWER SHUT-OFF DELAY........................................................................................................................................ 44
CONTROL OF HYDRAULIC DRIVEN FAN ................................................................................................................. 45
FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION............................................................................. 54
POWER TRANSISTOR PROTECTION ....................................................................................................................... 56
MONITOR DISPLAY .................................................................................................................................................... 57

Normal Display ......................................................................................................................................................... 57
Message Display ...................................................................................................................................................... 60

Copyright ©
4001-3
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) ................................................................. 61
Access to monitor displays .......................................................................................................................................61
Machine condition .....................................................................................................................................................62
Diagnostic code ........................................................................................................................................................65
Machine history .........................................................................................................................................................70
Resetting ...................................................................................................................................................................73
MACHINE INFORMATION ........................................................................................................................................... 77

Setting of machine model .........................................................................................................................................77
Changing the language code ....................................................................................................................................79
Display of engine information ...................................................................................................................................79
Re-setting of engine information ...............................................................................................................................79
Selection of injector ..................................................................................................................................................80
TROUBLESHOOTING .................................................................................................................................................. 83
Prior inspections .......................................................................................................................................................83
Reading the organisation charts ...............................................................................................................................84
Procedures ...............................................................................................................................................................85
Fuel ...........................................................................................................................................................................86
Add coolant solution .................................................................................................................................................87
Low engine oil pressure ............................................................................................................................................88
Overheating ..............................................................................................................................................................89
Defective battery charge circuit ................................................................................................................................92
Electrical system troubleshooting .............................................................................................................................94
ELECTRICAL INSPECTION OF COMPONENTS ........................................................................................................ 96

Main pump proportional solenoid ............................................................................................................................100
6 solenoid valve bank .............................................................................................................................................100
Hydraulic oil temperature sensor ............................................................................................................................101
Pressure sensor ......................................................................................................................................................101

Copyright ©
4001-4
ELECTRIC CIRCUITS OPERATION EXPLANATION
System Chart of Function
ITEM FUNCTION METHOD
1 Engine control Electronic control (common-rail)
2 Work mode selection a) H/S/L mode Maximum engine speed, pump current,
and pressurizing solenoid valve are con-
Machine setting can be selected accord-
trolled according to the selected work
ing to conditions such as of workload or
mode.
fuel efficiency preference, and lifting oper-
ation.
b) Auto-mode Selection of auto-mode allows the load to
be calculated with pressure of negative
Suitable work mode is automatically
control P1 and P2 which in turn work
selected.
mode is switched.
c) Load prefectch control Pump current and engine controller are
controlled by signal from pressure switch.
Pump current is kept at 0 mA while
machine is not being operated.
3 Throttle control Engine can be controlled continuously Engine speed is adjusted by control of
from idling to high idling speed by opera- throttle valve.
tor's instruction.
4 Idling control Engine speed can be switched to/form Pushing knob of switch on the right allows
idling by control of onetouch switch. the engine to run idle and pushing it again
to return it as it was.
It makes engine to run idle while machine Selection of auto-idle allows the engine to
is not being operated. run at idling speed automatically in 5 min-
utes after he lever is shifted to its neutral.
Shifting lever makes the engine to return
to its normal speed automatically.
5 Breaker mode Pressing the breaker pedal allows the Turning ON the pressure switch in breaker
engine to run at the set speed automati- pilot line allows the engine to run at previ-
cally and boosting pressure will be cut. ously set speed. Also, pump current will
be set as that in S-mode and boosting
pressure is to be cut.
6 Auto preheat It helps the engine to start easily at a low Depending on cooling water temperature
temperature. Also, it stabilizes engine at the time when the key switch is turned
speed immediately after start of the ON, the glow plug is energized for a
engine to reduce exhausting smoke. period of time being set. It is to be ener-
gized for a certain period of set time after
the engine has been started to reduce
exhausting smoke.
7 Auto warm-up When coolant temperature is low, it allows In case where no operation of the
the engine to start warming up automati- machine after the engine has been started
cally after it has been started. is carried out when coolant temperature is
low, it automatically increases engine
speed gradually to warm it up.
8 Overheat protection When engine coolant temperature has When coolant temperature goes over
been increased, reduce injection quantity 100°C, reduce fuel injection quantity.
to protect engine. Coolant temperature sensor to ECM.

Copyright ©
4001-5

9 Correction of atmos- It prevents black smoke and engine dam- Fuel is to be restricted by an atmospheric
pheric pressure age when intake air quantity is decreased sensor when altitude is over 2500 meters.
such as operating in highland.
10 Control on engine It increases fuel injection according to It monitors coolant temperature when it is
start coolant temperature to improve starting under 0°C. It watches a lapse of time after
performance.It improves starting perform- cranking has been started.
ance when sufficient fuel fails to be
injected due to wear in the machine as it
has been operated for a long time.
11 Engine stop control Engine controller (ECM) recognizes It stops fuel injection from injector.It
engine key OFF by turning key switch insructs pressure control valve to opened
OFF fully. It makes EGR valve to be fully open.
12 Emergency engine Emergency stop switch is set up with no Signal of emergency stop switch is trans-
stop engine stop by key switch in mind. ferred to engine controller (ECM) to per-
form engine stop control.
13 Engine protection When the engine is operated with water Water temperature, boost temperature,
function temperature, boost temperature, and and engine oil pressure are supervised,
engine oil pressure exceeded the level and engine is protected
respectively specified, it is to protect by
limitation of the engine output or by stop-
ping the engine
14 Lever lock It allows the machine not to be operated When the lever is raised by control of the
by control of levers while cab is being gate lever on the left console, the lever
moved Up/Down or when the machine will lock solenoid turns OFF which in turn pilot
not be needed for operation. pressure is cut off.
15 Auto boost control Boost control Whether boost of pressure is needed or
not is judged by the input data on load fac-
It increases main relief pressure by
tor of the engine and on pump discharge
approx. 10%.
pressure. (Boosting for 8 seconds.)
Boost -cut control Boosting will not function when reserve
pressure switches are turned OFF.
It does not allow boosting according to a
certain condition to protect machine and
equipment.
16 Swing lock It disables swing even when the swing Turning ON the swing lock switch allows
lever is mistakenly controlled. the swing brake solenoid to be energized
to actuate mechanical brake.
17 Swing brake control When swing lock is OFF, in order to pro- It controls swing brake solenoid valve by
tect swing device, it controls swing the data obtained from switches of swing,
mechanical brake ON/OFF automatically attachments, and travel pressure, and
according to operating conditions. also from pump discharge pressure.
18 Travel speed switch- It allows travel speed to switch to either It controls solenoid valve by the travel
ing-over one of 2 levels. mode switch to switch over tilt angle of
swash plate in the traction motor.
19 Travel alarm Alarm buzzer functions when traveling. Travel pressure switch controls the
buzzer.
20 Power shut-off delay This ensures power supply for engine stop It allows a time-lag until main relay shuts
function. off after key switch has been turned OFF.
21 Hydraulic driven fan It performs proper cooling control while It controls fan motor speed by current out-
control monitoring coolant temperature by driving put obtained by entering coolant tempera-
cooling fan hydraulically. With cleaning ture. Attached reversing function allows
mode. Low noise and low fuel consump- radiator fan to be cleaned.
tion.
22 Fuel supply pump It makes an automatic stop when fuel tank Enter signal of fuel sensor to turn OFF
control becomes full on refueling. switch.
Copyright ©
4001-6

23 Power transistor pro- It protects controller in case where a cir- Over-current detection shuts off transistor
tection cuit connected to transistor output is short- output.
circuited.
24 Travel speed switch- a) Normal display Temperature of hydraulic oil and of coolant
ing-over temperature, and fuel level are displayed
It displays current status of the machine.
in bar graphs on LCD monitor and work/
travel mode is also displayed.
b) Message display Each information is to be displayed by let-
ters on LCD monitor.
Warning.
Functioning operation.
When to service the machine

Copyright ©
4001-7
ENGINE CONTROL
Fuel Injection Control (Common rail type)
1. Process to determine quantity of fuel injection
1) System diagram
Engine control module (ECM)
CAN communication Shovel

Controller
Basic fuel injection amount
Boost pressure sensor input
CKP sensor input
CMP or G sensor input
Correction
Engine coolant temperature correction ECT Sensor input
Barometric Pressure
Fuel temperature boost pressure correction
Correction between cylinders
Q-key correction
QR correction
Correction
SCV or PCV
opening time Injector coil energizing time
determination Timing determination
Common rail pressure sensor
Common rail
Injector coil
SCV or PCV
Injector
Supply pump
Fuel tank

Copyright ©
4001-8
2) Operation
Engine controller (ECM) gets information (signal from mounted sensors) such as engine speed and engine load.
Based on the information, ECM sends electric signals to supply pump and to injector to make a proper control of fuel
injection quantity and injection timing for each cylinder.
1) Injection quantity control
Based mainly on engine speed and load given to actual machine, Injection rate control is carried out for optimum
injection by controlling fuel injector.
2) Injection pressure control
Injection pressure is controlled by control of fuel pressure in the common-rail.
The right pressure in the common-rail is calculated by using engine speed and fuel injection quantity.
The supply pump and the pressure control valve are controlled according to the calculated pressure so that it can
discharge proper quantity of fuel to pressure-feed into the common-rail for control.
3) Injection timing control
The control substitutes timer function and an appropriate fuel injection timing is calculated by mainly using engine
speed and fuel injection quantity to control the injector.
4) Injection rate control
In order to improve fuel consumption in the cylinder, a small amount of fuel is injected (pre injection) for ignition at
first, then 2nd time injection (main injection) into the ignited cylinder is carried out.
In this control, the injection quantity control in section 1) and the injection timing control in section 3) are carried out
by controlling injector.

Copyright ©
4001-9
2. Mounting position of accessories related to engine
B3 B50 B51 B47
B1
B49
M9
B6
B48
Engine
harness
connector
S62
R5
A2
EST
connector
Tech 2
connector
ECM memory
clear
700.1.04.01.28F
A2 Engine controller B50 Camshaft position sensor (or G sensor: cylinder
B1 Coolant temperature sensor recognition sensor (detects rotation of cam shaft))
B3 Fuel temperature sensor B51 Boost temperature sensor
B6 Air intake temperature sensor M9 Air conditioner condenser fan motor
B47 Boost pressure sensor R5 Fuel sensor
B48 Atmospheric pressure sensor S62 Air cleaner sensor
B49 Crankshaft position sensor (or engine speed sen-
sor (flywheel mounted))

Copyright ©
4001-10
3. Appearances of accessories related to the Tier 3 emission control regulation
A2. Engine controller (ECM)
700-1-04-01-23AF
Controller for the engine meeting Tier 3 emission control regulation (hardware is common to the vehicle).
Quantity of pin is 121 as against 104 for the engine meeting Tier 2 emission control regulation.
Reliability is equivalent to the unit for current engine meeting Tier 2 emission control regulation (evaluation of single
unit has been completed).
In area indicated by an arrow, ISUZU part number and TRANSTRON part number, and serial number are recorded.
B1. Coolant temperature sensor B3. Fuel temperature sensor
700.1.04.01.23AI
700.1.04.01.23AG
1 Power, positive (+) B6. Intake air temperature sensor
2 Power, negative (-)
3 For water temperature indicator (not in use)
700.1.04.01.23AH

Copyright ©
4001-11
B47. Boost pressure sensor B50. Camshaft position sensor (or G sen-
sor)
700.1.04.01.23AM
B51. Boost temperature sensor
700.1.04.01.23AK
B48. Atmospheric pressure sensor
700.1.04.01.23AH
R5. Fuel level sensor
700.1.04.01.23AJ
1 Power, positive (+)
2 Power, negative (-)
3 Output
B49. Crankshaft position sensor
700.1.04.01.23AO
S62. Vacuum sensor

Operating negative pressure: 6.27 ± 0.29kPa.
700.1.04.01.23AN
700.1.04.01.23AL

Copyright ©
4001-12
GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)
M3 A4
S54
S15 S16
S51
P1
S63 S14
S17 R3
S53 S1
S64 P6
S13 E4
E52 E51
F21
X8
A1
A2 B61
K5 K6 K32 K11 K10 K3 K2 K33 U1
CS01M598A

Copyright ©
4001-13
A1 Computer M3 Wiper motor
A2 Engine controller P1 Instrument panel
A4 Wiper controller P6 Air conditioner control panel
B61 Sunload sensor R3 Throttle volume
E4 Cab light S1 Key switch
E51 Cigarette lighter S13 Overload switch
E52 Air conditioner S14 Breaker/crusher switch
F21 Fuse box S15 Horn switch
K2 Relay-glow plug S16 One touch idle
K3 Relay-horn S17 Boom raising priority switch
K5 Relay-rotary light S51 Hydraulic function cancellation lever switch
K6 Relay-air conditioner condenser fan S53 Door limit switch
K10 Relay-working light (upperstructure/attachment) S54 Front window limit switch
K11 Relay-working light (cab) S64 Cooling hydraulic motor switch
K32 Relay, hydraulic fan U1 DC-DC (24 V-12 V) converter
K33 Main relay X8 Radio connector
RELAYS AND MAIN FUSES (BATTERY COMPARTMENT)
F23 F24 F25 F22
K7
K8
700.1.04.07.20A2
1 Battery cable
F22 Fuse 20 A; main fuse for F11 and F12 circuits
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20
circuits
F24 Fuse 20 A; main fuse for F2 circuit
F25 Fuse 20 A; main fuse for F1 circuit
K7 Relay battery
K8 Relay safety

Copyright ©
4001-14
FUSE BOX
CM00E005
F1 Fuse 20 A: Engine controller

F2 Fuse 5 A: Computer control, instrument panel and diagnostic test socket
F3 Fuse 20 A: Computer power
F4 Fuse 10 A: Hydraulic function cancellation lever switch
F5 Fuse 10 A: Air conditioner condenser fan
F6 Fuse 10 A: Rotary light
F7 Fuse 30 A: Fuel filler pump
F8 Fuse 20 A: Fuel feed pump
F9 Fuse 30 A: Glow plug
F10 Fuse 20 A: Lubricator (option) connector
F11 Fuse 10 A: Back-up
F12 Fuse 20 A: Key switch
F13 Fuse 20 A: Heater /air conditioner
F14 Fuse 5 A: Air conditioner compressor
F15 Fuse 15 A: Working light (upperstructure/attachment)
F16 Fuse 15 A: Working light (cab) and option connector
F17 Fuse 10 A: DC-DC (24V - 12V) converter
F18 Fuse 15 A: Wiper and washer
F19 Fuse 15 A: Horn
F20 Fuse 15 A: Cigarette lighter and cab seat compressor adjustment

Copyright ©
4001-15
WORK MODE SELECTION
1) Circuit configuration
Y7
S3 1
S4
3
P4 2 A1 A2
P1
700-1-04-01-23AP
1 Engine P1 Instrument panel
2 SERIAL communication P4 Monitor display
3 CAN communication S3 Work mode switch
A1 Computer S4 Auto mode switch
A2 Engine controller Y7 Main pump proportional solenoid
2) Timing diagram
S3
S4
700-1-04-01-23 AQ
S3 Work mode switch
S4 Auto mode switch

Copyright ©
4001-16
3) Mode selection switch 4) Operation
1. If the machine was in H/S/L mode and was turned 1. Pushing the mode switch on the monitor display will
off by the key switch, it will restart in S-Mode when it send a signal to the controller. The controller then
is turned on through the key switch again. (The pre- switches modes according to the signal it received.
vious data is reset.) 2. The controller signals the currently selected mode to
2. By pressing the work mode switch (S3), the modes the monitor via serial communication. The LCD screen
alternate as follows: S→H→L→S→H. switches according to the data sent.
3. No matter what mode is selected (S4) to start with, 3. The controller transmits the current mode to the
pushing the auto-mode switch (S4) once will switch engine controller via CAN communication. The engine
the mode to «auto». Pushing the switch again will controller regulates the engine governor according to
switch the auto-mode to S-mode, regardless of the the data.
mode that was selected prior to auto-mode. 4. Also, the engine controller transmits via CAN commu-
4. During the auto-mode operation, the work mode nication the data on current mode and the actual
switch stays deactivated. The switch will not work to engine speed.
change modes. 5. The controller determines the pump current based on
5. After the machine has been turned off with auto-mode the following data: current mode, actual engine speed,
selected, it will restart in the auto-mode even when the target engine speed. The controller then transmits the
key switch is turned on. (Previous data is retained.) result to the pump.
6. The LCD on the monitor switches, reflecting the trans-
mission received from controller via serial communica-
tion.

Copyright ©
4001-17
5) Switches and LCD
P4 S2 S3 S4 S7 S8 S9 P5
H1 S5 S22 S10 S11 S12
CD00E007A
H1 Audible warning device

P4 Monitor display 1 2 3 P4
P5 Hourmeter
S2 Travel mode switch
S3 Work mode switch
S4 Auto mode switch
S5 Cushion control switch
S7 Audible alarm cut out switch
S8 Swing brake switch
S9 Emergency engine stop switch
S10 Working light switch
S11 Wiper switch
S12 Washer switch 4 5 6
S22 Rotary light switch (Europe only)
CS00F521
S22 Free swing switch (North America only) 1 Travel speed indicator
2 Work mode indicator
3 Idle mode indicator
4 Coolant temperature indicator
5 Hydraulic oil temperature indicator
6 Fuel level indicator

Copyright ©
4001-18
A) Auto Modes
1) Alteration
The current value of «I min» in mode H is changed to that value equivalent in mode L.
The engine speed sensing control is carried out even in mode S and «I maxi» is set to the current value equivalent in
mode S and «I min» to that equivalent in mode L.
The engine speed sensing control is carried out even in auto mode and control it within the range from «I maxi» to «I
min» (equivalent in mode L) for both Sa and La.
2) Purpose
It lowers pump output automatically to cope with drop of engine power due to use of poor quality fuel and operation in
highland.
It applies optimum load with fuel cost and cycle time in mind when operated in automatic mode.
Y7
P1 A1 A2 1
700-1-04-01-23AP
1 Engine
A1 Computer
A2 Engine controller
P1 Instrument panel
Y7 Main pump proportional solenoid

Copyright ©
4001-19
Max.torque point = X engine speed
H mode
A
S mode Torque
A mode
Target speed (min-1)
B
L mode H mode
Engine horsepower
C
S mode
Horsepower
L mode
900
0 0.5 4.5 5.0

Trottle volume (V)
900 C B A
HImax ((1) mA)
Engine speed (min-1)
Quantity of flow (Q)
SImax ((2) mA) H mode
S mode
Imin=L mode ((3) mA)
Pressure (P)
P-Q chart of pump
700.1.04.01.23AT2
Mode H: 4) Operation in mode H, S, and L
When engine speed is between A rotation and X rota- 1. When the target speed of the engine is lower than the
tion at maximum torque point, it controls current value speed at maximum torque, the pump current comes to
range from HI maxi ((1) mA) to I min ((3) mA). the current value in mode L even if it is operated in
Mode S:
mode H or S. (To prevent engine stop).
When engine speed is between B rotation and X rota-
tion at maximum torque point, it controls current value 2. When operating travel alone even it is operated in
range from SI maxi ((2) mA) to I min ((3) mA) mode L, the current value in mode S is to be taken (to
Mode L: prevent endless travelling).
When engine speed is C rotation, current value is of 3. When using a backup line (breaker, crusher etc.), the
mode L ((3) mA). current value in mode S is to be taken.
Auto mode:
Sa: 4. Even if it applies to the section 2) or 3) above, the cur-
When engine speed is between B rotation and X rota- rent value in mode L is to be taken in the case of sec-
tion at maximum torque point, it controls current value tion 1). (To prevent engine stop.)
range from ((1) mA) to l min ((3) mA). 5. .When in auto idling, put the idling engine speed at
La: 1200 min-1. (For measures against black smoke gen-
When engine speed is between C rotation and X rota- erated when restoring engine speed by manual con-
tion at maximum torque point, it controls current value trol of lever).
range from HI maxi ((1) mA) to I min ((3) mA).

Copyright ©
4001-20
6. When temperature of engine cooling water is too low 4. Once water temperature reaches more than 50°C
or when power-supply voltage applied to the engine (122°F) and oil temperature more than 25°C (77°F)
controller is too low, increase the idling speed to pre- however, control in auto mode starts and continues
vent over-cooling and/or running out of battery. operating in this mode if water and/or oil temperature
is dropped again.
5. Operation in auto mode
5. If travel pressure switch is turned ON during control in
1. When auto mode has been selected, start the
auto mode, work mode will not be changed over while
machine with mode La first then select mode «Sa»
it is being turned ON.
according to working conditions.
6. (If travel pressure switch is turned ON during control
2. In addition, the mode can be changed automatically
in mode Sa, mode Sa is to be held, and similarly if
from Sa to La.
the switch is turned ON during control in mode La,
3. When water temperature is less than 50°C (122°F) this mode is to be held).
and oil temperature is less than 25°C (77°F), control in
auto mode will not be carried out even if the auto
mode has been selected and the mode is fixed to La
selected on starting.
Set value in each mode
Mode Designation Unit Set value

-1
(MAX) min 2000
Engine speed
-1
(When travelling) min -
H (I MAX) mA 490
Pump current (I MIN) mA 240
(When in no control) mA < 50
-1
Engine speed (MAX) min 1800
(I MAX) mA 405
S
Engine speed (MAX) min-1 1700
L (STD) mA < 50
Pump current
Mode Sa (I MAX) mA 490
Pump current
(I MIN) mA 240
(I MAX) mA 490
Mode La
Engine speed in idling min-1 900
-1
Engine speed in auto idling min 1200
-1
Engine speed at maximum torque min 1500

Copyright ©
4001-21
B) Load pre-fetch control
1) Purpose
Pump current is controlled as measures against black smoke.
Y7
B26
A2
B27
A1
700.1.04.01.23AU
1 Engine B26 Upper pilot pressure switch (yellow band)
A1 Computer/Controller B27 Travel pilot pressure switch
3) Operation
1. .When no operation is carried out (attachment and
travel pressure switches OFF), the pump current is
always 0 mA regardless of operation mode and
engine speed.
2. .When attachment or travel pressure switch is turned
ON, the controller provides pump current so that it can
get to the set current for the work mode being selected
after 0.8 second.
* No control for decreasing transient load has been
employed for machines above current model of
CX330.
Control for decreasing transient load is illustrated
below:
Since engine response (or returning property) has
been improved (or no difference between target speed
and actual speed), if an abrupt engagement of the
lever from inching operation is carried out, and when
difference between target speed and actual speed
reaches within 150 min-1, pump current of 0 mA is to
be applied to ease the engine load.
This is for the purpose of taking measures against
black smoke and of prevention from engine stop.

Copyright ©
4001-22
THROTTLE CONTROL
The analog voltage signal from throttle potentiometer is provided to the controller in the machine to transfer it to the
engine controller (ECU) via CAN communication circuit together with work mode.
1) Purpose
Engine speed can be set by no dependence of the engine controllers on ISUZU side.
TARGET SPEED ENGINE SPEED
5V
SIG CAN-H
THROTTLE VOLUME A1 A2 1
GND CAN-L
ENGINE
CONTROLLER ENGINE CONTROLLER H mode
5.0
A
S mode
L mode
Input voltage (V)
B
C
A mode
900
0 100 0 0.5 4.5 5.0
Throttle Volume Position (%) Input voltage (V)
700.1.04.01.23AV
1 Engine A2 Engine controller
A1 Computer/Controller
3) Operation
1. The controller determines the target speed from the 4. When CAN communication linking between the con-
position of throttle potentiometer and the work mode troller and the engine controller (ECM) is stopped,
currently being entered to transfer the data to the the engine speed is fixed to a certain specified
engine controller (ECM) via CAN communication cir- speed and the throttle potentiometer specifying
cuit. engine speed will not be functioning. (Specified
2. ECM determines fuel injection quantity from the calcu- speed: 1050min-1).
lated target speed and the data obtained from each The specified speed, for the purpose of emergency
sensor (such as actual engine speed, fuel tempera- escape, has been set as the engine speed which
ture, and boost temperature) to transfer it to the supply will not damage the breaker while the engine is run-
pump and to the injector for engine control. ning.
3. When the engine is rotated at a speed less than that at

the maximum torque by controlling throttle potentiom-
eter, the pump current becomes that of mode L even if
work mode is selected either to mode S or to mode H.

1
ENGINE
K7
S1
EGR MOTOR
R3
3LR GLOW PLUG
BATTERY RELAY U
KEY SWITCH V M
CN.A6
THROTTLE B G1 G2 ACC M ST W
M15
VOLUME
R1
HEAT
1.25LgR 0.75WB 8
OFF EGR POSITION
0.75GB 7 SENSOR
Lep SC4604001-0EN
ACC 1.25RW 1 1.25RW 0.75YB 6
WR
ON 0.75WG 4
U
1.25LgR 3 1.25LgR 0.75G 3
ST V
0.85GrR 4 0.85GrR 0.75YG 2
W
0.75GR 1
0.85LY 6 0.85LY 1.25LgR 2 1.25LgR
1
2
3
3
6
1
COMMONRAIL
2
5
0.85L 7 0.85LG WR 3 WR SAFETY RELAY PRESS. SENSOR
CN.A4
0.85BL 8 0.85BL
CN.50 CN.52
0.85GrR 5 0.85GrR 0.85GrR 3
0.85L
0.85LY
0.85BL
1.25RW 4
CN.19
1.25LgR
0.85GrR
LgR
GrR
K8
CN.22
CN.T3
0.85LgR
CRANK ANGLE
(MPU) SENSOR
0.75R 12
0.75W 13
-
CONTROLLER MAIN RELAY GLOW RELAY 0.75G 14 +
0.75G 1
24VB 0.75L 2 G(MRE) SENSOR
CN.6
BW 3
ENGINE STOP 21 WR 0.75L 5
BL 6
K2
0.75WR 7
K33
15 WATER TEMP.
0.75WL SENSOR
0.75RG 8
3
4
5
1
2
5
1
3
4
t ˚C
0.75GR 16
CN.1
0.75BR 17
BG
BrR
2LR
YR
LgR
2LR
2WR
0.75RY 9
BOOST TEMP.
1.25GR
0.75YB 10
SENSOR
5V THROTTLE 11 0.85LY 0.75BY 11 t ˚C
SIG THROTTLE VOLUME 4 0.85LG
WR
A GND 5 0.85BL
A1
CN.A2
4) Throttle Control Relation Electric Circuit Diagram
BOOST PRESS.
SENSOR
S9
CN.3
MONITOR SWITCH
ENGINE STOP 43 BrR ENGINE STOP

OIL PRESS.
SENSOR
CAN H 29 0.85P
39 0.85PL 2LR 3 3LR
CAN L
1.25GR 5 1.25GR
FUEL LEAKAGE
CN.21
TEMP. SENSOR
B6
AIR INTAKE t ˚C
WR 16 WR TEMP. SENSOR
CN.A7
0.85LgR 17 0.85LgR 0.75Y 1

GrR 18 GrR 0.85BO 1 t ˚C 0.75P 2
BrR 19 BrR 0.75OL 2 0.75W 3 PCV1
YR 20 YR 4
0.85P 21 P 0.75GR 5
0.85PL 22 PL 6
BARO SENSOR
CN.A8
PCV2
CN.A5
CN.23
0.85Y 1
0.85YL 3
0.85BY 2
B53 B52 B49 B50 B1 B51 B47 B21 B3 Y33 Y34
B48
1.25RG 1
1.25RW 2
No.1 CYLINDER
0.75GW 5
0.75WL 6
No.6 CYLINDER
0.75GB 7
0.75G 8
0.75WB 9 No.5 CYLINDER
0.75WR 10
No.3 CYLINDER
A2
CN.A3
CN.A0 CN.A1 No.2 CYLINDER

0.75Y
0.75W
0.75G
0.75P
0.75WR
0.75G
1.25RG
0.75WR
0.75W
0.75RG
0.75W
0.75GR
0.75YG
0.75G
0.75WG
0.75R
0.75W
0.75L
0.75P
0.75G
0.75L
0.85BW
0.75BR
0.75YB
0.75WB
0.75WB
1.25RW
0.75WL
0.75GW
0.75GB
1.25B
0.85BG
0.85BG
BrR
YR
0.85LgR
0.75L
1.25B
1.25B
0.85BG
1.25GR
1.25GR
P
PL
YR
BL
GrR
WR
0.85BY
0.85Y
BL
BL
0.85YL
0.75OL
2
5
1
80 0.75YR
3
46
63
67
4
21
60
61
71
79 0.75BY
97
81
24
40
41
47
64
74 0.75WL
84
89
95
91
92
93
87
82
90
98
62
18
37
72
83
94
43
10
121
107
113
117
101
103 0.75GB
109
111
114
100 0.85BL
105
106
108
110
115
116
119
120
118
No.4 CYLINDER
ENGINE CONTROLLER (ECM)

Copyright ©
700-1-04-01-23 aw
Issued 03-07
4001-23
Copyright ©
4001-24
1 Engine
A1 Computer
B1 Coolant temperature sensor
B3 Fuel temperature sensor
B6 Air intake temperature sensor
B21 Engine oil pressure switch
B47 Boost pressure sensor
B48 Ambient air (barometric) pressure sensor
B49 Crankshaft position sensor
B50 Camshaft position sensor
B51 Boost temperature sensor
B52 Common rail pressure sensor
B53 Exhaust gas recirculation valve position sensor
K2 Relay-glow plug
K7 Relay battery
K8 Relay safety
K33 Main relay
M15 Exhaust gas recirculation motor
R1 Glow plug
R3 Throttle volume
S1 Key switch
S9 Engine emergency stop switch
Y33 Supply pump valve (pcv1)
Y34 Supply pump valve (pcv2)

Copyright ©
4001-25
IDLING CONTROL (AUTO/ONE-TOUCH)
P1 B26
H1
B27
S16
B25
P4 A1 B22 A2 1
700.1.04.01.1.23AX
1 Engine B27 Travel pilot pressure switch
A1 Computer/Controller H1 Audible warning device
A2 Engine controller P1 Instrument panel
B22 Swing pilot pressure switch P4 Monitor display
B25 Breaker pilot pressure switch S16 One touch idle
B26 Upper pilot pressure switch (yellow band)
2) Switching between auto idle and one-touch 8. LCD displays “IDLING” on the monitor during idling
idle control.
1. Pushing the knob switch (IN1) down and holding it 3) Switching between auto idle and one- touch
for 3 seconds will trigger the modes to toggle idle
between auto and one-touch. When the mode
1. When setting idling revolutions based on conditions
switches, the ON/OFF display on the auto idle sec-
described in 2). Switching between auto idle and
tion of the LCD also switches, and the buzzer
one-touch idle, the controller transmits an idling sig-
buzzes for 3 seconds.
nal to the engine controller via CAN communication.
2. At the time of auto idle/one-touch idle selection, the Also, a signal is sent to the monitor display via serial
previous setting will still prevail even after the key communication to display “IDLING” on the screen.
switch was turned ON. (Previous data is retained.)
2. The engine controller, upon receiving the signal,
3. The LCD will display ON/OFF status of auto idle. selects idling mode and adjusts engine speed to
ON on the display indicates the auto idle, OFF indi- that of the idling state.
cates one-touch idle.
3. The monitor displays “IDLING” on the LCD accord-
4. If there occurs no handling through the lever for 5 ing to the signal sent.
seconds with auto idle turned ON (both attachment 4. When recovering from idle control based on the
pressure switch and travel pressure switches are conditions described in 2). Circuit configuration, the
OFF), the engine speed automatically goes back to controller transmits a signal to the engine controller
the idling state. (For 5 seconds, the initial setting via CAN communication conveying the previous
prevails. Programming is possible through adjusting engine mode selection. Also, the serial transmission
settings on the back panel for the duration between that has been sent to the monitor for displaying
1 and 30 seconds.) “IDLING” on the screen will be terminated.
5. During auto idle, if operated via lever while engine is 5. The engine controller, depending on the mode sig-
idling (either attachment pressure switch or travel nal received, switches the idling mode back to the
pressure switch is on), the engine speed automati- previous mode and adjusts the engine speed.
cally goes back to the previous rate.
6. The monitor recognizes the termination of the idling
6. Even during auto idle, idling/recovery operation is signal transmission and stops the “IDLING” display
attained by pressing the knob switch (one-touch on LCD.
switch).
7. When auto idle is OFF (i.e. during one-touch idle),
idling/recovery is attained by simply operating the
knob switch (one-touch idle switch), whether or not
the machine was manoeuvred though the lever.

Copyright ©
4001-26
4) Timing diagram
1) Timing diagram for auto idle ON/OFF selection
POWER 24V
0V
IN1 OFF (5V)

(KNOB SW) ON (0V)
AUTO IDLE
700-1-04-01-23 AY2
2) Timing diagram when auto idle is ON
IN1 OFF (5V)

(KNOB SW) ON (0V)
IN3 OFF (5V)

PRESSURE SW
(TRAVEL) ON (0V)
ENGINE SPEED
IDLE
700-1-04-01-23 AZ2
3) Timing diagram when auto idle is OFF
IN1 OFF (5V)

(KNOB SW) ON (0V)
IN2 OR IN3 OFF (5V)
ON (0V)
ENGINE SPEED
IDLE
700-1-04-01-23 BA2

Copyright ©
4001-27
BREAKER MODE
1. Alteration 2. Purpose
Optimization of pump current in mode S and in mode Although in the breaker mode up to now, pump current
L at the engine speed with the breaker being used. in mode S is to be applied at engine speed of more
Pump current at engine speed of between 1200 and than 1500 min-1, It spreads the speed range in mode
1500min-1 is applied from that in mode L to that in S so that the machine can be operated in less than
mode S. that of the flow-rate.
R3
Y7
1
S14
B25
A2
A1
700.1.04.01.23BB
1 Engine R3 Throttle volume
A1 Computer/Controller S14 Breaker/crusher switch
B25 Breaker pilot pressure switch
4) Operation
1. When the breaker mode switch is turned ON by
locker switch on the console (left side) and the pres-
sure switch in backup line is turned ON, it controls
to rotation of the breaker.
2. When the engine is rotated at a speed less than that
set for the breaker by controlling the throttle potenti-
ometer, engine speed will not be increased to the
speed set for the breaker even if the breaker is oper-
ated.
3. If the pressure switch in backup line is turned ON
regardless of breaker mode switch input, the pump
current is to be at the current value in mode S irre-
spective of operation of at that time. (However, when
the engine speed is less than 1200min-1, pump cur-
rent becomes that in mode L).

Copyright ©
4001-28
AUTO PREHEAD (GLOW CONTROL)
1) Alteration ture, at the same time when the key switch is turned
Only the circuit structure and the pre-glow control are ON.
different. (Refer to time chart attached) It is the same
that the pre-glow starts, according to water tempera-
ENGINE CONTROLLER CONTROLLER ENGINE

KEY SWITCH
S1 B M ST
A2 GLOW
OFF PLUG
ON
ST
ENGINE START A1
1
KEY ON
TO BATTERY RELAY
CAN-H
GLOW RELAY
TO STARTER RELAY K2 CAN-L
GLOW RELAY
700.1.04.01.23BC
1 Engine K2 Relay-glow plug
A1 Computer/Controller S1 Key switch
3) Operation
1. When the key switch is turned ON, the engine con- 6. Since the control mentioned above starts immedi-
troller (ECM) calculates pre-glow time from engine ately after the key switch has been turned ON,
cooling water by using the attached map. «ENG PREHEAT» will not be displayed on the mon-
itor unless the pre-glow time passes more than 3
2. ECM turns ON the glow relay output during calcu-
seconds (below -5°C) (23°F).
lated pre-glow time to transfer the glow lamp signal
*The glow lamp time map is added from the engines
through CAN communication circuit to the controller
meeting the emission control regulation of 3rd-stage.
displaying «ENGPREHEAT» on the monitor.
*Refer to attached sheets for the glow control time
3. The glow relay output continues regardless of ON/ according to water temperature and for the time chart.
OFF of the glow lamp signal.
4. After the engine has been started, it turns ON the
glow relay output again only when cranking the
engine. The glow lamp signal will not be transferred
at this time.
5. When the key switch returns to ON from the «start»
(when cranking is completed), it calculates after-
glow time by using the attached map. The glow lamp
signal will not fee transferred at this time.

Copyright ©
4001-29
4) Water temperature control map
1) Glow lamp time (it transmits by CAN communication)
GLOW LAMP TIME (sec)
°C
-4 14 32 50 68 86 104 °F
ENGINE COOLANT TEMPERATURE
700-1-04-01-23 BD2
2) Pre-glow time
PRE GLOW TIME (sec)
°C
-4 14 32 50 68 86 104 °F
700-1-04-01-23 BE2
3) After glow time

AFTER GLOW TIME (sec)
°C
-4 14 32 50 68 86 104 °F
700-1-04-01-23 BF2

Copyright ©
4001-30
5) Timing chart
1) When in normal operation
START
KEY ON
SWITCH
OFF
ON
GLOW
LAMP OFF
ON
GLOW OFF
RELAY
GLOW LAMP TIME PRE GLOW TIME AFTER GLOW TIME
700-1-04-01-23 BG2
2) When the engine has been started after pre-glow is completed
START
ON
KEY
SWITCH OFF
ON
GLOW OFF
LAMP
ON
OFF
GLOW
RELAY
GLOW LAMP TIME PRE GLOW TIME CRANKING AFTER GLOW TIME
GLOW TIME
700-1-04-01-23 BH
3) When the engine has been started before glow lamp goes off
START
KEY ON
SWITCH
OFF
GLOW ON
LAMP
OFF
GLOW
ON
RELAY
OFF
GLOW LAMP TIME CRANKING AFTER GLOW TIME

PRE GLOW TIME GLOW TIME
700-1-04-01-23 BI2

Copyright ©
4001-31
AUTO WARM UP
R3
B26
S16
H1
A2 1
P4 A1
700.1.04.01.23BJA
1 Engine H1 Audible warning device
A1 Computer/Controller P4 Monitor display
A2 Engine controller R3 Throttle volume
B26 Upper pilot pressure switch (yellow band) S16 One touch idle
2) Operation
1. A coolant temperature sensor is installed inside the 5. Once auto warm-up control is cancelled, the control-
engine. The signal from this sensor goes out to the ler does not initiate auto warm-up control again
engine controller and is converted into a tempera- unless key switch is turned from OFF to ON.
ture value. The engine controller then transmits the
6. While controller is executing the auto warm-up con-
coolant temperature data to the controller via CAN
trol, an “AUTO WARM UP” message is displayed on
communication.
the monitor's LCD.
2. If the coolant temperature is below 50°C (122°F)
after engine starts, the controller transmits the auto
warm-up signal to the engine controller via CAN
communication.
3. The engine controller executes the auto warm-up
control upon receiving the signal transmission from
the controller.
4. The controller terminates the auto warm-up control
on the following conditions. The engine controller
terminates the auto warm-up control once the com-
mand is cancelled.
*When one of the following switches turns on: attach-
ment pressure switch, travel pressure switch, and
knob switch (one-touch idle switch).
*When throttle volume is changed.
*When engine speed stays above 1800 min-1 for 3
minutes.

Copyright ©
4001-32
3) Auto warm-up control
AUTO WARM-UP AUTO WARM-UP
COMPLETE COMPLETE
ENGINE SPEED (MIN -1)
ENGINE SPEED (MIN -1)

TIME TIME
THROTTLE DURATION OF OPERATION THROTTLE DURATION OF OPERATION
POSITION POSITION
700-1-04-01-23-BK2
OVERHEAT PROTECTION
1) Purpose water temperature exceeds 100°C (212° F).
It is the function protecting the engine by restriction of * Waning «OVER HEAT» is to be displayed on the
fuel injection quantity which in turn reduces engine out monitor in actual machine when temperature exceeds
put forcibly when water temperature has kept on ris- 105°C (221° F).
ing.
The control starts functioning at the moment when
2) Water temperature-fuel injection quantity
Q RESTRICTION BY OVERHEAT PROTECTION
120
Q RESTRICTION RATE (%)
100
80
60
40
20
0
95 100 105 110 115 120 125 130 °C
32 203 212 221 230 239 248 257 266 °F
700.1.04.01.23BL2

Copyright ©
4001-33
ATMOSPHERIC PRESSURE COMPENSATION
1) Purpose prevent the engine from being damaged (prevention of
Purpose is to prevent black smoke from increasing over-revolution of turbo) due to temperature rise of
because an excessive fuel is fed in the combustion exhaust gas.
chamber of the engine due to lack of intake air and to
2) Map
ALTITUDE _ TORQUE
OUTPUT DROP DUE TO OUTPUT DROP DUE TO

(lbf-ft) (N- CHANGE IN ENVIRONMENT FUEL COMPENSATION
1032
959
885
TORQUE
811
737
664
590
(m)
1640 3285 4921 6562 8202 9842 11483 13123 14764 16404 (ft)
ALTITUDE
450.1.04.01.28AO

Copyright ©
4001-34
CONTROL WHEN STARTING ENGINE
1) Starting control (by monitoring water temperature
1. Purpose in cold temperature by making fuel injection according
When water temperature is below 0°C (32°F), Pur- to water temperature.
pose is to ensure starting performance of the engine
2) Long cranking control
1. Purpose starting Q (fuel injection) will not be injected in such
While aiming at reduction of black smoke when start- case where an injector is worn out, after the specified
ing engine, the purpose is to improve starting perform- time has passed from the time when cranking was
ance by increasing starting Q (fuel injection) by fixed started.
quantity, as a backup when sufficient
2. Time chart
START
KEY ON
SWITCH OFF 1.5 sec
ENGINE IDLING
SPEED CRANKING
0
UP-Q
STARTING Q ST-Q
NL-Q
0
ST-Q: Standard starting Q, UP-Q: Starting Q after increase of quantity, NL-Q: Q in no lord
700.1.04.01.23BN2
3) Starting control when number of effective cylinders is reduced

1. Purpose 1. Fuel quantity to be injected by faulty injectors is allot-
Purpose is to correct fuel injection quantity to assure ted to other normal injectors (total quantity is to be the
starting performance of the engine with a view to same).
escaping in an emergency when a certain number of 2. In case where number of faulty cylinders is over half of
stopped injectors are detected by trouble diagnosis. the total numbers, increase of fuel injection.
2. Operation
3. Number of cylinders-Correction factor
Number of effective cylinders 6 5 4 3 2 1 0

Correction factor 1.0 1.2 1.5 2.0 1.0 1.0 1.0

Copyright ©
4001-35
CONTROL WHEN STOPPING ENGINE
1. Operation
1) Turn OFF the key switch. 5) EGR valve is instructed so that it is fully closed
2) When the engine controller recognizes that the and its initial point is corrected.
key is turned OFF, steps 3) through 5) below are 6) After steps 3) through 5) have been completed,
carried out simultaneously. information such as history failure is written in
3) Fuel injection quantity stops to be calculated. EPROM in the ECM.
4) Pressure control valve (PCV) is instructed so that 7) Turn OFF the main relay and turn OFF the power
it is fully closed. supplied to ECM.
EMERGENCY STOP OF THE ENGINE

1. Alteration
In current type 3 (engine meeting emission control regulation of 2nd-stage), depression of the emergency stop switch
allows the engine stop motor to rotate to the stop position by way of the relay and allows the engine governor to con-
trol for stopping engine by the engine stop signal from the engine controller (ECU).
In the next type (engine meeting emission control regulation of 3rd-stage), depression of the emergency stop switch
allows the controller to transfer engine stop signal to ECM controlling the engine to be stopped.
2. Circuit configuration
MONITOR DISPLAY
24V-OUTPUT ENGINE STOP

P4 CN6-21(PNP)
WR501
1
BrR530
CN3-43
S9 A1 A2 ENGINE
SWITCH CONTROLLER ENGINE CONTROLLER

(EMERGENCY STOP)
700.1.04.01.23BO
1 Engine P4 Monitor display
A1 Computer/Controller S9 Engine emergency stop switch
3. Operation
1) Depression of emergency stop switch on the mon-
itor display allows the output signal from transistor
in the controller to be turned ON and at the same
time, the engine stop signal is transferred from the
controller to the engine controller (ECM)
2) ECM performs stopping control for the engine.

Copyright ©
4001-36
ENGINE PROTECTION FUNCTION (EPF)
1) Purpose
When the engine is operated with water temperature, boost temperature, and engine oil pressure exceeded the level
respectively specified, it is to protect by limitation of the engine output or by stopping the engine.
2) Operation
1) Water temperature monitoring
Error Monitor
Setting Time Engine control Reset
codes message
100°C - - - -
Indication in bar graph for ECM: Decrease of fuel injection rate
105°C water temperature: Machine controller: Normal M00F0 Indication in bar graph for
At 8th graduation water temperature:
Below 8th graduation OVER
ECM: Decrease of fuel injection rate
110°C 5 sec. M00F1 HEAT
Machine controller: Idling
ECM: Decrease of fuel injection rate Turn ON key after engine
120°C 5 sec. M00F2
Machine controller: Engine stop has been stopped.
1. Engine protection will not function if error codes, E0117 (water temperature sensor low voltage abnormality)
and E0118 (water temperature sensor high voltage abnormality), are indicated.
2. Engine protection will not function if error codes, E2104 (CAN-bus abnormality), E2106 (CAN time-out abnor-
mality), and M0090 (CAN communication error), are indicated.
3. Engine protection by water temperature will start functioning 1 minute after the engine has been started (in
order to detect water temperature in steady state).
2) Boost temperature monitoring
Error Monitor
codes message
When temperature below
ECM: Normal
80°C 5 sec. M00F3 70°C continues for 30
Machine controller: Idling OVER
sec.
HEAT
ECM: Normal Turn ON key after engine
90°C 5 sec. M00F4
Machine controller: Engine stop has been stopped
1. Engine protection will not function if error codes, E1112 (boost temperature sensor low voltage abnormality)
and E1113 (boost temperature sensor high voltage abnormality), are indicated.
3. Engine protection by boost temperature will start functioning 1 minute after the engine has been started (in
order to detect boost temperature in steady state).

Copyright ©
4001-37
3) Engine oil pressure monitoring
Error Monitor
codes message
ECM: Normal Turn ON key after engine LOW OIL
40KPa 5 sec. M00F5
Machine controller: Engine stop has been stopped PRESS
1. Engine protection will not function if error codes, E0522 (engine oil pressure sensor low voltage abnormality)
and E0523 (engine oil pressure sensor high voltage abnormality), are indicated.
3. Engine protection will not function if error code of E1633 (5V power supply 3 voltage abnormality) is indicated.
4. Engine protection by engine oil pressure will start functioning 30 seconds after the engine has been started (in
order to detect engine oil pressure in steady state).
*Introduce failure codes of machine system for setting error codes.
*Pump output is always functioning according to “L” mode while idling.
*Turning key switch OFF allows function of engine protection to be reset. (Engine runs for 30 sec. even if something
is wrong.)
*Error codes are to be recorded as well as recording other codes.
*The engine is to be stopped by means of emergency engine stop signal from PNP output.
*The engine is to be judged as started if it runs at a speed of more than 500 min-1.
4) Select for setting of engine protection function
Since engine protection function has been set as standard, the setting can also be cancelled.
RESET (RST1) Selection of engine

protection function
Engine protection function

(0=ON, 1=OFF)
800-1-04-01-26F
1. Every time the traveling mode switch turns ON, the setting at “AU” is to be shifted as in the order of
0000→0001→0010→0011→0000 repeatedly.
2. Turn ON the operation mode switch for 10 seconds.
3. Buzzer sounds to indicate that the settings have been memorized.
4. Turn the OFF key switch.
*If “NO against engine protection function” is chosen, function of engine output limitation/engine stop is cancelled but
error codes are displayed and saved as records.
NOTE: At "AU" selection, auto boost control and engine protection function can be set at the same time.

Copyright ©
4001-38
FUNCTION LOCKING
F21
K7
F4
F23
Y2
G1 S51
700.1.04.01.23BP
F4 Fuse 10 A; hydraulic function cancellation lever G1 Battery
switch K7 Relay battery
F21 Fuse box S51 Hydraulic function cancellation lever switch
F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20 Y2 Pilot pressure solenoid valve (blue band)
circuits
2) Timing diagram
KEY
SWITCH
POWER
GATE BAR RUN

POSITION STOP
LEVER LOCK
SOLENOID VALVE
OPERATION ENABLE
DISABLE
700-1-04-01-23 BQ2
3) Operation
1) By positioning the gate lever on cab console (left) 3) By positioning the gate lever toward entering/leav-
toward operation (gate lever sticks out when this is ing cab (gate lever stays housed), the limit switch will
done) while the machine is powered on, the limit be turned OFF (open) and the lever lock solenoid
switch will be turned ON (closed) and the lever lock valve turns OFF.
solenoid valve will be ON. 4) When the lever lock solenoid valve turns off, pres-
2) When the lever lock solenoid valve is ON, pressure sure cannot reach the pilot line. Thus the operation of
can reach the pilot line, enabling the machine to oper- the machine will be disabled.
ate.

Copyright ©
4001-39
POWER BOOST
A2
B42
A
B44
B27
Y5
B25
A1
700.1.04.01.23BR
A Main relief (standard) B27 Travel pilot pressure switch
A1 Computer B42 Pump pressure sensor (P1)
A2 Engine controller B44 Pump pressure sensor (P2) (yellow band)
B25 Breaker pilot pressure switch Y5 Power-up solenoid valve (yellow band)
2) Increasing the pressure in each work mode
Automatic power boost (*)

Mode Auto
31.4 to 34.3 MPa (4554 ↔ 4974 psi)
H mode Automatic power boost (*)
(Pressure) 31.4 to 34.3 MPa (4554 ↔ 4974 psi)
S mode Automatic power boost (*)
L mode Constant power boost (*)
* When the travel pilot pressure switch (B27) or the optional breaker pilot pressure switch (B25) is activated, power boost
is deactivated.
3) Operation If the pump pressure (P1) or (P2) is greater than 29.9
MPa (4351 psi) and the load ratio is within a range of ±
When operating in H or S mode, the computer (A1)
5% for 2 seconds, the computer (1) activates the
records the ratio between:
power-up solenoid valve (yellow band) (Y5) for 8 sec-
- The engine load transmitted by the engine con-
onds, which increases the main pressure.
troller (A2).
- The hydraulic circuit load transmitted by the pump When the travel pilot pressure switch (B27) or the
pressure sensors (P1) (B42) and (P2) (B44). optional pilot pressure switch (B25) is activated, the
computer (A1) deactivates the power-up solenoid valve
(yellow band)(Y5).

Copyright ©
4001-40
SWING BRAKE
S8
B22
B26
S1 B27
B42 1
B44
P1 Y3
A1
700.1.04.01.23BS
1 Swing brake B44Pump pressure sensor (P2) (yellow band)
A1 Computer P1 Instrument panel
B22Swing pilot pressure switch S1 Key switch
B26Upper pilot pressure switch (yellow band) S8 Swing brake switch
B27Travel pilot pressure switch Y3 Swing brake solenoid valve (pink band)
B42Pump pressure sensor (P1)
2) Operation of the swing brake control
1) Overview
1. Pressing the swing lock switch on monitor display will turn on the red LED, activating the swing lock control.
Pressing the swing lock switch again will turn off the LED, and the swing lock is deactivated.
2. During swing lock control, controller's transistor output turns on and the mechanical brake that is built in the
swing motor turns on.
3. The ON/OFF state of the swing lock holds when turning the key switch from OFF to ON.

Copyright ©
4001-41
2) Timing diagram
KEY SWITCH
POWER
SWING LOCK
SWITCH
OUT
(IN1)
SWING
PRESSURE
SWITCH (IN3)
SWING LOCK
LED
700-1-04-01-23 BT2
3) Swing brake auto control

1) Overview
The auto control of the swing brake takes place when the swing lock is OFF.
The auto control also releases the mechanical brake automatically during a digging operation as well as during swing
operation. If the operation is halted, the auto control turns on the mechanical brake automatically.
The detailed conditioning for ON/OFF of the swing mechanical brake is shown below.
• The swing brake will be turned OFF based on the following conditions.
1. Pressure switch (swing) is ON
2. P1>15 MPa (2175 psi) or P2>15 MPa (2175 psi)
• The swing brake will be turned ON based on the following conditions.
1. Pressure switch (attachment) stays OFF for 5 seconds
2. Key switch is OFF
• The swing mechanical brake will be deactivated once when the pump delivery pressure (P1 or P2) grows over 15
MPa (2175 psi) during travel. However, it will take effect in 5 seconds.

Copyright ©
4001-42
TRAVEL MODE
P1
A1
B42
B44
S2 B43
B27
Y4
P4
700.1.04.01.23BU
A1 Computer P1 Instrument panel
B27Travel pilot pressure switch P4 Monitor display
B42Pump pressure sensor (P1) S2 Travel mode switch
B43Pressure sensor (nega-cont.) Y4 2 stage travel solenoid valve (red band)
B44 Pump pressure sensor (P2) (yellow band)
2) Timing diagram
24 V
Power supply
0V
Travel mode ON
switch OFF
IN1 5V
0V
Speed I II I II I II I I II
700-1-04-01-23 BV

Copyright ©
4001-43
3) Operation Travel speed II selected
When the starter motor switch is positioned in the 1. When the pressure of the pumps P1 or P2 is less
«ON» position, the 1st speed is selected by default. than 580 psi, the output from the computer
(OUT)(A1) of the 2 stage travel solenoid valve (Y4)
Every time the travel mode switch is pressed (S2), the
is deactivated (1st speed).
computer (A1) registers a signal (IN1: 0 volts).
2. When the pressure of the pumps P1 or P2 is greater
The computer (A1) changes the travel speed in the fol-
than 580 psi, the output from the computer
lowing way I-> II, II -> I and transmits the modifications
(OUT)(A1) of the 2 stage travel solenoid valve (Y4)
to the monitor display (P4).
is activated (2nd speed).
Travel speed I selected When the attachment controls are operated, the out-
put from the computer (OUT)(A1) of the 2 stage
The output from the computer (OUT)(A1) of the 2 stage
travel solenoid valve (Y4) cannot be activated or
travel solenoid valve (Y4) is deactivated (1st speed).
deactivated.
3. When the travel pressure is greater than 3582 psi,
the travel motor displacement change spool is
pushed back and the swash plate angle is in high
displacement (1st speed).
4. Travel speed II may still be selected if necessary, for
example for cleaning tracks.
TRAVEL ALARM
Pressure switch
(Travel)
B27
Travel alarm
Controller
H2
A1
700.1.04.01.23BW
A1 Computer H2 Travel alarm
B27Travel pilot pressure switch
2) Timing diagram
The pressure switch (travel) will be turned ON through the travel lever operation. The travel alarm will sound for 10 sec-
onds, then stop.
Power
Travel alarm
700.1.04.01.23BX

Copyright ©
4001-44
POWER SHUT-OFF DELAY
1) Alteration
Power being supplied to the engine controller is shut off via main relay and at the same time, the battery relay stops
to be energized shutting off the power to the machine.
Delayed operation time is 4 seconds (immediately after 0 min-1 of engine speed) from the key is turned ON to OFF,
and approximately 7 seconds after starting to stopping the engine.
BATTERY RELAY
KEY
SWITCH KEY
S1 SWITCH
B M ST
A1 CONTROLLER OFF - + - + K7
ON
ST
IS-IGKEY
IS-START
OS-MAINR
OS-MAINR
MAIN
K33 RELAY
PS-+B
PS-+B
A2 ENGINE CONTROLLER
700.1.04.01.23BY
A1 Computer/Controller K33 Main relay
A2 Engine controller S1 Key switch
K7 Relay battery
3) Timing diagram
ON
KEY SWITCH S1
OFF
ENGINE SPEED 0
˜ 7 sec.
MAIN RELAY ON
K33 OFF
4 sec. 4 sec.
ON
BATTERY RELAY K7
OFF
700-1-04-01-23BZ

Copyright ©
4001-45
CONTROL OF HYDRAULIC DRIVEN FAN
1) Outline of control
Main control of hydraulic driven fan is illustrated below.
Detailed description for each section is shown after next section.
1) Fan speed control according to water temperature
2) Spool stick prevention control
3) Engine start/stop control
4) Reversing fan control (cleaning mode)
5) Actual fan speed checking mode
2) Basic circuit configuration
A1 CONTROLLER ENGINE CONTROLLER

ENGINE
THROTTLE TARGET SPEED
VOLUME 5V b
SIG CAN-H
R3 A2 1
GND CAN-L
a
FAN REVERSING
ENGINE SPEED
SWITCH
5V ENGINE COOLANT TEMP.
S64 FAILURE CODE FAN MOTOR
M
MONITOR
UART M9
KEY SWITCH P1
24V
S1 FAN REVERSING
Y31 SOLENOIDE VALVE
PNP out
24V
GATE LIMIT LEVER LOCK

S51 SWITCH SOLENOID Y1
RELAY
ELECTROMAGNETIC
PROPORTIONAL VALVE
Y32 FOR CONTROLLING
PWM out FAN SPEED
PWM return
700.1.04.01.23CA
a) Target speed information,
b) Engine speed, engine coolant temperature and
failure mode information
1 Engine
A1 Computer/ controller
R3 Throttle volume
S1 Key switch

Copyright ©
4001-46
1. Fan speed control according to water temperature
Set the fan rotation at a low speed to prevent over-cooling and carry out quicker warming-up when engine cooling
water temperature is low, and conversely, set the fan at a proper speed to realize low noise and low fuel consumption
when engine cooling water temperature is high.
1) Outline
1) The controller calculates command current value from the map illustrated below according to engine cooling water
temperature transferred from the engine controller through CAN communication circuit and then transfers the
command current to «PWM out» (electromagnetic proportional valve for controlling fan speed) so that the fan may
rotate at a speed in response to the command current.
2) Judged value of fan speed at the command current value is to be decided only at the maximum and at the mini-
mum rotation (values shown in Fig. below are both at oil temperature of 50°C (122°F)), therefore, the fan speed
at medium range varies from fan to fan.
2) Engine cooling water- Command current characteristics
ENGINE SPEED
(min-1)
1570 1570 +100
0
HIGH IDLING
FAN SPEED
IDLING
REF. max.1000
(500)
VALUE
COMMAND CURRENT VALUE
(mA)
600
550
500
450
400
350
300
250
200
150
100
50
0
80 83 85 90 95 100 105
RADIATOR COOLANT (˚C)
TEMPERATURE
RANGE FULL OPEN MAX.COOLING

START CONDITION
WORKING THERMOSTAT FUNCTIONING
700.1.04.01.28BE

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4001-47
3) Back-up operation
1) When failure code illustrated below appears, it allows the command current supplied from the controller to the
electromagnetic proportional valve for control fan speed to be 0 mA. In addition, when failure code illustrated be-
low occurs, the error will not be returned as fan rotation may become unstable due to poor connection and the like.
Failure codes related to engine system
E0335 : Crank sensor trouble
E0340 : G sensor trouble
E2104 : CAN-bus trouble
E2106 : CAN time-out
E0117 : Trouble with water temperature sensor in low voltage
E0118 : Trouble with water temperature sensor in high volt-
age
Failure codes related to mechanism
E0070 : Key switch error
E0090 : CAN communication error
2) When the message «ELEC PROBLEM» is displayed on the monitor due to functioning of «power transistor pro-
tection», it allows the command current stated above to be 0mA.
4) Time chart (back-up operation)
START START
KEY SWITCH
ON ON
OFF
FAILURE CODE
ON
OFF
BACK UP
600mA
Fan speed control based Fan speed control based
on water temperature. on water temperature.
Spool stick prevention
PMW out Spool stick prevention
control.
control.
0mA
700-1-04-01-23CC
2. Spool stick prevention control

Spool stick is a phenomenon that the spool with clearance seal is stuck because actuating force of the spool is in-
creased by building-up of fine particles in the oil to the clearance seal when a certain position in the spool is loaded
with hydraulic force for a long time.
In order to avoid this, following control is carried out.
Spool stick prevention control for electromagnetic proportional valve for control fan speed
1) Outline
1) When the engine is started by key switch and the engine speed increases to reach 300min-1 (engine is judged as
started) or more, spool stick prevention current (100mA) is delivered from «PWM out» in the controller at regular
intervals (every 1min.) for a certain time (50m sec.).
2) Although the spool stick prevention current is delivered at regular intervals (every 1min.), when command current
value obtained by «fan speed control according to water temperature» is larger than that of spool stick prevention
current, the control becomes invalid and the spool stick prevention current stated above will not be delivered. (Re-
fer to figure below).

Copyright ©
4001-48
2) Time chart
Invalid range of spool stick prevention
mA)
600
500
Command current
400
300 Fan speed control according

1 min 1 min to water temperature
200
50 msec
100
0
Time
700-1-04-01-23CD
Solenoid valve for reversing fan Spool stick prevention control

1) Outline
Engine key ON/OFF mode
1) When the key switch is turned ON and 2 seconds have passed, spool stick prevention signal is delivered from
«PNP out» in the controller for a certain period of time (20msec.).
2) When the engine is started within 2 seconds after the key switch has been turned ON, the spool stick prevention
signal stated above will not be delivered.
3) Similarly, after the key switch has been turned OFF too, the spool stick prevention signal is delivered from «PNP
out» in the controller for a certain period of time (20msec.).
2) Time chart
Power-cut delay
START
KEY SWITCH ON
OFF
ON
POWER SUPPLIED
TO CONTROLLER OFF
2sec 20msec 20msec
ON
SOLENOID VALVE
FOR REVERSING
OFF
FAN
800.1.04.01.26IA

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4001-49
3. Engine start/stop control
1) Engine start control
When the engine has been started, lower the fan speed (to restrain surge pressure on discharging side of pump) to
carry out following control for easing load in starting engine.
1) Turning the key switch ON allows the controller to supply current of 600mA to «PWM out» (electromagnetic pro-
portional valve for control fan speed).
2) When the engine is started by key switch and the engine speed increases to reach 300min-1 (engine is judged as
started) or more, «PWM out» in the controller shifts to «fan speed control according to water temperature» and
«spool stick prevention control».
2) Engine stop control
In order to prevent cavitation due to fan rotation by inertia when the engine has been stopped, following control is
carried out.
1) Turning the key switch OFF allows the controller to supply current of 600 mA to «PWM out» (electromagnetic pro-
portional valve for controlling fan speed).
2) «PWM out» in the controller keeps on supplying current of 600mA while «Power-cut delay» is functioning.
3) Time chart
Power-cut delay
START
KEY SWITCH ON
OFF
POWER SUPPLIED ON
TO CONTROLLER
OFF
SOLENOID VALVE Spool stick prevention control

FOR REVERSING OFF
FAN
Judgment of start
300min-1
ENGINE SPEED
STOP
600mA 600mA
Fan speed control according to water

temperature.
PWM out Spool stick prevention control.
0mA
Fan speed control according to water

temperature.
FAN SPEED
STOP
700-1-04-01-23CF

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4001-50
4. Reversing fan control
Flowing direction of air is reversed by reversing fan revolution so that trifling dust clogged in the radiator core is pos-
sible to be removed.
Since heat radiation capacity declines while the fan rotation is being reversed by which overheat of the engine be-
comes possible, do not operate any control lever.
Change over of mode
1) Outline
1) Turning ON fan reversing switch (momentary) after the key switch has been turned ON allows the fan to change
rotation from normal mode to reverse mode.
During this period, the buzzer gives warning sound of 2Hz from the monitor to inform that the fan is rotated in
reverse mode. When the reversing switch is turned ON again, it changes rotation from reverse to normal and the
buzzer stops sounding.
2) For reverse mode, previous data are to be reset.
This means that turning OFF the key switch in either of mode, reverse or normal, allows it to be operated in normal
mode when the key switch is turned ON next time.
3) When warning message «OVER HEAT» is displayed on the monitor, it will not be operated in reverse mode. The
fan reversing switch functions and the mode can be switched over after overheated condition is released and
warning message «OVER HEAT» is disappeared from the monitor.
4) When the message «ELEC PROBLEM» is displayed on the monitor due to functioning of «power transistor pro-
tection», it will not be operated in reverse mode as stated above.
2) Time chart
ON
KEY SWITCH
OFF
FAN REVERSING ON ON ON ON ON
SWITCH OFF
Normal Reverse Normal Reverse Normal Normal Reverse

MODE
700-1-04-01-23CG

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4001-51
Function of reversing fan
1) Outline
1) When the fan reversing switch (momentary) is turned ON after the key switch has been turned ON, reversing sig-
nal is delivered to the fan reversing solenoid valve to allow the fan to change rotation from normal mode to reverse
mode.
And at the same time, a signal is transferred to the lever lock relay from «PNP out» in the controller and the lever
lock solenoid valve turns OFF.
This allows the machine operation to be impossible regardless of where the gate lever is positioned.
At this time, command current from «PWM out» in the controller drops from 600mA to 0 mA.
2) Starting the key switch in the situation above allows the engine to be started in fan reverse mode and the fan
rotates at maximum speed as the command current value from «PWM out» in the controller is 0 mA.
3) When the key switch is turned OFF in reverse mode, it switches to be operated in normal mode when the key
switch is turned ON again because previous data are to be reset.
4) Even if it has set up the auto-idle during reversal operation, an auto-idle dose not function.
2) Time Chart
START
ON
KEY SWITCH
OFF
FAN REVERSING ON
SWING OFF
SOLENOID VALVE ON
FOR REVERSING FAN OFF
(PNP out)
ON
LEVER LOCK
OFF
SOLENOID VALVE
(PNP out) ON=2Hz sounds Normal mode
MONITOR BUZZER OFF
MODE
Max.speed
Max. speed
Normal mode
Reverse mode
ENGINE SPEED Low speed

(TARGET PEED)
STOP Low speed
600mA 600mA(WT< 90˚C)
PWM out
0mA
Max. speed
FAN SPEED
STOP
700-1-04-01-23 CH

Copyright ©
4001-52
5. Checking mode of actual fan speed
The actual fan sped is possible to be checked as the fan speed can be set at any point within a certain range by
operation of the switch.
1) Outline
1) Command current of “PWM out” in the controller can be set at any point by 10mA pitch within the range of between
100mA and 600mA at «OUT» in «RST1 (reset)» screen in «Service support indication» (refer to service support
items for operation) on the monitor.
2) After «OUT» is selected on the reset screen (refer to figure below) with the buzzer stop switch, displayed figures
change every time the travel mode switch is turned ON.
Displayed figures show command current and indication immediately after selection is command current value at
present.
Once the travel mode switch is turned ON, it shows figures «0100» and every time switch is turned ON, the figures
change by 10 as illustrated below.
->0100->0110->0120->0130->0140->0150->0550->0560->0570->0580->0590->0600-> Current value at present
3) For confirmed fan rotation check mode, data in last time are reset.
That is, even if the key switch has been turned OFF with the current set at a certain value, it will be turned in nor-
mal mode when the key switch is turned ON next time.
2) Service support screen
This mode is to be used to check if the fan speed changes according to current variation.
6. Fan speed control according to oil temperature
Fan speed control according to oil temperature is added and the temperature of the hydraulic oil is prevented from
overheating.
1) Outline
1) The controller adjusts the instruction current value to 0mA more than the temperature shown from the tempera-
ture of the hydraulic oil transmitted from the sensor of the temperature of the hydraulic oil in the figure below.

Copyright ©
4001-53
2) Temperature of the hydraulic oil - Command current characteristics
Ref. value
Control start point of

Command current value
temperature of oil
Fan speed control according Fan speed control according to

to water temperature oil temperature
(°C)
(176 (185 (194 (203 (212 (°F)
Hydraulic oil temp.
450.1.04.01.32A
3) Back-up operation
1) When failure code illustrated below appears, it allows the command current supplied from the controller to the
electromagnetic proportional valve for control fan speed to be 0 mA.
In addition, when failure code illustrated below occurs, the error will not be returned as fan rotation may become
unstable due to poor connection and the like.
Failure codes related to mechanism.
M0020: Trouble with hydraulic oil temperature sensor in low voltage
4) Time chart (back-up operation)
START START
KEY SWITCH
ON ON
OFF
FAILURE CODE
ON
OFF
BACK UP
600mA
Fan speed control based Fan speed control based
on water and oil on water and oil
temperature. Spool stick temperature. Spool stick
PMW out prevention control. prevention control.
0mA
700-1-04-01-23CC

Copyright ©
4001-54
FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION
1) Control outline
The controller detects fuel quantity by fuel sensor allowing the fuel supply pump to make an automatic stop when the
fuel tank is filled up.
Fuel tank Fuel sensor Battery relay
Fuse 20A
Battery
Rf
Controller
R5
SIG K7
GND
G1
A1
Re
S61
Main relay
(for fuel supply pump) (Manual) (Automatic)
3-position roker switch
(*1)
Fuel supply K30
pump)
K31 CN6-17(PNP)
Motor
P BZ
M14 GND
(*2)
Switch
Relay
(automatic)
(*1) Fuel supply pump: Made by JABSCO (manufacturer in UK).

(*2) Buzzer: Same buzzer used as travelling alarm to MSR.
700-1-04-01-23CK3
*All components other than controller, battery, and fuel level sensor are stored in the tool box (in house in front-right).
A1 Computer/controller
G1 Battery
K7 Relay battery
K30 Refuel pump relay
K31 Refuel pump stop relay
M14 Fuel feed pump motor
R5 Fuel sensor
S61 Refuel pump switch

Copyright ©
4001-55
3) Operation
1) Automatic stop
1. Assemble it with the switch built-in the fuel supply pump turned ON. (No control is required for customers.)
2. Put the 3-position rocker switch to Automatic side after the key switch has been turned ON. (Center: OFF,
Automatic Alternate: ON, Manual: Momentary ON.)
3. This operation allows electric power to be supplied to the fuel supply pump by way of both relays of «auto»
and «main» so that fuel is pumped up into the fuel tank out of an fuel drum.
4. The controller is always monitoring quantity of fuel remained in the tank by using fuel sensor.
5. When the fuel sensor comes to the full level (Rf) position or above, the controller gives output signal to the
relay (auto). (NPN output.)
6. The relay (auto) is switched over by the output signal allowing the power supplied to the fuel pump to be shut
off.
7. At the same time, the buzzer sounds to inform that refueling has been made an automatic stop.
8. When the 3-position rocker switch is turned OFF, the buzzer stops sounding and automatic refueling mode is
released.
9. Even if the automatic refueling mode has been released, the controller keeps on sending output signal to the
relay (auto) if the position of fuel sensor is at the full level (Rf) or above.
10. The controller stops giving the output signal to the relay (auto) when the fuel sensor comes down below the
full level (Rf) position.
2) Manual refueling
1. In case where automatic refueling fails functioning due to troubles such as in the fuel sensor, the controller,
and the relay (auto).
2. In case where a machine cannot fill up the fuel to its full by automatic refueling.
3. Supply fuel while monitoring fuel gauge with the 3-position rocker switch turned to manual side (momentary).
4. Power is supplied to the fuel supply pump via the relay (main) from the manual switch so that fuel can be sup-
plied to the tank.

Copyright ©
4001-56
POWER TRANSISTOR PROTECTION
CONTROLLER
24V (PNP)
17 FUEL SUPPLY PUMP
18 FREE SWING (NA) BEACON (EU)
19 TRAVEL ALARM
21 ENGINE STOP (EMERGENCY STOP)
22 HYDRAULIC DRIVEN FAN REVERS
27 SWING BRAKE
28 2-SPEED TRAVEL
2-
2
29 CUSHION
30
31 SWING SHUT-OFF
32 BACKUP 1
20 BACKUP 2
700-1-04-01-23 CL
In the event that a solenoid valve or a relay develops a short circuit, the power transistor output will be shut off in
order to protect the controller. A «ELEC PROBLEM» message will be displayed during the failure. Perform the ser-
vice support check to have the location of failure pinpointed and displayed.
Then follow the display result and inspect the wire or the equipment that seems to be experiencing the failure.

Copyright ©
4001-57
MONITOR DISPLAY
3 2 1
CD00E007A2
1. Fuel level indicator 3. Coolant temperature indicatora2
2. Hydraulic oil temperature indicator
Normal Display
1.Radiator coolant temperature
A1
A2
B1
P4
SCALE
°
104 122 140 158 176 194 212 230 °
COOLANT TEMPERATURE
700-1-04-01-23CN2
A1 Computer/controller B1 Coolant temperature sensor
A2 Engine controller P4 Monitor display
2) Operation
1. Coolant temperature sensor is installed inside the engine. The signal from this sensor (Vtw) will be transmitted
to engine controller as an analog signal (voltage).
2. The engine controller converts the transmitted signal into a temperature value. It then transmits this coolant
temperature data to the controller via CAN communication.
3. When the controller receives the signal, it uses to the graph shown above to determine the bar graph display
level for the signal level. The controller then transmits the data to monitor display via serial communication.
4. When the monitor display receives transmission, it reflects the data received as a bar graph on the display.
5. «OVER HEAT» will be displayed when level 8 lights up on the scale. (The engine does not stop.)

Copyright ©
4001-58
2. Hydraulic oil temperature
P4
B2
A1
SCALE
°C
68 86 104 122 140 158 176 194 212 °F
OIL TEMPERATURE
700-1-04-01-23CO
A1 Computer/controller P4 Monitor display
B2 Hydraulic oil temperature sensor
2) Operation
1. Hydraulic oil temperature sensor is installed inside the suction piping. The signal from this sensor (Vto) will
be transmitted to controller as an analog signal (voltage).
2. When the controller receives the signal, it first converts it into a temperature value. The controller then uses
to the graph shown above to determine the bar graph display level for the signal level. The controller then
transmits the data to monitor display via serial communication.
4. «OVER HEAT» will be displayed when level 8 lights up on the scale.

Copyright ©
4001-59
3. Fuel level
P4
B3
A1
700-1-04-01-23 CP2
A1 Computer/controller P4 Monitor display
B3 Fuel temperature sensor
Fuel sensor Input voltage

Remaining fuel (L) Bar graph
resistance (W) Vf1 (V)
480 < 10 to 18 0.455 to 0.766 8
420 to 480 18 to 24 0.766 to 0.964 7
364 to 420 24 to 30 0.964 to 1.142 6
300 to 364 30 to 37 1.142 to 1.337 5
244 to 300 37 to 46 1.337 to 1.582 4
136 to 244 46 to 61 1.582 to 1.891 3
81 to 136 61 to 75 1.891 to 2.138 2
< 81 75 to 80 2.138 to 2.222 1 (Refill fuel)
2) Operation
1. Fuel sensor is installed inside the fuel tank. The signal from this sensor (Vf1) will be transmitted to the con-
troller as an analog signal (voltage).
2. When the controller receives the signal, it uses to the graph shown above to determine the bar graph display
level for the signal level. The controller then transmits the data to monitor display via serial communication.

Copyright ©
4001-60
Message Display
START MESSAGES DISPLAYED
KEY SWITCH ON KEY SWITCH AND ENGINE RUNNING
ELEC PROBLEM
LOW FUEL ALTERNATOR
LOW OIL PRESS
LOW COOLANT
AIR FILTER
YES
WARNING OVER HEAT
ENG PRE HEAT ENG IDLING

NO SERVICE DUE AUTO WARMUP
POWER UP
MODE DISPLAYS TRAVEL MODE DISPLAT

I : LOW-SPEED TRAVEL
H : SUPER HEAVY MODE
II : HIGH-SPEED TRAVEL
S : REGULAR MODE
AUTO IDLE DISPLAYS
L : FINISHING MODE
ON : AUTO IDLE
AUTO : AUTO MODE
OFF : ONE-OUCH IDLE
700-1-04-01-23 CQ
Buzzer Message Display Meaning and Measures to be Taken

ENG PRE HEAT Engine warm up (glow) is indicated.
Indicates automatic warming of the engine. The automatic warming is released by mov-
AUTO WARN UP
ing the throttle volume or operation levers.
ENG IDLING Indicates the engine is running at low idling.
POWER UP Indicates the system is in automatic digging power up.
At the time of every 500 hour service intervals, one minute indication appears for 5
SERVICE DUE
times when the engine starts.
Sounds LOW FUEL Indicates the fuel level is very low. Add fuel.
Sounds LOW COOLANT Indicates the coolant water level is low. Add coolant water.
Indicates the engine oil pressure is abnormally low. Stop the engine, check engine oil
Sounds LOW OIL PRESS
level and add oil.
Indicates the engine coolant temperature or hydraulic oil temperature abnormally rises.
Sounds OVER HEAT Put the engine in low idling and reduce water or oil temperatures.
Check the radiator & oil cooler.
Sounds ALTERNATOR Indicates problems in battery charging system. Check the electric circuit.
Indicates electric problems (short circuit or disconnection) in the electric system.
Sounds ELEC PROBLEM
Check the electric circuit.
Indicates the air filter clogged.
Sounds AIR FILTER
Air filter are cleaned or exchanged promptly.

Copyright ©
4001-61
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode)
Access to monitor displays
Normal A Service support (a)

display display
(b)
B
H
Status B Diagnostic B Usage B
Machine Reset
I information display trouble history
D E
B
C
B
CHK7 CHK1 DIAG1 HR 12 HR 1 RST1
C C C C
F
CHK5 CHK2 DIAG2 D HR 11 HR 2 RST2
G C C C C J
CHK6 CHK3 DIAG3 D HR 10 HR 3 RST11
C C C C C
CHK4 DIAG4 HR 9 HR 4 RST12
C C C C C
CHK5 DIAG5 D HR 8 HR 5 RST13
C C C C C
DIAG6 D HR 7 HR 6 RST14
C C C
RST15
RST16
800.1.04.04.08A
a) Bar graph (Hydraulique oil temperature, coolant temperature, fuel level)
b) Mode (Travel, work, auto, idle)
Operating Switches
A. To be switched after the travel & work mode switch has F.
been turned ON for more than 3 seconds. G. Output with the protection circuit actuated is to be
B. To be switched when the auto mode switch is turned checked when the travel mode switch is turned ON.
ON. H. Automatic detection of short circuit is to be indicated
C. To be switched when the buzzer stop switch is turned after the travel mode switch has been turned ON for
ON. more than 10 seconds.
D. Data is to be cleared after the work mode switch has I. To be switched after the auto mode switch has been
been turned ON for more than 10 seconds (buzzer turned ON for more than 10 seconds.
sounds when the data have been cleared). J. Selected machine model is be cleared after the auto
E. Reset function is to be selected when the buzzer stop mode switch has been turned ON for further 10 sec-
switch is turned ON, the selected function is to be onds (buzzer sounds when it has been cleared).
reset when the travel mode switch is turned ON, and K. To be switched after the one-touch idle switch has
the data are to be reset after the work mode switch been turned ON for more than 10 seconds at anytime
has been turned ON for more than 10 seconds (buzzer while the service support screen is being displayed.
sounds when the data have been reset).

Copyright ©
4001-62
Machine condition
1. Machine condition CHK1
MODE: Travel - work
CHK MODE II H ENG 2000 rpm P1: Main pump (P1) pressure
1 P2: Main pump (P2) pressure
P1 030.0 MPa I 0300 mA N: Negative pressure (N)
ENG: Engine rpm
P2 030.0 MPa WT 0080 °C Pump control current value
I Fan motor current value (when Travel Mode
switch ON))
N 03.00 MPa OT 0055 °C
Radiator coolant temperature
WT:
Hydraulic oil temperature
Intake air temperature (only when Travel
OT:
Mode switch ON))

R: Engine load ratio
CHK MODE II H TR1 0000 Fuel temperature
2 FT: Boost temperature (only when Travel
R 0080 % TR2 0000 Mode switch ON)
TV: Throttle volume degree of opening
FT 0000 °C TR3 0000 TR1 Controller transistor output
TR2 Controller transistor output
TV 0100 % TR4 0000
Transistor output: «0» = OFF; «1» = ON
TR1 0 0 0 0 TR2 0 0 0 0 TR3 0 0 0 0

Swing brake X Free swing (NA)
2-speed travel Soft/hard (EU,NA) Engine stop
Hyd Fan reverse
Travel alarm Swing shutoff reverse(CX460to800, E805)
Boosting High dump(CX700/800, E805) Lift (LBX-MH)
TR4 0 0 0 0
Fuel supply pump
(EU)
X
X
Drop (LBX-MH)
X: Not used

Copyright ©
4001-63
SW1 to SW3 Controller switch input (sensor switch)
CHK MODE II H SW4 0000 Controller switch input (operation
3
SW4 to SW7
switch)
SW1 0000 SW5 0000
SW2 0000 SW6 0000
SW3 0100 SW7 0000
Pressure switch electronic control box switch inputs: «0» = OFF; «1» = ON
SW1 0 0 0 0 SW2 0 0 0 0 SW3 0 0 0 0

Attachment press. SW Air cleaner Battery charge
Travel press. SW Coolant SW Engine stop
Swing press. SW 2nd auxiliary press. SW Drop (LBX-MH)
Auxiliary pressure SW Boom up press. SW Lift (LBX-MH)
SW4 0 0 0 0 SW5 0 0 0 0 SW6 0 0 0 0

Soft/hard (EU, NA) Swing lock Windshield washer
Alarm change
Free swing (NA) Emergency stop (EU, NA)

High dump (CX700/800, E805) Working lamp Breaker mode
One-touch idle Wiper L/M mode
SW7 0 0 0 0
Anti-theft protection
Key switch
Fan reverse(CX460 to
800; E805)
X
X = Not used
FS: Fuel sensor resistance
CHK MODE I H TG 0000 rpm AC: A/C control temperature
4 TR5: Engine oil pressure
TG: Target engine speed
FS 0080 (Ω) BP 0000 MPa
Boom bottom pressure (Europe only)
BP: Overload alarm pressure display (only when bea-
AC 0005 SP1 0000 con switch ON)
SP1 Atmospheric pressure
TR5 0010 SP2 0000 SP2 Boost pressure
AC 0 0 0 4
1: below 30°C
2: between 30°C and 45°C

Copyright ©
4001-64
Setting of unit fir each shipping territory NOTE: Below a decimal point is not displayed but it is
as fallows.
TR5, SP1, SP2
Default When switched
Japan kPa kgf/cm2 kPa

.
kgf/cm2 kgf/cm2
Export kPa .
psi
North America psi kPa .
Europe kPa -
800.1.04.04.08D

R Engine load ratio
CHK MODE II H TR1 0001 FT Fuel temperature
5 TV Throttle volume degree of opening
Transistor output status when over-current
R 0080 % TR2 0001 TR1
detected
FT 0000 °C TR3 0000 TR2
detected
TR3
TV 0100 % TR4 0000 detected
TR4
1. While the travel mode switch is ON on the «CHK2» detected
screen, the output status when over-current has
been detected in the past is displayed.
2. Data is cleared by resetting the trouble code on the
trouble diagnosis screen.
3. The example in the figure above shows that a travel
alarm, swing braking, and battery relay output were
being carried out when over-current was detected.

TR3 Results of automatic short detection
CHK MODE II H TR1 0010
6 4. This data is cleared when the key switch is switched
OFF.
R 0080 % TR2 0000
* For CHK1 to 6, the units can be switched with the
work lamp switch. Status held as is when key OFF
FT 0040 °C TR3 0000
TV 0100 % TR4 0000
1. Shorts are automatically detected if the key switch

is switched ON while the one-touch idle switch is
ON.(* The engine must not be running.)
2. If you switch to the «CHK2» screen and switch the
travel mode switch ON for 10 seconds, the auto-
matic detection results are displayed.
3. The example in the figure above shows that the 2-
speed travel line is currently shorted.
R Engine load ratio

FT Fuel temperature
TV Throttle volume degree of opening

Copyright ©
4001-65
Diagnostic code
2. Detection of engine failures DIAG1 to 6
1) Trouble diagnosis (DIAG1), Engine system current trouble status (trouble code)
Engine system trouble code

DIAG MODE II H E 0000 E: For the engine error code list, refer to Page
1 68
Example Water temperature sensor abnormality
E 0118 E 0000
E 0000 E 0000
E 0000 E 0000
2) Trouble diagnosis (DIAG2), Engine system past trouble status (trouble code)
E: Engine system trouble code

DIAG MODE II H E 0000 Example CAN time-out abnormality
2
E 2106 E 0000
E 0000 E 0000
E 0000 E 0000
3) Trouble diagnosis (DIAG2), Engine system past trouble status (time of trouble: controller hour meter value)
E: Engine system trouble code trouble code.

DIAG MODE II H E 0000 CAN time-out abnormality: Abnormality
3
Example
occurred at 200 hours
E 0200 E 0000 1. Switching the work mode switch ON for longer than
10 seconds clears the data on past trouble codes
E 0000 E 0000 and their times of occurrence.
2. The time displayed with «DIAG3» is the time at
E 0000 E 0000 which the first trouble code occurred after the data
was cleared. (The times for the second and subse-
quent trouble codes are not recorded.)
3. When the data is cleared, the «DIAG2» and
«DIAG3» data is stored into EEPROM.

Copyright ©
4001-66
4) Trouble diagnosis (DIAG5), Machine main unit system Current trouble status (trouble code)
M: Machine main unit system trouble code

DIAG MODE II H M 0000 Example Oil temperature sensor abnormality
4
M 0020 M 0000
M 0000 M 0000
M 0000 M 0000
M0000: No defect
M0010: Transistor output short
M0020: Oil temperature sensor
M0030: Fuel surface sensor
M0040: Pressure sensor (P1)
M0050: Pressure sensor (P2)
M0060: Pressure sensor (N)
M0070: Key switch
M0080: Pressure switch (attachments or travel)
M0090: CAN communications error
M00A0: Controller reset
M00B0: Engine controller mismatch
M00C0: Boom pressure sensor (Europe)
M00F0 Overheat (at cooling water temperature of over 105°C (221°F)
M00F5 Engine oil pressure drop (at pressure of below 40kPa

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4001-67
5) Trouble diagnosis (DIAG5), Machine main unit system Past trouble status (trouble code)

DIAG MODE II H M 0000 Oil temperature sensor abnormality, fuel sen-
5
Example
sor abnormality
M 0020 M 0000
M 0030 M 0000
M 0000 M 0000
6) Trouble diagnosis (DIAG6), Machine main unit system Past trouble status (time of trouble: controller hour
meter value)

DIAG MODE II H M 0000 Oil temperature sensor abnormality: Abnor-
6 mality occurred at 2000 hours
Example
Fuel sensor abnormality: Abnormality
M 2000 M 0000
occurred at 1000 hours
M 1000 M 0000 1. Switching the work mode switch ON for longer than
10 seconds clears the data on past trouble codes
M 0000 M 0000
and their times of occurrence.
2. The time displayed with «DIAG6» is the time at
which the first trouble code occurred after the data-
was cleared. (The times for the second and subse-
quent trouble codes are not recorded.)
3. When the data is cleared, the «DIAG5» and
«DIAG6» data is stored into EEPROM.

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4001-68
7) Engine error code list
Engine Type Restora-

Trouble
Trouble contents 6U/ Monitor display tion from
code 4H 6H
6W troubles
0087 No pump pressure send (fuel leak) O O O ELEC PROBLEM 1

0088 Common rail pressure abnormality O O O ELEC PROBLEM 1
(1st stage. 2nd stage)
0089 Common rail pressure abnormality O O O ELEC PROBLEM 1
(pump overpressure send)
0090 SCV drive system cut line, +B short, ground O O O ELEC PROBLEM 2
short
PCV1 drive system cut line or ground snort
0092 PCV1 drive system +B short -- -- O ELEC PROBLEM 1
0107 Atmospheric pressure sensor abnormality O O O ELEC PROBLEM 2
(low voltage abnormality)
0108 Atmospheric pressure sensor abnormality O O O ELEC PROBLEM 2
(high voltage abnormality)
0112* Intake air temperature sensor abnormality O O O ELEC PROBLEM 2
0113* Intake air temperature sensor abnormality O O O ELEC PROBLEM 2
0117* Water temperature sensor abnormality O O O ELEC PROBLEM 2
0118* Water temperature sensor abnormality O O O ELEC PROBLEM 2
0182* Fuel temperature sensor abnormality O O O -- 2
0183* Fuel temperature sensor abnormality O O O -- 2
0192 Common rail pressure sensor abnormality O O O ELEC PROBLEM 2
0193 Common rail sensor abnormality O O O ELEC PROBLEM 2
0201 Injection nozzle #1 drive system open line O O O ELEC PROBLEM 1
0205 Injection nozzle #5 drive system open line -- O O ELEC PROBLEM 1
0206 Injection nozzle #6 drive system open line -- O O ELEC PROBLEM 1
0219 Overrun O O O ELEC PROBLEM 2
0237 Boost pressure sensor abnormality O O O ELEC PROBLEM 2
0238 Boost pressure sensor abnormality O O O ELEC PROBLEM 2
(nigh voltage abnormality)
0335/ Crank sensor abnormality O O O ELEC PROBLEM 1
0336 (no signal, abnormal signal)
0340/ Cam (G) sensor abnormality O O O ELEC PROBLEM 1
0341 (no signal, abnormal signal)
0380 Glow relay abnormality O O O ELEC PROBLEM 1
0487 EGR position sensor abnormality O O O ELEC PROBLEM 1
0488 EGR valve control abnormality O O O ELEC PROBLEM 2

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4001-69
Engine Type Restora-

Trouble
Trouble contents 6U/ Monitor display tion from
code 4H 6H
6W troubles
0522 Engine oil pressure sensor abnormality O O O ELEC PROBLEM 1

0523 Engine oil pressure sensor abnormality O O O ELEC PROBLEM 2
0601 ROM abnormality O O O ELEC PROBLEM 2
0603 EEPROM abnormality O O O ELEC PROBLEM 2
0606 CPU abnormality O O O ELEC PROBLEM 2
0611 Charge circuit 1 abnormality O O O ELEC PROBLEM 2
0612 Charge circuit 2 abnormality O O O ELEC PROBLEM 2
1093 No pump pressure send (2nd stage) -- -- O ELEC PROBLEM 1
1095 Pressure limiter open O O O ELEC PROBLEM 1
1112* Boost temperature sensor abnormality O O O -- 2
1113* Boost temperature sensor abnormality O O O -- 2
1173 Overheating O O O -- 2
1261 Injection nozzle common 1 drive system O O O ELEC PROBLEM 1
abnormality
1262 Injection nozzle common 2 drive system O O O ELEC PROBLEM 1
abnormality
1291 PCV2 drive system cut line or ground short -- -- O ELEC PROBLEM 2
1292 PCV2 drive system +B short -- -- O ELEC PROBLEM 1
1345 Cam (G) sensor out of phase O O O ELEC PROBLEM 1
1625 Main relay system abnormality O O O ELEC PROBLEM 2
1630 A/D conversion abnormality O O O ELEC PROBLEM 2
1631 5V power supply 1 voltage abnormality O O O -- 2
1632 5V power supply 2 voltage abnormality O O O ELEC PROBLEM 2
2104 CAN bus abnormality O O O ELEC PROBLEM 2
2106 CAN time-out abnormality O O O ELEC PROBLEM 2
1 Item marked with «O» in the table means that it can be applied.
2 Restoration from troubles.
There are 2 ways as illustrated below to restore it from troubles.
In order to clear an error code depending on circumstances, control of main switch is necessary as follows:
1) Turn ON the key switch to start the engine, hold the switch for 10 second as it is turned ON, and then turn it OFF
to restore it to be normal.
2) Turn ON the key switch, hold the switch for 10 second as it is, and then turn it OFF to restore it to be normal
3 For temperature sensors marked with «*» in the table however, hold the key switch for 3 minutes after it has been
turned ON, then turned it OFF.

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4001-70
Machine history
1. Screen HR1
ENG : Hour meter (alternator generation time)
WRK : Machine operation time (attachment ON or travel
ON)
U : Attachment operation time
T : Travel operation time
S : Swing operation time
PU : Boost time
BRK : Breaker usage time
2. Screen HR2
H : H mode usage time
S : S mode usage time
L : L mode usage time
A : A mode usage time
WT : Maximum coolant temperature
OT : Maximum hydraulic oil temperature
FT : Maximum fuel temperature
3. Screen HR3
1 : Controller power supply ON time
2 : 1-speed mode usage time
3 : 2-speed mode usage time
4 : Travel hydraulic only time
5 : Maintenance time
6 : *****
7 : *****
4. Screen HR4
[P1 pressure distribution]
1 : Time P1 10 MPa or less
2 : Time P1 10 to 15 MPa
7 : Time P1 35 MPa

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4001-71
5. Screen HR5
[P2 pressure distribution]
1 : Time P2 10 MPa or less
7 : Time P2-35 MPa
6. Screen HR6
[Engine speed distribution]
1 : Time N 1175 min-1 or less
2 : Time N 1175 to 1375 min-1
3 : Time N 1375 to 1575 min-1
4 : Time N 1575 to 1775 min-1
5 : Time N 1775 to 1975 min-1
6 : Time N 1975 to 2175 min-1
7 : Time N 2175 min-1 or more
7. Screen HR7
[Coolant temperature distribution]
1 : Time TW 77°C or less (Marks 1 and 2 on the bar
graph)
2 : Time TW 77 to 82°C (Mark 3 on the bar graph)
7 : Time TW 105°C or more (Mark 8 on the bar graph)
8. Screen HR8
[Hydraulic Oil temperature distribution]
1 : Time TO 45°C or less (Marks 1 and 2 on the bar
graph)
2 : Time TO 45 to 60°C (Mark 3 on the bar graph)
7 : Time TO 98°C or more (Mark 8 on the bar graph)

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4001-72
9. Screen HR9
[Fuel temperature distribution]
1 : Time TF 30°C or less
2 : Time TF 30 to 40°C
7 : Time TF 80°C or more
10. Screen HR10
[Load ratio distribution]
1 : Time R 30% or less
2 : Time R 30 to 40%
3 : Time R 40 to 50%
4 : Time R 50 to 60%
5 : Time R 60 to 70%
6 : Time R 70 to 80%
7 : Time R 80% or more
11. Screen HR11
[H mode high idle load ratio distribution]
2 : Time R 30 to 40%
3 : Time R 40 to 50%
4 : Time R 50 to 60%
5 : Time R 60 to 70%
6 : Time R 70 to 80%
12. Screen HR12
[S mode high idle load ratio distribution]
2 : Time R 30 to 40%
3 : Time R 40 to 50%
4 : Time R 50 to 60%
5 : Time R 60 to 70%
6 : Time R 70 to 80%
Switching any of the work mode switches for the HR1 to 12 display ON for longer than 10 seconds clears all the
usage history data.

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4001-73
Resetting
Resetting (RST1, 2)
MODE : Travel mode, work mode

BRK : Breaker engine speed set
L/M : Lifting magnet engine speed set
AI : Auto idle time set (1 to 30 sec.)
PA : Pump output adjustment
AU : Automatic boost rise
: Engine protection function
HLD : Previous data hold set
OUT : Oil pressure drive fan inspection mode
1) Breaker speed set
1 Select the breaker speed set (BRK) with the Buzzer Stop switch. (The selected item switches from light-on-dark
display to dark-on-light display.)
2 Now, set the breaker speed (BRK) to 1800 min-1. While watching the monitor, adjust the engine speed with the
throttle volume. When the adjustment is complete, turn ON the work mode switch for 10 seconds. Buzzer sound to
indicate that the settings have been memorized.
3 Switch OFF the key switch.
4 To check, see the «CHK1» engine speed.
2) Lifting magnet speed set
1 Select the lifting magnet speed set (L/M) with the buzzer stop switch. (The selected item switches from light-on-
dark display to dark-on-light display.)
2 Now, set the lifting magnet speed (BRK) to 2000 min-1. While watching the monitor, adjust the engine speed with
the throttle volume. When the adjustment is complete, turn ON the work mode switch for 10 seconds. Buzzer
sound to indicate that the settings have been memorized.
4 To check, see the «CHK1» engine speed.

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4001-74
3) Auto idle time change
1 Select the auto idle time change (AI) with the buzzer stop switch. (The selected item switches from light-on-dark
2 Now, set the auto idle time to 10 seconds. Turn ON the travel mode switch untl the number reaches 10. The
number increases each time the switch is switched ON and can be set from 1 to 30. When the setting is complete,
turn ON the work mode switch for 10 seconds. Buzzer sound to indicate that the settings have been memorized.
3 Turn OFF the key switch.
4) Pump output change
PA=0000 : Normal output mode
PA=0001 : Low output mode 1 (-100 mA)
1 Select the pump output adjustment (PA) with the buzzer stop switch. (The selected item switches from light-on-
dark display to dark-on-light display.)
2 Now, set the pump output to low-output mode. Turn ON the travel mode switch so that the number reaches 1, 2, or
3. Each time the switch is switched ON, the number displayed moves to the next step in the sequence 0, 1, 2, 3,
…… When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzer sounds to indicate that
the settings have been memorized.
3 Switch OFF the Key switch.
5) Automatic pressure rise release setting
AU 0 0 0 0
Automabic boost rise (0=ON, 1=OFF)
Engine protection function (0=ON, 1=OFF)
*****
*****
1 Select the automatic boost rise release and engine protection function release (AU) with the buzzer stop switch.
(The selected item switches from light-on-dark display to dark-on-light display.)
2 Now, set the automatic boost rise engine protection fanction to none. Turn ON the travel mode switch so that the
number reaches 1. Each time the switch is switched ON, the number displayed moves to the next step in the
sequence: 0000 ->0001 ->0010 ->0011 ->0000. When the setting is complete, turn ON the work mode switch for
10 seconds. Buzzuer sounds to indicate that the setteings have been memorized.

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4001-75
6) Previous data hold condition change
Auto mode (0 = default setting, 1 = previous data held)

Work mode (0 = default setting, 1 = previous data held)
Travel mode (0 = default setting, 1 = previous data held)
*****
1 Select the previous data hold (HLD) with the buzzer stop switch. (The selected item switches from light-on-dark
2 Now, set the work mode to previous data hold.
Switch the travel mode switch ON so that the number reaches 1.
Each time the switch is switched ON, the number displayed moves to the next step in the sequence:
0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111
700-1-04-04-07BJ2
When the setting is complete, switch the work mode switch ON for 10 seconds. The buzzer buzzes to announce
that the storing the setting into memory is complete.
7) Hydraulic drive fan inspection mode (only for specifications with hydraulic drive fan)
1 Select the previous data hold (OUT) with the buzzer stop switch. (The selected item switches from light-on-dark
2 The number displayed shows the command current value. The display immediately after the selection is the com-
mand current value. When the travel mode switch is turned ON once, the display becomes «0100» and each time
the switch is turned ON, the value displayed moves to the next step in the sequence:
->0100->0110->0120->0130->0140->0150->->0160->0170->0180->0190->0580->0590->0600-> Current value at present ->
3 For the hydraulic drive fan inspection mode, the previous time's data is reset. In other words, even if the key switch
is switched OFF with some current value set, the next time the Key switch is switched ON, the mode is normal
mode.

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4001-76
8) Maintenance time setting
1 Move to RST2 with the buzzer stop switch and select (2). (The selected item switches from light-on-dark display to
dark-on-light display.)
2 The number displayed shows the time for displaying «Maintenance time». The display immediately after the selec-
tion is the default maintenance time. Each time the travel mode switch is turned ON, the number displayed moves
one step through the cycle «0050->0250->0500-> 1000-> 2000-> 5000-> 0050-> 0250…».
When the setting is complete, turn ON the work mode switch for 10 seconds. Buzzer sounds to indicate that the
settings have been memorised.
* If the buzzer stop switch is held ON for 20 seconds, the time until maintenance display (1) is reset.
9) Injector test mode
1 Move to RST2 with the buzzer stop switch and select (3). (The selected item switches from light-on-dark display to
dark-on-light display.)
2 Now, after the engine has been started, injector test mode is to be set here. Turn ON the travel mode switch so
that the number reaches 1. The number toggles between 0 and 1 each time you switch ON the switch.
When the number reaches 1, the engine speed is fixed at 500 min-1.
3 For the injector test mode, the previous time's data is reset. In other words, even if the key switch is turned OFF
with a value set, the next time the Key switch is turned ON, the mode is normal mode.

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4001-77
MACHINE INFORMATION
Setting of machine model 4. Press the travel mode switch until the required desti-
nation code is displayed.
The excavator model is selected after re initialising the
machine code or replacing an electronic control box. Destination Pressure
Destination T° unit
1. Key switch ON, the screen below appears and «?» code unit
for machine is selected: 3 EUROPE MPa °C
4 Rest of world KgF °C
MACHINE: SH ? -4 5. Press the work mode switch. The screen below

appears and «?» for language is selected.
TERRITORY:? LANGUAGE:?
MACHINE: SH0300- 4
CONT. P / N KHR3320
TERRITORY: 3 LANGUAGE: ?
2. Press the travel mode switch until the required
machine code is displayed.
CONT. P / N KHR3320
MACHINE CODE MACHINE MODEL
6. Press the travel mode switch to display the required
SH0120 CX130
language code:
SH0150 CX160 0 = Japanese
SH0180 Not used 1 = English
SH0200 CX210 2 = Thai
3 = Chinese
SH0220 CX240
4 = German
SH0250 CX290 5 = French
SH0300 CX330 6 = Italian
SH0400 CX460 7 = Spanish
8 = Portuguese
SH0700 CX700
9 = Dutch
SH0800 CX800/E805 10 = Danish
11 = Norwegian
12 = Swedish
MACHINE: SH0300- 4 13 = Finnish
14 = Icons
CONT. P / N KHR3320 MACHINE: SH0300- 4
TERRITORY: 3 LANGUAGE: 5
3. Press the work mode switch. The screen below
appears and «?» for territory is selected.
CONT. P / N KHR3320
MACHINE: SH0300- 4 Example:

The screen above corresponds to a CX330 model
TERRITORY: ? LANGUAGE:? excavator for Europe in French.
CONT. P / N KHR3320

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4001-78
7. After selecting the machine code, the destination 10. To confirm the excavator model selection, press the
code and the language code, press the auto mode auto mode switch for 10 seconds:
switch and the screen below will appear: The screen below will appear
MACHINE: SH0300- 4
CONT. P / N KHR3320
11. Press the auto mode switch again and the work
CS00F533 screen will appear:
Then the work screen is displayed:
CS00F521
CS00F521 12. Re-initialising the data
8. If the machine code does not correspond to the In the excavator model selection screen, if the auto
engine controller installed, the error code: «E. mode switch is pressed for 10 seconds, all the data
CONT. ERROR» appears on the screen and the will be erased and the audible warning device will
audible warning device sounds. sound.
If the key switch is turned OFF and then ON, the
screen below will appear and the procedure starts
MACHINE: SH0300- 4 again from the beginning.
MACHINE: SH ? -4
CONT. P / N KHR3320
E. CONT. ERROR
CONT. P / N KHR3320
9. Check that the machine code corresponds to the

engine controller installed on the excavator.
- If the machine code is wrong, start the procedure
again from the beginning.
- If the engine controller installed is not correct,
change it.

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4001-79
Changing the language code Re-setting of engine information
Display the excavator model confirmation screen
(press the auto mode switch for 10 seconds). CHK MODE ,S 4 0060
To change the language code, press the travel mode 7
switch to display the required code. 1 0089 5 4005
To confirm the language code, press the work mode
switch and the audible warning device sounds. 2 8008 6 0000
Turn the key switch to OFF.
3 9543 7 0A79
800.1.04.04.08H
MACHINE: SH0300- 4
RST Injector number
TERRITORY: 3 LANGUAGE: 1 MODE Selection places when entering ID code
CONT. P / N KHR3320 4 e f g h
1 a b c d 5 m n o p
2 i j k l 6 u v 0 0
Example: 3 q r s t 7 w x 0 0
In the screen opposite, the language code has changed Ab: Engine code
from 5 (French) to 1 (English). C to x: QR code
* 2 places of figure on the left both at the 6th and the
Display of engine information 7th lines are fixed to 0.
Example:
CHK MODE ,S 4 0060
7
1 0089 5 4005 ID code ID code
2 8008 6 0000 5 5 3 A 6 B1 8
361 F 3017
3 9543 7 0A79 194 4 5200
800.1.04.04.08H 0000 4F
Example:
Engine controller (ECM) number 898008-9543

Injector
Engine serial number 604005
Q adjustment number A79
Engine controller (ECM) number: A to J
* 2 places of figure on the left at the 1st line are fixed to
0.
800.1.04.04.08L-1
1 0 0 A B List of engine code-machine models applied.
2 C D E F
3 G H I J ab Engine code 4 Machine models
55 6HK1 5 CX330, CX350
Engine serial number: K to P
5B 6UZ1 6 CX460
* 2 places of figure on the left at the 4th line are fixed to
63 6WG1 7 CX700/800, E805
0.
4 0 0 K L 1st line 4th line

5 M N O P
2nd line 5th line
Q adjustment number: Q to S 3rd line 6th line
* 1 place of figure on the left at the 7th line is fixed to 0.
7th line
7 0 Q R S
800.1.04.04.08L-2

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4001-80
Selection of injector
(for checking ID code entered)
RST11 : Injector number 1
RST MODE Hi ,S 4 6B18 RST12 : Injector number 2
11 RST13 : Injector number 3
1 553A 5 3017 RST14 : Injector number 4
2 361F 6 5200
3 1944 7 4F00
1 Select an injector number (RST11 ->RST12 . . . ->RST116) intending to check or enter with the buzzer stop switch.
2 The injector number on the fan side is assigned as 1 and the one on the pump side as 6 (refer to the figure below).
Fan Pump
Engine
800.1.04.04.08K1
Remarks:
1 Engine information re-setting screen will appear from any service support screen by turning the one-touch idle
switch ON for more than 10 seconds.
2 Once you have entered the engine information re-setting screen, you cannot exit the screen until the key switch is
turned OFF.
3 While the engine is running, you cannot access the engine information re-setting screen even if the remarks "1"
above has been carried out.
4 Although the engine can be started while the engine information re-setting screen is being displayed, the ID code
cannot be entered.

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4001-81
Entering injector ID code (after injector has been replaced)
MODE Hi : Upper 2 places of figure on each line
MODE Lo : Lower 2 places of figure on each line
RST MODE Lo,S 4 6B18
11
1 553A 5 3017
2 361F 6 5200 Injection ID code
3 1944 7 4F00
800.1.04.04.08L.2
1 Select the replaced injector number 1 (RST11) with the buzzer stop switch.
2 Each time the auto mode switch is turned ON, 2 places of figure to be selected will shift in the order of "1Hi ->1Lo -
>2Hi -> 2Low -> 3Hi -> 3Lo -> 4Hi -> 4Lo -> 5Hi -> 5Lo -> 6Hi -> 7Hi -> 1Hi . . ." . (Selected line will change from
"light-on-dark" to "dark-on-light" indication.)
3 Keep on entering the ID code and enter lower 2 places of figure on 2nd line here. (At this time, the 2nd line is indi-
cated "light-on-dark "and the mode shows "Lo".) For setting the upper place of 2 places, since the figure shifts in
the order of "0 -> 1 -> 2 . . . 9-> A -> B -> C -> D -> E -> F -> 0 . . ." each time the travel mode switch is turned ON,
select "1" here. For setting the lower place of 2 places, since the figure shifts in the order of "0 -> 1 -> 2 . . . 9 -> A
-> B -> C -> D -> E -> F -> 0 . . ." each time the travel mode switch is turned ON, select "F" here.
4 Check that any line does not indicate "light-on-dark " after completion of entering all ID codes by repeating steps 2)
and 3) above, then turn the work mode switch ON for more than 10 seconds to allow data communication with the
engine controller (ECM). The buzzer sounds when the data have been written correctly.
NOTE: The buzzer will not sound in case where any one of figures has been mistakenly entered. When the key is
turned OFF without sounding the buzzer, the ID codes already memorized remain unchanged.
6 Access the engine information setting screen again to check that the data have been rewritten correctly.

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4001-82
Entering sheet of ID code of injector
Example: Injection N° 2
ID code ID code
5 5 3 A 6 B1 8
361 F 3017
194 4 5200
0000 4F
800.1.04.04.080-3
Injection N° 3
Injector
800.1.04.04.08L-1
Fan Pump
Engine 800.1.04.04.080-4
Injection N° 4
800.1.04.04.08K-1
Injection ID code
800.1.04.04.080-5
Injection N° 5
800.1.04.04.08K-1
Injection N°
800.1.04.04.080-6
Injection N° 6
800.1.04.04.080-1
Injection N° 1
800.1.04.04.080-7
800.1.04.04.080-2

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4001-83
TROUBLESHOOTING
Prior inspections
Item Value Action
POINTS TO BE CHECKED WHEN STARTING
Lubricants - Coolants
1. Check the quantity of fuel --- Add fuel
2. Check that fuel is not contaminated --- Clean, drain
3. Check the quantity of hydraulic fluid --- Fill with fluid
4. Inspect the hydraulic fluid filter --- Drain, clean
5. Check the quantity of oil in each reduction gear --- Fill with oil
6. Check the quantity of engine oil --- Fill with oil
7. Check the quantity of coolant --- Fill with coolant
-
Electrical equipment
8. Check the battery terminals and wiring for tightness and corrosion
--- Tighten or replace
9. Check the alternator terminals and wiring for tightness and corrosion
--- Tighten or replace
10. Check the starter motor terminals and wiring for tightness and --- Tighten or replace
corrosion
OTHER POINTS TO CHECK
Hydraulic system - Mechanical equipment
11. Abnormal noise or smell --- Repair
12. Check for oil leaks --- Repair
13. Air in the system --- Bleed the air
Electrical system - Electrical equipment
14. Check the battery voltage (with the engine shut down) 23-26 V
15. Check the quantity of fluid in the battery Replace
---
16. Make sure that the cables are not discoloured, burnt or stripped Add or replace
---
17. Check for missing or loose cable retaining clips Replace
---
Repair
18. Check for damp on cables (especially on connectors and terminals) ---
Disconnect and dry if damp
Replace
19. Check fuses for condition and corrosion ---
Replace
20. Check the alternator voltage (with the engine speed above the 27.5-29.5 V
throttle mid-point) (when battery charge is insufficient, there can be
25 V only at start up) Replace
---
21. Noise from relay battery (with starter motor ON or OFF)

Copyright ©
4001-84
Reading the organisation charts
Error code and description of problem
The error code and the description of the problem are shown in the organisation charts.
Error code Description of the problem

1 The message is still displayed even after refuelling
2 The message is still displayed even after adding coolant solution
Prior checks Wire colour

Before identifying the cause of the problem, always When troubleshooting, refer to the table below for the
make prior checks. wire colours. (For connector numbers, refer to the fol-
lowing pages).
How to proceed
Table showing wire colours
After checking or measuring the items described in one
step, depending on the results, choose YES or NO and
pass on to the next step. Symbol Colour Symbol Colour
B Black R Red
The description in the YES or NO branches refers
W White Y Yellow
directly to the cause of the problem as the result of
checks or measurements made. Refer to the descrip- Br Brown Lg Light green
tion of the cause and carry out the repair procedures P Pink Sb Sky blue
described on the right-hand side. V Violet L Blue
The inspection methods/measurements are described G Green Gr Grey
in one step. YES should be chosen if the criteria or O Orange
questions meet the situation; NO if they do not meet it.
BR indicates a wire of colour B striped with R.
The necessary preparation work, operating method and
Example: BR indicates a black wire with red stripes
the criteria are described under one step. This should
be carefully read before starting the inspection and the IMPORTANT : Before removing or installing a connec-
measurements and the procedures should be followed, tor, always turn the key switch OFF.
starting with step (1) since negligent preparation work
or incorrect operating methods can cause damage to
the machine.

Copyright ©
4001-85
Procedures
1 This is how one has to proceed to detect defects when the message is still displayed after all necessary measures
have been taken to correct the error.
Message displayed Description of the problem Problem No.

Fuel The message is still displayed even after refilling the fuel tank. 1
Low coolant The message is still displayed even after refilling with coolant solution. 2
The message is still displayed even after adjusting the engine oil pres-
Low oil press. 3
sure
The message is still displayed even when the hydraulic oil temperature
Overheating is 84°C (183° F) or less and the engine coolant temperature is 92°C 4
(197° F) or less.
Alternator The message is still displayed. 5
Elect. problem The message is still displayed. 6
2 This is how one has to proceed if the problem is not indicated by a message but machine operation is not correct.
A. Engine
Description of the problem Problem No.
The engine does not YES

«ELEC. PROBLEM» is shown on the monitor. 6
start.
NO 7
3 Problem without message.
Description of the problem Problem No.
Impossible to change travel speed 8

Copyright ©
4001-86
Fuel
Description of problem No. 1
- The message is still displayed even after refilling the fuel tank.
R5
CN1 CN23 CNB3 FUEL SENSOR
A1 CONTROLLER
14 GL413 9 GL413
BG660
KEY SWITCH OFF
700.1.04.06.11E
A1 Computer/Controller R5 Fuel sensor
Troubleshooting Cause Action

Key switch ON
Measure the fuel sen-
sor resistance (R5) YES Replace the
Computer/con-
using maintenance computer/
troller (A1)
support CHK4. (Refer controller
defective
to the table below for (A1)
the resistance).
Key switch OFF
Disconnect the fuel sen-
sor connector (R5) to
NO measure the resistance NO Replace or
Fuel sensor
on the connector at the check the fuel
(R5) defective
fuel sensor end. (Refer sensor (R5)
to the table below for
the resistance).
Disconnect the CN23
connector to measure
the resistance between NO Bad connec- Clean the
YES
GL female and the GND tion on fuel connection
earth. (Refer to the sensor (R5) terminal
table below for the
resistance).
Disconnect connector
CN1 to measure the
resistance between GL Clean CN23
Bad connec-
YES female and GND earth. NO connection
tion on CN23
(Refer to the table terminal
below for the resist-
ance).
Replace the
computer/
Defective com-
controller
puter (A1) or
YES (A1) or clean
incorrect CN1
the CN1 con-
connection
nection termi-
nal
Note: All the bar-graph indicators are off when the circuit is open
Resistance between GL and BG

Monitor 1. Refill the tank 2 3 4 5 6 7 8
Resistance (OHM) 70-80 61-75 46-61 37-46 30-37 24-30 18-24 10-18

Copyright ©
4001-87
Add coolant solution
- The message is still displayed even after adding coolant solution.
RESERVOIR 2
CNB8 LEVEL SWITCH
GrG438
BG642
S56
RESERVOIR 1
CN4 CN23 CNB8 LEVEL SWITCH
CONTROLLER 57 GrG437 6 GrG437
BG641 S55
A1
700.1.04.06.11F2
A1 Computer/Controller S56 Reservoir tank low switch
S55 Reservoir tank low switch

Key switch ON
Replace the
Disconnect the minimum cool- YES Defective mini-
minimum cool-
ant solution level switch con- mum coolant
ant solution
nector (S55) to see if the solution level
level switch
message disappears switch (S55)
(S55)
Short-circuit on
wire GrG
YES between the min-
Disconnect connector CN23 to Repair wire
NO imum coolant
see if the message disappears GrG
solution level
switch (S55) and
CN23
Short-circuit on
NO Disconnect connector CN4 to YES wire GrG Repair wire
see if the message disappears between CN23 GrG
and CN4
NO Defective com- Replace the

puter/controller computer/con-
(A1) troller (A1)

Copyright ©
4001-88
Low engine oil pressure
- The message is still displayed even when the engine oil level is satisfactory.
OIL PRESSURE
CNA0 CNA2 SENSOR
ENGINE 80 RY478 9
A2 CONTROLLER 67 YB488 10
B21
79 BY498 11
700.1.04.06.11G
A2 Engine controller B21 Engine oil pressure switch

Check the following points during the 12 seconds following starting the engine
Replace the
Disconnect the engine oil pres- YES Oil pressure
engine oil
sure switch connector (B21) to switch (B21)
pressure
see if the message disappears defective
switch (B21)
YES Short-circuit on
Disconnect connector CNAO
wire between
to see if the message disap- Repair wire
CNAO and
pears
NO CNA2
Replace
NO Defective engine
engine control-
controller (A2)
ler (A2)

Copyright ©
4001-89
Overheating
- The message is still displayed even when the actual temperature is lower than the following:
Hydraulic oil temperature 98°C (208°F), engine coolant temperature 105°C (221°F).
Prior check:
1 Make sure that 8 bars are displayed on the hydraulic oil and engine coolant temperature gauge bar-graphs.
ENGINE CONTROLLER
CNA1
84
A2
CNA0
79
THERMO-SENSOR
CNA2 (COOLANT)
WR484 7
CONTROLLER
B1
BY498 11
CN1 THERMO-SENSOR
A1 CN23 CND3 (OIL)
6 10 OL415
B2
13 11 BO425
700.1.04.06.11H
A1 Computer/controller B1 Coolant temperature sensor
A2 Engine controller B2 Hydraulic oil temperature sensor

Copyright ©
4001-90

1 The 8 bars on the coolant temperature bar-graph are displayed.
Key switch ON
The temperature of the

coolant temperature
sensor (B1) is abnormal
compared to mainte-
nance assistance CHK1 YES
(comparison between
the actual temperature
and the indicated tem-
perature).
See coolant tempera-
ture in CHK1 WT.
Measure the actual
temperature
Check problem code
E0015 for the coolant
temperature sensor
(B1) with the mainte-
nance diagnostic (DIAG
1)
YES
NO Defective Replace the
CNA2 on the coolant
coolant tem- coolant tem-
temperature sensor
perature sen- perature sen-
(B1) to measure the
sor (B1) sor (B1)
resistance
Disconnect the connec-
Bad connec- Clean the
tors CNA1 and CNAO
NO tion on the coolant tem-
to measure the resist-
coolant temperature sen-
YES ance between the male
perature sensor
terminals. (Refer to the
sor connector connecting
table below for the
(B1) terminal (B1)
resistance).
Replace con-
Bad connec-
troller or
tions on
YES clean CNAO,
CNAO, CNA1
CNA1 con-
or defective
nector termi-
controller
nal
Note: In the event of a short-circuit, the bar-graph goes off completely.

Copyright ©
4001-91
Overheating (continued)

2 The hydraulic temperature bar-graph displays 8 bars.
Key switch ON
The hydraulic oil tem-

perature sensor (B2)
temperature is abnor-
mal compared to main-
tenance assistance YES
CHK1 (comparison
between the actual tem-
perature and that indi-
cated).
See hydraulic oil tem-
perature in CHK1 OT.
Measure the actual
temperature
See problem code
M0020 for the oil tem-
perature sensor (B2)
using maintenance
diagnostic (DIAG 4)
YES
CND3 on the hydraulic
Defective Replace the
oil temperature sensor NO
hydraulic oil hydraulic oil
(B2) to measure the
temperature temperature
resistance. (Refer to the
sensor (B2) sensor (B2)
table below for the
resistance).
Disconnect the CN23
Bad connec- Clean the
connector to measure
NO tion on the hydraulic oil
the resistance between
hydraulic oil temperature
YES the male terminals OL
temperature sensor con-
and BO. (Refer to the
sensor connecting termi-
table below for the
nector (B2) nal (B2)
resistance).
CN1 to measure the
Clean the
resistance between the NO Bad connec-
connecting
YES female terminals OL tions on
terminal on
and BO. (Refer to the CN23
CN23
table below for the
resistance).
Replace the
Defective
computer/
computer/
controller
controller
YES (A1) or clean
(A1) or bad
the connect-
connection
ing terminals
on CN1
on CN1
Note: In the event of a short-circuit, the bar-graph goes off completely.

Copyright ©
4001-92
Coolant and hydraulic oil temperature sensor resistance
NOTE: The resistance varies with temperature.
Coolant or hydraulic oil Hydraulic oil temperature

Coolant temperature sensor (B1)
temperature sensor (B2)
20°C (68°F) 2.50 kΩ 2.45 kΩ
30°C (86°F) 1.73 kΩ 1.66 kΩ
40°C (104°F) 1.20 kΩ 1.15 kΩ
50°C (122°F) 0.84 kΩ 0.81 kΩ
60°C (140°F) 0.61 kΩ 0.58 kΩ
70°C (158°F) 0.45 kΩ 0.43 kΩ
80°C (176°F) 0.31 kΩ 0.32 kΩ
Defective battery charge circuit

- The message is still displayed.
CN13
S1
19 K7 G2
P5 KEY SWITCH
BATTERY RELAY ALTERNATOR
E
LgR540
LgR540
HOUR METER
B
CN22 CNC9
2 LgR540 G020 R SG
A1 CN26
L
CN1 1 BrR544 4
7 LgR542 ENGINE
CONTROLLER
CONTROLLER 2 BrW545
A2 BrR030
M1
BrR543 STARTER
700.1.04.06.11J2
A1 Computer/controller M1 Starter motor
A2 Engine controller P5 Hourmeter
G2 Alternator S1 Key switch
K7 Relay battery

Copyright ©
4001-93

NO CN1 to measure the volt- NO
The hour meter (P5) Break in wire between
age between the female Repair wire
does not work CN1 and CN22
terminal on wire WR and
YES Ground. 10V or above.
YES
Clean CN1 connector
Bad connection on CN1
terminal or replace con-
or defective controller
troller
Disconnect the connector CNC9 on alternator R ter-

Replace the alternator
minal to measure the voltage between alternator NO Defective alternator (G2)
(G2)
side and ground. 10 V or above.
YES
Break in wire between
CN22 to measure the
CN22 and alternator or Repair wire between
voltage between the NO
bad connection on alter- CN22 and alternator or
male terminal on wire
nator connector terminal clean the connector
LgR and ground. 10 V or
of alternator
above
YES

Copyright ©
4001-94
Electrical system troubleshooting
- The message is still displayed
TRAVEL ALARM
W 2
K32 K5
0.85B 1
H2
HYDRAULIC
FAN RELAY BEACON RELAY
1.25RW 1 R
1.25B 2 Y
HYDRAULIC
MOTOR (FAN)
SOLENOID
Y31
S51
A1
5
1
2
3
GR 4
4
5
2
3
GW 1
B 2
YR
PW
RW
GrR
LR
B
B
LIMIT SWITCH
(GATE) BEACON
CONTROLLER
GrR
FREE SWING
SOLENOID Y18
VR 1 VR B
CN.5
1 GW 1
2 YR B 2
CN.19
2 STAGE RELIFE 8 YW
CN22
RW
24VB SOLENOID VALVE

Y2
PW
GR 6 0.85GR 0.85GR 1 LEVER LOCK

REFUEL PUMP 17 OW OW 8 OW 0.85B 2
FREE SWING/BEACON 18 GW VW 9 0.85VW (BLUE TAPE)
WARNING BUZZER
ENGINE STOP
19
21
W
WR
W 7 W
0.85VW 1 SWING BRAKE Y3
HYD. FAN REVERSE 22 RW 0.85B 2
SWING BRAKE 27 VW (PINK TAPE)
2 SPEED TRAVEL 28 LW LW 1 0.85LW
CUSHION 29
30
LgW
OR
LgW
OR
3
6
0.85LgW 0.85LW
0.85B
1
2
2 SPEED TRAVEL Y4
SWING SHUT-OFF 31 BrW BrW 4 0.85BrW (RED TAPE)
SPARE 1 (PNP) 32 WL GW 5 GW
20
SPARE 2 (PNP)
23
WV YW 2 0.85YW 0.85YW
0.85B
1
2
2 STAGE RELIEF
Y5
1 (YELLOW TAPE)
2
CN24 0.85LgW 1
CN.6
SOFT/HARD
0.85B 2
Y6
WR
CN.23
(LIGHT GREEN TAPE)
16
CONNECTOR 0.85BrW 1 SWING SHUT-OFF

(OPTION) 0.85B 2
(GREEN TAPE)
Y1
WR
CN.A0
47
STOP SWITCH
IS-ENGINE
A2
OPTION (REFUEL PUMP)
REFUEL PUMP PUMP STOP S61
ENGINE CONTROLLER (ECM) RELAY RELAY
K31
AUTO / MANUAL
SELECT SWITCH
K30 VR
GW
1
2
L 3
1
5
3
4
5
3
2
1
2
B82
B
VR
VR
2LR
OW
2GrR
0.85BrR
AUTO STOP
ALARM
0.85BrR
0.85B
M14 REFUEL PUMP
1 2GrR
OW 3 OW 2LR 1 2R
2 2B 2B 2 2B M
700.1.04.06.11KA
A1 Computer S61 Refuel pump switch
A2 Engine controller Y1 Swing pilot shut-off solenoid valve (green band)
B82 Refuel pump stop alarm Y2 Pilot pressure solenoid valve (blue band)
H2 Travel alarm (North America) Y3 Swing brake solenoid valve (pink band)
K5 Relay-rotary light Y4 2 stage travel solenoid valve (red band)
K30 Refuel pump relay Y5 Power-up solenoid valve
K31 Refuel pump stop relay Y6 Cushion control solenoid valve (light green band)
K32 Relay, hydraulic fan Y18 Free swing solenoid valve (North America)
M14 Fuel feed pump motor Y31 Cooling hydraulic motor solenoid valve
S51 Hydraulic function cancellation lever switch

Copyright ©
4001-95

Troubleshooting using the diagnostic system
Key switch ON
Refer to the
Failure code displayed in DIAG 1 engine trouble-
YES shooting manual
NO
Find troubled location by DIAG4
M0020
YES
appears
To CHK2
With automatic detection for short-circuit

YES
The failure code disappears after disconnecting the solenoid valve Defective (Yn) solenoid Replace the solenoid
connector YES valve valve (Yn)
NO
The failure code disappears when either one of connectors CN21,
Short-circuit on wire Repair the wiring
CN22, CN23 in short-circuit line is disconnected YES
NO
The failure code disappears after disconnecting connector CN6
YES
NO
Defective controller Replace controller

Copyright ©
4001-96
ELECTRICAL INSPECTION OF COMPONENTS
Details of service connector kit
(380050017) 0.85
WY
0.85
BW 02A 01A 50 200 50
01A
0.85BW
0.85
WL 03A 50
BrG
50
0.85WY
50
100 02A
BrG BrG
150
0.85 0.85
01B 02B
50 100 BW WY
100 101 0.85

WL 03B 03A
150 BrB 0.85WL
100 700.1.04.02.14AH
700.1.04.02.14AA
8. For pressure sensor (3P)
1. For solenoid valve and fuel sensor 0.85YL
200
50 50
01A 02A 03A 01A
50
BrB
102 0.85 0.85 0.85
50
50
YL BY Y
BrB BrG
100 150 0.85BY
50 02A
102 103
BrG 03B 02B 01B
150
103 03A
0.85 0.85 0.85
Y BY YL 0.85Y
700.1.04.02.14AB
700.1.04.02.14AI
2. For electromagnetic proportional valve of hydraulic
pump 9. For atmospheric pressure sensor
BrG 0.85BO
104 01A
BrG BrB
100 150 50
50 300
104 105 01A 02A
50
50
150 BrB 0.85BO 0.85OL
105
02A
700.1.04.02.14AC 0.85OL
3. For electromagnetic proportional valve of hydraulic 700.1.04.02.14AJ

pump 10. For intake air temperature sensor
L
1.25YG
106
L BY 01A
100 150
50
106 107 50
50 600
150 BY 1.25 1.25
YG BY 01A 02A
50
107
50
01B
700.1.04.02.14AD 1.25 1.25 02A 01B
BY Y 1.25Y
4. For pressure switch
700.1.04.02.14AK
BY
108
11. For electromagnetic proportional valve of control-
BY L
50 100 150 ling fan speed (2P)
108 109
150 L 1.25RW
109 01A
700.1.04.02.14AE 50
50 800
5. For the harness side of pressure switch 1.25RW

01A 02A
1.25B
50
C 02A
814 1.25B
C C
100 150
50 700.1.04.02.14AL
814 850
150 C 12. For fan reversing solenoid valve (2P)
450
3B
700.1.04.02.14AF
01A
6. For receiver dryer (2P) 6
50
50 200
0.85BP 3B 01A
50
01A
0.85PL 0.85BP 50
150
50
50 6
02A 01A
02A
50
3LR 02A 3LR
02A
0.85PL
700.1.04.02.14AM
700.1.04.02.14AG
7. For oil temperature sensor 13. For glow (1P)

Copyright ©
4001-97
700.1.04.02.14AN
14. For fuel pump (6P)
700.1.04.02.14AP
16. For injector (12P)
700.1.04.02.14AO
15. EGR (8P)
700.1.04.02.14AQ
17. For sensor (20P)

Copyright ©
4001-98
Details of service connector kit (380350031) for breaker from engine controller (ECM) to main
harness assembly
Engine controller C-2 Engine controller C-1
700.1.04.02.21P
1. For ECM-terminal

Copyright ©
4001-99
Engine controller (ECM)
700.1.04.02.21Q
2. For Main-terminal
1.250 1.250
150
50 50
001 001
50
1.250
002
700.1.04.02.21R
3. For Joint-terminal

Copyright ©
4001-100
Main pump proportional solenoid 6 solenoid valve bank
1. Disconnect connector (A) from one of the solenoids
on the 6 solenoid valve bank (52)
1
Y1 Y5 Y4
Y7
Y2
700.1.04.02.21UA
Y6
Y3
1. Disconnect connector (1) from the main pump
hydraulic solenoid (Y7). 52
5
A
2 3
CD00F023
4 Marking Function
CS00E534 Y1 Swing pilot shut-off solenoid valve (green band)

2. Connect the appropriate service connector (2P) (4) Y2 Pilot pressure solenoid valve (blue band)
between the connector at the pump end (2) and the Y3 Swing brake solenoid valve (pink band)
connector at the main harness end (3) and install the Y4 2 stage travel solenoid valve (red band)
voltmeter (5).
Y5 Power-up solenoid valve (yellow band)
NOTE: The + terminal of the voltmeter should be con- Y6 Not used (light green band)
nected to wire BrB (brown/black) on the service con-
nector coming from the main harness and the - terminal
to wire BrB (brown/black) on the service connector 2
Yn
coming from the hydraulic pump.
3. When the connections have been made, start the
engine and check the current on the voltmeter (5) in 3
each work mode, at maximum speed.
Current in mA
H S Auto
L
Maxi Min Maxi Min S L 1
490 240 405 240 <50 490 490
CS99A843
2. Connect the appropriate service connector (2P)(3) to
the connector on the disconnected solenoid (1) only
(Yn) and install the voltmeter (2).
3. When the connection has been made, the solenoid
resistance reading on the voltmeter (2) should be 45 Ω
at 20°C (68° F).
NOTE: The resistance value varies with temperature.

Copyright ©
4001-101
Hydraulic oil temperature sensor 3. When the connection has been made, place the tem-
perature sensor (B2) in the beaker (5) containing
water. Place the beaker (5) on the tripod (7). Using the
spirit lamp (8) gradually increase the water tempera-
ture in the beaker (5). Using the voltmeter (9), check
the resistance value in function of the temperature
read on the thermometer (4) (see table below).
Oil Temperature Oil temperature sensor

20°C (68°F) 2.45 kΩ
30°C (86°F) 1.66 kΩ
40°C (104°F) 1.15 kΩ
50°C (122°F) 0.81 kΩ
B2 60°C (140°F) 0.58 kΩ
70°C (158°F) 0.43 kΩ
80°C (176°F) 0.32 kΩ
Pressure sensor
700.1.04.02.21AB
B2 Hydraulic oil temperature sensor B42
1. Remove the oil temperature sensor (B2) from the
machine.
B44
3
4
9
5
6
700.104.02.21AD1
CS99A851
3 Service connector (2P)
4 Thermometer
5 Beaker B43
6 Temperature sensor (B2)
7 Tripod
8 Spirit lamp
9 Voltmeter
2. Connect the appropriate service connector (2P) (3) to
the temperature sensor (B2) connector (1) or (2) and
install the voltmeter (9).
700.1.04.02.21AB1
B42 Pressure sensor P1

B43 Pressure sensor (nega-cont.) (N)
B44 Pressure sensor P2
1. Disconnect the connector from the main hydraulic
pump pressure sensor.

Copyright ©
4001-102
(psi) (MPa)
5 (7252)
(725)
(580)
B42
1 2 3 (435)
4
B43 (290)
B44 (145)
Pressure
Voltage (V)
700.1.04.02.21.AG
CS00E541
2. Connect the appropriate service connector (3P)(4)
between sensor (B42), (B43) or (B44) and the corre-
sponding connector (1), (2) or (3) of the main harness
(5) and install the voltmeter (6).
NOTE: The + terminal on the voltmeter should be con-
nected to wire YL (yellow/blue) on the service connec-
tor and the - terminal to the machine earth.
3. When the connection has been made, start the engine
and check the voltage read on the voltmeter (6) in
accordance with the pressures indicated in the table
below.
Pump pressure sensor (B42) and (B44)
Pressure (MPa) Voltage (V)

50 (7252 psi) 4.5
43.7 (6338 psi) 4
37.5 (5439 psi) 3
25 (3626 psi) 2
17.5 (2538 psi) 1
0 0.5
Pressure sensor (nega-cont.) (B43)
Pressure (MPa) Voltage (V)

5 (725 psi) 4.5
4.37(634 psi) 4
3.75 (544 psi) 3
2.50 (362 psi) 2
1.25 (181 psi) 1
0 0.5
NOTE: Formula for converting pressure:

1MPa = 1.019 x 10 kgf/cm2

Copyright ©
Section
4003
4003
MAIN ELECTRONIC CONTROL BOX

ENGINE ELECTRONIC CONTROL BOX

Printed in France
Copyright ©
4003-2
TABLE OF CONTENTS
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX ................................................. 3
Removal ...................................................................................................................................................................... 3
Main electronic control box ......................................................................................................................................... 3
Engine electronic control box ...................................................................................................................................... 4
Installation ................................................................................................................................................................... 4

Copyright ©
4003-3
MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC
CONTROL BOX
Removal STEP 4
STEP 1
B
A C
CD00F011
Remove the panel (A) located behind the operator’s
JS00001A seat, taking care to disconnect the connector from the
Park the machine on hard, flat ground. Lower the cigarette lighter (B) and the solar radiation detector (C).
STEP 2
Main electronic control box
Shut down the engine and position the starter switch on
STEP 5
OFF.
STEP 3
B
CD00F047
Disconnect the connectors CN1 to CN6 from the main
electronic control box (B).
Disconnect the main earth cable (-) (1) from the battery. STEP 6
Remove the 4 retaining screws (A) from the main
electronic control box (B).
STEP 7
Remove the main electronic control box (B).

Copyright ©
4003-4
Engine electronic control box
STEP 5
CNA1
K10 K11 K32 K6 K5

CNA0
D
C
Identify and remove the relay-rotary light (K5), the

relay-air conditioner condenser fan (K6), the relay,
hydraulic fan (K32), the relay-working light (cab) (K11)
and the relay-working light (upperstructure /attachment)
(K10).
STEP 6
Disconnect the connectors CNA0 and CNA1 from the
engine electronic control box (C).
STEP 7
Remove the retaining screws (D) from the engine
electronic control box (C).
STEP 8
Remove the engine electronic control box (C).
Installation
To install, proceed in the reverse order from that of
removal.
NOTE: To reprogram the main and engine electronic
control boxes, see Section 4001.

Copyright ©
5001
Section
5001

OF THE TRACKS SET

Printed in France
CNH Lep SM160B5001-0EN May 2007
Copyright ©
5001-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS..................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................... 3
TRACKS SET................................................................................................................................................................. 4
Description ................................................................................................................................................................. 4
Removal ..................................................................................................................................................................... 5
Installation .................................................................................................................................................................. 8
Track tension adjustment ......................................................................................................................................... 10
Checking pin and bushing wear ............................................................................................................................... 12
WARNING: This symbol is used in this manual to indicate important safety messages. Every time you see this
! symbol, read carefully the message that follows, as it indicates that there is a risk of serious injury.
SPECIFICATIONS
See Section 1002

See Section 1002
Lep SM160B5001-0EN Issued 05-07

Copyright ©
5001-3
SPECIAL TOOLS
926407
1. Track removal hydraulic press CAS 10044

2. Loctite 262
3. Hammer
4. Lifting jib
5. Impact wrench
6. Torque spanner
7. Supports 10 T
8. Roller pump
9. Protractor attachment CAS 2162

Copyright ©
5001-4
TRACKS SET
Description
Lower mechanism
12 6
5
7
8
7
4
14
9
11
13
14
3
10
CI00E511
1 TRACK PAD 8 END OF CHAIN PIN SPACER
2 SCREW 9 RETAINER PIN
3 NUT 10 RH STANDARD TRACK PIN HALF-LINK
4 END OF CHAIN PIN HALF-LINK 11 LH STANDARD TRACK PIN HALF-LINK
5 END OF CHAIN HALF-LINK 12 STANDARD TRACK PIN
6 END OF CHAIN PIN 13 STANDARD TRACK PIN SPACER
7 SHIM 14 UNION

Copyright ©
5001-5
Removal
STEP 1
Park the machine on hard, flat ground. Rotate the
upperstructure of the machine so that the cab is over
the track to be removed.
2
STEP 2
JD00272A
Operate the machine until the main axle is close to the
centre of the sprocket. Operate machine to lower track
to be removed to ground. Rotate the upper structure of
the machine so that the cab is facing the front. Shut
down the engine.
STEP 4
JD00270A
Lower the bucket or the tool to lift the track a few
centimetres off the ground.
NOTE: If the machine does not have a bucket or tool
installed, install wood blocks under the dipper and
lower the dipper onto the wood blocks. Then, lower the
dipper to raise the machine.
STEP 3
JD00273A
Do not remove the non-return check valve. The grease
1 in the track adjustment cylinder is under high pressure.
Slacken the track by gradually loosening the non-return
check valve by about two turns. The grease will escape
from a port on the check valve thread.
WARNING: Grease is under heavy spring

pressure. Disassembly without releasing
JD00271A
pressure may result in serious injury or death.
The main axle (1) can be identified by flat surfaces on
Do not disassemble the track compensating
one end and the pin (2) that fastens it at the other end. ! system before completely releasing the
grease pressure. Release grease pressure by
loosening check valve. Do not remove the
non-return check valve or retaining bracket.

Copyright ©
5001-6
STEP 5 STEP 7
JD00274A JD00277A
Remove the four screws (1) and the track pad nuts on Remove the four screws and the nuts from the track
top of the end of chain axle. Remove the track pad. pad under the end of chain axle. Remove the track pad.
STEP 6 STEP 8
JD00275A B504423M
Install a portable hydraulic press CAS 10044 on the
end of chain axle. Using the portable hydraulic press,
force the end of chain axle out.
STEP 9
Remove the portable hydraulic press.
JD00276A
Straighten up one end of the pin (1) and remove the pin
from the end of chain axle.

Copyright ©
5001-7
STEP 10 STEP 12
JD00278A JS00280A
Using a crowbar, separate the chain links. Remove the Sling the lower end of the track. Start the engine.
two spacers (1) from the end of chain axle. Operate the machine backwards and move the dipper
out at the same time. When the track is free from the
STEP 11 sprocket, stop reversing the machine. Continue
operating the dipper out until the track is pulled from
beneath the machine. Stop the engine, move the track
to be replaced away from the machine.
JD00279A
Start the engine. Using the attachment, lift the
upperstructure on the side of the track to be removed.
Install supports under the machine to hold the machine
in place and lower the machine onto the supports. Shut
down the engine.

Copyright ©
5001-8
Installation STEP 4
STEP 1
CD00F057
Connect lifting equipment to the track. Lift the track on
JD00279A the idler wheel.
Lift the undercarriage. Install supports under the
machine to hold the machine in place. STEP 5
STEP 2
JS00283A
Sling the track to the attachment. Start the engine,
JD00281A operate the machine forward and move the dipper out
Place and align the new track under the lower roller. at the same time to pull the track on the sprocket. Keep
STEP 3 the track engaged on the sprocket teeth.
Lower the machine onto the track chain.

Copyright ©
5001-9
STEP 6 STEP 9
B5573689M JD00284A
Connect suitable pulling equipment to both ends of the Remove the portable hydraulic press. Install a new pin
track chain. Operate the pulling equipment to pull both (1) in the end of chain axle. Bend the ends of the pins
ends of the track chain together. to brake the end of chain axle.
STEP 7 STEP 10
Install the two track pads, the screws and the nuts.
1 STEP 11
JD00278A
Install two spacers (1) in the two half links where the
end of chain axle is assembled.
STEP 8 B5171389M
Tighten the track pad screws to a torque (see the
specifications).
STEP 12
See "Track tension adjustment" in this section and
adjust the track tension.
B5491989M
Install the end of chain axle with the portable hydraulic
press CAS 10044.

Copyright ©
5001-10
Track tension adjustment STEP 4
Check the tension of the tracks as required. Adjust the Do the following procedure to increase the track
tension for the type of surface the machine will be tension:
operating on. Tighten the track for operation on hard
1. Clean the grease fitting of the track adjustment
surfaces and loosen the track for operation on soft
cylinder.
surfaces.
STEP 1
Park the machine on hard, flat ground. Rotate the
upper structure of the machine so that the cab is over
the track to be checked.
STEP 2
JD00273A
2. Check that the check valve is tight.
JD00270A
Lower the attachment to lift the machine until the track
to be checked is lifted off the ground by a few
centimetres.
STEP 3
JD00287A
3. Inject grease into the track tension cylinder until the

required tension is obtained.
JD01074A
Measure the distance between the bottom surface of
the track frame and the top surface of the track shoe.
Compare the values with the specifications.

Copyright ©
5001-11
STEP 5
Do the following procedure to decrease the track
tension:
JD00273A
1. Do not remove the non-return check valve. Grease

in the track tension cylinder is under high pressure.
Release the track by gradually loosening the non-
return check valve by about two turns, the grease
escapes from a port in the check valve thread.
WARNING: Grease is under havy spring

! system before completely releasing the
non-return check valve or retaining bracket.
2. When the track tension is correct, tighten the check

valve.
3. Clean the grease from the check valve.

Copyright ©
5001-12
Checking pin and bushing wear
The wear on the pins and bushings can be measured STEP 2
with a micrometer or an outside calliper.
Measure the inside diameter of the bushing. Compare
STEP 1 the values with the specifications. Replace them if
necessary.
1 2
STEP 3
Measure the outer diameter of the track pin. Compare
the values with the specifications. Replace them if
necessary.
JS00288A
1 OUTSIDE CALLIPER
2 BUSHING
Measure the outer diameter of the bushing. Compare

the values with the specifications. Replace them if
necessary.

Copyright ©
Section
5003
5003
UPPER AND LOWER ROLLERS

Printed in France
Copyright ©
5003-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
SPECIAL TORQUE SETTINGS...................................................................................................................................... 3
SPECIAL TOOLS ............................................................................................................................................................ 3
LOWER ROLLER............................................................................................................................................................ 4
Description ................................................................................................................................................................. 4
Removal ..................................................................................................................................................................... 5
Reconditioning ........................................................................................................................................................... 6
Disassembly ............................................................................................................................................................... 6
Inspection ................................................................................................................................................................... 7
Assembly ................................................................................................................................................................... 7
Installation .................................................................................................................................................................. 9
UPPER ROLLER........................................................................................................................................................... 10
Description ............................................................................................................................................................... 10
Removal ................................................................................................................................................................... 11
Reconditioning ......................................................................................................................................................... 12
Disassembly ............................................................................................................................................................. 12
Inspection ................................................................................................................................................................. 14
Assembly ................................................................................................................................................................. 15
Installation ................................................................................................................................................................ 17
CHECKING FOR LEAKS .............................................................................................................................................. 18
! symbol, carefully read the message that follows, as there is a risk of serious injury.

Copyright ©
5003-3
SPECIFICATIONS
See Section 1002.

See Section 1002.
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 for the leak checks
shown below.

Copyright ©
5003-4
LOWER ROLLER
Description
A
B
C 7
F
3
E
D
G
1 6 8 5 4
KTA1106Z-C02
1 LOWER ROLLER 5 FACE SEAL
2 DRAIN PLUG 6 SHAFT
3 WIRE CLIPS 7 O-RING
4 END BEARING 8 BUSHING
A.......................................................................................................................................................... 406 mm (15.88 in)

B........................................................................................................................................................... 318 mm (12.52 in)
C............................................................................................................................................................. 223 mm (8.78 in)
D......................................................................................................................................................... Ø 200 mm (7.87 in)
E ............................................................................................................................................................... 36 mm (1.42 in)
F ............................................................................................................................................................. 170 mm (6.69 in)
G........................................................................................................................................................... Ø 85 mm (3.35 in)

Copyright ©
5003-5
Removal STEP 5
STEP 1
Park the machine on hard, flat ground. Swing the
upperstructure of the machine so that the cab is over
the lower rollers to be removed.
STEP 2
1
JD01076A
At each end of the track, install wood blocks (1) under
the track.
STEP 6
JD00273A
Do not remove the non-return check valve. The grease
in the track adjustment cylinder is under high pressure.
Slacken the track by slowly loosening the non-return
check valve by about two turns, the grease will escape
from a port in the check valve thread.

Do not disassemble the track compensating JD00299A
! system before completely releasing the Install a wood block under the lower roller to support it.
grease pressure. Release grease pressure by Remove the screws and the retaining washers and
loosening check valve. Do not remove the remove the lower roller.
non-return check valve or the retaining
bracket.
STEP 3
Lower the attachment to lift the machine until a
sufficient gap between the track frame and the track is
obtained so that the lower roller can be removed.
STEP 4
JD01075A
Install supports (1) of suitable capacity under the
machine.

Copyright ©
5003-6
Reconditioning STEP 3
When the roller is worn out or is leaking, it must be
reconditioned or replaced by a new one. See Section 4
1002 for limits of wear.
5
Disassembly
STEP 1
JS00303A
2 Remove the face seals (5) from the end bearings (4)
with a screwdriver or similar tool. Be careful not to
damage the seal bore in the end bearing. Discard the
face seals.
STEP 4
000-6-04-0021B
Clean the lower roller (1) using a suitable solvent.
Remove the two drain plugs (2) and drain the oil.
STEP 2
4 7
7
3 6
3
6
1
JS00304A
Remove and discard the O-rings (7) from the shaft (6).
Remove the shaft (6) from the lower roller (1).
4 STEP 5
000-6-04-0021C
Remove the retainer rings (3) and the end caps (4) from 1
the shaft (6). Discard the retainer rings.
5
JS00305A
Remove and discard the face seals (5) from the lower
roller (1) or the shaft (6).

Copyright ©
5003-7
STEP 6 Assembly
STEP 1
8
1
8
8
1
JS00306A 8
NOTE: Carry out this step only if inspection reveals that
JS00309A
the bushings (8) need to be replaced.
If the bushings (8) were removed, install new bushings
Using a hammer and a brass drift, drive the bushings (8) in the lower roller (1) using a hydraulic press and an
(8) out of the lower roller (1). Be careful not to damage appropriate centring piece.
the seal bore in the lower roller. Discard bushings.
STEP 2
Inspection
5
STEP 1
Clean all components with solvent.
STEP 2
Inspect the bushing surfaces on the shaft (6) for 5
scoring, pitting, and other damage. Measure the
diameter of the shaft at four opposing points. Compare
the values with the specifications, replace them if
necessary.
1
STEP 3
Inspect bushings (8) for wear and damage. Measure
the inner diameter and width of the bushing. Compare JS00310A
the values with the specifications, replace them if Install an O-ring and a face seal metal bushing (5) in
necessary. the seal bore on each side of the lower roller.
STEP 4
Inspect the bore in each end bearing and in the lower
roller for damage that will result in leakage. Use new
parts as required.

Copyright ©
5003-8
STEP 3 STEP 5
3
1
3
7 4
6
1 4
7
JS00311A 000-6-04-0021C
Apply clean grease on the shaft surface (6) and install Install the end caps (4) on the shaft (6) and install new
the shaft in the lower roller (1), lubricate and assemble retainer rings (3).
the O-rings (7) on the shaft (6).
NOTE: Check the adjustment settings of the face seal
STEP 4 covers as well as those of the retaining pitch holes, see
page 4.
4 STEP 6
See the chapter on leak checks, carry out an inspection
to ensure that the lower roller has been correctly
5 installed.
STEP 7
3
JS00312A
000-6-04-00-21M
Install the wire clips (3) using a hammer.
5
JS00313A
Install the O-ring and remaining face seal metal
bushings (5) in the seal bore of the end cap (4). Apply
clean oil copiously to the face seals (A).

Copyright ©
5003-9
STEP 8 Installation
STEP 1
1
000-6-04-0021B
Fill the lower roller (1) with clean oil, see specifications.
Install the drain plug (2) in the end cap (4). JD00316A
Align the lower roller in position under the lower
undercarriage.
STEP 2
JD00299A
Apply Loctite 262 to the screw threads. Assemble the
hardened washers and the screws.
STEP 3
Tighten the retaining screws of the lower roller end
bearings to torque (see Specifications). Remove the
wood blocks.
STEP 4
At each end of the track, remove the wood blocks from
beneath the track. Remove the two supports from
beneath the machine.
STEP 5
Refer to "Track tension setting" in Section 5001.

Copyright ©
5003-10
UPPER ROLLER
Description
A B C
4 K
11
5
E
D 2
3
F
J
6 7 9 10 8 1 G H
300.6.03.01.08ABIS
1 UPPER ROLLER 7 SHAFT
2 OIL DRAIN PLUG 8 FACE SEAL
3 SCREW 9 BUSHING
4 COVER 10 BUSHING
5 SEAL 11 BRACKET
6 THRUST PLATE
A............................................................................................................................................................. 186 mm (7.32 in)

B............................................................................................................................................................. 103 mm (4.05 in)
C............................................................................................................................................................ 11.5 mm (0.45 in)
D......................................................................................................................................................... Ø 150 mm (5.90 in)
E ........................................................................................................................................................... Ø 65 mm (2.55 in)
F ............................................................................................................................................................. 147 mm (5.78 in)
G............................................................................................................................................................... 50 mm (1.96 in)
H............................................................................................................................................................. 152 mm (5.98 in)
J ............................................................................................................................................................... 30 mm (1.18 in)
K............................................................................................................................................................. 104 mm (4.09 in)

Copyright ©
5003-11
Removal STEP 3
STEP 1
JD00317A
Install a hydraulic jack on the side frame. Using the
JS00163A jack, lift the track just enough to remove the upper
Park the machine on hard, flat ground. Lower the tool to roller.
the ground.
STEP 4
STEP 2
JD00318A
JD00273A Place wooden shims between the track and the
Do not remove the non-return check valve. The grease undercarriage.
in the track adjustment cylinder is under high pressure.
Slacken the track by slowly loosening the non-return STEP 5
check valve by about two turns, the grease will escape
from a port in the check valve thread.

! system before completely releasing the
non-return check valve or the retaining
bracket.
JD00319A
Unscrew the screws which fasten the upper roller to the
undercarriage. Support and remove the upper roller.

Copyright ©
5003-12
Reconditioning STEP 3
When the upper roller is worn or is leaking, it must be
reconditioned or a new upper roller installed. See
Section 1002 for limits of wear.
Disassembly
STEP 1 3
6
1
7
1
2
CS02B507
Secure the upper roller in a vice. Remove the screws
(3) holding the thrust plate (6). Remove the thrust plate
(6).
STEP 4
1
CS02B505
Clean the upper roller (1) using a suitable solvent.
Remove the drain plug (2) and drain the oil. 7
STEP 2
3
4 CS02B508
Pull the upper roller (1) from the shaft (7).
5
NOTE: Carry out Step 5 only if inspection reveals that
the shaft (7) needs to be replaced.
1
STEP 5
CS02B506 Using a press, remove the shaft (7) from the bracket
Remove the screws (3) and the cover (4) from the (11). Be careful not to damage the seal bore in the
upper roller (1). Remove and discard the O-ring (5) bracket.
from the cover (4).

Copyright ©
5003-13
STEP 6 NOTE: Carry out Step 8 only if inspection reveals that
the bushings (9) and (10) need to be replaced.
STEP 8
1
9
8
1
10
CS02B509
Remove and discard the face seal (8) on the upper
roller (1) using a screwdriver or equivalent tool. Be
CS02B511
careful not to damage the seal bore in the upper roller.
Using a hammer and a brass punch, drive the bushings
STEP 7 (9) and (10) from the upper roller (1). Be careful not to
damage the seal bore in the upper roller.
7
8
7
8 11
11
000.6.03.00.24H
Remove and scrap the face seal (8) from the bracket
(11) using a screwdriver or other suitable tool. Be
careful not to damage the seal bore in the bracket.

Copyright ©
5003-14
Inspection
STEP 1
Clean all components with solvent.
STEP 2
Inspect the bushing surfaces on the shaft (7) for
scoring, pitting and other damage. Measure the
diameter of the shaft at four opposing points. Compare
the values with the specifications, replace if necessary.
STEP 3
Check for wear and damage to the bushings. Measure
the inner diameter and width of the bushing. Compare
the values with the specifications, replace if necessary.
STEP 4
Inspect the thrust plate for wear and damage. Measure
the thickness of the thrust plate. Compare the values
with the specifications, replace if necessary.
STEP 5
Inspect the bore in the bracket (11) and the upper roller
(1) for damage that could result in leakage. Use new
parts as required.

Copyright ©
5003-15
Assembly STEP 3
STEP 1
7 1
8
11
CS02B509
Install an O-ring and a face seal (8) metal bushing in
CS02B512 the seal bore of the upper roller (1). Liberally apply
If the shaft (7) has been removed from the bracket (11), clean oil on the edge of the face seal.
install the shaft in the bracket using a press. Be careful
not to damage the seal bore in the bracket. STEP 4
NOTE: The retaining ports of the thrust plate (6) should
be perpendicular to the retaining plane of the bracket
(11).
NOTE: Respect the recess dimension of the shaft in
the bracket, see page 10.
8 11
STEP 2
8
9 10
7
1
000.6.03.00.24K
Install the the face seal (8) in the bracket seal bore (11).
9 Apply clean oil copiously to the face seal.
1 STEP 5
10
1
10
CS02B513 7
Install the bushings (9) and (10) in the upper roller (1).
NOTE: The grooves of the bushings should be rotated
by 90°.
CS02B508
Apply clean grease on the surface of the shaft (7) and
install the shaft in the upper roller (1).

Copyright ©
5003-16
STEP 6 STEP 9
2
3
6
1
CS02B515 CS02B505
Apply grease on the inside of the thrust plate (6). Fill the upper roller (1) with synthetic oil (see the
Position the thrust plate on the shaft (7) and install the specifications for quantity). Install the drain plug (2) in
screws (3). Apply brake thread fluid to the screws and the cover (4). Tighten the plug to a torque of 24.5 Nm
tighten to a torque of 62.8 to 72.6 Nm (46.32 lbf-ft) to (18.07 lbf-ft).
(53.55 lbf-ft).
STEP 7
3
4
5
1
CS02B506
Apply grease on the seal (5) and install in the groove of
the cover (4). Install the cover on the upper roller (1)
using screws (3). Apply brake thread fluid to the screws
and tighten to a torque of 62.8 to 72.6 Nm (46.32 lbf-ft)
to (53.55 lbf-ft).
STEP 8
Check for leaks to ensure that the upper roller has been
correctly reassembled and check for any damage which
could give rise to leaks at seals and other components.

Copyright ©
5003-17
Installation STEP 3
STEP 1
JD00317A
Remove the wood blocks between the track pad and
JD00338A the undercarriage.
Place the shims on the undercarriage, then install and
support the upper roller. STEP 4
Operate the hydraulic jack to lower the track onto the
STEP 2 upper roller. Remove the jack.
STEP 5
Refer to "Track tension setting" in Section 5001.
JD00319A
Apply Loctite 262 to the screw threads. Install two
tempered washers and screws to fasten the upper
roller bracket to the undercarriage. Tighten the screws
to torque (see specifications).

Copyright ©
5003-18
CHECKING FOR LEAKS
Use CAS 1450 and CAS 1682 for the leak checks STEP 4
shown below. Connect the pressure gauge pipe to the quick coupler.
STEP 5
Make sure that the shut-off valve (1) is open.
1 STEP 6
Adjust the pressure regulator (2) until the pressure
gauge shows 1.9 bar (0.2 MPa/29 PSI).
STEP 7
Turn the shaft of the unit under test four revolutions.
STEP 8
2 Adjust the regulator until the pressure gauge shows
1 bar.
B407320M STEP 9
STEP 1 Close the shut-off valve. Maintain the air pressure of
Connect the shut-off valve (1) to the pressure regulator Step 8 for 10 seconds. A reduction in air pressure
(2). Connect a union for the air supply hose to the shut- during this period shows a defective component or
off valve. incorrect assembling.
STEP 2
Install the adaptor and a quick coupler to the oil filler
orifice. Use a seal washer with the adapter.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).

Copyright ©
Section
5004
5004
SPROCKET

Printed in France
CNH Lep SM160B5004-0EN May 2007
Copyright ©
5004-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
SPROCKET.................................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
SPECIFICATIONS
See Section 1002.

See Section 1002.

Copyright ©
5004-3
SPROCKET
Removal STEP 4
STEP 1
See “Removing and installing the tracks”
(Section 5001) and removing the sprocket from the
chain. 1
STEP 2
JD00292A
To facilitate reassembly, make alignment marks (1) on
the sprocket and the reduction gear.
STEP 5
JD00290A
Move the machine so that the track is in the position
shown.
STEP 3 1
JD00293A
Remove the screws (1) and the hardened washers that
attach the sprocket to the reduction gear.
STEP 6
JD00291A
Rotate the upperstructure so that the cab is over the
side of the machine where the sprocket to be removed
is located. Using the attachment, lift the side of the
machine until the teeth of the sprocket are free from the
chain.
NOTE: The photos below do not correspond to the
machine model, but the procedure is the same.
JD00294A
Drive the sprocket from the reduction gear housing
using a soft hammer. Remove the sprocket from the
machine.

Copyright ©
5004-4
Installation STEP 3
STEP 1
JD00293A
Apply Loctite 262 to the screw threads (2). Assemble
the hardened washers and the screws.
STEP 4
JD00292A
Install the sprocket on the drive reduction gear taking
1
care to align the reference marks (1).
STEP 2
3 4
JS00296A
Tighten the four screws to torque in the order shown,
see "specifications". Then progressively tighten the
remaining screws to the same torque setting.
JD00295A STEP 5
If necessary, use a soft hammer to seat the sprocket
properly on the flange of the reduction gear. To install the tracks, see “Removing and installing the
tracks”.

Copyright ©
Section
5005
IDLER WHEEL AND TENSION SHOCK ABSORBER
5005

Printed in France
Copyright ©
5005-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
SPECIAL TOOLS ............................................................................................................................................................ 3
REMOVAL AND INSTALLATION OF THE IDLER WHEEL AND THE TENSION SHOCK ABSORBER ....................... 4
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 6
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL .......................................................................................... 8

Description ................................................................................................................................................................. 8
Reconditioning ........................................................................................................................................................... 8
Disassembly ............................................................................................................................................................... 9
Inspection ................................................................................................................................................................. 10
Assembly ................................................................................................................................................................. 11
Leakage test ............................................................................................................................................................ 13
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER .............................................................. 14

Description ............................................................................................................................................................... 14
Disassembly ............................................................................................................................................................. 15
Assembly ................................................................................................................................................................. 15
TRACK TENSION CYLINDER ...................................................................................................................................... 16

Description ............................................................................................................................................................... 16
Removal ................................................................................................................................................................... 17
Disassembly ............................................................................................................................................................. 17
Inspection ................................................................................................................................................................. 18
Assembly ................................................................................................................................................................. 18
Installation ................................................................................................................................................................ 19

Copyright ©
5005-3
SPECIFICATIONS
Idler wheel............................................................................................................................................. See Section 1002

Shock absorber spring yoke screw* ......................................................... 267 to 312 Nm (196,93 lbf-ft) to (230.12 lbf-ft)
Tension cylinder screw* ............................................................................ 267 to 312 Nm (196,93 lbf-ft) to (230.12 lbf-ft)
Tension cylinder non-return valve .......................................................................................................59 Nm (43.52 lbf-ft)
Mounting length of spring..................................................................................................................... 740 mm (29.13 in)
* Apply Loctite 262 to the threads
SPECIAL TOOLS
B407320M
Use CAS 1450 and CAS 1682 to check for leaks as
below

Copyright ©
5005-4
REMOVAL AND INSTALLATION OF THE IDLER WHEEL
AND THE TENSION SHOCK ABSORBER
Removal STEP 4
STEP 1
Disconnect the chain.
See "Removal and installation of the tracks", Section
5001.
STEP 2
JD00341A
Using a crowbar, move the idler wheel and the shock
absorber spring assembly out of the housing in the
undercarriage.
STEP 5
JD00339A
Start the engine. Move the machine until the track chain
is disengaged from the idler wheel. Shut down the
engine.
STEP 3
JD00342A
Move the idler wheel and the shock absorber spring
assembly out of the housing in the undercarriage, using
a crowbar, until the nylon sling can be attached to the
shock absorber spring assembly.
JD00340A
Attach the nylon sling from the lifting equipment to the
idler wheel.

Copyright ©
5005-5
STEP 6 STEP 8
JD01077A JD00345A
Raise and remove the idler wheel and the shock Connect the lifting equipment to the idler wheel.
absorber spring assembly. Remove the four screws and hardened washers which
attach the idler wheel to the yoke. Remove the idler
STEP 7 wheel from the yoke.
JD01078A
Place the idler wheel and the shock absorber spring on
wooden blocks. Remove the lifting equipment from the
shock absorber spring assembly.

Copyright ©
5005-6
Installation STEP 3
STEP 1
JD00342A
Raise the idler wheel and the tension shock absorber
and install them in the undercarriage housing. Push the
idler wheel and the tension shock absorber into the
undercarriage. Remove the lifting device from the idler
JD00362A
Attach a suitable lifting device to the idler wheel and wheel and from the back of the tension shock absorber.
bring it into position on the yoke. Apply Loctite 262 to STEP 4
the threads of the idler wheel retaining screws. Install
four hardened washers and screws to fasten the idler
wheel to the tension shock absorber yoke. Tighten the
screws to torque (see specifications).
STEP 2
JD00363A
Insert the lifting device nylon sling into the central
orifice of the tension shock absorber yoke.
JD01078A
Attach the lifting device nylon sling to the assembly.

Copyright ©
5005-7
STEP 5
JD00365A
Raise the assembly and slide it into the undercarriage,
with the help of a crowbar. Remove the lifting
equipment.
STEP 6
See "Removal and installation of the tracks"
(Section 5001), for installing the track.

Copyright ©
5005-8
DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL
Description
8 7 5 6 3 4
B
A
CS02B516
1 PLUG 5 SEAL
2 IDLER WHEEL 6 SHAFT
3 RETAINER PIN 7 FACE SEAL
4 SLIDE 8 BUSHING
A........................................................................................................................................................... 386 mm (15.19 in)

B........................................................................................................................................................... 278 mm (10.94 in)
Reconditioning
If the idler wheel is worn to the indicated limits or if it shows traces of leaks, it must be reconditioned or changed. See
Section 1002 for limits of wear.

Copyright ©
5005-9
Disassembly STEP 3
STEP 1
2
5
2 6
4
4 CS02B519
Remove and scrap the O-ring (5) from the shaft (6).
CS02B517 Remove the shaft (6) with the slide (4) from the idler
Clean the idler wheel (2) with a suitable solvent. Install wheel (2).
the idler wheel (2) on supports, with the drain plug (1)
at the bottom. Remove the drain plug (1) from the slide STEP 4
(4) and drain the oil.
STEP 2
3
6 4
3 6
5
4
4
2
CS02B520
Remove the retainer pin (3) from the slide (4). Remove
the slide (4) from the shaft (6), remove and scrap the O-
CS02B518 ring (5) from the shaft (6).
Remove the retainer pin (3) at one end. Remove the
slide (4) from the shaft (6). STEP 5
7
4
7
CS02B521
Remove and scrap the face seal (7) from the slide (4)
using a screwdriver or equivalent tool. Be careful not to
damage the seal bore in the slide.

Copyright ©
5005-10
STEP 6 Inspection
7 2 7 STEP 1
Clean all the components with cleaning solvent. Also
clean the cavity in the idler wheel. Dry all the
2 components with compressed air at low pressure and
apply clean oil to all the components.
STEP 2
Inspect the bushing surfaces on the shaft for scoring,
7 pitting and other damage. Measure the diameter of the
shaft at four opposing points. Compare the values with
7 the specifications. Change them if necessary.
CS02B522 STEP 3
Remove and scrap the face seal (7) from the idler
wheel (2) using a screwdriver or suitable tool. Make Check for wear and damage to the bushings. Measure
sure you do not damage the idler wheel seal bore. the inner diameter and width of the bushing. Compare
the values with the specifications. Change them if
STEP 7 necessary.
8 STEP 4
Check for damage which could give rise to leaks at the
slide seal and idler wheel bores. Replace the
components with new components as required.
Measure the depth of the slide seal bores. Compare the
8 values with the specifications. Change them if
necessary.
2
CS02B523
NOTE: Carry out this step only if the inspection in Step

3 reveals that the bushings (8) have to be changed.
Using a hammer and a brass drift, drive the bushings
(8) out of the idler wheel (2). Make sure you do not
damage the idler wheel seal bore.

Copyright ©
5005-11
Assembly STEP 3
STEP 1 7
4
7
A
8 8
CS02B521
2 Install the remaining O-rings and remaining face seal

(7) metal bushing in the slider seal bore (4). Apply
8 clean oil copiously to the face seals.
STEP 4
2 3
4
CS02B524
A. Clean the inside 6
Carefully install the bushings (8) in the idler wheel 5
using a press and a suitable rod.
STEP 2
CS02B520
7 2 7 Lubricate the O-rings (5) with clean grease. Install an
O-ring on the shaft (6), then install the shaft in the hub
(4). Secure the slider and the shaft with a retainer pin
2 (3).
7
CS02B522
Install an O-ring and a face seal metal bushing in the
idler wheel bore (2). Apply clean oil to the face seal lips.
Repeat this step to install the face seal on the other
side of the idler wheel.

Copyright ©
5005-12
STEP 5 STEP 8
5
1
2 6
4 4
CS02B519 CS02B517
Apply clean grease around the shaft (6). Install the Fill the idler wheel (2) with clean oil (see specifications).
shaft and slide (4) assembly in the idler wheel (2). Install the drain plug (1) in the slide (4).
STEP 6
6
3
4
2
5
1
CS02B572
Apply clean grease on the O-ring (5) if this has not
already been done and install the O-ring on the shaft
(6). Install the slide (4) on the shaft and install a retainer
pin (3) to fasten the slide and the shaft. Install a drain
plug (1).
NOTE: Check the pitch of the retaining ports of the
tension shock absorber yoke, see page 8.
STEP 7
Check for leaks to ensure that the idler wheel has been
correctly reassembled and check for any damage which
could give rise to leaks at seals and other components.

Copyright ©
5005-13
Leakage test STEP 5
Use CAS 1450 and CAS 1682 for the leak checks Make sure that the shut-off valve (1) is open.
shown below.
STEP 6
Open the pressure regulator (2) until the pressure
1 gauge shows 1.9 bar.
STEP 7
The shaft being checked should now be rotated four
times.
STEP 8
Close the regulator until the pressure gauge shows
1 bar.
2 STEP 9
B407320M Close the shut-off valve. Maintain the air pressure of
STEP 1 Step 8 for 10 seconds. A reduction in air pressure
during this period shows a defective component or
Connect the shut-off valve (1) to the pressure regulator incorrect assembling.
(2). Connect a union for the air supply hose to the shut-
off valve.
STEP 2
Install the adaptor and a quick coupler to the oil filler
orifice. Install a seal with the adaptor.
STEP 3
Turn the knob anti-clockwise to close the pressure
regulator (2).
STEP 4
Connect the pressure gauge pipe to the quick coupler.

Copyright ©
5005-14
DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER
Description
4 5
3
2
CI02B500
1 SHOCK ABSORBER SPRING 4 COMPENSATOR
2 RETAINER PIN 5 SPRING GUIDE
3 SLOTTED NUT

Copyright ©
5005-15
Disassembly Assembly
STEP 1 STEP 1
Clean the shock absorber - spring assembly. Fix the spring guide (5) in a hydraulic press.
STEP 2
WARNING: The shock absorber spring is
! highly compressed. Place the shock absorber spring (1) and the
compensator (4) in the hydraulic press on the spring
guide (5).
STEP 2
STEP 3
Operate the hydraulic press to compress the shock
absorber spring (see specifications for the value).
1
STEP 4
Install the slotted nut (3) and install a new retainer pin
(2) in the slotted nut and the spring guide shaft (5).
STEP 5
Remove the shock absorber spring from the hydraulic
press.
CS02E656
Place the shock absorber spring in a hydraulic press.
Use the press to compress the shock absorber spring
(1).
STEP 3
Drive out the retainer pin (2) from the slotted nut (3).
Remove the slotted nut from the spring guide (5).
STEP 4
Operate the hydraulic press so as to very slowly
release tension in the shock absorber spring (1).
STEP 5
Remove the compensator (4) and the shock absorber
spring (1) from the spring guide (5).

Copyright ©
5005-16
TRACK TENSION CYLINDER
Description
1
2
3
15
14
4
13
12
5
11
7
6
8
9
10
JS01084A
1 SCREW 9 BALL
2 FLAT WASHER 10 NON-RETURN CHECK VALVE BODY
3 SCREW 11 CYLINDER ROD
4 LOCKING WASHER 12 WIPER SEAL
5 BRACKET 13 THRUST RING
6 GREASE FITTING 14 O-RING
7 CHECK VALVE 15 CYLINDER BARREL
8 SPRING

Copyright ©
5005-17
Removal STEP 3
STEP 1
A JD01082A
Using a crowbar, push the track tension cylinder piston
rod into the cylinder barrel. The grease will flow out of
the non-return check valve pressure release orifice.
Remove the track tension cylinder from the machine.
JD01080A
See Section 5003 "Removal of the lower roller" and
remove the roller (A) located under the track tension
Disassembly
cylinder. STEP 1
STEP 2 Using a suitable cleaning solvent and clean cloths,
remove impurities and grease from the outside of the
track tension cylinder.
STEP 2
Remove the two screws (3) and the locking washers
(4). Remove the bracket (5).
STEP 3
Remove the grease fitting (6) from the non-return check
valve.
STEP 4
Remove the non-return check valve from the cylinder
JD01081A
barrel (15).
NOTE: Do not allow any part of your body to pass
under the tension cylinder. You could be seriously STEP 5
injured by the tension cylinder falling, when the screws
are removed which fasten it to the machine. If necessary, disassemble the non-return check valve
by removing the check valve (7), spring (8) and the ball
Unscrew the non-return check valve. As soon as the (9) from the non-return check valve (10).
grease starts to flow, stop unscrewing the tension
cylinder check valve. Place wooden blocks under the
tension cylinder to prevent it falling off the machine
when the two screws which attach it to the machine are
removed. Remove the two screws and the flat washers
(2).

Copyright ©
5005-18
STEP 6 Assembly
STEP 1
Apply clean grease to a new O-ring (14) and new thrust
ring (13). Install the O-ring and the thrust ring in the
cylinder barrel (15).
11 15
12 14
STEP 2
A
13
JS01083A
Remove the cylinder rod (11) from the cylinder barrel
(15).
STEP 7
Using a screwdriver, remove the wiper seal (12) from
the cylinder barrel (15). Scrap the wiper seal.
JS00372A
STEP 8 Apply clean grease to a new wiper seal (12). Using a
hammer and a sleeve (A), drive the wiper seal into the
Remove and scrap the thrust ring (13) and the O-ring
cylinder barrel (15) with the lip orientated towards the
(14).
outside of the cylinder barrel. Drive the wiper seal into
Inspection the cylinder barrel until it touches the cylinder barrel
shoulder. Apply clean grease to the wiper seal lip.
STEP 1
STEP 3
Clean all the components with cleaning solvent.
Apply clean grease around the cylinder rod (11). Install
STEP 2 the cylinder rod in the cylinder barrel (15).
Check for deep grooves, scratches or other damage STEP 4
inside the cylinder. If necessary, use a lamp to look
inside the cylinder. Use medium abrasive emery paper If the non-return check valve has been disassembled,
to eliminate grooves or scratches. If the grooves or install the ball (9), spring (8) and check valve (7) in the
scratches are too deep or if there is other damage, non-return check valve body (10). Install the grease
change the cylinder. fitting (6) in the non-return check valve body.
STEP 3 STEP 5
Check for deep grooves, scratches or other signs of Install the non-return check valve assembly on the
wear or damage on the cylinder rod. Use medium cylinder barrel (15). Tighten the non-return check valve
abrasive emery paper to eliminate grooves or to torque (see specifications).
scratches. If the cylinder rod is worn or damaged, STEP 6
replace the cylinder rod.
Install the bracket (5) on the cylinder barrel (15). Install
STEP 4 two locking washers (4) and screws (3) to fasten the
Check for wear or damage on the non-return check bracket to the cylinder barrel.
valve assembly. Check for signs of irreparable seizure
of the spring. Change all defective components.

Copyright ©
5005-19
Installation STEP 3
STEP 1
Check that the cylinder rod (11) is driven as far as
possible into the cylinder barrel (15).
STEP 2
JD01080A
See "Installation of the lower roller" for installing the
roller (A) under the track tension cylinder.
JD01082A
JD01081A
Move the tension cylinder into position. Apply
Loctite 262 to the threads of the two screws (1).
Support the tension cylinder while an assistant installs
two flat washers (2) and screws (1) to fasten the
tension cylinder. Tighten the screws to torque (see
specifications).

Copyright ©
5005-20
NOTES
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Copyright ©
6001
Section
6001
REMOVAL AND INSTALLATION OF

THE TRAVEL-MOTOR REDUCTION GEAR ASSEMBLY

Printed in France
Copyright ©
6001-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
SPECIAL TORQUE SETTINGS ...................................................................................................................................... 2
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY ...................................................................................................... 3
Removal and installation ............................................................................................................................................. 3
SPECIFICATIONS
Hydraulic fluid.........................................................................................................................................See Section 1002
Lubricant for reducing gear pinion
Type....................................................................................................................................................See Section 1002
Quantity.............................................................................................................................................. See Section 1002
Weight of the travel motor/reduction gear assembly ..............................................................................See Section 1002

Travel motor/reduction gear assembly to track frame retaining screw ...................................................See Section 1002
(apply Loctite 262 to the screw threads)
Drain plug, oil filling and oil level plug ........................................................147.1 ± 14.7 Nm (108.49 lbf-ft) ± (10.84 lbf-ft)
(put Teflon tape around the threads)

Copyright ©
6001-3
TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY
Removal and installation
STEP 1 STEP 5
To prevent any fluid leaks when disconnecting hydraulic
lines, connect a vacuum pump to the hydraulic reser-
voir (see Section 8000).
STEP 6
1
JS00163A
STEP 2
Release pressure in the hydraulic system and in the CD00F067
hydraulic reservoir (see Section 8000). Remove the four screws and washers (1) then remove
the access panel to the travel motor.
STEP 3
STEP 7
CD02B005
CD01K026
Remove the oil filler plug and the oil level plug (1) and To facilitate reassembly, attach identification tags to the
the drain plug (2) and drain the oil. different hoses connected to the travel motor (1).
NOTE: When installing, refer to Section 1002 for the STEP 8

recommended quantity and type of oil. Tighten the Start the vacuum pump.
plugs to a torque of 147.7 ±14.7 Nm (108.49 lbf-ft) ±
(10.84 lbf-ft).
STEP 4
Put Teflon tape around the plug thread and put it back
in place. Install the filling plug.

Copyright ©
6001-4
STEP 9 STEP 13
2
CD02B005 JD00838A
Disconnect the hoses (1) from the travel motor (2). Plug Remove the retaining screws from the travel motor/
the hoses and the unions. reduction gear assembly of the undercarriage.
Remove the travel motor/reduction gear assembly from
STEP 10 the machine.
Stop the vacuum pump.
NOTE: When installing, tighten the screws to the torque
STEP 11 specified in Section 1002.
Refer to Section 5004 and carry out the steps for the
removal of the sprocket wheel. STEP 14
STEP 12
6002-11
Place the travel motor/reduction gear assembly on a
JD00836A flat surface with the drive motor turned upwards.
Connect a suitable lifting device to the travel motor/ Remove the lifting equipment.
reduction gear assembly.
NOTE: When installing, follow the same procedure in
NOTE: See Section 1002 for the weight of the travel the reverse order. Replace all O-rings with new O-rings.
motor/reduction gear assembly. Fill the housing with hydraulic oil using the leak return
port. Before operating the machine, check the circuit for
leaks. Check the hydraulic oil level in the reservoir and
the oil level in the housing of the travel reduction gear,
top up if necessary.

Copyright ©
Section
6003
6003

OF THE SWING REDUCTION GEAR

Printed in France
Copyright ©
6003-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
TOOLS REQUIRED ........................................................................................................................................................ 2
SWING REDUCTION GEAR........................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
SPECIFICATIONS
Swing motor and swing reduction gear
Weight ............................................................................................................................................... See Section 1002
Swing reduction gear
Capacity ............................................................................................................................................ See Section 1002
Type of oil .......................................................................................................................................... See Section 1002

Swing motor retaining screws on swing reduction gear .............................. 294 to 336 Nm (216.84 lbf-ft to 247.82 lbf-ft)
Screws which attach the swing reduction gear to the upperstructure frame900 to 1050 Nm (663.80 lbf-ft to 774.43 lbf-ft)
TOOLS REQUIRED
- Hand pump CAS-10090

Copyright ©
6003-3
SWING REDUCTION GEAR

Removal STEP 5
STEP 1
Carry out Steps 1 to 10 of "Removal of the swing motor"
(see Section 8008).
STEP 2
1
JD00437A
2 Carefully lift the upperstructure swing motor and
reduction gear assembly, move it away from the
machine.
STEP 6
CD02E001
Attach an identification tag to the hoses (1) and (2),
disconnect them and plug the ports.
STEP 3
Mark the position of the swing reduction gear on the
upperstructure frame by making alignment marks on
the swing reduction gear and the upperstructure frame.
STEP 4
JS00379A
Place a container of 15 litres capacity under the swing
reduction gear drain plug. Remove the drain plug (1)
and drain the oil. Install the drain plug.
JD00449A
Remove the swing reduction gear retaining screws (1)
and the centring pin.

Copyright ©
6003-4
STEP 7 Installation
Lower the swing motor/reduction gear assembly to the
ground and place it on suitable stands. STEP 1
NOTE: The stands must be high enough to prevent the
pinion touching the ground.
STEP 8
2 1
JD00446A
Connect a suitable lifting device to the swing motor and
move it into position above the reduction gear. Carefully
lower the swing motor onto the reduction gear.
JD00386A STEP 2
To facilitate reassembly, make an alignment mark (1)
on the swing motor and on the reduction gear. Remove
the swing motor retaining screws (2).
STEP 9
Carefully raise the swing motor and move it away from
the swing reduction gear. Place it in a clean area.
JD00386A
Install the swing motor retaining screws (1).
NOTE: Tighten the screws to torque.
STEP 3
Clean the upperstructure mating surface.

Copyright ©
6003-5
STEP 4 STEP 6
AA
JD00437A JD00473A
Raise the swing motor/reduction gear assembly off the Connect the hand pump CAS-10090 to the swing motor
ground. Apply No. 2 EP lithium grease over the pinion brake release orifice (A).
(A).
STEP 7
NOTE: Before installing the swing motor/reduction gear Check that the hand pump is filled with fluid.
assembly, check that the drain hose (B) is installed on
the side of the reduction gear housing. STEP 8
Operate the hand pump until the pressure gauge shows
STEP 5 29 bar. The swing motor brake should be released, thus
allowing the reduction gear output shaft to turn.
STEP 9
Lower the swing motor/reduction gear assembly onto
the upperstructure mating surface, using a dowel pin.
NOTE: Make sure that the reduction gear output gear is
correctly engaged in the upperstructure crown wheel.
STEP 10
JD00385A
Raise the swing motor/reduction gear assembly and
bring it into position above the upperstructure mating
surface, ensuring that it is in line with the alignment
marks previously made.
1
JD00449A
Apply Loctite 262 to the screw threads (1) and tighten
them to the torque specified in Section 1002.

Copyright ©
6003-6
STEP 11 Fill the swing reduction gear with the quantity (capacity)
and type of oil specified in Section 1002. Install the oil
dipstick and check the oil level. The oil level should be
on the lower part of the dipstick. Add oil as required and
install and tighten the oil filler plug.
STEP 13
2
JD00473A
Release the hydraulic pressure in the hand pump CAS-
10090 and disconnect it from the swing motor brake
release orifice (A). Remove the lifting equipment from
the swing motor.
STEP 12 CT07A028
1 AIR BLEED PLUG
2 LUBRICATION ORIFICE
3 Remove the air bleed plug on the side of the swing
reduction gear. Pump No. 2 EP lithium grease into the
reduction gear until grease comes out of the air bleed
orifice. Install the air bleed plug.
STEP 14
2 Connect a vacuum pump to the hydraulic reservoir (see
Section 8000). Start the vacuum pump.
CT07A010
CT07A041
Check that the swing reduction gear oil drain plug (1) is
correctly tightened. Remove the oil level dipstick (2)
and the oil filler plug (3).

Copyright ©
6003-7
STEP 15 STEP 18
1
2
CD02B034 CT07A009
Remove the plugs and connect the hoses (1) and (2). Connect the earth cable to the battery.
STEP 16 STEP 19
Refer to the removal of the hydraulic swing motor and See Section 8001 and adjust the swing motor
carry out Step 8 in the reverse order. secondary relief valves.
STEP 17 STEP 20
Stop and disconnect the vacuum pump from the
1
2
CS02B555
Install the upper panel (1) using retaining screws (2).
NOTE: Before operating the machine, start the engine,
check the system for leaks and check the fluid level in
the hydraulic reservoir, top up if necessary.

Copyright ©
6003-8
NOTES
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Copyright ©
Section
6004
6004
DISASSEMBLY AND ASSEMBLY

Printed in France
Copyright ©
6004-2
TABLE OF CONTENTS
SWING REDUCTION GEAR........................................................................................................................................... 3

Description ................................................................................................................................................................. 3
Disassembly ............................................................................................................................................................... 4
Assembly ................................................................................................................................................................... 7

Copyright ©
6004-3
Description
13 15
14 16
12
21 17
18
11
10 19
9 8
6 20
4 5
2 3
1
7
CI02B502
1 PINION 12 RING GEAR
2 SPACER 13 FIRST STAGE SUN GEAR
3 SNAP RING 14 SHIM
4 PLATE 15 FIRST STAGE PLANETARY GEAR
5 SPHERICAL ROLLER BEARING 16 FIRST STAGE PLANET WHEEL CARRIER
6 HOUSING 17 SECOND STAGE PLANETARY GEAR
7 SHAFT 18 RETAINER PIN
8 LIP-SEAL 19 SECOND STAGE PLANET WHEEL CARRIER
9 SPACER 20 SPACER
10 SPHERICAL ROLLER BEARING 21 SECOND STAGE SUN GEAR
11 PIN

Copyright ©
6004-4
Disassembly STEP 4
NOTE: The swing reduction gear is extremely heavy.
Use suitable lifting equipment to lift and move the 1
components.
machine model, but the procedure remains the same.
STEP 1
Place the reduction gear in a clean working area.
STEP 2
CD02B037
Remove the second stage sun gear (1).
STEP 5
CD02B035
Remove the first stage sun gear (1) and thrust ring.
STEP 3
1 CD02B038
Remove the second stage planet wheel carrier (1).
CD02B036
Remove the first stage planet wheel carrier (1).

Copyright ©
6004-5
STEP 6 STEP 8
4 3
5
6
7
1
2
2 1
6003-090 JD01465A
Remove the ring gear (1) from the reduction gear Remove the two screws (1), the brake plate (2), the end
housing (2) using the notch in the housing for leverage. plate (3) and the pinion (4). Remove the snap ring (5),
the stop (6) and the plate (7).
NOTE: The planetary gear axles are assembled in two
ways: A = assembly by hubbing the axle; B = assembly STEP 9
by blocking the axle (roll pin). According to the type of
assembly, replace the entire planet wheel carrier or
individual spare parts.
STEP 7
1
6003-096
Install the swing reduction gear in a suitable press.
Place shims under the flange on the housing to hold the
shaft upright.
JD01464A STEP 10
Turn the swing reduction gear upside down to be able
to access the pinion (1). Straighten up the corners of
the brake plate (2) to free the screws (3).
2
1
A
6003-097
Place a jack (A) under the shaft (1) and the bearing (2)
under the press to hold and support the shaft when it
has been pressed out of the housing. Press the shaft
from the housing. Remove the shaft and the bearings
from the press.

Copyright ©
6004-6
STEP 11 STEP 13
3
1
4
CD02B039 2 2
Remove the roller bearing (1) from the gear housing.
STEP 12
CI02B503
Place the shaft (1) under a press. Insert two shims (2),
1 press the shaft (1) from the bearings (3). Remove the
spacer (4).
STEP 14
JD00459A
Using a suitable tool remove the lip seal (1) from the
gear housing. Discard the lip seal.
1
CD02B040
Place the planetary gear assembly on a workbench.
Press the retainer pins (1) in the axles just enough to
remove the axles.

Copyright ©
6004-7
STEP 15 Assembly
2 NOTE: The photos below do not correspond to the
machine model, but the procedure remains the same.
STEP 1
Place the planet wheel carrier on a clean workbench.
STEP 2
2 1
1
CD02B041
Support the planetary gears and remove the axles from
the planet wheel carrier (2). Press the pins completely
from the axles (1). Remove the pins.
STEP 16
6003-106
Assemble the planetary gears (1), slide the thrust
washers (2) under the pinions (boom).
STEP 3
1
1
6003-105
Remove the planetary gears (1).
STEP 17
1
6003-105
Align the pinions with the bores of the planet wheel
carrier and install the axles. Take care to position the
axle retaining bore correctly (1) with respect to the bore
of the planet wheel carrier.
6003-106
Remove the thrust washers (1) from the planetary
gears.

Copyright ©
6004-8
STEP 4 STEP 6
WARNING: Take precautions (gloves), risk of

B ! burns.
A
2
3
6003-107
Install a new pin (A) in the shaft using a suitable tool.
Recess dimension in the planet wheel carrier:
B = 1 mm.
Lock it, using two strokes of a punch.
1
STEP 5
Position the retainer pins in the second stage planet
wheel carrier.
CI02B504
Install the spacer (1) on the shaft (2). Heat the bearing
(3) to 50°C above the ambient temperature. Assemble
the hot bearing on the shaft (2), use protective gloves.
STEP 7
CS00K512
Boom: direction of rotation.
JD00465A
Degrease the reduction gear housing and apply Loctite
504. Fix the reduction gear housing in a press, install
the lip seal in the reduction gear housing. Lubricate the
lip seal with No. 2 EP lithium grease. Install the
spacers, then install the bearing on the reduction gear
side.

Copyright ©
6004-9
STEP 8 STEP 10
6 6 1
5 1
2
7
1
JD00469A
Degrease the mating surfaces of the gear housing, ring
3 gear and the four dowel pins. Install the four dowel pins
(1) into the gear housing. Apply Loctite 504 liquid
4 4 packing to the mating surfaces.
STEP 11
CI02B505
Coat the roller bearings (1) with 800 grams of No. 2 EP
lithium grease (2). Place the shaft assembled (3) on the
shims (4) under a press. Position the housing (5) 2
equipped with the bearing and the lip seal on the shaft
(3). Position the shims (6) on the bearing (7). Assemble
the housing using the press (booms).
STEP 9
1
1 JD00470A
Install the ring gear (1) ensuring the alignment marks
are aligned. Assemble four screws (2) in opposition to
hold the ring gear (1).
4 3
5 7 6
CI02B506
Assemble the plate (1). Assemble the snap ring (2) with
a gap of about 30 mm with respect to the notch on the
housing. Install the spacer (3). Lubricate and assemble
the pinion (4). Assemble the stop plate (5). Install the
brake plate (6), assemble and tighten the screws (7).
Bend the corners of the brake plate (6) on the screw
heads (7).

Copyright ©
6004-10
STEP 12 STEP 14
1
1
CD02B038 CD02B036
Install the second stage planet wheel carrier (1) so that Install the first stage planetary assembly (1) so that it
it meshes correctly with the internal teeth of the ring meshes with the internal teeth of the ring gear. Turn the
gear. Turn the planetary assembly slightly to engage planetary assembly slightly to mesh the teeth of the
the splines of the pinion shaft. planetary gears with the teeth of the second stage sun
gear.
STEP 13
STEP 15
1
1
CD02B037
Install the second stage sun gear (1) so that it meshes CD02B035
with the planetary gear assembly. Install the thrust shim on the second stage sun gear.
Install the first stage sun gear (1) so that it meshes
correctly with the teeth of the planetary gears. Turn the
first stage planetary assembly by hand and check that
the output shaft rotates smoothly.

Copyright ©
6004-11
STEP 16
CS00K516.
Measure the dimension (A), position of the sun gear.
Make sure that the distance between the end surface of
the sun gear No.1 (13) and the ring gear (12) is 3.653 to
5.66 mm. If the distance falls short of reaching 3.653
mm:
Gear shaft (7) and the roller bearing (5) are dislocated.
The roller bearing (10) is not inserted completely.
Foreign substances are engaged.
If the distance is larger than 5.66 mm:
The wire (3) is not installed properly.
The ring gear (12) is not completely tightened into the
gear case (6).
Foreign substances are engaged.

Copyright ©
6004-12
NOTES
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Copyright ©
Section
6005
TRAVEL REDUCTION GEAR
6005
ASSEMBLY AND DISASSEMBLY

Printed in France
Copyright ©
6005-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
SPECIAL TORQUES ...................................................................................................................................................... 2
REDUCTION GEAR........................................................................................................................................................ 3
Description .................................................................................................................................................................. 3
Disassembly................................................................................................................................................................ 4
Inspection.................................................................................................................................................................... 9
Assembly .................................................................................................................................................................. 10
SPECIFICATIONS
See Section 1002.
SPECIAL TORQUES
Screw *(4).............................................................................................................. 461 ± 44.1 Nm (340.01 ± 32.52 lbf-ft)
Screw *(6) ............................................................................................................. 53.9 ± 5.9 Nm (39.75 ± 4.35 lbf-ft)
Screw *(28)..................................................................................................................68.6 ± 6.9 Nm (50.60 ± 5.09 lbf-ft)
Plug (29).................................................................................................................147 ± 14.7 Nm (108.42 ± 10.84 lbf-ft)
* .............................................................................................................................................(With applying Loctite #242)

Copyright ©
6005-3
REDUCTION GEAR
Description
1 HOUSING 16 SPRING PIN

2 BEARING 17 SPACER
3 RING GEAR 18 SUN GEAR 2
4 SCREW 19 CARRIER 1
5 COVER 20 PLANETARY GEAR 1
6 SCREW 21 THRUST WASHER 1
7 FLOATING SEAL 22 NEEDLE BEARING
8 SHIM 23 CARRIER PIN 1
9 LOCK WASHER 24 SPRING PIN
10 SUPPORT RING 25 SUN GEAR 1
11 CARRIER 2 26 THRUST PLATE
12 PLANETARY GEAR 2 27 COVER
13 RETAINING RING 28 SCREW
14 BEARING 29 PLUG
15 CARRIER PIN 2 30 O-RING

Copyright ©
6005-4
Disassembly
WARNING: Safety is priority while disassem-
General precautions bling. Be careful and avoid hands from being
1. It’s common that a reduction unit which has been ! caught between parts or lifted parts from falling
dismounted from the machine is covered with dirt or on your feet.
dust. Wash and dry the exterior of the unit.
2. Loosen the drain and filler plug (29) to drain oil in STEP 2
the reduction unit.
WARNING: If the oil is still hot, internal pressure

! still remains. Care should be taken because the
oil can blow out.
3. Placing counter marks. Place counter marks on the

outer side of each mating face in order to put the
faces back into their original locations when assem-
bling.
NOTE: Numbers in parentheses following the part
names shown in the description below correspond to
symbols in the structural drawings.
STEP 1 Remove the srews (28) that secure cover (27).
STEP 3
As the cover (27) is adhered to ring gear (3), remove

cover (27) by lightly hammering slantwise upward by
wooden bar aiming at projection of cover (23).
Remove the screws (28) at 3 places from cover (27)

almost equally apart each other, then install M12 eye
bolts.
Lift up the unit using them and place it on work stand
with cover (27) upward.

Copyright ©
6005-5
STEP 4 STEP 7
Remove the lock washer (9) by placing a screwdriver or

Remove thrust plate (26). equivalent to the washer’s split part and tapping the
Screw three M10 eye bolts in carrier 1 (19) and lift up driver with a hammer.
and remove carrier 1 as sub-ass'y (19), (20), (21), (22),
STEP 8
(23), (24).
Remove sun gear 1 (25).
STEP 5
Remove sun gear 2 (18).

Screw three M10 eye bolts in carrier 2 (11) and lift up Screw three M12 eye bolts in ring gear (3) almost
and remove carrier 2 as sub-assembly (11), (12), (13), equally apart each other, then lift it up horizontally and
(14), (15), (16) and (17). remove housing assembly including ring gear (3), hous-
STEP 6 ing (1), angular bearing (2), seal cover (5), floating seal
(7) and screws (4) together.
Remove the support ring (10).

Copyright ©
6005-6
STEP 9 STEP 12
OVER 300
Screw three M24 eye bolts in housing (1) almost

equally apart each other. Lift up the housing assembly
and place it on work stand with housing (1) upward.
Put a mating mark outside of housing (1) and ring gear
(3).
NOTE: Take care not to damage the sliding surface of
floating seal (5) or its O-ring.
Bearings (2) have been tightly press fitted in housing
(1). Don't remove the bearings (2) unless otherwise
their exchange is needed. Knock spring pins 6 x 36 (24) fully into carrier pins 1
In case bearings (2) removed, don't re-use them. (23).
New bearings (2) should be used and shim (8) adjust- Tap carrier pins 1 (23) out from carrier 1 (19).
ing be required. Remove thrust washers 1 (21), planetary gears 1 (20)
and needle bearings (22) from carrier 1 (19).
STEP 10
NOTE: When carrier pins 1 (23) are to be re-used,
mark each pin with its mated hole of carrier 1 (19) to
assure the same combination as before.
Remove floating seal (7) from seal cover (5).

Remove the srews (6), and remove seal cover (5) from
housing (1).
Remove the screws (4), leaving two of them diagonally.
Loosen the other screws (4) and tap lightly the head of
them then ring gear (3) can be easily removed from
housing (1).
STEP 11
Remove a piece of floating seal (7) of motor side.

Copyright ©
6005-7
STEP 13 STEP 14
Knock out spring pins 6 x 36 (24) from carrier pins 1

(23) for re-assembling.
NOTE: When carrier pin 1 (23) or planetary gear 1 (20)
is needed to be exchanged, three pins or three gears Knock spring pins 10 x 63 (16) fully into carrier pins 2
should be all exchanged. (15).
Tap carrier pins 2 (15) out from carrier 2 (11).
NOTE: When carrier pins 2 (15) are to be re-used,
mark each pin with its mated hole of carrier 2 (11) to
assure the same combination as before.

Copyright ©
6005-8
STEP 15 Inspection
1. Thrust washers
Inspect if there is any seizure, abnormal wear, une-
ven wear, or other.
Check that the wear is within allowable values.
2. Gears
Check for pitching and seizure on the face of tooth.
Check the colour on the root of tooth to find out
cracks.
3. Bearing
Make sure that there are no noises or engagement
by manually rotating the bearing.
4. Floating seal
Check if there is any damage on the sliding faces of
O-rings.
Remove planetary gears 2 (12), bearing (14) and

retaining ring C-type (13) from carrier 2 (11).
Remove spacer (17) from carrier 2 (11).
Knock out spring pins 10 x 63 (16) from carrier pins 2
(15) for re-assembling.
NOTE: Take great care not to pinch your hand between
gears and carrier 2 (11) while disassembling.
NOTE: When carrier pin 2 (15) or planetary gear 2 (12)
is needed to be exchanged, three pins or three gears
should be all exchanged.

Copyright ©
6005-9
Mark Item Reference value (mm) Allowable value (mm) Remedy
A Wear on the planetary Smooth, no abnormal Smooth, no abnormal Replace 3 pieces

shaft wear and seizure wear and seizure as a set
B Conditions on face of Smooth, no abnormal No pitching of dia. 1.6 Replace

tooth and root of tooth wear and seizure or more, no cracks on (Replace 3 pieces as a
the root of tooth set for planetary gears)
C Thrust spaces in the inner - 0.08 to 0.02 - 0.08 to 0.02 Adjust shim
race of angular bearings thickness
(2) (see page 12)
D Thickness of thrust From 3.9 mm 0.1 of wear Replace

washer 1 (21) To 4.1 mm
E Thickness of spacer (17) From 4.2 mm 0.15 of wear Replace

To 4.6 mm
F Thickness of thrust plate From 4.34 mm 0.15 of wear Replace

(26) To 4.66 mm
G Lubrication oil 2,000 working hours (engine hour meter) Replace

Copyright ©
6005-10
Assembly STEP 3
General precautions
1. Wash each part with treated oil, then dry it com-
pletely with air. For the surfaces to which Loctite is
applied, degrease with thinner or equivalent.
2. Check for any abnormality on each part.
3. Tighten hexagonal socket head cap screws upon
application of Loctite.
4. Apply a thin coat of gear oil to assembly parts prior
to the assembly.
WARNING: Be careful and avoid hands from

! being caught between parts or lifted parts from
falling on your feet. SLOT DIRECTION TURNS CALK TWO PLACES
TO COVER SIDE 180° DEGREE POSITION
STEP 1 COVER SPRING PIN OF 5 mm BY
CALKING
SINK SPRING PIN OF 1 to 2

mm FROM SURFACE
PINION
Calk carrier 2 (11) on diagonally position to prevent

spring pin 10 x 63 (16) from coming out.
NOTE: Refer to "Detail of calking
Install spacer (17), planetary gears 2 (12), bearings
(14) and retaining ring C-type (13) into carrier 2 (11). STEP 4
STEP 2
Install planetary gears 1 (20), needle bearings (22) and

thrust washers 1 (21) into carrier 1 (19).
Install carrier pins 2 (15) into carrier 2 (11) where the
holes for spring pins 10 x 63 (16) are to be in line with
those of carrier 2 (11).
Install spring pins 10 x 63 (16) into carrier 2 (11) and at
the same time into carrier pins 2 (15).
(Sink spring pins of 1 - 2 mm from surface).

Copyright ©
6005-11
STEP 5
CORRECT INCORRECT INCORRECT
NOTE: Clean the groove for floating seals (7) to elimi-

Install carrier pins 1 (23) into carrier 1 (19) where the
nate oil, dust, paint or other foreign material.
holes for spring pins are to be in line with those of car-
rier 1 (19). NOTE: Apply gear oil slightly on sliding surfaces of
Install spring pins 6 x 36 (24) into carrier 1 (19) and at floating seals (7) before assembling but strictly dry on
the same time into carrier pins 1 (23). O-rings and on its grooves
(Sink spring pins of 1 - 2 mm from surface) NOTE: Confirm that O-ring of floating seals (7) are not
STEP 6 twisted and that floating seals are correctly installed.
i.e. parallel as shown each other between seal cover
(5) and motor casing after assembled. It is recom-
mended to use jig to install floating seal
STEP 8
LOCTITE No. 515
Calk carrier 1 (19) on diagonally position to prevent

spring pin 6 x 36 (24) from coming out.
Apply Loctite No. 515 to the mating surfaces of housing
NOTE: Refer to "Detail of calking" (See step 3). (1) and ring gear (3) without a gap.
Install seal cover (5) on housing (1).
STEP 7 Then, after applying Loctite #242 on the threads of 16
pieces of screws M10 x 25 (6) without removing rust
preventive agent, tighten them with torque wrench.
Tightening torque of screw M10 x 25 (6) is 53.9 ± 5.9N-
m (39.75 lbf-ft ± 4.35 lbf-ft).
NOTE: Refer to below "How to apply Loctite #242".
Install main bearing (2) to inner surface of housing (1).

Install a piece of floating seal (7) on motor casing and
also install another piece of floating seal (7) on seal
cover (5).
Soak 20mm length from the tip
of bolt in loctite #242

Copyright ©
6005-12
STEP 9 STEP 11
NOTE: This process is necessary when any motor
LOCTITE No. 515
(casing), housing (1), bearing (2) or lock washer (9) is
changed. As this is not the case, use the old shims (8)
as they are.
Apply Loctite #515 on mating surfaces of housing (1)

and ring gear (3) without a gap.
STEP 10
1. Fit in two bearings (2) on housing (1) pressing their

outer laces
2. Press inner laces of two bearings (2) lightly and
evenly, measure the assembling width "A" of inner
laces.
NOTE: When measuring the assembling width "A",
rotate bearings (2) at least 5 times and become the
width "A" stably.
Install three M24 eye bolts equally apart on housing (1). 3. Measure the motor side assembling width "B" for
Using the eye bolts, hang the housing (1) by wire rope bearings (2).
and place it on ring gear (3), coinciding mating marks. 4. Measure the groove width "C" of motor casing.
After applying Loctite #242 on the threads of 26 pieces
of screws M20 x 120 (4) without removing rust preven- 5. Measure the thickness "D" of lock washers (9).
tive agent tighten them with torque wrench. NOTE: Measure them at 4 places evenly apart on the
Tightening torque of screw M20 x 120 (4) is 461± circumferences then calculate and use those mean val-
44.1N-m (340.01 lbf-ft±32.5 lbf-ft). ues. Measure them to the accuracy of 0.01 mm.
NOTE: Refer to step 8, "How to apply Loctite #242". 6. Suppose the thickness of a shim (8) to be used is S,
the space X is expressed as follows:
X = (B + C) - (A + D + S)
7. Select a shim (6) so as the clearance X to come to -
0.08 mm (interference) - +0.02 mm (clearance) on
this unit.

Copyright ©
6005-13
STEP 12 STEP 15
Place motor on work stand with the shaft upward, and
put the selected shim (8) (Refer to step 11, page12) on
the bearing mating surface of motor casing.
STEP 13
Press
Install support ring (10) over outside of lock washers

(9).
STEP 16
Install three M12 eye bolts on ring gear (3) almost

equally apart and lift it up. Descend it concentric with
motor and put bearings (2) on housing (1) into motor
casing. Use press machine and press inner lace of
bearing (2) into full depth.
STEP 14
Install three M10 eye bolts equally apart on carrier 2
(11).
Using the eye bolts, hang the carrier 2 assembly by
wire rope and place three planetary gears 2 (12), put
carrier 2 assembly into ring gear (3) and mesh the
splines to those of motor.
NOTE: Positioning carrier 2 assembly is important to
obtain better lubrication (see the figure below).
Carrier 2 Planetary gear 2
While pressing inner lace of bearing (2), install lock

washers (9) into groove.
Motor port

Copyright ©
6005-14
STEP 17 STEP 20
Insert and mesh sun gear 2 (18) on center. LOCTITE No. 515
STEP 18
Apply Loctite No. 515 on mating surfaces of cover (27)

and ring gear (3), and install the cover (27) on ring gear
(3).
NOTE: Gear oil can be filled before installing cover (27)
if you can measure prescribed volume of oil.
Install three M10 eye bolts equally apart on carrier 1
(19). NOTE: Refer to Step 8, page 11 "How to apply Loctite
Using the eye bolts, hang the carrier 1 assembly by #242".
wire rope and place it in ring gear (3), rotate planetary STEP 21
gears 1 (20) by hand and adjust carrier 1 (19) to mesh
with sun gear 2 (18).
Making sure that coupling is on the shaft end, install
sun gear 1 (25) on center.
STEP 19
Cover
Sharp edge R
Apply Loctite No. 242 to the screws (28) and fasten

them with tightening torque of 68.6 ±6.9 Nm (50.60 lbf-
Thrust plate ft ± 5.08 lbf-ft).
STEP 22
Fill gear oil (GEAR 135H EP)15 litters from two G3/4
ports.
Place thrust plate (26) on carrier 1 (19). STEP 23
NOTE: Face sharp edged side to cover (27) (see the Tighten taper screw plugs (29) to a torque of 147.1 ±
figure above). 14.7N-m (108.49±10.84 lbf-ft).

Copyright ©
Section
8000
DEPRESSURISING AND DECONTAMINATING THE

HYDRAULIC SYSTEM, USE OF THE VACUUM PUMP
AND BLEEDING THE COMPONENTS
8000

Printed in France
Copyright ©
8000-2
TABLE OF CONTENTS
SPECIAL TOOLS ............................................................................................................................................................ 3
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM............................................................................................. 4
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS ................................................................. 5

Hydraulic pump .......................................................................................................................................................... 5
Hydraulic swing motor ................................................................................................................................................ 5
Attachment cylinders .................................................................................................................................................. 5
VACUUM PUMP ............................................................................................................................................................. 6

Installation .................................................................................................................................................................. 6
Removal ..................................................................................................................................................................... 6
CLEANING THE HYDRAULIC SYSTEM ........................................................................................................................ 7

General ...................................................................................................................................................................... 7
Types of contamination .............................................................................................................................................. 7
Decontamination of the hydraulic system .................................................................................................................. 8

Copyright ©
8000-3
SPECIAL TOOLS
806128
CAS 10508 - Kit for unions
806127
CAS 10162A - Portable filter
CS99B532
CAS 30038 - Set of hydraulic flow and pressure test
unions
M1325
CAS 10193 - Kit for vacuum pump

Copyright ©
8000-4
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM
IMPORTANT: Before carrying out any operation on the STEP 5
hydraulic system, pressure in all the hydraulic circuits
must first be at zero.
STEP 1
Place the machine on flat, level ground, with the
attachment lowered to the ground, then shut down the
engine.
STEP 2
Place the starter switch key (1) in the "OFF" position.

STEP 6
Place the starter switch key (1) in the "ON" position.

STEP 3
Press the button (1) located above the breather to

release any remaining pressure.
Lower the function cancellation control arm (exit safety

bar).
STEP 4
Operate the control levers ten times to right and left and
backwards and forwards.

Copyright ©
8000-5
BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS
IMPORTANT: After having bled the air from the Hydraulic swing motor
components, shut down the engine for five minutes and
then check that no air bubbles appear in the hydraulic
fluid reservoir.
Hydraulic pump
CT07A010
Start the engine and run it at idle. Loosen the air bleed
plug and make sure that hydraulic fluid flows out of that
orifice. If necessary, shut down the engine and top up
CT07A037 via that orifice. Install the plug, without tightening it,
Using a solvent, clean the upper surface of the pump
then start the engine and run it at idle. Let it run until
and the air bleed plug. Remove the air bleed plugs.
hydraulic fluid flows out of the orifice. Completely
Fill the pump with hydraulic fluid via that orifice. Install retighten the air bleed plug. Perform at least two
and tighten the air bleed plugs. complete swings of the upperstructure, both to right
Start the engine, engine speed in idle mode. Loosen and to left.
the pump air bleed plugs. Retighten the plugs as soon
as the fluid flows without air bubbles from the ports. Attachment cylinders
Clean carefully around the plugs Start the engine and run it at idle. Extend and retract all
the cylinder rods four or five times without bringing
them against the stops, then do the same again three
or four times, but this time bringing the cylinder rods
against the stops.

Copyright ©
8000-6
VACUUM PUMP
Installation Removal
STEP 1 STEP 1
Release pressure in the hydraulic system, see page 4. Disconnect the vacuum pump harness from the
batteries.
STEP 2
STEP 2
Disconnect the vacuum pump from the elbow union of
A the adaptor plate (B).
STEP 3
Remove the adaptor plate (B) from the hydraulic
reservoir and scrap the O-ring.
STEP 4
Install a new O-ring on the hydraulic reservoir and
install the plate (A).
Remove the plate (A) on top of the hydraulic reservoir.

NOTE: Do not remove the O-ring from the reservoir.
STEP 3
B
JD00019A
Install the adaptor plate (B) from the kit CAS 30028 on
the hydraulic reservoir.
STEP 4
JD00020A
Connect the vacuum pump CAS 10193 to the elbow
union of the adaptor plate. Connect the vacuum pump
harness to the batteries.

Copyright ©
8000-7
CLEANING THE HYDRAULIC SYSTEM
General Types of contamination
Contamination of the hydraulic system is a major cause Contamination exists basically in two forms:
of incorrect operation of hydraulic components. microscopic or visible.
Contamination manifests itself by the presence of
1. We speak of microscopic contamination when very
foreign bodies in the hydraulic fluid. Contamination of
small particles of foreign bodies are in suspension
the hydraulic system can occur in any of the following
in the hydraulic fluid. These particles are too small
situations:
to be seen or felt. Microscopic contamination can be
1. When draining fluid or disconnecting a hydraulic identified by the problems connected with
line. microscopic contamination or by tests in the
laboratory. Here are a few examples of the
2. When disassembling a component.
problems caused by microscopic contamination:
3. Due to normal component wear.
A. Cylinder rod seals leak.
4. Due to damaged or worn seals.
B. Control valve spools do not return to the neutral
5. Due to a damaged component in the hydraulic position.
system.
C. The hydraulic system working temperature is high.
All hydraulic systems can still operate even when
D. Components wear quickly.
slightly contaminated. Components of the hydraulic
system are designed to withstand a slight degree of 2. We speak of visible contamination when the presence
contamination. Any increase in the degree of of foreign bodies can be detected visually or by touch
contamination causes serious problems in the hydraulic or smell. Visible contamination can cause a sudden
system. failure of a component. Here are a few examples of
problems caused by visible contamination:
Here is a non-exhaustive list of these problems:
A. The fluid contains metal or other debris.
1. Cylinder rod seals leak.
B. The fluid contains air.
2. Control valve spools do not return to the neutral
position. C. The fluid is dark and thick.
3. Control valve spools are hard to move. D. The fluid smells burnt.
4. Hydraulic fluid is too hot. E. The fluid contains water.
5. Hydraulic components wear quickly.

6. Safety valves or non-return check valves do not close,
due to contamination.
7. Repaired components soon fail again.
8. Cycles are slow; the machine does not have enough
power.
If one of the above situations occurs, it shows
excessive contamination of the hydraulic system. To
eliminate this contamination effectively, use the
portable filter CAS 10162A.

Copyright ©
8000-8
Decontamination of the hydraulic STEP 7
system
STEP 1 2
Prepare the portable filter CAS 10162A as follows:
1
1. Eliminate all hydraulic fluid from the inlet and outlet
hoses of the portable filter.
2. Remove the cartridge of the portable filter.
3. Eliminate all the hydraulic fluid from the portable
filter.
4. Clean the interior of the cartridge housing.
5. Install a new filter cartridge. CD00E178
Remove the bleed lever valve (1) under the hydraulic
STEP 2 reservoir. Do not remove the adaptor (2).
Release pressure in the hydraulic system, see page 4. STEP 8
STEP 3 Install the shut-off valve from the union kit CAS 10508 on
Drain the hydraulic fluid from the reservoir, see the the adaptor (2).
operator’s manual. NOTE: Make sure that the shut-off valve is closed.
NOTE: Do not assemble the access door under the STEP 9
hydraulic reservoir.
Fill the hydraulic reservoir with clean hydraulic fluid.
STEP 4 See the Operator’s Manual.
Change the breather cartridge, the return filter and STEP 10
clean the inlet filter, see the operator’s manual.
Install the inlet hose from the portable filter on the shut-
NOTE: Do not install the plate complete with the off valve under the hydraulic reservoir.
breather.
STEP 11
STEP 5
Install the long pipe from the union kit CAS 10508 on
Change the pilot circuit filter, see the operator’s manual. the portable filter return hose.
STEP 6 STEP 12
Change the Ultra Clean filter, see the operator’s Insert the long pipe in the hydraulic reservoir. Move the
manual. inlet filter long pipe as far away as possible.
STEP 13
Open the shut-off valve under the hydraulic reservoir.

Copyright ©
8000-9
STEP 14 STEP 25
Install the portable filter on the upperstructure in such a Stop the portable filter and the engine.
manner that the machine can be operated. Attach the
portable filter firmly to the machine. STEP 26
Close the shut-off valve under the hydraulic reservoir.
STEP 15
Connect the electric cable from the portable filter to the STEP 27
batteries. Make sure that the electric cable is away from Remove the inlet pipe from the shut-off valve under the
any moving components. hydraulic reservoir.
STEP 16 STEP 28
Start the portable filter running. Remove the long pipe from the hydraulic reservoir.
STEP 17 STEP 29
Start the engine, run it at half maximum speed for ten Disconnect the portable filter electric cable from the
minutes. During those ten minutes, stir the hydraulic batteries and remove the portable filter from the
fluid in the hydraulic reservoir with the long pipe. machine.
STEP 18 STEP 30
Set engine speed to maximum and bring the hydraulic Install a vacuum pump on the hydraulic reservoir. See
fluid up to its operating temperature by the following page 6.
procedure:
STEP 31
1. Operate the bucket and dipper controls in one
direction (against the cylinder stops) for Start the vacuum pump.
30 seconds.
2. Operate the bucket and dipper controls in the other
direction (against the cylinder stops) for 30 seconds.
3. Repeat steps 1 and 2 until the hydraulic fluid
temperature reaches 45 to 55°C (third bar on the
hydraulic fluid temperature gauge on the illuminated
instrument panel control screen).
STEP 19
With the engine at full speed; operate each cylinder
(retract, extend) two times, one after another, for
45 minutes.
STEP 20
With the engine at full speed; operate the swing control
several times 180° to the left and then to the right.
STEP 21
With the engine at full speed; position the attachment at
right angles to the undercarriage. Use the attachment
to raise the track off the ground. Operate the travel
pedal, in one direction for two minutes and then in the
other direction for two minutes. Repeat this cycle for ten
minutes.
STEP 22
Repeat Step 21 for the other track.
STEP 23
Reduce the engine speed to idle.
STEP 24
Stir the hydraulic fluid in the hydraulic reservoir for
10 minutes with the long pipe.
Copyright ©
8000-10
STEP 32
2
1
CD00E178
Remove the shut-off valve from the adaptor (2) and
install the bleed lever valve (1).
NOTE: Make sure that the bleed lever valve is closed.
STEP 33
Stop the vacuum pump and remove it from the
hydraulic reservoir. See page 6.
STEP 34
Install the access panel under the hydraulic reservoir.
STEP 35
Change the return filter and clean the inlet filter. See
the Operator’s Manual.
STEP 36
Change the pilot system filter. See the Operator’s
Manual.
STEP 37
Change the Ultra-Clean filter, see the operator’s
manual.
STEP 38
Check the level of the hydraulic fluid. Top up as
necessary. See the Operator’s Manual.

Copyright ©
8001
Section
8001
SPECIFICATIONS, TROUBLESHOOTING,
INSPECTIONS AND HYDRAULIC PRESSURE SETTING

Printed in France
Copyright ©
8001-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS .................................................................................................................................................... 3
SPECIAL TOOLS ...................................................................................................................................................... 3

Tester .................................................................................................................................................................... 3
IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................... 5

Pump..................................................................................................................................................................... 5
Control valve ......................................................................................................................................................... 6
6 solenoid valve row ............................................................................................................................................. 7
PREPARATION BEFORE INSPECTION.................................................................................................................. 8

Releasing pressure in the hydraulic system.......................................................................................................... 8
Main pressure measuring port .............................................................................................................................. 9
Installing the pilot pressure test point.................................................................................................................... 9
Flow curve........................................................................................................................................................... 10
Display on the "CHK1" monitor display ............................................................................................................... 11
Warming up the engine ....................................................................................................................................... 11
Warming up the hydraulic fluid............................................................................................................................ 11
CHECKING AND SETTING PROCEDURE ............................................................................................................ 12

Main pilot system relief (H).................................................................................................................................. 13
Checking the pilot accumulator ........................................................................................................................... 13
Main relief (A)...................................................................................................................................................... 13
Attachment control valve secondary reliefs......................................................................................................... 15
Swing port secondary relief................................................................................................................................. 16
Checking the pressure delivered by the proportional valve ................................................................................ 17
PROCEDURE FOR CHANGING OPERATION TYPE ............................................................................................ 18

ISO type .............................................................................................................................................................. 18
Old Sumitomo type ............................................................................................................................................. 18
Old Mitsubishi type.............................................................................................................................................. 19
Old Kobelco type................................................................................................................................................. 19

Copyright ©
8001-3
SPECIFICATIONS
See section 1002.
SPECIAL TOOLS
Tester
1 2
3
CD01B005
2. FEMALE COUPLING JOINT E47894 (1)
PRESSURE TEST POINT 14X1.5 A3237549 (2)
MALE COUPLING JOINT WITH UNION (3) AND
PLUGS (4) CONTAINED IN THE SUITCASE CAS
CP96E001
30038
1. TEST KIT E5444449 FOR MULTI-HANDY 2051
The Multi-Handy tester can be used every day in the
workshop for normal operations.
The Multi-Handy can be used for:
Checking pressure (two pressure scales), maximum
pressure, differential pressure (P delta), temperature,
engine rpm and flow.
1 Multi-Handy 2051 tester .......................... D5444448
2 pressure detectors (0-600 bar)................ V5344460
2 straight unions for detector..................... W5344461
1 elbow union for detector .......................... X5344462
1 engine rpm detector ................................ Z5344463
3 cables (5 m long)..................................... E3144472
CD98M009
1 electric socket 220 V - 50 Hz .................. D5344467
3. 600 LITER FLOWMETER, ORDER THE
1 cigarette lighter cable .............................. E5344468
FOLLOWING:
1 instruction manual .................................... -------------
1 carrying case........................................... N5344476 ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45X2) D4323359
TWO FLANGES (Ø 24) B8230183
FOUR HALF FLANGES D4024267
EIGHT SCREWS (12X75) Z1232983

Copyright ©
8001-4
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND
HYDRAULIC FLOW CAS 30038.
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES
CAS XXXXX (INCLUDING TWO HIGH
PRESSURE HOSES).

Copyright ©
8001-5
IDENTIFICATION OF HYDRAULIC COMPONENTS
Pump
Pi1 Dr Psv Pi2
a4
A3
Psv
B1 a3
Dr6
a1 a2
B3
A1 A2
CI02C509
Port Description Location

A1 - A2 Main pump output SAE6000 psi 1"
B1 Main pump intake SAE2000 psi 3"
Dr Leak return G 3/4 - 23
Psv Proportional valve supply port G 1/4 - 15
Pi1 - Pi2 Negative pressure port G 1/4 - 15
a1 - a2 - a3 - a4 Pressure test port G 1/4 - 15
A3 Pilot pump output G 1/2 - 19
B3 Pilot pump intake G 3/4 - 20.5
Dr6 Pilot pump leak return G 3/8 - 15

Copyright ©
8001-6
Control valve
Ps2 Pa10
Ps1 Pc5
CI02C508
T3 T1
Pc4 T2
Pc1 DR1'
A5 A8 T5
B5 Pc2 DR2' B8
A4
A2 A7 B7
B4
PA A6 B6
B2
PP Pr2
P3
B1 PT P2
PH
P1 Pr1 A1
CI01N508 CI01N507
Port Description Port Description

B8 Bucket opening Ps1 - Ps2 Negative pressure
A8 Bucket closing PT Travel pilot pressure switch
B7 Boom lowering PA Attachment pilot pressure switch
A7 Boom raising Pr1 - Pr2 Pressure text point P1 and P2
B6 RH front travel PH Main relief power boost control
A6 RH rear travel PP Pilot pressure
B5 Dipper out DR1' - DR2' Load holding valve leak return
A5 Dipper in T3 Swing motor leak return
B2 LH swing T5 Leak return to Ultra-clean filter
A2 RH swing T6 To pilot cushion (pre-heating)
B4 Option circuit Pc1 Dipper load holding
A4 Option circuit Pc2 Boom load holding
B1 LH forward travel Pc4 Priority to the swing (dipper)
A1 LH reverse travel Pc5 Priority to boom raising
P1 - P2 Pump pressure Pa10 By-pass 2nd flow on option
T1 - T2 Return to reservoir

Copyright ©
8001-7
6 solenoid valve row
Y1 Y5 Y4
Y6 Y3 Y2
CD00E143
Port Description
B Pilot manifold supply
T Return to reservoir
Y1 Swing pilot shut-off
Y2 Pilot pressure cancellation control
Y3 Swing brake control
Y4 Select travel 2nd speed
Y5 Power boost
Y6 Pilot cushion control cancellation

Copyright ©
8001-8
PREPARATION BEFORE INSPECTION
WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also cause or
infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a doctor immedi-
ately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction. Before pressuris-
ing the circuits, make sure that all the connections are correctly tightened and that the hoses and pipes are in
! good condition. Release pressure in the circuits completely before disconnecting pipes or carrying out any
operation on the hydraulic system. Always use a small piece of cardboard or wood to detect leaks of fluid under
pressure. Never use your hands.
WARNING: Any incorrect use or maintenance WARNING: The accumulator of this machine
of a construction machine can cause acci- is charged with nitrogen under pressure. In the
dents. Only persons who have read, under- event of incorrect operation of the circuit,
! stood and who observe the instructions in the
! change the accumulator. Never attempt to
operator's manual are accredited to use or repair it. Non-observance of these instructions
maintain this machine. and the procedure shown below can cause
serious or fatal injury.
Releasing pressure in the hydraulic system

NOTE: Operation to be carried out before every service 7. Lower the pilot control cancellation lever.
operation on the hydraulic system. 8. Operate each control more than 10 times in both
1. Position the machine on hard, flat ground. directions to release pressure in the circuits.
2. Open the bucket until the cylinder rod is completely
retracted.
3. Extend the dipper until the cylinder rod is com-
pletely retracted. Lower the boom so that the end of
the dipper is resting on the ground. Lower the tool
to the ground.
4. Check with the diagnostic display in "S" mode that
the following values are shown.
CS00E544
CH
MODE II S ENG 1800 rpm
K
9. Press the button located on the hydraulic reservoir
1 breather to release pressure in the reservoir.
P1 034.3 MPa I 0405 mA
P2 034.3 MPa WT 0080 °C
N 0.25 MPa OT 0055 °C
Engine rpm 1800±10 rpm

Current 405 mA
5. Lower the engine speed to idle for 30 seconds, then

shut down the engine.
6. Turn the starter key switch to "ON", without starting
the engine.

Copyright ©
8001-9
Main pressure measuring port
B44
B42
330-1-05-00-29AA
A pressure sensor is mounted on the control valve and
the circuit pressure can be displayed on the monitor
(except for pilot pressure).
B42, Pump pressure sensor P1.
B44, Pump pressure sensor P2.
Pressure on each relief valve (except for pilot pressure)
can be confirmed on the monitor display.
Installing the pilot pressure test

point
a3 (M3)
330.1.05.00.29EE
Install a pressure test point (M3) on the port (a3) of the
pilot pump.

Copyright ©
8001-10
Flow curve
Curve valid for a new pump
CI02C511

Copyright ©
8001-11
Display on the "CHK1" monitor N: Pump negative pressure in MPa (B43 pressure
sensor).
display
ENG: Engine speed in rpm (B41 sensor).
To access this screen: Select work mode H or S using I: Pump control current value.
control (2).
Fan motor current value (when Travel Mode
switch ON).
WT: Radiator coolant temperature.
Hydraulic oil temperature.
OT: Intake air temperature (only when Travel Mode
switch ON).
Warming up the engine

1. Start the engine. The engine will have warmed up
1 in 10-15 minutes.
2
2. Run the engine until the message "Auto warm up"
disappears from the display monitor.
CM00E001 Warming up the hydraulic fluid

Press simultaneously on the travel speed control (1)
and on the work mode selector control (2) as shown 1. Display the "CHK1" monitor display.
above until the diagnostic screen CHK1 appears 2. Actuate the bucket and dipper controls in one direc-
(3 seconds). tion (against the cylinder stops) for 30 seconds.
3. Actuate the bucket and dipper control in the other
CH direction (against the cylinder stops) for
MODE II H ENG 2000 rpm
K 30 seconds.
1 4. Repeat Steps 1 and 2 until hydraulic temperature
P1 030.0 MPa I 0300 mA reaches 45-55°C on display "CHK1".
5. Actuate the boom, swing and travel controls in both
P2 030.0 MPa WT 0080 °C directions to warm up all the circuits to 45-55°C.
N 03.00 MPa OT 0055 °C
P1: P1 pump pressure in MPa

(Pressure B42 sensor)
Boom raising
Dipper retracting and extending
Pressure checked
LH and RH swing
LH travel
P2: P2 pump pressure in MPa

(Pressure B44 sensor)
Raising - lowering boom

Dipper extending - retracting
Pressure checked
Bucket opening - closing
RH travel

Copyright ©
8001-12
CHECKING AND SETTING PROCEDURE
Location of secondary relief valves
E D
F
G
C
A
CI01N508
CI01N507
I J K
H
L
CI01N510
CI02C510 CS00M501
Tool used Pressure for 1 turn of

Item Description Adjusting Set pressure the screw (or for 1
Look nut shim*)
screw
Main relief (standard pressure) 22 mm 19 mm 314 bar (31.4 MPa) 213 bar (21.3 MPa)
A
Main relief (power boost) 32 mm 26 mm 343 bar (34.3 MPa) 257 bar (25.7 MPa)
Hexagon
B Boom raising port secondary relief 17 mm wrench 363 bar (36.3 MPa) 212 bar (21.2 MPa)
6 mm
Hexagon
Boom lowering port secondary
C 22 mm wrench 245 bar (24.5 Mpa) 131 bar (13.1 MPa)
relief
8 mm
D Dipper out port secondary relief
E Dipper in port secondary relief Hexagon
17 mm wrench 363 bar (36.3 Mpa) 212 bar (21.2 MPa)
F Bucket open port secondary relief 6 mm
G Bucket close port secondary relief
Hexagon
H Pilot circuit main relief 24 mm wrench 39 bar (3.9 MPa) 20 bar (2.0 MPa)
6 mm
I RH swing port secondary relief Hexagon
41 mm wrench 293 bar (29.3 MPa) 48 bar (4.8 MPa)
J LH swing port secondary relief 14 mm
K Reverse travel secondary relief
xx bar (xx MPa) xx bar (xx MPa)
L Forward travel secondary relief

Copyright ©
8001-13
Main pilot system relief (H) Main relief (A)
Test Test
1. Connect a 0-100 bar pressure gauge to pressure 1. Display the "CHK1" monitor display.
test point P3. 2. With the engine at full speed, select mode "S".
2. With the engine at full speed, select mode "S". 3. Operate and hold in position the dipper retracting
3. Move the pilot cancellation lever to its low position. control (against cylinder stops).
4. With the attachment, swing and travel controls in 4. Read the pressure on the monitor display:
neutral, read the value on the pressure gauge: The
value should be 39 to 41 bar (3.9 to 4.1 MPa).
2
Adjustment 1
1. Loosen the lock nut and turn the valve adjusting
screw (H) until 39 to 41 bar (3.9 to 4.1 MPa) is
reached.
2. Tighten the lock nut while holding the adjusting 1
screw in position.
3. When the adjusting screw has been tightened,
check the pressure again and make sure there are APPROX.
2 SEC 8 SEC
no leaks.
Checking the pilot accumulator 1. Standard pressure

1. Raise the boom completely and extend the dipper. 2. Power boost
2. Shut down the engine, with the starter key switch When the dipper cylinder is against the stops, the
on "ON". pressure is the standard value for 2 seconds, then
at the valve over-setting for 8 seconds before falling
3. Operate the boom lowering or dipper retracting
back to standard pressure.
control several times consecutively.
4. The pressure in the accumulator should enable the Pump Standard pressure 2-stage relief level
boom lowering or dipper retracting function to be
309 to 319 bar 338 to 348 bar
performed about six times. P1-P2
(30.9 to 31.9 MPa) (33.8 to 34.8 MPa)
NOTE: To read the higher pressure - 2-stage relief level

again, the control lever should be released, then oper-
ated against the cylinder stops.

Copyright ©
8001-14
Setting the power boost pressure Adjusting the standard pressure
NOTE: Carry out the procedure below only if the power
2 boost pressure is correct, otherwise carry out the power
1 boost pressure setting procedure.
4 3
4 3
330.1.05.00.29YA
1. Disconnect and plug the power boost pilot hose on

the main relief. 330.1.05.00.29XA
2. Using a wrench, hold the adjusting screw (3) in 1. Disconnect and plug the power boost pilot hose on
position and loosen the lock nut (4). the main relief.
3. Tight the adjusting screw (3) up to the stop. 2. Using a wrench, hold the adjusting screw (3) in
position and loosen the lock nut (4).
4. Tighten the lock nut (4).
3. Start the engine and run it at maximum speed,
select mode "S".
select mode "S".
4. Operate and hold in position the dipper retracting
control (against cylinder stops).
5. Turn the adjusting screw (3) until the standard pres-
7. Loosen the lock nut (2) and turn the adjusting
sure is reached.
screw (1) until the power boost pressure is
reached. NOTE: Tighten the screw (3) to increase the pressure.
Loosen the screw (3) to reduce the pressure.
NOTE: Tighten the screw (1) to increase the pressure.
Loosen the screw (1) to reduce the pressure. 6. Using a wrench, hold the adjusting screw (3) in
position and tighten the lock nut (4).
8. Using a wrench, hold the adjusting screw (1) and
tighten the lock nut (2). 7. Check the pressure again. If the desired value is
not obtained, repeat steps 2 to 6.
9. Check the pressure again. If the desired value is
not obtained, repeat steps 6 to 9. 8. Stop the engine.
10. Cary out the standard pressure setting. 9. Reconnect the power boost pilot hose to the main
relief.

Copyright ©
8001-15
Attachment control valve secondary 8. Read the pressure on the monitor display, the pres-
sure should be:
reliefs
(B, C, D, E, F and G) Boom raising P1-P2 363±5 bar
(36.3±0.5 MPa)
NOTE: If the excavator is equipped with safety valves
245±5 bar
on the boom and the dipper, secondary reliefs (B) and Boom lowering P2
(24.5±0.5 MPa)
(D) are not fitted or are overset. In this case it is neces-
363±5 bar
sary to set the pressures on the reliefs (B1-B2 and D1) Dipper in P1-P2
(36.3±0.5 MPa)
mounted on the safety valves.
363±5 bar
Dipper out P1-P2
NOTE: The attachment main reliefs are set to a higher (36.3±0.5 MPa)
pressure than the main relief valve. To check or set the Bucket opening P2 363±5 bar
attachment main reliefs, the main relief must be overset. (36.3±0.5 MPa)
363±5 bar
NOTE: Since the pressure of the boom lowering valve is Bucket closing P2
(36.3±0.5 MPa)
lower than the main relief, there is no need the overset
9. Carry out Steps 10 to 14 only if one of the attach-
the main relief (Steps 1 to 4 and 15 to 19).
ment secondary reliefs has to have its pressure set.
Checking and setting the pressure Otherwise go on to Step 15.
2 3
4
1
CS01K554
10. Using a wrench, hold the adjusting screw (4) of the
330.1.05.00.29YA
secondary relief concerned in position and loosen
1. Disconnect and plug the power boost pilot hose on
the lock nut (3).
the main relief.
11. Operate and hold in position the corresponding
2. Using a wrench, hold the adjusting screw (1) in
attachment control (against the cylinder stops).
position and loosen the lock nut (2).
12. Turn the adjusting screw (4) of the secondary relief
3. Tighten the adjusting screw (1) 180°.
concerned until the correct pressure is obtained.
14. Check the pressure again. If the desired value is
select mode "S".
not obtained, repeat steps 10 to 14.
6. Display the "CHK1" monitor display.
15. Using a wrench, hold the adjusting screw (1) of the
7. Operate and hold in position the corresponding main relief concerned in position and loosen the
attachment control (against the cylinder stops). lock nut (2).
17. Turn the adjusting screw (1) until the correct stan-
dard pressure of the main relief concerned is
obtained.
NOTE: Tighten the screw (1) to increase the pressure.
Loosen the screw (1) to reduce the pressure.

Copyright ©
8001-16
18. Using a wrench, hold the adjusting screw (1) in Adjustment
19. Check that the standard pressure of the main relief
is correct, otherwise carry out Steps 15 to 19 again.
20. Stop the engine. J
21. Reconnect the power boost pilot hose to the main I
relief.
22. If the value is not correct, loosen the lock nut (1)
and turn the pressure setting screw (2) to adjust the
pressure. Tighten to increase the pressure,
untighten to decrease. When the pressure is cor-
rect, hold the screw (2) and tighten the lock nut (1).
Reset the control valve main relief (A).
Swing port secondary relief CS99B596
(I, J) (I) RH swing port secondary relief

(J) LH swing port secondary relief
Test
1
330.1.05.00.29AD1
CD00E143 1. Carry out Steps 1 to 5 in "Checking".

1. Disconnect the connector (green) from the swing 2. Using a wrench, hold the adjusting screw (2) and
cancellation solenoid valve (Y1). tighten the lock nut (1).
2. Display the "CHK1" monitor display. 3. Slowly operate the swing control lever to the right
3. Start the engine and select mode "S". and gradually increase the engine speed to full
4. Switch on the swing brake control on the instrument speed to make sure that the swing is locked.
panel (indicator lamp ON). 4. Turn the adjusting screw (2) until the standard pres-
5. Slowly operate the swing control lever to the right sure is reached.
and gradually increase the engine speed to full 5. Using a wrench, hold the adjusting screw (2) and
speed to make sure that the swing is locked. tighten the lock nut (1).
6. Repeat Step 5. for the LH swing, the pressures 6. Check the pressure again. If the desired value is
must be: not obtained, repeat steps 2 to 6.
Function
RH swing P1 293±4 bar

(29.3±0.4 MPa)
LH swing P1 293±4 bar

(29.3±0.4 MPa)

Copyright ©
8001-17
Checking the pressure delivered by
the proportional valve
Port a4(G 1/4)
KTJ10480-C01
1. Connect a pressure test point and a 0-100 bar

pressure gauge to pump port G4.
2. Display the "CHK1" monitor display.
3. With the engine at full speed (no load engine),
select mode "H" and then mode "S".
Upper
Limit
Secondary pressure (MPa)
Upper
Limit
Input current (mA)

Controlled line graph
330.1.05.00.29R1
H mode S mode
12.9 bar 20 bar
Pressure
(1.29 MPa) (2.0 MPa)
Intensity 490 mA 405 mA

Copyright ©
8001-18
PROCEDURE FOR CHANGING OPERATION TYPE
Select operation type by changing hoses located under the bulkhead joint behind the cab.
After it has been changed, replace the instruction sticker for operation and take off ISO approved label.
ISO type Old Sumitomo type

Adopted manufacturers: KATO, IHI, YUTANI, CAT, Adopted manufacturers: SUMITOMO, KOMATSU,
LBCE. HITACHI.
Operation Levers Operation Levers
V1 S1 V1
A1
A1 A2 B2 B1
S1 S2
B2
B1
A2
V2 V2
S2
CS00F530 CS00F530S
Illustration of changing hoses Illustration of changing hoses

A1: Arm out (move to S1)
A1: Arm out A2: Arm in (move to S2)
A2: Arm in B1: Bucket open
B1: Bucket open B2: Bucket closed
B2: Bucket closed V1: Boom down
V1: Boom down V2: Boom up
V2: Boom up S1: Swing left (move to A1)
S1: Swing left S2: Swing right (move to A2)
S2: Swing right
000-8-02-01-07B
000-8-02-01-07B

Copyright ©
8001-19
Old Mitsubishi type Old Kobelco type
Adopted manufacturers: MITSUBISHI, NIKO. Adopted manufacturers: KOBELCO, FURUKAWA.
Operation Levers Operation Levers
V1 V1
A2 A1
S1 S2 S1 S2
B1 B2 B1 B2
A2
A1
V2 V2
CS00F530M CS00F530K
Illustration of changing hoses Illustration of changing hoses

A1: Arm out (move to V1)
A1: Arm out (move to V1) A2: Arm in (move to V2)
A2: Arm in (move to V2) B1: Bucket open (move to S2)
V1: Boom down (move to A2) B2: Bucket closed (move to S1)
V2: Boom up (move to A1) V1: Boom down (move to A1)
V2: Boom up (move to A2)
S1: Swing left (move to B1)
S2: Swing right (move to B2)
B1: Bucket open (move to S2)

B2: Bucket closed (move to S1)
S1: Swing left (move to B1)
S2: Swing right (move to B2)
000-8-02-01-07B

Copyright ©
8001-20
NOTES
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Copyright ©
8002
Section
8002

OF THE HYDRAULIC RESERVOIR

Printed in France
Copyright ©
8002-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
HYDRAULIC RESERVOIR ............................................................................................................................................ 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 4
Description ................................................................................................................................................................. 6
SPECIFICATIONS
See Section 1002.

Copyright ©
8002-3
HYDRAULIC RESERVOIR
Removal
NOTE: The numbers within brackets refer to the figures STEP 8
on pages 5 and 6.
Remove the screws (7) and the protective plate (8) on
STEP 1 top of the control valve.
STEP 9
Loosen the screws (9) located under the machine.
Open the side door on the right of the machine and
remove the two screws (10). Remove the screw (10)
located on the right of the fuel reservoir. Remove the
protective plate of the reservoir (11).
STEP 10
Loosen the circlips (12) and disconnect the hose (13)
under the hydraulic reservoir.
STEP 11
JS00163A1
Park the machine on hard, flat ground. Lower the Attach identification tags to the output hoses. Discon-
attachment to the ground. nect the hoses.
STEP 2 STEP 12
Release pressure in the hydraulic system and in the Remove the screws (14) and the retaining shims (15).
hydraulic reservoir (see Section 8000). STEP 13
STEP 3 Using a hoist, remove the hydraulic reservoir (1) from
Attach a "DO NOT OPERATE" tag to the ignition key in the machine.
the cab.
STEP 4
Remove the screws and the access panels under the
hydraulic reservoir (1).
STEP 5
Using a container of suitable capacity, drain the hydrau-
lic reservoir (1), by removing the plug (2).
STEP 6
Remove the screws (4) on top and inside the front boot,
then remove the protective housing (3).
STEP 7
Remove the screws (5) and the protective plate (6) on
top of the hydraulic reservoir (1).

Copyright ©
8002-4
Installation
NOTE: The numbers within brackets refer to the figures
on pages 5 and 6.
STEP 1
Using a hoist, position the hydraulic reservoir (1) on the
machine.
STEP 2
Install the screws (14) and the retaining shims (15) to
hold the hydraulic reservoir (1) to the machine under-
carriage, tighten the screws to a torque, see the specifi-
cations. Install the drain plug (2).
STEP 3
Connect the hose (13) using the two circlips (12).
Tighten the nut.
STEP 4
Connect the output hoses taking help of the tags
installed during removal.
STEP 5
Install the reservoir protective plate (11) using screws
(9) and (10).
STEP 6
Install the protective plate (6) under the hydraulic reser-
voir using retaining screws (5).
STEP 7
Install the protective plate (8) under the control valve
using screws (7).
STEP 8
Install the protective housing (3) using screws (4), then
install the screw mask inside the front boot.
STEP 9
Fill the hydraulic reservoir, see the section "Filling the
reservoir" in the operator's manual and check for leaks.
STEP 10
Start the engine. Pressurise the hydraulic reservoir
then stop the engine. Check again for leaks.
STEP 11
Install the protective plate under the machine using
screws and flat washers.

Copyright ©
8002-5
Hydraulic reservoir
12
13
15 2
14
1 HYDRAULIC RESERVOIR 13 HOSE

2 PLUG 14 SCREW
12 CIRCLIP 15 SHIM

Copyright ©
8002-6
Description
Location
3 4 8
10 7
4
7
11
6
10 9
5
3 PROTECTIVE HOUSING
4 SCREW
5 SCREW
6 PROTECTIVE PLATE OF THE HYDRAULIC RESERVOIR
7 SCREW
8 PROTECTIVE PLATE OF THE CONTROL VALVE
9 SCREW
10 SCREW
11 PROTECTIVE PLATE OF THE RESERVOIR

Copyright ©
Section
8003
8003
REMOVAL AND INSTALLATION OF THE MAIN

HYDRAULIC PUMP AND THE PILOT PUMP

Printed in France
Copyright ©
8003-2
TABLE OF CONTENTS
SPECIFICATIONS ........................................................................................................................................................ 3
SPECIAL TORQUE SETTINGS .................................................................................................................................... 3
MAIN HYDRAULIC PUMP ............................................................................................................................................ 4
Removal and installation ............................................................................................................................................ 4
PILOT PUMP ................................................................................................................................................................. 8
HYDRAULIC PUMP COUPLING .................................................................................................................................. 9
Cross-sectional view ................................................................................................................................................. 9
Removal and installation .......................................................................................................................................... 10

Copyright ©
8003-3
SPECIFICATIONS
See Section 1002.

Screw (7) for fixing the main pump to the coupling flange (5) ..............................367 to 496 Nm (270.68 to 365.83 lbf-ft)
Screw (3) for fixing the coupling flange (5) to the engine ...........................................88 to 108 Nm (64.90 to 79.66 lbf-ft)
Screw (6) for fixing the coupling (9) to the shaft of the hydraulic pump (8) .....................................295 Nm (217.58 lbf-ft)
Screw (1) for fixing the coupling flange (2) to the engine flywheel ......................................................49 Nm (36.14 lbf-ft)
Nuts for fixing the circlip of the silencer..................................................................68.7 to 98.1 Nm (50.67 to 72.35 lbf-ft)
Silencer bracket fastening screw............................................................................68.3 to 76.3 Nm (50.37 to 56.28 lbf-ft)

Copyright ©
8003-4
MAIN HYDRAULIC PUMP
Removal and installation STEP 4
STEP 1
JS00163A1
STEP 2
Release pressure in the hydraulic system and in the
1
STEP 3
Remove the access panel (1) below the hydraulic

reservoir.
STEP 5
Put an appropriate container under the hydraulic
reservoir. Open the drain cock and drain the hydraulic
fluid. Close the cock.
Disconnect the battery ground (-) cable (1) from the

battery.

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8003-5
STEP 6 STEP 8
A
1
CD02H004
Remove all the retaining screws (A) from the panel (B),
then remove the panel (B).
STEP 9
Remove the engine hood (1) then the protective grille 1

(2).
STEP 7
CD00F108
B Remove the circlip (1) fastening the silencer pipe to the
turbocharger.
NOTE: All the engine and the exhaust system to cool
down before starting any disassembly.
CD02C147
Disconnect all the hoses from the quick coupling
control block (A). Remove the block (A) from the panel
(B).

Copyright ©
8003-6
STEP 10 STEP 13
CD00F110 CD02H004
Remove the four retaining nuts from the silencer To facilitate proper installation, attach identification tags
circlips, then remove the two circlips. to all hoses and electrical connections of the main
hydraulic pump and the pilot pump.
NOTE: When installing, tighten the nuts to the torque
specified on page 3. STEP 14
STEP 11 Remove the pipes, the hydraulic hoses and the
electrical connections. Seal all hoses and unions of the
main pump as well as those of the pilot pump.
STEP 15
Install an appropriate lifting apparatus on the hydraulic
pump. Do not leave any slack so that the pump can be
supported once the fastening screws of the pump are
removed.
STEP 16
1 Remove the retaining screws of the hydraulic pump.
CD00F111 specified on page 3.
Remove the silencer assembly (1) from the machine.
STEP 17
STEP 12
Remove the hydraulic pump from the motor and put it
away from the machine. Place the hydraulic pump on a
clean workbench using suitable brackets.
NOTE: Carry out the following step only if a new
1 hydraulic pump needs to be installed.
STEP 18
Remove the connections of the hydraulic pump that has
just been removed and install them on the new
hydraulic pump. Remove and install the connections
one after another to avoid improper installation of the
connections on the new hydraulic pump.
CD00F076
NOTE: For installing the hydraulic pump, proceed in the
Remove the three retaining screws (1) from the silencer reverse order to that of removal. Replace all rings with
bracket, then remove the silencer bracket. new rings.
specified on page 3.

Copyright ©
8003-7
STEP 19 NOTE: Before carrying out any work with the machine,
operate the swing, travel and the attachment for five
minutes with the engine at idle speed. Check that there
are no leaks in the system, check the oil level in the
hydraulic reservoir. Top up if necessary, refer to Section
8001.
2
CD00E176
Remove the four screws and washers (1). Remove the
cover (2) and the O-ring from on top of the hydraulic
reservoir. Scrap the O-ring. Fill the hydraulic reservoir
with hydraulic fluid (see Section 1002) up to a level in
between the "high" and "low" marks on the visual
gauge. Install the cover with a new O-ring, fasten it
using four screws and washers (1).
Connect the ground (-) cable (1) of the battery.

STEP 20
NOTE: Always drain the air out from the hydraulic
pump before starting the engine. If the air has not been
drained out, the pump can get damaged. For the
procedure, see Section 8000.

Copyright ©
8003-8
PILOT PUMP
STEP 1 NOTE: When installing, proceed in the reverse order to
that of removal. Replace the O-rings with new O-rings.
Refer to "Removal of the hydraulic pump" in this section Bleed the hydraulic pump.
and carry out Steps 1 to 3.
NOTE: Stop the vacuum pump.
STEP 2
NOTE: Before carrying out any work with the machine,
To prevent any fluid leaks when disconnecting hydraulic operate the swing, travel and the attachment for five
hoses, connect a vacuum pump to the hydraulic minutes with the engine at idle speed. Check that there
reservoir (see Section 8000). Start the vacuum pump. are no leaks in the system, check the level of oil in the
hydraulic reservoir, top up if necessary. Adjust the
STEP 3 hydraulic pump, refer to Section 8001.
2
1
4
3
CD02H004
Place an appropriate container under the pilot pump (1)
to recover the hydraulic fluid that could escape from
one of the disconnected hoses or from the hydraulic
pump when the pilot pump (1) has been removed.
Disconnect the hoses (2), (3) and (4). Plug the union
and the hoses.
STEP 4
Remove the pilot pump retaining screws and remove
the pilot pump.

Copyright ©
8003-9
HYDRAULIC PUMP COUPLING
Cross-sectional view
A
9
1 8 5
3 4
CS02H583
1 SCREW 6 HUB RETAINING SCREWS
2 COUPLING FLANGE 7 SCREW
3 SCREW 8 HYDRAULIC PUMP
4 WASHER 9 COUPLING HUB
5 PUMP FLANGE

Copyright ©
8003-10
NOTE: The numbers within brackets refer to the
schematic on page 9.
STEP 1
Remove the screws (3) and the washers (4) from the
coupling flange (5). Remove the assembly from the
hydraulic pump.
STEP 2
Remove the retaining screws (6) from the splined hub
(9), then remove the hub.
2 5
CS02H584
STEP 3
Disassemble the screws (1) from the coupling flange
(2) and remove the flange. Visually check the condition
of the coupling splines. Change them if necessary.
STEP 4
Remove the screws (7) and the coupling flange (5) from
the hydraulic pump (8).
NOTE: When installing the hydraulic pump coupling,
proceed in the reverse order to that of removal. Adjust
the position of the coupling by aligning the splined hub
(9) with the end of the pump shaft (arrows)
corresponding to the stop on the pump shaft. Assemble
and tighten the splined hub retaining screw (6).

Copyright ©
Section
8004
8004
OF THE MAIN HYDRAULIC CONTROL VALVE

Printed in France
Copyright ©
8004-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
MAIN CONTROL VALVE ............................................................................................................................................... 3

SPECIFICATIONS
Weight of control valve .......................................................................................................................... See Section 1002
Adjusting the valves............................................................................................................................... See Section 8001

Control valve mounting on upperstructure frame ................................................ 333 to 392 Nm (245.61 to 289.12 lbf-ft)

Copyright ©
8004-3
MAIN CONTROL VALVE
STEP 1
JS00163A
Remove the upper access panel retaining screws and
remove the panels.
STEP 2 NOTE: When installing, tighten the screws to torque
Release pressure in the hydraulic system and in the (see special torque settings on page 2) (apply
hydraulic reservoir (see Section 8000). Loctite 262 on the threads).
STEP 3 STEP 6
Start the vacuum pump.
STEP 7
Attach identification tags to all hoses, pipes and
electrical wires of the control valve. Disconnect and
seal the hoses and pipes. Seal the control valve
unions. Disconnect the electrical connections.
STEP 8
STEP 9
Disconnect the earth (-) cable (1) from the battery.

STEP 4
To prevent any fluid leaks when disconnecting
hydraulic lines, connect a vacuum pump to the
Install lifting rings in the threaded orifices on the top of

the control valve.

Copyright ©
8004-4
STEP 10 NOTE: The following step is to be performed only if the
control valve has to be changed.
STEP 13
Remove the unions and manifolds from the control
valve which has just been removed and mount them on
the new control valve. Remove and install the unions
and manifolds one after another to make sure that they
are correctly installed on the new control valve.
the reverse order. Replace all seals with new seals.
NOTE: Before carrying out any work with the machine,
operate the swing, travel and the attachment for five
minutes with the engine at idle speed. Check that there
Install a lifting device on the control valve rings. are no leaks in the system, check the level of oil in the
hydraulic reservoir, top up if necessary. Adjust the
STEP 11 valves in the control valve (see Section 8001).
CS02J502
Remove the retaining screws (1) and washers from the
control valve.
NOTE: When installing, tighten the screws to torque
(see special tightening torques on page 2).
STEP 12
Carefully raise and guide the control valve out of the

upperstructure frame. Move all the hoses and pipes out
of the way. Remove the control valve from the machine
and place it on suitable stands.

Copyright ©
Section
8005
8005
OF THE ATTACHMENT CYLINDERS

Printed in France
Copyright ©
8005-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
PREPARATION BEFORE REMOVAL/INSTALLATION.................................................................................................. 2
BOOM CYLINDER .......................................................................................................................................................... 3

Description ................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 6
DIPPER CYLINDER........................................................................................................................................................ 8
Description ................................................................................................................................................................. 8
Removal ..................................................................................................................................................................... 9
Installation ................................................................................................................................................................ 11
BUCKET CYLINDER..................................................................................................................................................... 14
Description ............................................................................................................................................................... 14
Removal ................................................................................................................................................................... 15
Installation ................................................................................................................................................................ 17
SPECIFICATIONS
See Section 1002.
PREPARATION BEFORE REMOVAL/INSTALLATION

- Completely retract the bucket and dipper cylinder rods and lower the attachment to the ground.
- Release pressure in the hydraulic circuit and install a vacuum pump on the hydraulic reservoir (see Section 8000).

Copyright ©
8005-3
BOOM CYLINDER
Description
4
2
6
3
4 5
1
8
4
7
5 7
6
3
8
9 2
CS02B563
1 NUT 6 SCREW
2 SCREW 7 SHAFT
3 LOCKING BUSHING 8 BOOM CYLINDER
4 SHIM 9 SHAFT
5 WASHER

Copyright ©
8005-4
Removal STEP 3
NOTE: The numbers within brackets in the following 2 2
steps refer to the boom cylinder schematic on page 3.
9
STEP 1
4
A 3
1
JS00579A
Remove the nuts (1) and the screws (2). Remove the
screws from the shaft (9) and the locking rings (3).
Push the shaft far enough so that it does not intefere
with the removal of the boom cylinder. Remove the
JS00577A
Disconnect the lubrication hose (A) from the boom cyl- shims (4) and the locking rings.
inder. STEP 4
NOTE: Lift the cylinder carefully, the cylinder is heavy,
its weight has to be balanced with slings during lifting.
STEP 2
JS00580A
Install a support (A) in front of the boom cylinder. Lower
the front of the boom cylinder on the support.
JS00578A
STEP 5
Attach a suitable lifting device to the boom cylinder.
Use the total movement to get sufficient support during
removal of the boom cylinder.
JS00581A
Attach a sling (B) to hold the cylinder rod to the cylinder
barrel.

Copyright ©
8005-5
STEP 6 STEP 10
Start the vacuum pump. Repeat steps 1 to 9 to remove the other cylinder.
STEP 7
Disconnect the hydraulic supply hoses (A) from the

boom cylinder.
STEP 8
Plug the hoses with plugs and the unions with caps.
STEP 9
6
5
7
B
Remove the screw (6) and the washer (5).

Remove the shaft (7), using a steel bar and hammer.
Carefully lift the boom cylinder and move it away from

the machine. Place the boom cylinder on suitable sup-
ports. Remove the sling that holds the cylinder rod to
the cylinder barrel.

Copyright ©
8005-6
Installation STEP 3
STEP 1
6
5
7
B
B
Install the shaft (7) using washers (5) and screws (6).
Using a strip thickness gauge, check that there is a
JS00586A
Attach a suitable sling (B) to the boom cylinder to hold clearance of 1 to 3.5 mm (0.05 to 0.11 in) between the
the cylinder rod to the cylinder barrel. mounting bracket and the mounting ring of the cylinder
barrel. If necessary, remove the screw, the shaft and
NOTE: Lift the cylinder carefully. The cylinder is heavy, add one or more shim(s) as required in order to get the
its weight has to be balanced with slings during lifting. correct clearance. Install the pin and the screw.
STEP 2
A
A
Start the vacuum pump. Remove the plugs from the

Using a suitable lifting device, lift the boom cylinder. hydraulic hoses (A) and the caps from the unions. Con-
Align the boom cylinder with the mounting brackets of nect the two hydraulic supply hoses on the boom cylin-
the frame. Place a suitable support under the boom cyl- der.
inder to support it.
STEP 4
JS00590A
Lift the boom cylinder and align the rod end of the cylin-
der with the mounting ports of the boom.
STEP 5
Repeat steps 1 to 6 to install the second boom cylinder.

Copyright ©
8005-7
STEP 6 STEP 8
9
Install the pin (9) and the shims (4). JS00656A
Connect the lubrication hose (A) to the boom cylinders.
STEP 7
STEP 9
2 Remove the vacuum pump and bleed the air from the
boom cylinders (see Section 8000).
STEP 10
Check the hydraulic fluid level in the reservoir. Top up
3 as required.
STEP 11
Lubricate the linkages.
1
JS00592A
Install the locking bushings (3). Install the screws (2)
through the locking rings and the shaft. Using a set of
spacer rings, check that there is a clearance of 1 to 3.5
mm (0.05 to 0.11 in) between the mounting bracket and
the mounting ring of the cylinder rod. If necessary,
remove the screws and the pin and add or remove one
or more shim (s) as required to obtain the correct clear-
ance. Install the pin and the screws. Install the first nut
(1) on the screw and tighten until the nut touches the
locking ring. Unscrew the nut by a quarter of a turn and,
using two wrenches, install the second nut (1) to lock
the first nut in position. Remove the sling from the boom
cylinder.

Copyright ©
8005-8
DIPPER CYLINDER
Description
6
5
4
2
1
CS02B564
1 SCREW 5 WASHER
2 WASHER 6 PIN
3 PIN 7 DIPPER CYLINDER
4 SCREW 8 SHIM

Copyright ©
8005-9
Removal STEP 4
NOTE: The numbers within brackets in the following
steps refer to the dipper cylinder schematic on page 8.
STEP 1
B
A
JS00586A
8 Attach a suitable sling (B) to hold the cylinder rod to the
cylinder barrel.
Place a wooden shim (A) under the dipper cylinder (8).

STEP 2
1
2

STEP 3
Remove the shaft (3) using a steel bar and hammer.

Copyright ©
8005-10
STEP 5 STEP 10
STEP 6
6
5
A

Disconnect the two hydraulic supply hoses (A) from the

dipper cylinder.
STEP 7
Plug the hydraulic hoses with plugs and the unions with
caps. Stop the vacuum pump.
STEP 8
JS00599A
Disconnect the lubrication hose (A) from the dipper
cylinder.
STEP 9
Attach a suitable lifting device to the dipper cylinder.

Use the total movement to get sufficient support during
removal of the dipper cylinder.

Copyright ©
8005-11
STEP 11 Installation
8 STEP 1
JS00602A
Carefully lift the dipper cylinder and move it away from
the dipper. Remove the shims (8). Place the dipper JS00586A
cylinder on suitable supports. Attach a suitable sling (B) to the dipper cylinder to hold
the cylinder rod to the cylinder barrel.
STEP 12
STEP 2
8
B
JS00586A
Remove the sling (B) that holds the cylinder rod to the
cylinder barrel.
JS00602A
Attach a suitable lifting device to the dipper cylinder, lift
the dipper cylinder and bring it in position. Align the
dipper cylinder mounting ports with the boom brackets
and install the shims (8).

Copyright ©
8005-12
STEP 3 STEP 5
6
5
4
CS02B567 Start the vacuum pump. Remove the plugs from the
Install the shaft (6) using washers (5) and screws (4).
hydraulic hoses (A) and the caps from the unions.
Using a set of spacer rings, check that there is a
Connect the hydraulic supply hoses on the dipper
clearance of 1 to 3 mm (0.03 to 0.11 in) between the
cylinder.
mounting bracket and the mounting ring of the cylinder
barrel. If necessary, remove the screw, the shaft and STEP 6
add or remove one or more shim(s) (8) as required in
order to get the correct clearance. Install the pin and
the screw.
STEP 4 B
JS00586A
cylinder barrel.
STEP 7
JS00604A
Connect the lubrication hose (A) to the dipper cylinder.
JS00606A
Align the dipper cylinder mounting ports with the dipper
ports.

Copyright ©
8005-13
STEP 8
3
2
1
CS02B566
Install the shaft (3), the washer (2) and the screw (1).
Using a set of spacer rings, check that there is a
clearance of 4.5 to 5.5 mm (017 to 0.21 in) between the
mounting bracket and the mounting ring of the cylinder
rod. If necessary, remove the screw and the shaft and
add one or more shim(s) as required in order to get the
correct clearance. Install the pin and the screw.
STEP 9
Remove the vacuum pump and bleed the air from the
dipper cylinder (see Section 8000).
STEP 10
as required.
STEP 11

Copyright ©
8005-14
BUCKET CYLINDER
Description
4
11
3
6 6
12 9
7 7
9
4 6
5
5 4 2
13
9 1
7 12
8
9 6
10 13
5
10 4
2
1
2
1
2 3
CRPH06C012G
1 NUT 7 NIPPLE
2 SCREW 8 LINK
3 SHAFT 9 SEAL
4 SHIM 10 O-RING
5 BUSHING 11 BUCKET CYLINDER
6 O-RING 12 COMPENSATOR
13 O-RING

Copyright ©
8005-15
Removal STEP 2
NOTE: The numbers within brackets in the following 2
steps refer to the bucket cylinder diagram on page 14.
STEP 1 1
A
12
JS00609A
11 Remove the nuts (1) from the screw (2) and remove the
screw from the compensator (12).
STEP 3
Place a wooden shim (A) under the bucket
cylinder (11). 3

STEP 4
Attach a suitable sling (B) to the bucket cylinder to hold

the cylinder rod to the cylinder barrel.

Copyright ©
8005-16
STEP 5 STEP 8
A
A
B
Start the vacuum pump. Disconnect the two hydraulic Remove the screw (A) and the washer (B).
hoses (A) from the bucket cylinder. Plug the hydraulic Remove the shaft (C) from the dipper.
hoses with plugs and the unions with caps. Stop the
vacuum pump. STEP 9
STEP 6 A
JS00614A
Carefully lift the bucket cylinder and move it away from
the dipper. Remove the shims (A). Place the bucket cyl-
Remove the grease hose.
inder on suitable supports.
NOTE: Remove the wooden shim when the bucket cyl-
inder is raised. STEP 10
STEP 7
JS00586A
cylinder barrel.
Lift bucket cylinder, using a sling.

Copyright ©
8005-17
Installation STEP 4
STEP 1
B
Start the vacuum pump. Remove the plugs from the

hydraulic hoses (B) and the caps from the unions. Con-
JS00586A
Attach a suitable sling (B) to the bucket cylinder to hold nect the hydraulic hoses to the unions of the bucket cyl-
the cylinder rod to the cylinder barrel. inder. Stop the vacuum pump.
NOTE: Lift the cylinder carefully, the cylinder is heavy, STEP 5

STEP 2
Install the grease hose to the bucket cylinder.

STEP 6
Install the bucket cylinder on the dipper.
STEP 3
C
B JS00586A
cylinder barrel.
With the cylinder and the shims in position, install the
shaft (C), the screw (A) and the washer (B). Using a set
of spacer rings, check that there is a clearance of 1 to 3
mm (0.039 to 0.11 in) between the mounting bracket
and the mounting ring of the cylinder barrel. If neces-
sary, remove the screw, the shaft and add or remove
one or more shim as required in order to get the correct
clearance. Install the pin and the screw.

Copyright ©
8005-18
STEP 7
11
12
Lift the bucket cylinder (11) to align the cylinder rod and
the compensators (12). Install the shims.
STEP 8
2
3
1
Install the pin (3) and the screw (2). Using a set of
spacer rings, check that there is a clearance of 1.5 to
2.5 mm (0.059 to 0.098 in) between the connecting rod
and the mounting ring of the cylinder rod. If necessary,
remove the screw and the shaft and add or remove one
or more shim(s) as required in order to get the correct
clearance. Install the pin and the screw. Install the first
nut (1) on the screw and tighten until the nut touches
the boss. Unscrew the nut by a quarter of a turn and,
using two wrenches, install the second nut (1) to lock
the first nut in position.
STEP 9
Remove the vacuum pump and bleed the air from the
bucket cylinder (see Section 8000).
STEP 10
as required.
STEP 11

Copyright ©
Section
8006

OF THE HYDRAULIC SWIVEL
8006

Printed in France
Copyright ©
8006-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
HYDRAULIC SWIVEL ..................................................................................................................................................... 3
Removal and installation ............................................................................................................................................. 3
SPECIFICATIONS
Weight ................................................................................................................................................... See Section 1002

Capscrews for retaining locking bar ...................................................................................................... See Section 1002
Capscrews for retaining hydraulic swivel outer sleeve on upperstructure ............................................. See Section 1002

Copyright ©
8006-3
HYDRAULIC SWIVEL
STEP 1
JS00163A1
Park the machine on flat, hard ground. Lower the
attachment to the floor. 1
STEP 2 CI00F500
Remove the retaining hardware (1) from the lower
Release pressure in the hydraulic system and release plates (2) then remove the plates.
pressure in the hydraulic reservoir (see Section 8000).
STEP 3
CT07A009
Disconnect the earth cable (1) from the battery.
STEP 4
To prevent any fluid loss when disconnecting hydraulic
lines, connect a vacuum pump to the reservoir (see
Section 8000).

Copyright ©
8006-4
STEP 6 STEP 11
1
3
2
CD02C137 CS02C504
To facilitate installation, attach identification labels to all Remove the retaining screws (1), the locking bar (2)
the hydraulic swivel hoses (outer and inner). and the retaining screws (3) from the hydraulic swivel
outer component.
STEP 7
NOTE: When installing, tighten to the torque specified
Start the vacuum pump. in Section 1002.
STEP 8 STEP 12
Raise the hydraulic swivel sufficiently to free it from its
bracket, so that it can be pivoted 90°. Place the
hydraulic swivel on the ground.
NOTE: When installing, use the same procedure in the
reverse order. Replace all O-rings with new O-rings.
Before operating the machine, operate the travel, stop
the engine and check that there are no leaks. If there is
a leak, tighten the hose connections, check the level of
hydraulic oil in the reservoir and top up if necessary.
CS02C503
Disconnect the hoses from the hydraulic swivel. Plug
the hydraulic swivel hoses and orifices.
STEP 9
STEP 10
Connect suitable lifting equipment to the hydraulic
swivel. Do not leave any slack since the hydraulic swivel
has to be supported once the retaining screws are
removed.

Copyright ©
Section
8007

OF THE PILOT FUNCTION BLOCKS
8007

Printed in France
Copyright ©
8007-2
TABLE OF CONTENTS
SPECIAL TORQUE SETTINGS .................................................................................................................................... 2
PILOT FUNCTION BLOCKS ......................................................................................................................................... 3
Travel pedal block ..................................................................................................................................................... 3
LH control lever ......................................................................................................................................................... 4
RH control lever ........................................................................................................................................................ 8
Swing shuttle block ................................................................................................................................................. 11
Cushion control valve .............................................................................................................................................. 12
Servo control and return manifold block .................................................................................................................. 12
6 solenoid valve block ............................................................................................................................................. 13

Control lever block lever locknut ......................................................................................................... 41 Nm (30.24 lbf-ft)

Copyright ©
8007-3
PILOT FUNCTION BLOCKS
Travel pedal block STEP 5
Removal and installation Attach identification tags on all hoses of the control
pedal block.
STEP 1
STEP 6
STEP 7
Provide for a container to recover any possible
hydraulic fluid leaks.
STEP 8
JS00163A
Park the machine on hard, flat ground. Lower the 1
STEP 2
STEP 3
Disconnect the battery ground (-) cable (1) from the

Remove and seal the hydraulic hoses (1). Remove the
battery.
junction joints (2), put plugs on the ports of the control
STEP 4 pedal, then discard the O-rings.
To prevent any fluid leaks when disconnecting hydraulic NOTE: When installing, replace all O-rings with new O-
lines, connect a vacuum pump to the hydraulic rings.
reservoir (see Section 8000).
STEP 9

Copyright ©
8007-4
STEP 10 LH control lever
1 NOTE: Refer to page 3 and carry out Steps 1 to 4.
STEP 1
4
5
2
3 6
CD00G047
Remove the screws (1), then remove the lever (4).
Remove the screws (2), then remove the pedal (5).
Remove the screws (3), then remove the bracket (6).
Proceed in the same manner for the second pedal.
CD00G048
STEP 11 Lift the boot. Loosen and remove the four retaining
screws from the front upper portion of the control arm.
STEP 2
1
CD00E046
1
CD00G049
Loosen and remove the retaining screw (1) from the
function cancellation lever (2), then remove the lever.
Put the floor carpet away from the pedals. Remove the
screws (1) that fasten the control pedal block to the cab
floor, then remove the control pedal block.
NOTE: When installing, proceed in the reverse order to
that of removal. Start the engine and operate the
control levers. Stop the engine, check the circuit for
leaks and the hydraulic oil level in the reservoir, top up if
necessary.

Copyright ©
8007-5
STEP 3 STEP 6
CD00G050 CD00G053
Loosen and remove the three retaining screws from the Loosen and remove the retaining screws from the arm
inner cab access bar, then remove the access bar. angle adjustment and function cancellation lever, then
remove the lever.
STEP 4
STEP 7
2
1
CD00G051
Label and disconnect the electrical connections (1), CD00G054
remove the compartment control casing assembly (2). Lift the upper portion of the control arm, label and
disconnect the electrical connections.
STEP 5
STEP 8
CD00G052
Loosen and remove the four retaining screws from the CD00G055
rear upper portion of the control arm. Loosen the locknut, unscrew the control lever and
remove the upper portion of the control arm.
NOTE: When installing, tighten the lock nut to torque
(see special torque settings on page 2).

Copyright ©
8007-6
STEP 9 STEP 11
4
3
5
2
6 1
2
JD00764A CD00G057
1 CLIP Loosen and remove the retaining screws from the left-
2 NUT hand side of the control arm.
3 HANDLE
4 GROMMET STEP 12
5 CONNECTOR
6 LEVER
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the connector
(5) from the lever (6). Remove the nut (2) to remove the
grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
1
STEP 10
CD00G058
Remove from the safety bar side, the rod (1) that links
the function cancellation lever to the safety bar.
STEP 13
CD00G056
Loosen and remove the upper retaining screws and the
two lower retaining screws from the front portion of the
control arm.
CD00G059
Loosen and remove the retaining screws from the plate
(1).

Copyright ©
8007-7
STEP 14 STEP 18
1
1
CD00G060 CD00G062
Loosen and remove the screws that fasten the retaining Attach identification tags to all hoses of the control lever
plate of the control lever (1) to the bracket (2). block. Remove and seal the hydraulic hoses. Remove
the junction unions, put plugs on the ports of the control
STEP 15 lever block, then discard the O-rings. Loosen and
remove the retaining screws (1) from the plate (2).
NOTE: When installing, replace all O-rings with new O-
rings.
STEP 19
2 NOTE: When installing, proceed in the reverse order to
1 control levers. Stop the engine, check the circuit for
leaks and the hydraulic oil level in the reservoir, top up
if necessary.
CD00G061
Take the control lever block (1) out from the bracket (2).
STEP 16
STEP 17

Copyright ©
8007-8
RH control lever STEP 3
NOTE: Refer to page 3 and carry out Steps 1 to 4.
STEP 1
CD00G068
Loosen and remove the retaining screws from the arm
angle adjustment lever.
STEP 4
CD00G065
CD00G069
Lift the boot. Loosen and remove the retaining screws
CD00G066 from the front upper portion of the control arm.
Remove the trim panel (1) then remove the retaining
screws from the air-conditioning control box. STEP 5
STEP 2
1
2
CD00G070
Loosen and remove the retaining screws from the rear
CD00G067 upper portion of the control arm.
Label and disconnect the electrical connection (1) then
remove the air-conditioning control box (2).

Copyright ©
8007-9
STEP 6 STEP 8
4
3
5
2
6 1
2
CD00G071 JD00764A
Lift the upper portion of the control arm, label and 1 CLIP
disconnect the electrical connections. 2 NUT
3 HANDLE
STEP 7 4 GROMMET
5 CONNECTOR
6 LEVER
Cut the clip (1) and discard it. Loosen the nut (2).
Unscrew and remove the handle (3) and the connector
(5) from the lever (6). Remove the nut (2) to remove the
grommet (4).
NOTE: Replace the grommet if it is damaged. The
grommet protects the unions from all types of
contamination.
STEP 9
CD00G072
Loosen the locknut, unscrew the control lever and
remove the upper portion of the control arm.
NOTE: When installing, tighten the lock nut to torque
(see special torque settings on page 2).
CD00G073
Loosen and remove the upper retaining screws and the
lower retaining screws from the front portion of the
control arm.

Copyright ©
8007-10
STEP 10 STEP 13
STEP 14
1 STEP 15
2
CD00G074
Loosen and remove the retaining screws from the plate
(1).
STEP 11
1
1
CD00G077
Attach identification tags to all hoses of the control lever
block. Remove and seal the hydraulic hoses. Remove
the junction unions, put plugs on the ports of the control
lever block, then discard the O-rings. Loosen and
remove the retaining screws (1) from the plate (2).
2 rings.
STEP 16
CD00G075
Loosen and remove the screws that fasten the control Stop the vacuum pump.
valve (1) retaining plate to the bracket (2). NOTE: When installing, proceed in the reverse order to
STEP 12 control levers. Stop the engine, check the circuit for
leaks and the hydraulic oil level in the reservoir, top up if
1 necessary.
CD00G076
Take the control lever block (1) out from the bracket (2).

Copyright ©
8007-11
Swing shuttle block STEP 6
1
STEP 1
To make installation easier, attach identification tags to
all hydraulic hoses and electrical connections of the
shuttle block.
STEP 2
2
STEP 3
CD00G064
Provide for a container to recover any possible Remove the screws (1), then remove the shuttle block
hydraulic fluid leaks. (2) from its bracket.
STEP 4 NOTE: When installing, proceed in the reverse order to
that of removal. Start the engine, operate the control
levers, stop the engine, check the circuit for leaks and
the hydraulic oil level in the reservoir, top up if
necessary.
CD00G063
Remove and seal the hydraulic hoses, remove the
pressure detector, remove the junction unions, put
plugs on the ports of the shuttle block, then discard the
O-rings.
rings.
STEP 5

Copyright ©
8007-12
Cushion control valve Servo control and return manifold
Removal and installation block
NOTE: Refer to page 3 and carry out Steps 1 to 4. Removal and installation
STEP 1 NOTE: Refer to page 3 and carry out Steps 1 to 4.
Open the left-hand side doors. STEP 1

STEP 2 To aid installation, put identification tags on all the
hydraulic hoses.
STEP 2
2 STEP 3
STEP 4
3
1
2
3
To aid installation, put identification tags on the
hydraulic hoses. 3
STEP 3
1
Start the vacuum pump. 3
STEP 4 Remove and seal the hydraulic hoses.
CS01N583
Disconnect the hydraulic hoses from the cushion

STEP 5
control valve (1). Plug the hydraulic hoses and the ports
of the cushion control valve (1). Stop the vacuum pump.
STEP 5 STEP 6
Stop the vacuum pump. Remove the screws (1) then remove the block (2).
Remove the junction unions (3), discard the O-rings,
STEP 6 put plugs on the ports of the block.
Remove the screws (2) from the bracket and from the NOTE: When installing, replace all O-rings with new O-
cushion control valve. Remove the cushion control rings.
valve.
NOTE: When installing, proceed in the reverse order to that of removal. Start the engine, operate the control
that of removal. Start the engine, operate the control levers, stop the engine, check the circuit for leaks and
levers, stop the engine, check the circuit for leaks and the hydraulic oil level in the reservoir, top up if
the hydraulic oil level in the reservoir, top up if necessary.
necessary.

Copyright ©
8007-13
6 solenoid valve block STEP 5
Removal and installation To aid installation, put identification tags on the
hydraulic hoses.
STEP 6
STEP 1
Open the left-hand side door of the machine.
STEP 7
STEP 2
Disconnect the hydraulic hoses connected to the

solenoid valve block. Seal the ports with caps and the
hoses with plugs.
STEP 8
STEP 9
Remove the screws and washers from the protective Loosen the retaining screws from the solenoid valve
housing. block. Remove the screws and washers, making sure to
STEP 3 support it. Remove the solenoid valve block from its
bracket.
Put the protective housing away to make it easier to
disconnect the connectors from the protective housing. STEP 10
STEP 4 For proper installation of the connections, mark the
locations of the elbow unions. Fasten the solenoid valve
block in a vice. Remove the elbow unions and the
straight unions from the ports. Plug the solenoid valve
block ports with plugs to avoid any penetration of
foreign bodies.
that of removal. Start the engine. Energise several
times the solenoid valves (second speed selection,
swing brake control, power boost, pilot cushion control
cancellation, swing locking, negative control, boom
priority, pilot pressure). Stop the engine, check the
circuit for leaks and the hydraulic oil level in the
1 reservoir, top up if necessary.
Disconnect the connectors (1) by pressing on the

tongue fastener and then by pulling to separate them
(the connectors are identified by rings of different
colours).

Copyright ©
8007-14
NOTES
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Copyright ©
Section
8008

OF THE SWING MOTOR
8008

Printed in France
Copyright ©
8008-2
TABLE OF CONTENTS
SWING MOTOR............................................................................................................................................................. 3

+50
Swing motor retaining screws .....................................................................................................................295 -0 Nm

Copyright ©
8004-3
SWING MOTOR
STEP 1 STEP 5
JS00163A
Remove the upper panel (2) retaining screws (1), then
STEP 2
remove the upper panel (2).
hydraulic reservoir (see Section 8000). STEP 6
To facilitate installation, attach labels to all the hoses
STEP 3
and hydraulic unions which are disconnected during
removal.
STEP 7
STEP 8
6
5
Disconnect the earth (-) cable (1) from the battery.

1
STEP 4 4
To prevent any fluid leaks when disconnecting hydraulic 2
lines, connect a vacuum pump to the hydraulic
reservoir (see Section 8000).
CD02E001
Attach identification tags to the hydraulic hoses.
Remove the hoses (1), (2), (3), (4), (5) and (6). Plug the
hoses and the unions.
rings.

Copyright ©
8008-4
STEP 9 STEP 13
Stop the vacuum pump. To prevent any contamination of the gear oil, cover the
reduction gear with a cloth or a suitable protection.
STEP 10
the reverse order.
STEP 14
See Section 8001 and adjust the swing motor
secondary relief valves.
NOTE: Before operating the machine, start the engine,
check the system for leaks and check the hydraulic oil
level in the reservoir, top up if necessary.
Connect a suitable lifting device to the swing motor.

STEP 11
1
2
To facilitate reassembly, make an alignment mark (1) on

the swing motor and on the reduction gear. Remove the
retaining screws (2) from the hydraulic swing motor.
NOTE: When installing, tighten the screws to torque
(see special tightening torques on page 2).
STEP 12
Carefully lift the swing motor and move it away from the
swing reduction gear. Move the swing motor away from
the machine and place it on a clean workbench.
NOTE: When installing, apply Loctite 504 to the mating
surfaces between the reduction gear and the swing
motor.

Copyright ©
Section
8010
MAIN HYDRAULIC PUMP

8010

Printed in France
Copyright ©
8010-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
REGULATOR ................................................................................................................................................................. 4
Exploded View ............................................................................................................................................................ 4
Sectional View ............................................................................................................................................................ 5
EXPLANATORY DIAGRAM OF REGULATOR OPERATION ........................................................................................ 7
HYDRAULIC PUMP ........................................................................................................................................................ 8

Exploded View ............................................................................................................................................................ 8
Cross-Sectional View .................................................................................................................................................. 8
Sectional View ............................................................................................................................................................ 9
PTO UNIT...................................................................................................................................................................... 11
Sectional View .......................................................................................................................................................... 11
Exploded View .......................................................................................................................................................... 12
REGULATOR DISASSEMBLY...................................................................................................................................... 13
HYDRAULIC PUMP DISASSEMBLY............................................................................................................................ 15
PTO UNIT DISASSEMBLY ........................................................................................................................................... 17
WEAR INSPECTION..................................................................................................................................................... 18
REGULATOR ASSEMBLY............................................................................................................................................ 20
HYDRAULIC PUMP ASSEMBLY.................................................................................................................................. 22
REGULATOR ADJUSTMENT....................................................................................................................................... 26

Copyright ©
8010-3
SPECIFICATIONS
See Section 1002.

Pump:
Screw (401)........................................................................................................................................................... 430 Nm
Screw (406)............................................................................................................................................................. 29 Nm
Plug (466) ............................................................................................................................................................... 36 Nm
Plug (468) ............................................................................................................................................................. 170 Nm
Plug (490) .............................................................................................................................................................. 8.8 Nm
Plug (492) .............................................................................................................................................................. 9.8 Nm
Pin (531) ............................................................................................................................................................... 430 Nm
Piston (532)........................................................................................................................................................... 430 Nm
Nut (808) ............................................................................................................................................................... 240 Nm
Regulator:
Screw (412), (413) .................................................................................................................................................. 29 Nm
Screw (436), (438) .................................................................................................................................................. 12 Nm
Plug (496) .............................................................................................................................................................. 8.8 Nm
Locknut (630) ........................................................................................................................................................ 160 Nm
Nut (801) ................................................................................................................................................................. 16 Nm
Nut (802) ................................................................................................................................................................. 19 Nm
PTO:
Screw (435)............................................................................................................................................................. 98 Nm
Plug (468) ............................................................................................................................................................... 74 Nm
NOTE: The numbers within brackets refer to the diagrams from page 4 to 12.

Copyright ©
8010-4
REGULATOR
Exploded View

Copyright ©
8010-5
Sectional View
SECTION A-A
SECTION B-B
HYDRAULIC CIRCUIT
VIEW C

Copyright ©
8010-6
Description
412 - HEX SCREW C.H.C 653 - SPRING SEAT
413 - HEX SCREW C.H.C 654 - RETURN SPRING
436 - HEX SCREW C.H.C 655 - SET SPRING
438 - HEX SCREW C.H.C 656 - BLOCK COVER
496 - PLUG 708 - O-RING
601 - CASING 722 - O-RING
611 - FEEDBACK LEVER 724 - O-RING
612 - LEVER (1) 725 - O-RING
613 - LEVER (2) 728 - O-RING
614 - CENTER PLUG 730 - O-RING
615 - ADJUSTING PLUG 732 - O-RING
621 - COMPENSATOR PISTON 733 - O-RING
622 - PISTON CASE 734 - O-RING
623 - COMPENSATOR ROD 735 - O-RING
624 - SPRING SEAT (C) 755 - O-RING
625 - OUTER SPRING 756 - O-RING
626 - INNER SPRING 763 - O-RING
627 - ADJUSTING RING (C) 801 - NUT
628 - ADJUSTING SCREW (C) 814 - SNAP RING
629 - COVER (C) 836 - SNAP RING
630 - LOCK NUT 858 - SNAP RING
631 - PF SLEEVE 874 - PIN
641 - PILOT COVER 875 - PIN
643 - PILOT PISTON 876 - PIN
644 - SPRING SEAT (Q) 887 - PIN
645 - ADJUSTING RING (Q) 897 - PIN
646 - PILOT SPRING 898 - PIN
651 - SLEEVE 924 - SET SCREW
652 - SPOOL 925 - ADJUSTING SCREW (Q)

Copyright ©
8010-7
EXPLANATORY DIAGRAM OF REGULATOR OPERATION
Regulator function diagram
330.7.01.01.55I

Copyright ©
8010-8
HYDRAULIC PUMP
Exploded View

Copyright ©
8010-9
Sectional View
SECTION B-B
VIEW A

Copyright ©
8010-10
983 - PIN 490 - PLUG
981 - PLATE 468 - PLUG
954 - SCREW 467 - PLUG
953 - SCREW 466 - PLUG
901 - BOLT 406 - SCREW
886 - PIN 401 - SCREW
885 - PIN 314 - VALVE PLATE (FRONT)
824 - SNAP RING 313 - VALVE PLATE (REAR)
808 - NUT 312 - VALVE BLOCK
806 - NUT 271 - PUMP CASING
792 - RING BACK-UP 263 - COVER SEAL (REAR)
789 - RING BACK-UP 261 - COVER SEAL (FRONT)
774 - SEAL 251 - SUPPORT
732 - O-RING 214 - BUSH
728 - O-RING 212 - SWASH PLATE
725 - O-RING 211 - SHOE PLATE
724 - O-RING 157 - SPRING
719 - O-RING 156 - SPHERICAL BUSH
717 - O-RING 153 - HOLDER PLATE
714 - O-RING 152 - SHOE
710 - O-RING 151 - PISTON
702 - O-RING 127 - BEARING SPACER
548 - PIN 124 - NEEDLE BEARING
545 - BALL 123 - ROLLER BEARING
544 - STOPPER 2 114 - 1st GEAR
443 - STOPPER 1 113 - DRIVE SHAFT (REAR)
541 - SEAT 111 - DRIVE SHAFT (FRONT)
535 - STOPPER (S) 012 - CYLINDER BLOCK
534 - STOPPER (L) 05 - PTO ASSEMBLY
532 - SERVO PISTON 04 - GEAR PUMP
531 - PIN
530 - TILTING PIN ASSEMBLY
492 - PLUG

Copyright ©
8010-11
PTO UNIT
Sectional View

Copyright ©
8010-12
Exploded View
115 - IDLE-SHAFT 435 - FLANGE SOCKET

117 - 2nd GEAR 468 - PLUG
118 - 3rd GEAR 710 - O-RING
125 - BEARING 728 - O-RING
126 - CYLINDRICAL ROLLER BEARING 825 - LOCKING RING
128 - BEARING SPACER 826 - LOCKING RING
262 - COVER 827 - LOCKING RING
326 - GEAR CASE 886 - PIN

Copyright ©
8010-13
REGULATOR DISASSEMBLY
NOTE: The numbers within brackets refer to the drawing from page 4 and 5.
NOTE: Always keep the components from different STEP 3
pumps separate from one another. During disassembly
of the pump, place the components on a rubber mat.
Handle the components carefully. Always mark the
position of the parts.
STEP 1
After removing the cover (629) subassembly, remove

the outer spring (625), inner spring (626), and spring
seat (624) from the compensation section, and pull out
the adjusting ring (645), pilot spring (646), and spring
seat (644) from the pilot section.
Remove the screws (412, 413) and then remove the
• The adjusting ring (645) can be easily removed by
regulator.
pulling it out with an M4 bolt.
STEP 2
Remove the screws (438), and remove the cover (629).

• The cover is assembled with an adjusting screw (628),
adjusting ring (627), lock nut (630), hexagon nut (801)
(802), and hexagon socket head stop screw (924). Do
not loosen these screws and nuts. Doing so changes
the adjusted pressure-flow setting.

Copyright ©
8010-14
STEP 4 STEP 7
Remove the screws (436 and 438) and remove pilot

Remove lever 2 (613). Leave pin (875) in.
cover (641).
After you remove the pilot cover, remove set spring • Tweezers will facilitate the process.
(655) from the pilot section.
STEP 5
Pull out pin (874) and remove feedback lever (611).

• Push out pin (874) (pin dia. 4) from top with a fine
Remove stop ring (814) to remove spring seat (653), steel rod. Avoid hitting lever (1) (612) during this pro-
return spring (654), and sleeve (651). cess.
• A snap ring (836) is fitted onto the sleeve (651).
STEP 8
• Return spring (654) will pop out while removing stop
Remove lever (1) (612). Leave pin (875) in.
ring (814); do not lose it.
STEP 9
STEP 6
Pull out pilot piston (643) and spool (652).
STEP 10
Pull out piston case (622), compensating piston (621),
and compensating rod (623). Now the regulator is com-
pletely disassembled.
• Piston case (622) can be removed by pushing out the
compensating rod (623) from the opposite side of the
piston case.
NOTE: The components are small. Be very careful not
to lose them.
Remove locking ring (858), and remove support plug

(614) and adjusting plug (615).
• Support plug (614) and adjusting plug (615) can be
easily pulled out if you use an M6 bolt.

Copyright ©
8010-15
HYDRAULIC PUMP DISASSEMBLY
NOTE: The numbers within brackets refer to the draw- STEP 4
ing from page 4 to 12.
NOTE: Always keep the components from different
pumps separate from one another. During disassembly
of the pump, place the components on a rubber mat.
Handle the components carefully, always mark the
position of the parts.
STEP 1
Remove the oil drain port plug (468) and drain the oil
from the pump casing (271).
• Remove the plugs from both the front and rear pumps.
STEP 2
CD01G104
Place the pump horizontally with the regulator installa-
tion side facing down on the workbench and disconnect
the pump casing (271) and valve block (312).
• When placing the pump with the regulator installation
side facing down, make sure that the workbench is
covered with rubber plates or equivalent to prevent
damage on the installation side.
• When disconnecting the pump casing and valve block,
remove the 1st gear at the same time.
STEP 5
CD01G103
Remove the screws (412, 413) and remove the regula-
tor.
STEP 3
Loosen the screws (401), which lock the swash plate
support (251), pump casing (271), and valve block
(312).
NOTE: If a gear pump and others are attached to the
back side of the pump, this procedure should be done
after disconnecting the gear pump and others.
CD01G105
Remove the cylinder (012) straight out from the pump
casing (271) toward the drive shaft (111), and remove
the piston subassembly (151), holder plate (153),
spherical bush (156), and cylinder spring (157) at the
same time.
• Be careful not to damage the sliding surfaces of the
cylinder, spherical bush, shoes, and swash plate.

Copyright ©
8010-16
STEP 6 STEP 10
CD01G106 CD01G109
Remove the retaining screws (406) and remove the Remove the drive shaft (111) and 113) from the swash
seal cover (F) (261). plate support using a plastic mallet.
• Remove the seal cover (F) with a bolt inserted in the STEP 11
tapping hole for easier operation.
• Handle with care when removing the seal cover (F), to
prevent scratches on the oil seal, which is attached to
the seal cover (F).
STEP 7
Remove the screws (406) and remove the seal cover
(R) (263).
STEP 8
CD01G118
Remove the valve plates (313 and 314) from the valve
block (312).
NOTE: They may be removed during the step 4.
STEP 12
If necessary, remove the stopper (L) (534), stopper (S)
(535), servo piston (532), tilting pin (531) from the
pump casing (271) and needle bearing (124) from the
CD01G107 valve block (312).
Remove the front flange (251) by gently tapping it with
• When removing the tilting pin, use appropriate tools to
a plastic mallet. Discard the seal.
prevent damage to the top of the tilting pin.
STEP 9 • Be careful not to damage the servo piston because
Loctite is applied to the connecting part of the tilting
pin and the servo piston.
• The needle bearing should not be removed except
when it wears out.
• Do not loosen the hexagon nut for the valve block and
swash plate support. Loosening the nut causes the
flow rate to change.
NOTE: Operation to be carried out in case of wear of
the piston or the control pivot.
CD01G108
Remove the shoe plate (211) and swash plate (212)
from the pump casing (271).

Copyright ©
8010-17
PTO UNIT DISASSEMBLY
NOTE: The numbers within brackets refer to the drawing from page 11 and 12.
NOTE: Disassemble PTO Subassembly following the steps described below after reading the entire disassembling
instructions.
STEP 1 STEP 6
Choose a work area for disassembly.
• Choose a clean area.
• Place rubber plates or cloth on a workbench to pre-
vent scratches on the parts.
STEP 2
Remove debris or rust on the surface of pump with
cleaning oil or equivalent.
STEP 3
Remove the drain port plug (468) on the pump
casing and drain oil.
• Drain oil from each plug on the front pump and the
rear pump. CD01G111
Disconnect the retaining ring (827), remove the idler
STEP 4 shaft (115), and pull out the 2nd gear (117), the roller
Disconnect the flange socket and remove the gear bearing (126), and the bearing spacer (128).
pump. • The roller bearing (126) cannot be removed from the
STEP 5 2nd gear (117).
STEP 7
CD01G110
Disconnect the screws (435) and remove PTO Sub-
CD01G112
assembly. Disconnect the retaining ring (825) and remove the 3rd
gear (118) and the ball bearing (125).
• The ball bearing (125) cannot be removed from the
3rd gear (118).
NOTE: Installation is done in the opposite order of dis-
assembly; however, keep in mind the following notes.
• Make sure to repair the damaged parts and prepare
replacement parts beforehand.
• Clean each part with solvent and install them after air-
blowing them.
• When installing the sliding parts or bearings, make
sure to apply clean lubricant.
• Replace sealing parts such as O-rings and oil seals
with new ones as a general rule.
• Use torque wrenches for each mounting bolt and
plugs, etc.

Copyright ©
8010-18
WEAR INSPECTION
Standard dimension / Replacement of parts

recommended
Location Pump types Part to be replaced

K3V63, K3V112, K3V180,
K3V140
K5V80 K5V140 K5V200
0.028 / 0.039 / 0.043 / 0.0375 / Replace the pistons or the

Play between piston/bore (D-d)
0.056 mm 0.067 mm 0.070 mm 0.078 mm cylinder
Play at the shoe piston and the 0-0.1 / 0.3 0-0.1 / 0.3 0-0.1 / 0.3 0-0.1 / Replace the pistons and the
guide (A) mm mm mm 0.35 mm piston retaining plate
Shoe thickness (t) 3.9 / 3.7 4.9 / 4.7 5.4 / 5.0 5.4 / 5.0 Replace the pistons and the
mm mm mm mm piston retaining plate
Free height of cylinder springs 31.3 / 41.1 / 47.9 / 40.9 / Replace the springs
(L) 30.5 mm 40.3 mm 47.1 mm 40.1 mm
Height of the base plate and 19.0 / 23.0 / 23.7 / 23.7 / Replace the base plate and
the spherical bushing (H-h) 18.3 mm 22.0 mm 22.7 mm 22.7 mm the spherical bushing
Overhaul dimension of the cylinder, the distribution machined plate and the swash plate (machined surface)
Distribution machined plate (sliding contact surface) Standard roughness after 3-Z
Swash plate (at the plate) grinding
Cylinder (sliding contact surface)
Roughness of the sur- 0.4 Z or lower (lapping)
Irregularity of each surface
face at the wear limit
d D
Piston to cylinder bore Free heigh of

clearance (D-d) cylinder spring (L)
A
H
t h
Piston, shoes, and Assembled height of holder plate
caulking section backlash (A) and spherical bush (Hh)

Shoe thickness (t)

Copyright ©
8010-19
STEP 1
Check for cracks, breakage and pitting on the shafts,
the cylinder block pump body.
STEP 2
Check for heavy wear, cracks, pitting, deep scratches,
rough areas on the plate, the piston housing, the pis-
tons, and the control spools.
STEP 3
If one of these conditions is present, change the com-
ponent.

Copyright ©
8010-20
REGULATOR ASSEMBLY
NOTE: Assembly is done in the reverse order of disassembly, taking into account the following instructions:
- Clean the components with detergent and dry them with compressed air.
- Tighten the screws and plugs to the recommended torque.
- Coat the moving parts with clean oil before assembling them.
- Install new seals and O-rings.
STEP 1 STEP 7
Select the location for assembling the regulator. Install pilot piston (643) into the negative control hole
Find a clean location to assemble the regulator. on casing.
Place a rubber plate or cloth on the work surface so as • Ensure that the pilot piston slides smoothly without
not to damage the parts. engagement.
STEP 2 STEP 8
Assemble the compensation rod (623) into the com-
pensation opening on the casing (601).
STEP 3
The pin that is press-fitted onto the lever 1 (612) is to
be inserted in the compensating groove. After you
insert the pin, install lever 1 onto the pin that is press-
fitted onto the casing.
STEP 4
The pin that is press-fitted onto lever 2 (613) is to be

inserted in the groove on pilot piston. Insert the pin and
install lever 2.
STEP 9
SPOOL FEEDBACK LEVER
Install spool (652) and sleeve (651) into the spool hole
on the casing.
• Ensure that the spool and sleeve slides smoothly in
casing without engagement.
• The spool must be oriented properly.
STEP 5
The pin that is press-fitted into support plug (614) goes

into the pin hole on lever 2. Install the support plug
LEVER (1) SIDE LEVER (2) SIDE (SUP-
(614) in this manner, and install locking ring (858).
PORT PLUG ADJUSTING
PLUG-SIDE STEP 10
Insert adjusting plug (615) and install the locking ring.
• Ensure that you placed the support plug and the
adjusting plug in the respective holes.
• At this point, move the feedback lever to see it is not
loose and there is no engagement.
Install feedback lever (611), align the pinholes on the
feedback lever, and insert pin (874).
• You can facilitate the process by slightly inserting the
pin into the feedback lever beforehand.
• The feedback lever must be facing the right direction.
STEP 6
Copyright ©
8010-21
STEP 11 STEP 14
Install return spring (654) and spring seat (653) into the Install cover (C) (629), into which you have already set
spool hole, and install stop ring (814). adjusting screw (628), adjusting ring (C) (627), lock nut
(630), hexagon nuts (801, 802), and set screw (924).
STEP 12
Then fasten the screws (438) to complete the assem-
bly.
Install set spring (655) into the spool hole, install com-
pensating piston (621) and piston case (622) into the
compensating hole, fit pilot cover (641), and fasten the
screws (436).
STEP 13
Install spring seat (644), pilot ring (646), adjusting ring

(Q) (645) into the pilot hole, then fit spring seat (624),
inner spring (626), outer spring (625) into compensat-
ing hole.
• The spring seat must face the right direction.

Copyright ©
8010-22
HYDRAULIC PUMP ASSEMBLY
NOTE: Assembly is done in the reverse order of disas- STEP 3
sembly, however, the following instructions need to be
followed:
• Respect the reference marks made during disassem-
bly.
• Lubricate the seals and the sliding parts.
• Do not mix the parts of the front and rear pumps.
• Use light Loctite when installing the control pivot.
STEP 1
CD01G115
Install the drive shaft (111) which are attached with the
roller bearing (123), bearing spacer (127) and stop ring
(824) on the swash plate support (251).
• Do not hit the drive shaft with a hammer, etc.
• Fit the outer ring of the bearing with a light strokes of
a plastic hammer and make sure that it is fit firmly
using a steel bar or equivalent.
STEP 4
CD01G113
Fit a new O-ring on the flange (1). Install the flange (1)
on the housing (2), respecting the reference marks
made during disassembly.
STEP 2
CD01G116
Assemble the seal cover (F) (261) with the pump cas-
ing (271) and secure them with the screws (406).
• Apply grease lightly on the oil seal inside the seal
cover (F)
CD01G114 • Make sure not to damage the oil seal when handling
Place the pump casing with the regulator installation it.
side facing down, push down the tilting pin (531) of the
• In case of a tandem pump attach the seal cover (R) or
swash plate, and install the swash plate (212) on the
seal cover (F) in the same way.
swash plate support (251) properly.
• Make sure the swash plate moves smoothly by push-
ing it with finger tips of both hands.
• Apply grease on the swash plate, swash plate support
or other moving part for the easy installation of the
drive shaft.

Copyright ©
8010-23
STEP 5 NOTE:
• Assemble the pump on the rear side first.
• Be careful not to mix up the orientation of the valve
block.
• In case of the pump for clock wise rotation (viewed
from the input shaft side) position of the discharge
port :left side.
• [position of the regulator : above]
• In case of the pump for counter clock wise rotation
(viewed from the input shaft side) position of the dis-
charge port :right side.
• [position of the regulator port : above]
CD01G117 • Insert the 1st gear in the valve block beforehand, and
Assemble the piston cylinder subassembly (cylinder then couple the spline on the joint section of the drive
block (141), piston subassembly (151 and 152), shaft.
retainer (153), spherical bush (156), cylinder spring
(157), spacer (158)) and insert them into the pump cas- STEP 8
ing aligning the phase angle of the spline with the
spherical bush and cylinder.
STEP 6
CDIG103
Clamp the feedback pin of the tilting pin on the feed-
back lever of the regulator, install the regulator, and
fasten the screws (412 and 413).
CD01G118
Install the valve plate (313) on the valve block (312) • Be careful not to mix up the regulator for the front use
with the pins aligned. and the rear use.
• Be careful not to mix up the inlet and outlet direction STEP 9
on the valve plate. Install the drain port plug (468) to complete the proce-
STEP 7 dure.
CD01G119
Install the valve block (312) on the pump casing (271),
tighten the screws (401) to the specifique torque.

Copyright ©
8010-24
TROUBLESHOOTING
1) General precautions
Following are countermeasures if you find abnormality during the operation of Kawasaki swash plate type axial piston
pump and motor.
General precautions are:
a) Considerations before starting repair.
Determine the characteristics of the abnormality before starting repair. Consider if the cause is originated from the
wrong circuit, failure of regulator, or attached valve. Double check that the problem involves the pump motor.
b) Before disassembling a system, make sure to read through the service manual. Conduct the disassembly in a correct
manner.
c) When disassembling a system, be careful not to allow dust to enter.
d) Parts are finished precisely. Be careful not to damage them when handling.
2) Troubleshooting for the pump main body
Pumps are often attached to a regulator, attached valves and attached pumps. It can be difficult to find the cause of the
problem. Checking the following points is useful to identify the problem area.
a) Filter check and drain oil check
Check the filter element. Check if a considerable amount of contamination is found.
It is normal that a little amount of metal dust originated from abrasion of the shoe or cylinders is seen. However, if the
amount of metal dust is extremely high in the filter, the shoe might be damaged. Check drain oil of inside the pump cas-
ing, as well.
b) Abnormal noise / abnormal vibration
Check for abnormal noise or abnormal vibration in the main pump. Examine if the sound repeats with regular frequency
such as, a hunching sound in the regulator or hunching sound of the valve relief.
If there is an abnormal vibration or sound, cavitation or damage inside the pump should be considered.
c) When using two pumps.
If piping uses two single pumps or two motors, change the pipe of each pump.
By changing the pipe, the problem can be identified whether it is caused by a pump failure or a piping failure after the
pump.
4) Perform pressure measurement.
If the problem is related to the controlling function, examine the problem areas using pressure measurement tools
instead of performing overhaul inspection.

Copyright ©
8010-25
3) Overload on the motor
Causes Countermeasures Notes

Rotational speed-check if pressure is Set pressure at an expected value.
set higher than expected value.
Check if the torque set of the regula- Recheck the regulator. Refer to the regulator instruction
tor is high. manual.
Damage and burning on the internal Replacement of damaged parts. Check filter and drain oil for abnor-
parts of the pump. mal dust from abrasion.
Wrong piping for the regulator. Correct the regulator piping.
4) When pump flow rate declines significantly or discharging pressure does not increase.

Faulty regulator. Repair the regulator. Refer to the regulator instruction
manual.
Damage and burning on the internal Replacement of damaged parts. Check filter and drain oil.
parts of the pump.
Attached faulty pump. Replace damaged parts. Disconnect the attached pump and
check the shaft coupling section.
Attached faulty valve. Check attached valve. (Check espe- Refer to the attached valve instruc-
cially puppets and seat springs.) tion manual.
Wrong regulator piping. Correct the regulator piping.
5) Abnormal noise / abnormal vibration

Cavitation Prevention of cavitation. Check - Boost pressure is too low.
hydraulic oil for white turbidness. - Failure of auxiliary pump.
- Air is drawn from the intake pipe.
- Intake resistance is too high.
Damage on the shoe Replacement of piston shoe, shoe
caulking area. plate or others.
Cracks on the cylinder Replacement of the cylinder
Failure of pump installation Reinstallation
Hunching of the regulator Repair of the regulator Refer to the regulator instruction
manual.
Hunching of the relief valve on the Repair the attached valve. Refer to the attached valve instruc-
attached valve tion manual.

Copyright ©
8010-26
REGULATOR ADJUSTMENT
Regulator type: KR3H-9N5A
Revolution (min-1) 1980
Adjusting screw (954) Fastening (turns) +1/4
Adjusting Maximum Flow
Changes in flow (L/min.) -7.6
Adjusting Minimum Flow
Changes in flow (L/min.) +7.6
Adjusting outer Changes in compensation control start pressure (MPa) +1.8

spring Changes in input torque (N+m) +91
Adjusting Input A +2.17

Power Adjusting ring (627) Fastening (turns) +1/4
Adjusting inner Changes in flow (L/min.) +13

spring Changes in input torque (N+m) +61
Set screw (924) Fastening (turns) +1/4
Adjusting Flow Controlling Changes in flow control start pressure (MPa) +0.17
Characteristics Changes in flow (L/min.) +21

Copyright ©
8011
Section
8011

OF THE CONTROL VALVE

Printed in France
Copyright ©
8011-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
TOOLS REQUIRED ........................................................................................................................................................ 2
CONTROL VALVE .......................................................................................................................................................... 4
Description .................................................................................................................................................................. 4
Identifying the ports..................................................................................................................................................... 9
Disassembly.............................................................................................................................................................. 10
Inspection.................................................................................................................................................................. 14
Assembly .................................................................................................................................................................. 15
Troubleshooting ........................................................................................................................................................ 20
SPECIFICATIONS
Weight of control valve .......................................................................................................................... See Section 1002
Safety valve settings.............................................................................................................................. See Section 8001
TOOLS REQUIRED
1. Loctite 262
2. Torque wrench OEM 6472, OEM 6474 and OEM 6476

Copyright ©
8011-3
Spool assembly
Screws (D) for the spools (3) to (7) and (8) to (11) .................................................................................... 24 to 26 Nm
Screw for the spool (49)............................................................................................................................. 19 to 22 Nm
Spool end (24) ........................................................................................................................................... 19 to 22 Nm
Load holding valve (37)
Plugs (A) and (F) ....................................................................................................................................... 28 to 30 Nm
Plug (H)...................................................................................................................................................... 14 to 18 Nm
Control valve assembly
Relief valve (38) ....................................................................................................................................... 93 to 108 Nm
Safety valves (39) ...................................................................................................................................... 78 to 88 Nm
Safety valves (40) .................................................................................................................................. 123 to 127 Nm
Relief valve (41) ..................................................................................................................................... 103 to 113 Nm
Retaining screws (56) of the control valve sections ............................................................................... 356 to 394 Nm
Plug (27) .................................................................................................................................................. 93 to 108 Nm
Plug (42) ................................................................................................................................................ 103 to 113 Nm
Plug (45) ................................................................................................................................................ 103 to 113 Nm
Plug (50) .................................................................................................................................................... 73 to 79 Nm
Plug (51) .................................................................................................................................................... 31 to 42 Nm
Plug (52) ................................................................................................................................................ 116 to 128 Nm
Plug (53) .................................................................................................................................................... 73 to 79 Nm
Plug (66) .................................................................................................................................................. 93 to 108 Nm
Plug (23) .................................................................................................................................................. 93 to 108 Nm
Plug (63) .................................................................................................................................................... 14 to 18 Nm
Cap retaining screws (34) and (54) ....................................................................................................... 103 to 113 Nm
Cap retaining screws (69) ................................................................................................................ 194.5 to 215.5 Nm
Cap retaining screws (12), (13), (63), (64), (72) and (73) ...................................................................... 103 to 113 Nm
Cap retaining screw (67)............................................................................................................................ 38 to 42 Nm
Plugs (91) .................................................................................................................................................. 49 to 59 Nm
Cap retaining screws (75) .......................................................................................................................... 58 to 64 Nm
Screw (55) ................................................................................................................................................. 58 to 64 Nm
Screw (68) .............................................................................................................................................. 14.4 to 16 Nm

Copyright ©
8011-4
CONTROL VALVE
Description
52
51
1 52 69 68
39 34
54 39
66
54
70
66 54
40
54 55
52 47
52 54 51 38 55 47
56 81
54
39
39
75
76
38 56 81
CS02K558

Copyright ©
8011-5
34 33 35
31
53
53 42
65
39 33 34 35 32
46
43 45
44
16
15 17 18 19
47
38 52
18
47
77
15
16 17 19
CS02K559

Copyright ©
8011-6
60 33 36 35 34 33
37 31
35
34 33 70
35
71 31 71
66
69
52 34 64 64
31 35 66
33 97
29
91
52
33 28
35 34 39
52
31 52
48
31
47 35
53
34 33
35 39
40
36 33 60 37
CS02K562

Copyright ©
8011-7
63 2 59
60
14
8 72
61
9
12 61
91
91
64
64
10
11 59
60
6
13
14 61
61
1
14
12 3
13
5
72
73
12 6
13
63 7
64
14
CS02K561

Copyright ©
8011-8
41 63 41
53
39 51 52 28 29 52 67
23
22 48
49
62
20 52
51
29
24 21 25 27 26 50 30
CS02K560

Copyright ©
8011-9
Identifying the ports
NOTE: Refer to Section 8001.
Description 59. O-ring
60. O-ring
1. Control valve housing
61. O-ring
2. Control valve housing
62. O-ring
3. Dipper spool 2
63. Port plug
4. Bucket spool
64. O-ring
5. Boom spool 1
65. Steel ball
6. Travel spool
66. Plug
7. Straight-line travel spool
67. Cap
8. Dipper spool 1
68. Screw
9. Option spool
69. Cap
10. Boom spool 2
70. Screw
11. Swing spool
71. O-ring
12. Cap
72. Cap
13. Cap
73. Cap
14. O-ring
75. Screw
15. Check valve
76. Plug
16. Spring
77. O-ring
17. Spacer
81. Washer
18. O-ring
91. Plug
19. Back up ring
97. Plug
20. Spool
21. Spring seat
22. Spring
23. Plug
24. Spool
25. Spring
26. O-ring
27. Plug
28. Check valve
29. Spring
30. Check valve
31. Check valve
32. Check valve
33. Spring
34. Cap
35. O-ring
36. Check valve
37. Load holding valve
38. Main relief
39. Safety valve
40. Safety valve
41. Safety valve
42. Plug assembly
43. Check valve
44. Spring
45. Plug
46. O-ring
47. Plug
48. O-ring
49. Spool
50. Plug
51. Plug
52. Plug
53. Plug
54. Screw
55. Screw
56. Screw

Copyright ©
8011-10
Disassembly STEP 3
NOTE: Remove the control valve from the machine, 59 61
see Section 8004.
General instructions 61 60
- Clean around the component to be removed and take
care to ensure that no foreign matter enters the
control valve. 61
- Label the parts removed and arrange them in a
manner that makes assembly easier.
- Since the spool is an integral part of the control valve
body and the sleeve, do not replace the spool.
60
NOTE: The numbers in brackets refer to the views on
pages 4 to 8.
Separating the sections
NOTE: Remove the sections only if required. If disas- 61 61
sembly is required, place the control valve body in a
horizontal plane.
CS02K564
STEP 1 Remove the O-rings (59), (60) and (61).
Clean the outside of the control valve with a suitable Spool assembly
cleaning solvent to eliminate all traces of impurities,
STEP 1
grease and other foreign bodies. Dry, using low pres-
sure compressed air. Loosen and remove the screws (54) that fasten the
caps (12) and (72) and remove the caps.
STEP 2
NOTE: If necessary, remove the complete plug assem-
81 56 bly (91) and the O-ring (64).
STEP 2
Remove the O-rings (14) from sections (1) and (2) of
the control valve.
STEP 3
Remove the spools (3) to (7) and (8) to (11) from the
control valve body as sub-assemblies, taking care not
to damage them.
NOTE: Identify each spool so that they can be put back
in their respective housings during assembly.
STEP 4
Loosen and remove the screws (54) that fasten the
caps (73) and (13) and remove the caps.
NOTE: If required, remove the plug assembly (91) and
81 56 the plug (97).
CS02K563
Separate the two sections (1) and (2) from the control
valve by removing the screws (56) and the washers
(81).

Copyright ©
8011-11
STEP 5 STEP 4
Remove the O-rings (14) from sections (1) and (2) of Loosen and remove the spool assembly (49), then
the control valve. remove the spring seats and the spring.
NOTE: To avoid abrasion of the spool surface during Spool assembly (20)
disassembly of the spool assembly, use a vice with pro-
NOTE: When removing the plug (23), make sure that
tective jaws and tighten the spool as close as possible
you do not drop parts which are under pressure from
to the head in order to avoid any deformity. When the
the springs.
threaded portion of the screw is coated with Loctite,
heat the head of the screw using an industrial drier until STEP 1
removal becomes easy (normally the temperature
should be in between 200 and 250°C). If this operation Loosen and remove the plug (23) and remove the
causes the spring to be deformed and malfunction, O-ring (62).
replace the spring. STEP 2
STEP 6 Remove the spring (22).
B C B D STEP 3
E B
A
CS01K596
Remove the spool screws (D) on the spring side of the
spools (3) to (7) and (8) to (11). Remove the spring D C
seats (B) as well as the springs (C). CS02K568
Remove the spool (A) from the sleeve (B). Extract the
NOTE: In the spools (5) and (8), only remove the check sleeve (B) from the control valve body. Remove the pis-
valves, the springs, the O-rings, the back up rings and ton (C), the O-ring (D) and the back-up ring (E).
the plugs if it is necessary. If it is necessary to remove
them, heat the periphery of the spool in order to make it Load holding block
easier to remove the plug. NOTE: Be careful when removing components, some
Dipper load holding valve decompression parts are subject to spring pressure.
spool 1 STEP 1
STEP 1 Loosen and remove the screws (54) and remove the
Loosen and remove the screws (68) that fasten the cap caps (34).
(67) and remove the cap (67).
STEP 2
STEP 2 Remove the springs (33), the check valves (31) and
Remove the O-ring (48) from the cap (67). (32), and the O-rings (35) from the control valve body.
STEP 3 NOTE: The straight-line travel valve does not have

springs or check valves (see cross-section H-H).
Remove the spool (49) from the control valve body tak-
ing care not to damage it. STEP 3
NOTE: For disassembly of the spool, refer to the Loosen and remove the screws (54) and remove the
instructions previously cited for disassembly of spool caps (47).
assemblies.

Copyright ©
8011-12
STEP 4 Remove the load holding valves (67)
Remove the spacer (17) from the control valve body, NOTE: Be careful when removing components, some
then remove the O-ring (18), the back-up ring (19) from parts are subject to spring pressure.
the spacer (17).
STEP 1
STEP 5
Loosen and remove the screws from the load holding
Remove the spring (33) and the check valve (31) from valves (37) then remove the load holding valve.
the control valve body.
STEP 2
STEP 6
Remove the O-rings (35) and (60) from the control
Loosen and remove the plug (52) (see cross-section C- valve body.
C).
STEP 3
STEP 7
Remove the spring (33) and the check valve (36) from
Remove the spring (29) and the check valve (28) from the control valve body.
STEP 8
Loosen and remove the plug (52) (see cross-section L-
L).
STEP 9
STEP 10
Remove the spring (33), the check valve (31) and the
O-ring (35) from the control valve body.
STEP 11
Loosen and remove the plug (45) and the O-ring (46).
STEP 12

Copyright ©
8011-13
Load holding valve (37) Valves
NOTE: Do not operate the valve components, as this
H I will affect the pressure, otherwise see Section 8001 for
the valve settings.
37 STEP 1
E
F
D
G
C
A 39
J CS02C563
A B Loosen and remove the safety valves (39) from the con-
CS02K566 trol valve body. Remove the O-ring (A) from the safety
NOTE: Be careful when removing components, some valve body.
parts are subject to spring pressure.
STEP 2
STEP 1
Loosen and remove the plug (A) and remove the O-ring
38
(B). A
STEP 2
Remove the spring (C), the spring seat (D) and the
spool (E).
STEP 3
CS02C560
Loosen and remove the plug (F) and remove the O-ring Loosen and remove the relief valve (38) from the con-
(G). trol valve body. Remove and discard the O-ring (A).
STEP 4 STEP 3
Disassemble the plug (H) and the O-ring (I).
A 42 B C
NOTE: The steel ball (J) is a press fit, do not remove it.
CS01K600
Loosen and remove the plugs (42) and remove the
O-rings (A), (B) and (C).

Copyright ©
8011-14
Auxiliary assembly Cleaning
STEP 1 Clean all the parts removed with clean oil. Dry with
compressed air and place each part on a clean sheet of
Loosen and remove the screws (54) from the caps (69) paper or vinyl for inspection.
and remove the O-rings.
STEP 2 Inspection
Loosen and remove the two plugs (66) and remove the Inspect the surface of each part for scratches, abrasion
O-rings and the back up rings. and other damage.
1. Check that there are no scratches or dents on the
Plug assembly
non-return load check valve seat in the control
STEP 1 valve body and that there are no traces of rust or
contaminants.
Loosen and remove the plug (42) and remove the
O-ring (see cross-section J-J). 2. Check that there are no scratches or dents on the
periphery of the spool. Use an abrasive product to
STEP 2 remove any small scratches.
Loosen and remove the plug (63) from its port (see 3. Check that all sliding surfaces are moving freely.
cross-section Z-Z). Check for the absence of foreign matter in holes
and in grooves.
STEP 3
4. Replace the springs in case of damage, deformity
Loosen and remove the plugs (52) and remove the
or wear and tear.
O-rings.
5. Replace all O-rings and back up rings with new
ones.
6. After removing the caps and plugs, ensure that
there is no trace of paint at the level of the port of
the body or on the rim of the plug. (Any trace of
residual paint is likely to cause contamination that
could cause the system to malfunction and lead to
possible leaks).
Precautions before assembly
Before beginning assembly, check the quantity of the
parts, be sure of their final position and get all the
required tools ready.

Copyright ©
8011-15
Assembly Dipper load holding valve decompression
spool 1
Spool assembly STEP 1
NOTE: Take care not to apply too much Loctite, it could
Apply Loctite 242 on the threaded portions of the spool
seep through inside the spool and cause it to malfunc-
(49) and install the spring seats, the spring and the
tion.
spool end.
NOTE: If the spool (5) boom section 1 (opposite the
spring) and the spool (8) dipper section 1 (spring side) STEP 2
have been removed for assembly, proceed in the follow- Install the spool in a vice with protective jaws. Tighten
ing manner: the end of the spool to torque (see page 3).
STEP 1 Load holding valve (37)
Install the check valve and the spring in the spool,
install the back up ring and the O-ring on the plug. I
H
Apply Loctite 242 on the threaded portion of the plug.
Install the spool in a vice with protective jaws and
37
tighten the plug at the end of the spools (5) and (8).
STEP 2 E
Apply Loctite 242 on the spring side on the threaded F
portions of the spools (3) to (7) and (8) to (11). Install
the spool in a vice with protective jaws. D
STEP 3 G
C
B C B D J
A B
CS02K566
STEP 1
Install the plug (H) complete with a new O-ring (I).
CS01K596
NOTE: Respect the positions of the O-rings and back
Install the spring seat (B) the spring (C), spring seat (B)
up rings. If installations are not carried out in the correct
on the screw (D) and tighten it on the spool to torque
order, the O-rings will be lacerated.
(see page 3).
STEP 2
Install the plug (F) complete with a new O-ring (G).
STEP 3
Lubricate and install the spool (E) in the valve (37),
install the spring seat (D), install the spring (C), install a
new O-ring (B) on the plug (A). Install the plug (A) and
tighten to torque (see page 3).

Copyright ©
8011-16
Valves STEP 3
NOTE: Do not operate the valve components, as this A 42 B C
will affect the pressure, otherwise see Section 8001 for
the valve settings.
STEP 1
38
A
CS01K600
Install the plugs (42) complete with an O-ring (A), (B)
CS02C560
and (C). Tighten to torque (see page 3).
Install the main relief (38) equipped with an O-ring (A).
Tighten to torque (see page 3). Load holding block
STEP 2 STEP 1
Install the O-rings (35) in the control valve housings,
dipper sections 1 and 2, boom sections 1 and 2, swing
and bucket sections, install the check valves (31) and
the springs (33).
STEP 2
Install the caps (34) and fasten them using screws (54).
A 39 Tighten to torque (see page 3).
CS02C563 STEP 3
Install the safety valves (39) complete with an O-ring
(A). Tighten to torque (see page 3). Install the O-rings (35) in the travel control valve sec-
tion, install the check valves (32) and the springs (33).
STEP 4
Install the caps (34) and fasten them using screws (54).
Tighten to torque (see page 3).
STEP 5
Install the O-ring (35) in the control valve straight-line
travel section housing.
NOTE: The straight-line travel valve is not equipped
with springs or check valves.
STEP 6
Install the cap (34) using screws (54). Tighten to torque
(see page 3).

Copyright ©
8011-17
STEP 7 NOTE: Respect the positions of the O-rings and back
up rings. Any wrong installation will cause lacerations
Install the check valve (15) and the spring (16) (see and external leaks.
cross-section I-I), install the spacer (17) complete with
an O-ring (18) and a back up ring (19). STEP 3
NOTE: Respect the positions of the O-rings and back Install the load holding valve (37) and fasten it using
up rings. If installations are not carried out in the correct screws (54). Tighten to torque (see page 3).
order, the O-rings will be lacerated.
Auxiliary assembly
STEP 8 STEP 1
Install the cap (47) using screws (54) and tighten to
Install the caps (69) equipped with an O-ring (71) and
torque (see page 3).
fasten them using the screws (70). Tighten to torque
STEP 9 (see page 3).
Install the O-ring in the option section (see cross-sec- STEP 2

tion E-E), install the check valve (31) and the spring
Install the plugs (66) complete with an O-ring and a
(33). Install the cap (34) and fasten it using screws (54).
back up ring. Tighten to torque (see page 3).
STEP 10
Install the check valve (43) and the spring (44) on the
travel portion (see cross-section G-G). Install the plug
(45) complete with an O-ring (46). Tighten to torque
(see page 3).
STEP 11
Install the check valve (28) and the spring (29) on the
dipper portion 1 (see cross-section C-C). Install the
plug (52) equipped with an O-ring. Tighten to torque
(see page 3).
Load holding valve
STEP 1
Install the O-rings (60) and (35) on the control valve
dipper section 1 (see cross-section D-D) and boom
section 1 (see cross-section F-F).
STEP 2
Install the check valve (36) and the spring (33).

Copyright ©
8011-18
Spool assembly (20) STEP 3
STEP 1 Install the caps (73) and the caps (13) on the control
valve body and fasten them using screws (54). Tighten
D E B to torque (see page 3).
A
STEP 4
Install the caps (12) and the caps (72) on the control
valve body and fasten them using screws (54). Tighten
to torque (see page 3).
C NOTE: Check the proper positioning of the caps (72)
and (73).
CS02K568
Install the O-ring (D) and the back up rings (E) on the STEP 5
sleeve (B). Install the piston (C) and the spool (A) in the
sleeve (B). Install the assembly in the control valve Install the plug (97) equipped with an O-ring on the
body. short cap of the option section (see cross-section E-E).
STEP 2
STEP 6
Install the spring (22) inside the plug (23) equipped with
an O-ring (62). Screw the plug on the control valve Install the plug (91) equipped with an O-ring (64) on the
body. Tighten to torque (see page 3). long cap of the option section (see cross-section E-E).
Dipper load holding valve decompression
spool 1 Plug assembly
STEP 1 STEP 1
Install the spool assembly (49) in the control valve body Install the plug (42) equipped with an O-ring. Tighten to
without forcing it. torque (see page 3) (see cross-section J-J).
NOTE: Ensure that it is functioning properly by making STEP 2

it slide manually.
Install the plug (63) in its port. Tighten to torque (see
STEP 2 page 3) (see cross-section Z-Z).
Install the cap (67) equipped with an O-ring (48) and

fasten it using screws (68). Tighten to torque (see page
3).
Spool assemblies (3) to (7) and (8) to (11)
STEP 1
Install the O-rings (14) on the control valve body.
STEP 2
Install the assembled spools (3) to (7) and (8) to (11) in
the ports of the control valve body.
NOTE: Ensure that the spool is installed in its original
port, install it without pressing too hard. After installing
the spool, make it slide manually to check its proper
functioning.

Copyright ©
8011-19
STEP 3 NOTE: For installation of the control valve, see Section
8004.
Install the plugs (52) equipped with an O-ring. Tighten
to torque (see page 3).
Assembling the sections
STEP 1
59 61
61 60
61
60
61 61
CS02K564
Install new O-rings (61) and (60).
STEP 2
56 81
56 81
CS02K563
Assemble the two sections (1) and (2) using screws (56)
and washers (81). Tighten to torque (see page 3).

Copyright ©
8011-20
Troubleshooting
Control valve in general
Problems Possible causes Countermeasures

Spool does not Remove any part causing resistance to oil
Oil temperature has abnormally risen.
move. flow in piping.
Change oil and clean circuit at the same
Dirty hydraulic oil
time.
Over-tightening of piping port joints Check torque.
Deformed valve housing by incorrect mount- Loosen mounting bolts and check their con-
ing dition.
Check pressure by placing a pressure gauge
Pressure is too high.
between pump and cylinder port.
Deformed spool Replace valve as an assembly.
Damaged return spring Replace damaged parts.
Loosen cap first, and then center and
Dislocated spring or cap
retighten it.
Temperature is not uniform inside the valve. Warm up entire circuit.
Valve is blocked with dirt. Eliminate dirt (flush).
Dislocated spring or cap Check pilot valve and pilot relief pressure.
Lack of pilot pressure Check seals in cylinder for damage.
Oil bypasses spool. Check spool for damage.
Clean valve housing seats and relief valve
Oil leakage from overload relief valve
seats.
Load cannot be Disassemble anti-drift valve and clean seat

held. section in each part.
If damage is found in seat section, replace
poppet or apply lapping to poppet together
Oil leakage from anti-drift valve
with the section.
If any abnormality is found on anti-drift valve,
replace spool and sleeve at the same time
because they are press-fit.
Load drops when Load check valve is blocked with dirt. Disassemble and clean check valve.
switching spool from
neutral to raised Damage on poppet or seats in the check Replace poppet or apply lapping to poppet
position. valve and seats.
Relief valve

Pressure does not Main poppet, sleeve or pilot poppet sticks
rise at all. and keeps open, or seats in valve are
blocked with dirt.
Unstable relief Seats in pilot poppet are damaged. Replace relief valve.
pressure
Piston or main poppet sticks.
Incorrect relief Wear in seats due to dirt
pressure
Reset pressure and tighten locknut to speci-
Looseness in locknut and adjuster
fied torque.

Copyright ©
8011-21
Oil leakage Damage on relief valve seats

Replace relief valve.
Each part sticks due to dirt.
Replace O-rings for adjuster or in mounting
Worn O-rings
section.
Hydraulic system in general
Faulty pump Check pressure or replace pump.
Faulty relief valve Replace relief valve.
Faulty cylinder Repair or replace it.
High load pressure on pump Check circuit pressure.

Hydraulic sys-
tem malfunctions Cracks on the valve Replace valve as an assembly.
or does not oper-
ate at all. Spool does not move with a complete
Check spool for its movement.
stroke.
Oil level in tank is too low. Refill hydraulic oil.
Filter blockage in circuit Clean or change filter.
Restricted circuit piping Check piping.

Copyright ©
8011-22
NOTES
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Copyright ©
8012
Section
8012

OF THE ATTACHEMENT CYLINDERS

Printed in France
Copyright ©
8012-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
SPECIAL TOOLS ............................................................................................................................................................ 4
CYLINDERS.................................................................................................................................................................... 6
Boom cylinder description .......................................................................................................................................... 6
Dipper cylinder description ......................................................................................................................................... 8
Bucket cylinder description ...................................................................................................................................... 10
Disassembly ............................................................................................................................................................. 12
Inspection ................................................................................................................................................................. 20
Assembly ................................................................................................................................................................. 21
SPECIFICATIONS
See Section 1002.

Copyright ©
8012-3
Boom cylinder
Piston nut..........................................................................................................................14 500 Nm (10 694.63 lbf ft)
Bearing retaining screw ...................................................................................1140 ± 206 Nm (840.82 ± 151.94 lbf ft)
Retaining clip retaining screw (15)...........................................................................31.5 ± 5.9 Nm (23.23 ± 4.35 lbf ft)
Piping retaining screw (5 A) ...................................................................................62.6 ± 11.7 Nm (46.17 ± 8.62 lbf ft)
Piping retaining screw (5 B) ...................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft)
Hydraulic pipes retaining screw (4)......................................................................92.4 ± 17.3 Nm (68.15 ± 12.75 lbf ft)
Piston nut screw ....................................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft)
Dipper cylinder
Bearing retaining screw ..................................................................................1560 ± 294 Nm (1150.59 ±216.84 lbf ft)
Piping retaining screw (5) ......................................................................................62.6 ± 11.7 Nm (46.17 ± 8.62 lbf ft)
Hydraulic pipes retaining screw (4)......................................................................145 ± 27.5 Nm (106.94 ±20.28 lbf ft)
Piston nut screw ...................................................................................................96.8 ± 18.2 Nm (71.39 ±13.42 lbf ft)
Air bleeder (48) ........................................................................................................44.1 ± 2.9 Nm (32.52 ± 2.13 lbf ft)
Bucket cylinder
Bearing retaining screw ...................................................................................1140 ± 206 Nm (840.82 ± 151.94 lbf ft)
Piping retaining screw (5) ......................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft)
Hydraulic pipes retaining screw (4)......................................................................92.4 ± 17.3 Nm (68.15 ± 12.75 lbf ft)
Piston nut screw ....................................................................................................56.9 ± 10.7 Nm (41.96 ± 7.89 lbf ft)

Copyright ©
8012-4
SPECIAL TOOLS
OEM 9797 Hydraulic cylinder repair bench
OEM 9798 Piston nut screw
PE.174E-220 Hydraulic/electric pump
OR
CAS 10918 Hydraulic cylinder repairing bench
OR
E/SCRS1 Hydraulic cylinder repair bench including:

- Repair bench
- Electric hydraulic motor-pump assembly
- Piston nut fastening wrench

Copyright ©
8012-5
OEM 9797 PE-174E-220

OR
E/SCRS1
OEM 9798
CAS10918

Copyright ©
8012-6
CYLINDERS
Boom cylinder description
26 28 20
24 44
27 21
23 43
42 22 15
16
1
47
25 11
41 17
7
10 4
8
19 34
35 6
36
33 5A
37 39
38 40 15 45
48 16
46
17
6
18
5B
44
8
43
4
9
CS02F584A

Copyright ©
8012-7
1 GREASE FITTING
2 NOT USED
3 NOT USED
4 SCREW
5 SCREW
6 WASHER
7 PIPE CLAMP
8 HYDRAULIC PIPE
9 O-RING
10 HYDRAULIC PIPE
11 O-RING
12 NOT USED
13 NOT USED
14 NOT USED
15 SCREW
16 LOCKING WASHER
17 RETAINING CLIP
18 SCREW
19 BEARING
20 SCREW
21 STEEL BALL
22 PISTON NUT
23 PISTON
24 SEAL
25 BACK-UP RING
26 SEALING RING
27 SEALING RING
28 SHIM
29 NOT USED
30 NOT USED
31 NOT USED
32 NOT USED
33 O-RING
34 BACK-UP RING
35 RING
36 SEAL
37 BACK-UP RING
38 WIPER SEAL
39 RETAINING RING
40 BUSHING
41 SEAL
42 CUSHION BUSHING
43 ANTI-DUST SEAL
44 BUSHING
45 CYLINDER ROD
46 CYLINDER BARREL
47 O-RING
48 BUSHING

Copyright ©
8012-8
Dipper cylinder description
6
5
7
8
4
33 34
19 15
9 16
17
48
1 39
40 4
35
44 37 36
18
43 38
10 5
11
6
22 20 21
7
5
44
6 24
26
23 43
7
47
27
42
41
17
45 46 16
15
CS02F586A

Copyright ©
8012-9
1 GREASE FITTING
2 NOT USED
3 NOT USED
4 SCREW
5 SCREW
6 WASHER
7 PIPE CLAMP
8 HYDRAULIC PIPE
9 O-RING
10 HYDRAULIC PIPE
11 O-RING
12 NOT USED
13 NOT USED
14 NOT USED
15 SCREW
16 LOCKING WASHER
17 RETAINING CLIP
18 SCREW
19 BEARING
20 SCREW
21 STEEL BALL
22 PISTON NUT
23 PISTON
24 SEAL
25 NOT USED
26 SEALING RING
27 SEALING RING
28 NOT USED
29 NOT USED
30 NOT USED
31 NOT USED
32 NOT USED
33 O-RING
34 BACK-UP RING
35 RING
36 SEAL
37 BACK-UP RING
38 WIPER SEAL
39 RETAINING RING
40 BUSHING
41 SEAL
42 CUSHION BUSHING
43 ANTI-DUST SEAL
44 BUSHING
45 CYLINDER ROD
46 CYLINDER BARREL
47 O-RING
48 BLEED SCREW

Copyright ©
8012-10
Bucket cylinder description
33 34
19
39
40
35
38
37 36
44
8
4
1 43 18 9 4 11
10 44
43
17
16
15
46
7
6
16 5
8
15
45 28 22
24
26
27
23 20 21
42
47
CS02F585

Copyright ©
8012-11
1 GREASE FITTING
2 NOT USED
3 NOT USED
4 SCREW
5 SCREW
6 WASHER
7 PIPE CLAMP
8 HYDRAULIC PIPE
9 O-RING
10 HYDRAULIC PIPE
11 O-RING
12 NOT USED
13 NOT USED
14 NOT USED
15 SCREW
16 LOCKING WASHER
17 RETAINING CLIP
18 SCREW
19 BEARING
20 SCREW
21 STEEL BALL
22 PISTON NUT
23 PISTON
24 SEAL
25 NOT USED
26 SEALING RING
27 SEALING RING
28 SHIM
29 NOT USED
30 NOT USED
31 NOT USED
32 NOT USED
33 O-RING
34 BACK-UP RING
35 RING
36 SEAL
37 BACK-UP RING
38 WIPER SEAL
39 RETAINING RING
40 BUSHING
41 NOT USED
42 CUSHION BUSHING
43 WIPER SEAL
44 BUSHING
45 CYLINDER ROD
46 CYLINDER BARREL
47 O-RING

Copyright ©
8012-12
Disassembly STEP 3
NOTE: The boom, dipper and bucket cylinders are Bucket cylinder
basically identical in construction. What changes is the
hydraulic tube connections. Before installing the
steps refer to the bucket cylinder diagram on page 10.
cylinder in the repair stand, remove the hydraulic tubes.
1. Remove the grease fittings (1) from the cylinder.
STEP 1
2. Remove the screws (4). Disconnect the hydraulic
Boom cylinder pipes (8) and (10) from the cylinder.
NOTE: The numbers within brackets in the following 3. Remove the screws (5), the washers (6) and the
steps refer to the boom cylinder schematic on page 6. pipe clamps (7). Remove the hydraulic tubes (8) and
1. Remove the grease fitting (1) from the cylinder. (10) from the cylinder. Remove and discard the two
O-rings (9) and (11).
2. Remove the screws (4) and disconnect the hydraulic
tubes (8) and (10) from the cylinder. 4. Remove the screws (15), the washers (16) and the
circlip (17).
3. Remove the screw (5), the washer (6) and the pipe
clamp (7). Remove the hydraulic tubes (8) and (10) NOTE: As an example, the repairing bench CAS 10918
from the cylinder. Remove and discard the two O- is used.
rings (9) and (11). STEP 4
4. Remove the screws (15), the washers (16) and the
circlip (17).
STEP 2
Dipper cylinder
1. Remove the screws (4) and disconnect the hydraulic
tubes (8) and (10).
2. Remove the screws (5), the washers (6) and the
pipe clamps (7). Remove the pipes (8) and (10) from
the cylinder. Remove and discard the two O-rings JD00620A
(9) and (11). Install suitable bushings on the cylinder head stock
3. Remove the screws (15), the washers (16) and the chuck wings.
circlips (17).

Copyright ©
8012-13
STEP 5 STEP 8
JD00621A JD00625A
Tighten the bushing retaining screws. Connect lifting equipment, if necessary, to the cylinder.
Position the cylinder in the repair stand with the rod end
STEP 6 of the cylinder at the head stock chuck. Loosen the
retaining screws of the tail stock chuck wings. When
positioning the cylinder rod end on the head stock
chuck wing, be sure that the chuck wing bushings are
centred in the rod bushing. Install the screw and nuts to
secure the cylinder rod end to the repair stand.
STEP 9
JD00623A
Install the stop pins on the boom tail stock.
STEP 7
JD00626A
On the cylinder repair stand, loosen the retaining
screws of the tail stock chuck wings. When positioning
the cylinder barrel end on the head stock chuck wing,
be sure that the bushings are centred in the cylinder
barrel bushing. Install the screw and nuts to secure the
cylinder barrel end to the repair stand.
JD00624A
Install suitable bushings on the cylinder tail stock chuck
wings. Tighten the retaining screws. Install the chuck
wings on the cylinder tail chuck. Tighten the locking
screws. Use the scale on the face of the chuck to aid in
centering the chuck wings.

Copyright ©
8012-14
STEP 10 STEP 12
JD00627A JD00629A
Check and ensure that the chuck wings are centred on Raise the cylinder barrel (46) support to support the
the repair stand centre line using scales scribed on the cylinder barrel. Tighten the nuts to lock the support in
head and tail stock chucks. position. Remove the lifting equipment.
NOTE: The numbers within brackets in the following STEP 13
steps refer to the boom cylinder, dipper cylinder and
bucket cylinder schematics on pages 6, 8 and 10.
STEP 11
JD00630A
To make reassembly easier, draw alignment marks on
the cylinder barrel (46) and the bearing (19). Remove
the screws (18).
JD00628A
Raise the cylinder rod (45) support to support the STEP 14
cylinder rod. Tighten the nuts to lock the support in
position.
JD00631A
Place a container beneath the bearing and cylinder
barrel to catch any hydraulic oil that may still be inside
the cylinder. Start the hydraulic pump to remove the rod
from the cylinder barrel.

Copyright ©
8012-15
STEP 15 STEP 18
Connect lifting equipment, if necessary, to the cylinder D
barrel (46) and remove from the repair stand. B
STEP 16
A
C
A
JD00635A
Check that both stop bars (A) are installed to prevent
the head stock (B) chuck from turning. Remove the tail
stock chuck wings and install the wrench (C) on the tail
JD00632A
stock. Check that the wrench is centred on the chuck
Move the bearing (19) away from the piston (23). and tighten the screws (D).
STEP 17 STEP 19
E
18
JD00633A JD00636A
Push the head stock chuck towards the piston nut (22)
and, if necessary, remove the stop bars (A) and turn the
chuck until the wrench (E) engages the piston nut.
JD00634A
Remove the screws (20) from the piston nut (22). Turn
the cylinder rod and remove the ball (21).

Copyright ©
8012-16
STEP 20 STEP 22
JD00637A JD00639A
Loosen the tail stock chuck screws. Tighten the wrench Start the hydraulic pump by pressing on the pedal to
nuts on the piston nut (22). Check that the wrench is loosen the piston nut. At the end of the stroke, remove
centred by using the scale on the chuck. the two stop bars; if necessary, depress the rear of the
pedal to retract the cylinder rod just enough to enable
STEP 21 removal of the stop bars. Depress the rear of the pedal
to retract the cylinder rod to lower the toggle assembly
B as far as possible on the circular plate then install the
stop bars.
STEP 23
Repeat Step 22, if necessary, until the piston nut has
been loosened.
STEP 24
JD00638A
Lower the toggle assembly (B) as far as possible on the
circular plate and install the stop bars (A).
JD00640A
Remove the piston nut (22) from the rod.

Copyright ©
8012-17
STEP 25 STEP 28
JD00641A JD00644A
Remove the shim (28) from the rod. Remove the two sealing rings (26) from the piston.
STEP 26 STEP 29
24 26 27
23
B
A
47 25
JD00642A JS00645A
Remove the piston (23) then remove the bearing rod. Install the piston (23) in a vice (A) with protective jaws
(B). Using a suitable tool, cut or break the seal ring
STEP 27 (24). Remove the seal ring and discard. Remove and
discard the two back up rings (25). Remove the piston
from the vice.
JD00643A
Remove the two sealing rings (27) from the piston.

Copyright ©
8012-18
STEP 30
JD00647A
JD00646A Use a suitable tool to remove the O-ring (47). Scrap the
O-ring.

Copyright ©
8012-19
STEP 31
34 33
38 35
40
37 36 A 39
JS00649A
JD00650A JD00652A
Remove and discard the O-ring (33) and back up ring
(34). Remove and discard the back up ring (37) and the
seal (36). Remove and discard the buffer ring (A)
consisting of a ring (35). Remove and discard the wiper
ring (38).
STEP 32
40
JD00651A
39
JS00653A
With a suitable tool, remove the retaining ring (39) from
the bearing. Place the bearing on a press and with a
suitable drift, force the ring (40) out of the bearing.

Copyright ©
8012-20
STEP 33 Inspection
NOTE: The bucket cylinder does not incorporate a seal STEP 1
on the cushion ring.
Inspect the seals, U-rings, back up rings, and O-rings
Remove and discard the seal (41) from the cushion ring prior to installation for any imperfections, tears, or other
(42). Remove the cushion ring (42). damage. If the seals or the bushings are worn out or
STEP 34 damaged, replace the component(s). Ensure seals and
bushings are installed correctly with no twisting of the
NOTE: Do the following step only if inspection indicates seal or bushing. Install all new seals and rings wet with
that the bushings (44) require replacement. hydraulic oil.
STEP 2
44 Check the sliding parts for wear or damage such as
scratches, dents, or bent parts. Small scratches can be
43 removed with a hone or crocus cloth.
STEP 3
Check for cracks in the welding or other damage.
STEP 4
Measure the internal diameter of the bushings (44). If
the internal diameter of the bushings is greater than the
specifications, replace the bushing(s).
JD00654A
43
44
JD00655A
Remove the four wipers (43) from the cylinder rod and
cylinder barrel. Use a suitable press and drift and
remove the two bushings (44) from the cylinder rod and
cylinder barrel.

Copyright ©
8012-21
Assembly STEP 3
steps refer to boom cylinder, dipper cylinder and bucket 40
cylinder schematics in this section on pages 6, 8 and
10.
STEP 1
43
44
19
JS00659A
Using a suitable press and drift, install the bushing (40)
in the bore of the bearing (19).
JD00655A STEP 4
43
40
44
39
JD00654A JS00653A
Using a suitable press and drift, install the two bushings Install the retaining ring (39) in the groove of the
(44). Install the four new wipers (43) with the lip side of bearing (19).
the wipers facing out.
STEP 2
NOTE: The bucket cylinder does not incorporate a seal
in the cushion ring.
Install the cushion bushing (42) on the cylinder rod (45).
Install a new seal (41) in the cushion bushing.

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8012-22
STEP 5
JD00650A
JD00652A Install a new O-ring (33) and back up ring (34). Install a
new wiper ring (38). Install a new U-ring (36) and back
up ring (37). Install a new buffer ring (A), consisting of a
ring (35).
JD00651A
34 33
38 35
40
37 36 A 39
JS00649A

Copyright ©
8012-23
STEP 6 STEP 8
JD00647A JD00642A
Install the bearing (19) then the piston (23) on the
cylinder rod.
STEP 9
JD00646A
Coat a new O-ring (47) with clean hydraulic oil. Install
the O-ring in the centre groove of the piston.
STEP 7 JD00641A
Install the shim (28) on the piston rod behind the piston.
24 26 27 STEP 10
23 B
A
47 25
JS00645A
(A) VICE
(B) HARD WOOD
JD00640A
Place a tapered tool over the piston (23). Coat a new Install the piston nut (22) on the cylinder rod and hand
seal ring (24) with clean hydraulic fluid. Slide the seal tighten.
onto the tool and install it in the groove of the piston on
top of the O-ring (47). Install two new back up rings
(25). Install four new sealing rings (26) and (27) in the
grooves of the piston.

Copyright ©
8012-24
STEP 11 STEP 13
Carry out Steps 4 to 12 of disassembly to install the
cylinder rod in the repair stand. A
STEP 12 C
B
JD00660A
Remove the toggle assembly (A) and the cylinder (D)
on the RH side of the repair stand, by removing the
stop bars (B) and the pins (C). Install the toggle
JD00637A
assembly and cylinder (D) on the left side of the repair
stand. Operate the hydraulic pump by depressing the
foot pedal to extend the rod end of the hydraulic
E
cylinder to rotate the circular plate clockwise to tighten
the piston nut. At the end of the stroke, remove the two
stop bars; if necessary, depress the rear of the pedal to
retract the cylinder rod just enough to enable removal
of the stop bars. Depress the rear of the pedal to retract
the cylinder rod to lower the toggle assembly as far as
possible then install the stop bars. Repeat this step as
required to tighten the piston nut to torque (see
"Specifications").
JD00636A
Carry out Steps 19 to 21 of disassembly to install
wrench (E) on the piston nut (22).

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8012-25
STEP 14 STEP 16
JD00634A JD00637A
Loosen the nuts to remove the wrench from the piston
nut (22). Move the repair stand support away from the
cylinder rod.
STEP 17
JD00633A
Install the steel ball (21) in the piston nut (22). Install
the screw (20) in the nut. Tighten the screws to torque
(see "Specifications").
STEP 15 JD00662A
Using suitable means of lifting, install the tube on the
repair stand in order to align the cylinder rod (45) and
the bearing. Install the tube and the bearing (19) by
aligning the markers.
A
20
21
JS00661A
(A) AWL
After tightening the screw (20) to the required torque,

caulk the screw at two places.

Copyright ©
8012-26
STEP 18 STEP 21
Dipper cylinder
1. Install the circlips (17) on the cylinder, using
washers (16) and screws (15). Tighten the screws to
torque (see "Specifications").
2. Install the hydraulic pipes (8) and (10) on the circlips
(17), using clamps (7), washers (6) and screws (5).
Tighten the screws to torque (see "Specifications").
3. Install the two new O-rings (9) and (11) on the
cylinder. Connect the hydraulic pipes (8) and (10) to
JD00630A
Install the screws (18) and tighten to torque. the cylinder using the screws (4). Tighten the
screws to torque (see "Specifications").
STEP 19
4. Install the new O-ring (3) on the pipe (8). Install the
Attach a suitable lifting device to the cylinder. Remove plug (2). Tighten the plug to torque (see
the screws and chuck wings to free the cylinder from "Specifications").
the repair stand.
5. Install the grease fitting (1) in the cylinder.
STEP 20 STEP 22
Boom cylinder Bucket cylinder
NOTE: The numbers within brackets in the following steps
steps refer to the boom cylinder schematic on page 6.
refer to the bucket cylinder schematic on page 10.
1. Install the circlip (17) on the cylinder, using washers
1. Install the circlip (17) on the cylinder barrel, using
(16) and screws (15). Tighten the screws to torque
washers (16) and screws (15). Tighten the screws to
(see "Specifications").
torque (see "Specifications").
2. Install the two hydraulic tubes (8) and (10) on the
2. Install the hydraulic pipes (8) and (10) on the circlip
circlip (17), using clamps (7), washers (6) and
(17), using clamps (7), washers (6) and screws (5).
screws (8). Tighten the screws to torque (see
"Specifications").
3. Install the two new O-rings (9) and (11). Connect
3. Install two new O-rings (9) and (11) on the cylinder.
the hydraulic pipes (8) and (10) to the cylinder and
Connect the hydraulic pipes (8) and (11) to the
fasten the pipes with screws (4). Tighten the screws
cylinders. Fasten the pipes using screws (4).
to torque (see "Specifications").
4. Install the grease fittings (1) in the cylinder.
4. Install two new O-rings (3) on the pipes. Install two
plugs (2) and tighten the plugs to torque (see
"Specifications").
5. Install the grease fitting (1) in the cylinder.

Copyright ©
Section
8013
8013

OF THE CONTROL LEVERS

Printed in France
Copyright ©
8013-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
CONTROL LEVER ......................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
STRUCTURE ................................................................................................................................................................. 4
FUNCTIONS .................................................................................................................................................................. 4
OPERATION .................................................................................................................................................................. 5
CONTROL LEVER ......................................................................................................................................................... 7
Disassembly ............................................................................................................................................................... 7
Inspection ................................................................................................................................................................. 10
Assembly ................................................................................................................................................................. 11
TROUBLESHOOTING ................................................................................................................................................... 5
SPECIFICATIONS
Torque settings
Orifice plate retaining screws ..................................................................................................................20.6 ± 1.5 Nm
Universal joint on control lever ................................................................................................................47.1 ± 2.9 Nm
Lock-nut on universal joint ......................................................................................................................68.6 ± 4.9 Nm
Primary pressure Maximum pressure 6.9 MPa

Secondary pressure 0 to 4.4 (Maximum control pressure) MPa
Allowable back pressure Maximum 0.3 MPa
Rated flow 20 L/min
Operating inclination ± 19°, ± 25° (single)
Mass 1.9 kg
Piping To obtain better response, suitable piping is inner diameter 8, length 3 M. In addition,
the return oil should be directly returned to the tank to avoid the influence of back
pressure.

Copyright ©
8013-3
CONTROL LEVER
Description
20
3
19
4
5
6
17 8
18 9
22 10
11
12
16
15
13
21
14
18
CRPH06B059G01
1 LOCK-NUT 14 HEXAGONAL ALLEN-TYPE SCREW
2 PROTECTIVE BOOT 15 O-RING
3 DISC 16 BUSHING
4 PUSH-ROD 17 PUSH-ROD
5 PLATE 18 SEAL WASHER
6 PLUNGER ASSEMBLY 19 LIP-SEAL
7 O-RING 20 UNIVERSAL JOINT
8 SPRING SEAT 21 PLASTIC PIN
9 SPRING 22 WASHER
10 SPRING
11 SPOOL
12 CONTROL LEVER BODY
13 ORIFICE PLATE

Copyright ©
8013-4
STRUCTURE
The structure of a pilot valve is as shown in the assembly sectional drawing. The casing has openings along the vertical
axis, in which pressure reducing valves are integrated.
The pressure reducing valve section consists of spools (201), springs (241) for setting secondary pressure, return
springs (221), spring seats 1 (216) and washers 2 (217). The spring (241) for setting secondary pressure is configured
to obtain reduced secondary pressures of 0.49 to 0.98MPa (depending on models). The spool (201) is pushed against
the push rod (212) by the return spring (221).
As the push rod (212) is pressed down when the operating part of the handle is inclined, the spring seat 1 (216) is also
lowered at the same time, as a result, the settings of the spring for setting secondary pressure (241) change.
The casing (101) and port plate (111) have oil entry ports P (Primary pressure) and exit ports T (Tank), and the
secondary pressure is delivered from the ports 1, 2, 3 and 4.
FUNCTIONS
1) Basic functions
The pilot valve is a valve designed for controlling the strokes and directions of the control valve spool. This is achieved
by acting output pressures from the pilot valve on the end of the control valve spool.
To meet requirements for this function, the pilot valve is composed of the following segments:
Entry port (P) through which the hydraulic pump supplies oil
Multiple output ports (1, 2, 3 and 4) which are designed to apply pressure supplied from the entry port on the end of
spool in the control valve.
Tank port (T) which is required to control the output pressures described above.
Spool which connects an output port to the entry port or tank port.
Mechanical measures including springs which act on the spool described above in order to control output pressure.
2) Major component functions
The function of the spool (201) is to receive pressure oil supplied from the hydraulic pump at the port P, and by switching
the oil paths, to introduce the pressure oil at port P to output ports (1, 2, 3 and 4) or introduce to port P. It is the role of
the spring for setting secondary pressure (241) to determine output pressure by acting on this spool (201).
The push rod (212) is inserted in the plug (211) so that it can slide and change the deflection of the spring for setting
secondary pressures (241).
The return spring (221), regardless of the output pressure, acts on the casing (101) and spring seat (216) to return the
push rod (212) in the direction of zero displacement, ensuring that the spool (201) can return to its neutral position. This
return spring also functions as reaction spring, to give good operational responsiveness.

Copyright ©
8013-5
OPERATION
This section describes the operation of pilot valves based on the Hydraulic Oil Circuit Drawing (Figure 1) and Operation
Description Diagrams (Figures 2 through 4). Figure 1 shows a typical usage of the pilot valve.
Figure 1. An example of pilot valve use
5 6
4
2
CRPH06B106E
1 PILOT VALVE 4 CONTROL VALVE
2 PILOT PUMP 5 HYDRAULIC MOTOR
3 MAIN PUMP 6 HYDRAULIC CYLINDER
1) When the handle is in neutral (Figure 2)

The force of the spring for setting secondary pressures (241), which
determines the output pressure on the pilot valve, is not applied on the
spool (201). Therefore, the spool (201) is pushed upward by the return
spring (221) (by the spring seat 1 (216)), the output ports (2, 4) are
connected with the port T. At this moment, the output pressure is equal
to the tank pressure.
216
241
221
201
000-7-06-01-15B

Copyright ©
8013-6
2) When the handle is inclined (Figure 3)
As the push rod (212) is pushed in by inclining the handle, the spool
(201) (spring seat 1 (216)) moves downward and the port P and ports
(2, 4) are connected. As a result, the oil supplied from the pilot pump
flows into ports (2, 4), thus generating pressure.
212
216
201
000-7-06-01-15c
3) When the handle is held (Figure 4)
When the pressures at ports (2, 4) rise up to a pressure equivalent to
the force of the spring (241), which was set by inclining the handle, the
hydraulic force and the force of the spring are in balance. When the
pressures at ports (2, 4) are more than the set pressure, ports (2, 4)
and port P close and ports (2, 4) and port T open. When the pressures
at ports (2, 4) are less than the set pressure, ports (2, 4) and port P
open and ports (2, 4) and port T close. As a result, secondary
pressures are maintained constantly.
(T) Port T
(P) Port P
241
000-7-06-01-15d
4) Operation in ranges where the handle is greatly

inclined (depends on models)
In some models, when the handle is inclined more than a given degree, the upper end of the spool touches the bottom
part of the push rod bore and the output pressure remains equal to the port P pressure as connected.
What's more, if a structure where the spring seat and spring are integrated in the inside of push rod is used, when the
handle is inclined more than a given degree, the bottom part of the push rod bore contacts the spring, and the force of
the spring causes the secondary pressure gradient to change. Afterwards, the bottom part of the push rod bore
contacts the upper end of the spring seat; thus the output pressure remains equal to the port P pressure as connected.

Copyright ©
8013-7
CONTROL LEVER
Disassembly STEP 3
NOTE: The numbers in brackets in the following steps
refer to the schematic on page 3.
Always handle high precision parts with the greatest
care to prevent them being damaged by being knocked
or dropped. The components of the control lever may
rust due to contamination and humidity if they are left
without protection after disassembly. If work has to be
stopped, the components must be protected against
contamination or corrosion.
STEP 1
CD00G089
Remove the disc from the control lever.
STEP 4
CD00G087
Install the control lever in a soft-jawed vice. Remove the
protective boot.
STEP 2
CRPH06B110A
CD00G088
Remove the lock-nut from the control lever.
CRPH06B111A
Used the special tool 380001055.
Install two nuts on the universal joint and tighten them
fully. While holding the upper nut, turn the lower nut
anti-clockwise to unscrew the universal joint. Remove
the universal joint from the control lever.
NOTE: Carefully remove the universal joint to prevent
the plate and the push-rods, which are under pressure
from the springs, from flying out too quickly.

Copyright ©
8013-8
STEP 5 STEP 7
CD00G091 CD00G093
Remove the plate. Remove the spool assembly from the control lever.
NOTE: Mark the components removed in the following STEP 8
steps to facilitate their insertion in the correct bore
during assembly.
STEP 6
CD00G094
Turn the control valve the other way up in the vice.
Unscrew and remove the six screws and the sealing
washers.
CD00G092
Depending on the condition of the return springs, the STEP 9
friction of the O-rings can keep the plunger assemblies
in place in the body. In this case, use a flat screwdriver
to remove the plunger assemblies. Slide the
screwdriver into the external groove of the plunger
assembly, taking care not to damage the plunger
assembly. This must be done carefully, since the
plunger assembly can be thrown out suddenly, due to
the action of the return springs.
CD00G095
Remove the orifice plates and the O-ring from the body.
Scrap the O-ring.

Copyright ©
8013-9
STEP 10 STEP 12
JD00774A CD00G098
Remove the bushing from the body of the control lever. Remove the spool (17) and the spring (18) from the
plunger assembly (6).
STEP 11
STEP 13
CD00G096
CD00G099
Remove the push-rod (4) from the plunger assembly
(6).
STEP 14
CD00G097
Press the spring down a few millimetres so as to free
the spool (11) from the spring seat (8). Separate the
spool (11) from the spring (10) and the washer (22).
Keep these components together for the reassembly CD00G100
procedure. Remove and scrap the plunger assembly O-ring.

Copyright ©
8013-10
STEP 15 Inspection
Change all the seals and O-rings which have been
removed. Also change the washers on all screws which
have been removed.
STEP 1
Inspect the spools to ensure that the finish is not
damaged, that they are not bent or damaged in any
other manner. Make sure that the spool slides freely in
the control valve body bore. If defects are found,
change the entire control valve.
STEP 2
CD00G101
Remove and scrap the plunger assembly seal.
STEP 16
Cleaning the components:
1. Soak them in a suitable cleaning solvent until
contamination and oil are removed. Components can
be damaged if they are washed while they are still
contaminated.
2. Final washing: Immerse the components in a clean
receptacle containing a suitable cleaning solvent.
Impart a rotary motion to the receptacle so as to wash
JS00784A
the inner surface of the components as well. Dry the Inspecting the controls. Change the components if
components with a clean cloth. wear on the shaft pin and seal create play in the
NOTE: Never dry them with compressed air. Dust and controls greater than 2 mm.
water contained in the air will damage and corrode their STEP 3
surfaces.
If it is impossible after inspection of the parts to
3. Corrosion prevention: Apply an anti-rust product to
determine the cause of an abnormal noise or a
all the components.
reduction in primary pressure, change the control lever.
NOTE: Components can rust if left in the open air after
cleaning.

Copyright ©
8013-11
Assembly STEP 3
Carry out the assembly with the very greatest care. Do
not hit or force the components, since that will damage
them and cause seizure or oil leaks which would result
in impaired performance of the machine. Before
reassembly, remove all traces of metal particles or
foreign bodies from all components. Check that there
are no burrs on the components and remove them with
an oil stone. Replace all O-rings and thrust rings with
new components. Lubricate the O-rings and thrust
rings to prevent any damage during assembly. Tighten
all cap screws to the specified torque. Plug all orifices
with plugs to prevent any contamination of the control A
lever by dust after reassembly.
CD00G103
Install the orifice plate (13) with the plastic pin (21) in
STEP 1
the orifice (A) in the control lever body.
STEP 4
JD00774A
Install the control lever body bushing.
STEP 2 CD00G104
Install the hexagonal Allen-type cap screws and the
sealing washers in the orifice plate (13). Tighten the
screws and retighten them alternately to a torque of
20.6 ± 1.5 Nm.
STEP 5
CD00G102
Install the O-ring in the groove in the control lever body.
CD00G105
Assemble the spool assembly by installing the washer
(22), the spring (10) and the spring seat (8) on the
spool (11).

Copyright ©
8013-12
STEP 6 STEP 8
CD00G106 CD00G108
Turn the control lever the other way up in the vice.
Install the return spring and the complete spool
assembly in the body, respecting the positions noted
during steps 5 to 7 (disassembly).
STEP 7
19
CI00G509
Install the lip seals (19) with their ends as shown above.
STEP 9
CD00G107
Install the O-ring on the plunger.
CD00G109
Coat the surfaces of the push-rod (4) with hydraulic
fluid and install it in the plunger (6).

Copyright ©
8013-13
STEP 10 STEP 13
CD00G110 CD00G112
Install the spool (17) and the spring (18) in the plunger Install the plate and retain it by means of the universal
(6). joint.
STEP 11 STEP 14
CD00G111 CRPH06B110A
Install the plunger in the body. Depending on the
condition of the return springs, the friction of the
O-rings may keep the plungers in place in the body.
STEP 12
Repeat steps 5 to 11 for the other three bodies.
CRPH06B111A
Used the special tool 380001055.
Tighten the universal joint to a torque of 47.1 ± 2.9 Nm
(34.7 ± 2.1 lb-ft).

Copyright ©
8013-14
STEP 15 STEP 17
CD00G113 CD00G115
Install the disc on the universal joint. Tighten until the Place a few spots of grease on the push-rods.
disc touches the four push-rods equally.
STEP 18
STEP 16
CD00G116
CD00G114
Install the protective boot (2) on the control lever.
Install the lock-nut and tighten it to a torque of
68.6 ± 4.9 Nm while holding the flats on the disc (3)
with a flat wrench.

Copyright ©
8013-15
TROUBLESHOOTING
It is not easy to find the faulty part. The following table lists some possible problems. As repairs are not easy, refer to the
possible causes and countermeasures in the table.
The table below shows general symptoms/possible causes and countermeasures. However, as a machine's trouble is
generally caused not by a single faulty component but by other related components as well, it may be necessary to
apply measures other than those listed in the Table.
The table shown below does not necessarily include all possible causes and remedies. Therefore, the technician in
charge of repairs must further investigate problems and their causes as necessary.
Problem Causes Countermeasures

Secondary pressure doesnot rise. 1.Lower primary pressure Ensure given primary pressure
2.Breakage and fatigue of secondary Replace with new one
pressure spring (241)
3.Abnormally large gap between Replace as a remote valve complete
spool (201) and casing (101) assembly
4.Loose handle section Disassemble/assemble and replace
handle section
Unstable secondary pressure 1.Engaged sliding part Repair engaged part
2.Fluctuations in tank line pressure Direct return to oil tank
3.Entrapped air in piping Bleed air by several operations
High secondary pressure 1.High tank line pressure Direct return to oil tank
2.Engaged sliding part Repair engaged part

Copyright ©
8013-16
NOTES
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Copyright ©
Section
8014
8014
OF THE CONTROL PEDALS

Printed in France
Copyright ©
8014-2
TABLE OF CONTENTS
TORQUE SETTINGS ..................................................................................................................................................... 2
CONTROL PEDAL ......................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
FOOT CONTROL ........................................................................................................................................................... 4
Disassembly ............................................................................................................................................................... 5
Inspection ................................................................................................................................................................... 6
Assembly ................................................................................................................................................................... 6
TORQUE SETTINGS
Cover retaining screws .............................................................................................................................53.9 to 63.7 Nm
Cam articulation pin locking screw (apply Loctite 241) ............................................................................13.3 to 16.1 Nm
Cap screw ....................................................................................................................................................3.9 to 5.8 Nm

Copyright ©
8014-3
CONTROL PEDAL
Description
5
7 6
9 10
3
11
8 12 4
2
13 30
14 19
15
21
16
20
17
22
18
25
23
24 26
27
1 28
29
CS02A503
1 BODY 16 PISTON
2 COVER 17 SPRING
3 LOCKING SCREW 18 SPRING
4 CAM SHAFT 19 SPRING SEAT
5 BOOT 20 BALL
6 BUSHING 21 RETAINER
7 CAM 22 BUSHING
8 BRAKE NUT 23 WASHER
9 SCREW 24 SPRING SEAT
10 RETAINING SCREW 25 SPRING
11 CAP 26 COMPRESSION SPRING
12 RETAINER 27 WASHER
13 PLUG 28 WASHER
14 O-RING 29 SPOOL
15 CONTROL ROD 30 PLUG

Copyright ©
8014-4
FOOT CONTROL
In neutral the foot control is a closed center hydraulic valve. The inlet oil from the pilot pump is blocked at both
regulator spools. The ports (1) and (2) are ported inside of the valve back to tank through a hole drilled
in the end, and a cross drilled hole in the regulator spool.
There are two springs for each regulator spool. The larger diameter spring provides the
return of the foot pedal and this spring is the resistance the operator feels in his foot.
Typically the return springs are stronger in foot control than in hand control.
If the dust cover under the foot control is torn, replace it. This will help prevent contamination from wearing
the U-seals on the push rods.
The gap between the push rod and the screw can be adjusted. A too tight adjustment can cause partial
actuation of the spool. The contact area between the push rod and the screw should be lightly lubricated
with grease.
As the foot control is moved, the push rod will push on both large and small diameter springs. The
smaller spring will push the spool and block of the return passage through the top meetering notches.
The bottom metering land will open a passage and allow pilot oil out to the work spool of the travel control spool.
As the travel spool moves and compresses the spring in the control valve, the pressure will increase and push up
on the bottom of the regulator spool. When the pressure of the oil pushing on the travel spool equals the
force of the spring behind the regulator spool the bottom metering land will block the pilot supply. When
the force of the spring equals the force of the pressure on the spool, the spool is in a balanced
position to maintain a proportional pressure with the compression of the spring.
The foot control must be moved further to compress the small spring and push the regulator spool
further to increase the pressure again.
The foot control is nothing more than an adjustable pressure regulator, and the operator provides adjustment.

Copyright ©
8014-5
Disassembly STEP 10
Always handle high precision parts with the greatest Remove the O-ring (14) from the plug (13).
care to prevent them being damaged by being knocked
or dropped. The components of the control pedal may
STEP 11
rust due to contamination and humidity if they are left Remove and label the control rod (15), as well as the
without protection after disassembly. If work has to be piston (16).
stopped, the components must be protected against
contamination or corrosion. STEP 12
NOTE: The numbers in brackets in the following steps Remove the springs (17), (18), the spring seat (19), the
refer to the description on page 3. ball (20), the retainer (21) and the bushing (22).
NOTE: Clean around the foot control pedal and take STEP 13
care to prevent any foreign material entering the sys-
Remove the washer (23) and the spring seat (24).
tem.
STEP 14
STEP 1
Remove the spring (25) and the compression spring
Tighten the control pedal in a vice with protective jaws.
(26).
Remove the bellows (5).
STEP 15
STEP 2
Remove the washers (27) and (28).
Remove the locking screw (3) from the cam shaft.
STEP 16
STEP 3
Remove and mark the spool (29).
Remove the cam shaft (4) using a drift, as well as the
ring (6). STEP 17
STEP 4 Remove the plug (30).
Identify the position of the cam (7) in relation to the
cover (2) and remove the cam.
STEP 5
Remove the brake nut (8) as well as the screw (9).
STEP 6
Remove the retaining screw (10).
STEP 7
Identify and remove the cover assembly (2).
NOTE: Repeat steps 1 to 7 for the other control pedal
body.
STEP 8
Remove the cap (11) and the retainer (12).
STEP 9
Remove the plug (13).

Copyright ©
8014-6
Inspection Assembly
STEP 1 NOTE: Immerse all parts in clean hydraulic fluid in
order to guarantee proper lubrication when installing
Check for cracks, distortion or blocking of the springs. If and restarting operation.
any one of these defects is found, replace the spring.
STEP 1
STEP 2
Fasten the spool (29) in a vice equipped with soft jaws.
Check the spools to ensure that their finish is not dam- Install the following in the order shown : the washers
aged, that they are not twisted, or chipped etc. Ensure (27) and (28) and the compression spring (26).
that the spools slide smoothly in the bore of the control
pedal body. If defects are found, change the entire con- NOTE: If the installation is performed incorrectly, this
trol pedal. can cause a change in the secondary pressure.
STEP 3 STEP 2
Check the sleeves and the clips to ensure that their fin- Carefully install the spool assembly (29), in the body
ish is not damaged, that they are not twisted, cracked (1), install the spring (25), the spring seat (24) and the
or chipped. If any one of these defects is found, replace washer (23).
the damaged part. NOTE: Repeat steps 1 and 2 for the three other ports of
STEP 4 the control pedal.
Check the bores for damage, internal damage of hous- STEP 3

ings, or signs of internal wear at the level of the control Install the bushing (22), then the ball (20), the retainer
pedal. If the control pedal is damaged, replace the (21), the spring seat (19) and the springs (17) and (18).
entire assembly.
STEP 5 STEP 4
Discard all the O-rings and use new O-rings. Install the piston (16) and the control rod (15) in the
body (1).
STEP 5
Install the O-ring (14) on the plug (13).
STEP 6
Install the retainer (12) in the plug (13).
STEP 7
Install the plug assembly (13) in the body (1).
STEP 8
Install the cap (11) on the plug (13).
NOTE: Repeat steps 1 to 8 for the other control pedal
port.

Copyright ©
8014-7
STEP 9
Assemble the cover assembly (2) on the body (1) in its
original position. Fasten them using screws (10).
STEP 10
Install the screw (9) on the cam (7) using the brake nut
(8).
STEP 11
Assemble the cam (7) on the cover (2). Install the bush-
ing (6) and the cam shaft (4). The surface of the cam
must be parallel with the cover surface (2).
STEP 12
Incline the cam and apply grease to the cam articula-
tion and to the steel ball.
STEP 13
Assemble and tighten the screws (3) to the torque
STEP 14
Assemble the upper portion of the boot on the cam,
apply a humidity inhibitor in the cover groove to avoid
oxidation, then assemble the lower portion of the boot
on the cover.

Copyright ©
8014-8
NOTES
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Copyright ©
Section
8015
DISASSEMPLY AND ASSEMBLY
8015
OF THE SIX SOLENOID VALVES BLOCK

Printed in France
Copyright ©
8015-2
TABLE OF CONTENTS
SIX SOLENOID VALVES BLOCK................................................................................................................................... 3
Assembly Drawing ...................................................................................................................................................... 3
Theory of operation ..................................................................................................................................................... 4
Disassembly and assembly......................................................................................................................................... 5
Inspection.................................................................................................................................................................... 6
Troubleshooting .......................................................................................................................................................... 7

Copyright ©
8015-3
SIX SOLENOID VALVES BLOCK
Assembly Drawing
Normally closed type solenoid: SP, S1, S3, S4, S5 Normally open type solenoid: S2
1. BODY 12. BINDING BAND

2. SPOOL 13. BINDING BAND
3. SPOOL 14. BINDING BAND
4. SPRING 15. BINDING BAND
5. SPRING 16. SOLENOID
6. ADAPTOR 17. O-RING
7. SNAP RING 18. SCREW
8. NAME PLATE 19. PLUG
9. SPRING WASHER 20. PLUG
10. BINDING BAND 21. RIVET
11. BINDING BAND

Copyright ©
8015-4
Theory of operation
The hydraulic fluid supplied from the port P is fed to the solenoid operated directional valves S1 to S5 when the valve
SP is energized. The hydraulic fluid is then fed to the ports C1 to C5 depending on whether or not the valves S1 to S5
are energized.
Electromagnetic selector valves S1, S3, S4 and S5:
Oil passes through when energized
Electromagnetic selector valve S2:
Oil passes through when not energized

Copyright ©
8015-5
Disassembly and assembly
TIGHTENING
TORQUE
1.7 TO 2.0 Nm
O-RING
SO - NA - A022
TIGHTENING
TORQUE
1.7 TO 2.0 Nm
O-RING
SO - NB - P18
ELECTRONIC SELECTOR VALVE SP, S1, S3, S4, S5 => ITEM N° (2) ASSEMBLY
ELECTRONIC SELECTOR VALVE S2 => ITEM N° (3) ASSEMBLY
NOTE: Disassemble the valve with due attention not to STEP 4

damage the O-ring and other parts, and store the parts
Pry the snap ring (7) off by inserting a flat head
in a safe place.
screwdriver or the like in the notch, and remove the
If there is any flaw on the O-ring, replace it with a new
adapter (6).
one.
Be careful to assemble the parts in the correct STEP 5
orientation and without forgetting any of the parts. Assemble the valve by reversing the order of
When assembling, reverse the order of disassembling disassembling.
and pay attention not to allow any foreign matters such When tightening the core, pay attention not to damage
as dirt to get into the valve. the edges of the flat portion of the core.
When mounting the adaptor, apply grease or other
STEP 1 appropriate lubricant to the O-ring (B) and pay attention
Remove the mounting bolts from the solenoid (C) and
not to damage the O-ring.
remove the coil part.
(Tool: 3 mm Hexagon wrench)
STEP 2
Remove the tube, while paying attention not to damage
the edges of the flat portion of the core. However, if the
core is removed, replace the O-ring (A) with a new one.
(Tool: 23 mm spanner)
STEP 3
Take out the spools (2) and (3) and the springs (4) and
(5).

Copyright ©
8015-6
Inspection
1. Clean all parts using suitable cleaning solvent.

Immerse the solenoid valve housing in a cleaning
solvent for several minutes to dissolve dirt or other
foreign matter inside the solenoid valve housing.
Use low pressure compressed air to blow out any
foreign matter from interior of valve housing. Dry
parts using clean cloths.
2. Inspect springs for cracks, distortion, or evidence
of permanent mis-setting. Replace a spring if any
of these defects are observed.
3. Check for cracks, holes, deformities and other
signs of wear on the spools. Check that the spools
slide easily in the bores of the solenoid valve block.
If any of the above conditions is seen, replace the
solenoid valve block.
4. Check that the internal threading is not worn out
and that the interior of the solenoid valve block
shows no signs of wear. If any of the above
conditions is seen, replace the solenoid valve
block.
5. Measure the play between the spool groove and
the spool. The clearance =ØD - Ød must be
approximately 0.01 mm. If this is not the case,
change the solenoid valve block.

Copyright ©
8015-7
Troubleshooting
Problem Cause Action

Spool malfunction Foreign matters galling the spool Remove the foreign matters, dismount the
valve, perform flashing, or replace the fluid.
Damaged parts or abnormal wear Replace the valve.
Solenoid malfunction Terminal disconnection Insert the terminal.
Damaged coil Replace the solenoid.
Broken lead wire
Fluid leakage to outside Loose bolts Tighten the bolt to the specified torque.
Damaged O-ring Replace the O-ring.
Loose hex socket plug Fasten the plug.

Copyright ©
8015-8
NOTES
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Copyright ©
Section
8016

OF THE CUSHION CONTROL VALVE
8016

Printed in France
Copyright ©
8016-2
TABLE OF CONTENTS
SPECIAL TORQUE ....................................................................................................................................................... 2
CUSHION CONTROL VALVE ...................................................................................................................................... 3
Description ................................................................................................................................................................. 3
System drawing ......................................................................................................................................................... 4
Changed over to "SOFT" ........................................................................................................................................... 5
Arm OUT, operating ................................................................................................................................................... 6
Arm OUT, stopped ..................................................................................................................................................... 7
Changed over to "SOFT" ........................................................................................................................................... 8
Disassembly .............................................................................................................................................................. 9
Inspection ................................................................................................................................................................ 11
Assembly ................................................................................................................................................................. 11
SPECIAL TORQUE
Plug (7).................................................................................................................. 60 Nm to 70 Nm (44.25 to 51.63 lbf-ft)
Plug (8).................................................................................................................. 40 Nm to 50 Nm (29.50 to 36.88 lbf-ft)

Copyright ©
8016-3
CUSHION CONTROL VALVE
Description
Identifying the ports
10 11 12 13
9
6 4 3 2 16 14 5 1
15 17
1 CONTROL VALVE HOUSING 10 SPRING

2 SPRING 11 SPRING GUIDE
3 SPOOL 12 O-RING
4 SPRING 13 SPOOL
5 SPOOL GUIDE 14 PLUG
6 O-RING 15 SPOOL
7 FLOW RESTRICTION ADAPTATER 16 SPOOL
8 PLUNGER ASSEMBLY 17 SPOOL
9 O-RING
NOTE: The cushion control valve can have a machined or moulded body. This manual deals with only the machined
body.

HYDRAULIC
8016-4
OIL TANK
ARM BOOM
Lep SM4608016-0EN
CONTROL VALVE CONTROL VALVE
System drawing
CUSHION VALVE LINE FILTER
SOLENOID VALVE
PILOT GEAR PUMP
CUSHION SWITCH
REMOTE
CONTROL VALVE
ARM
THROTTLE b REMOTE
THROTTLE c CONTROL VALVE
CLOSED
THROTTLE a UP
OPEN THROTTLE d BOOM
DOWN
Issued 09-07
Copyright ©
Copyright ©
8016-5
Changed over to "SOFT"
Lever in Neutral
(1) The heat oil separated from the oil cooler line enters the cushion valve Port R.
(2) Then, the oil passes the reverse notch spool and goes through passages e and f. After passing the outer circumfer-
ence of each cushion spool, the oil returns to the hydraulic oil tank via Port T of the cushion valve.
REVERSE NOTCH SPOOL
THROTTE b
THROTTE c
CUSHION SPOOL THROTTE d
THROTTE a
CUSHION SPOOL

Copyright ©
8016-6
Arm OUT, operating
(1) Pilot pressure enters the cushion valve at Port A from the remote control valve. As this pilot pressure enters the left
end of the cushion spool and the left end of the reverse notch spool, each spool moves to the right.
(2) The pilot pressure in the cushion spool enters the chamber g via the spool opening.
Then, the pressure passes the outer circumference of the reverse notch spool and goes into the control valve via Port C.
(3) The pilot pressure return oil from the control valve passes the outer circumference of the reverse notch spool and
goes into the chamber f via Port D. Then, the oil passes the outer circumference of the cushion spool and returns to the
hydraulic oil tank through Port T.
(4) At this time, as the reverse notch spool is switched over to the right, the passages e and f are closed to the heat oil
at the Port R. Therefore, the oil passes passage h and enters the left end of the cushion spool. The heat oil passes the
cushion spool throttles c and d and enters the remote control V via Port B. (The heat oil releases the remote control
valve).
TO CONTROL VALVE FROM CONTROL VALVE
TO HYDRAULIC TANK
FROM TO
REMOTE CONTROL REMOTE CONTROL
VALVE VALVE
THROTTE c
THROTTE d
CUSHION SPOOL CUSHION SPOOL

TO HYDRAULIC TANK
ARM OUT, OPERATING

Copyright ©
8016-7
Arm OUT, stopped
1) As the pilot pressure from the remote control valve stops, the reverse notch spool returns to the neutral position.
2) The cushion spool also returns to the neutral position and the pilot return oil from the control valve passes the throt-
tles a and b. Due to the differential pressure between the front and back of trottle, the cushion spool is moved to the left
and as a result, the pilot return oil is restricted by trottle a.
3) Due to this restricting effect, the spool of the main control valve returns gradually to the neutral position.
FROM CONTROL VALVE
TO
REMOTE CONTROL
VALVE THROTTE b
THROTTE a
CUSHION SPOOL
Arm OUT, stopped

Copyright ©
8016-8
Changed over to "HARD"
When the cushion switch is changed over to "HARD" position, the solenoid valve is changed over. The pilot pressure
(3.92 MPa) from the gear pump enters the cushion valve at Port S.
All the cushion spools (for booms and arms, 4 positions in total) are forcedly changed over to the inside.
FROM CONTROL VALVE FROM CONTROL VALVE
REVERSE NOTCH
SPOOL
FROM
FROM CUSHION SPOOL CUSHION SPOOL
REMOTE CONTROL ARM IN, STOPPED
SOLENOID
VALVE VALVE
As the cushion spools are forcedly pushed down, when the arm is OUT, both in operation and not in operation, the pilot
pressure goes through the inside of the cushion valve without passing the throttle.
The heat oil from Port R returns to the hydraulic oil tank via Port T when the lever is in neutral. While the lever is being
moved, the oil flows to the remote control valve.

Copyright ©
8016-9
Disassembly STEP 4
steps refer to the schematic on page 3.
STEP 1 10
13
7
7
JD00552A
Remove the spool (13) and the spring (10) from the
control valve.
STEP 5
JD00549A
If the cushion control valve has to be replaced, remove 11
the adaptors and elbow unions and install them on the
new control valve. Do not remove the four flow restric-
tion adapters (7) installed in the sides of the valve.
13
NOTE: Mark parts to ensure correct assembly in same
valve bore as removed from.
STEP 2
10
9
JD00553A
8 NOTE: Removal to be carried out in case of a leak
between the spool (13) and the spring guide (11).
Put the spool (13) in a vice using wooden shims to pro-
tect the spool. Remove the spring guide (11) from the
spool (13).
JD00550A
Remove the plug (8) with the O-ring (9) and the spring
(10).
STEP 3
10
8
9
JD00551A
Remove the spring (10) and the O-ring (9) from the
plug (8). Scrap the O-ring.

Copyright ©
8016-10
STEP 6 STEP 10
11
12
4
JD00554A JD00557A
Remove the O-ring (12) from the spring guide (11). Remove the spring (4).
Scrap the O-ring.
STEP 11
STEP 7
Repeat steps 2 through 6 for the other spool.
3
STEP 8
5
A
6
7 JD00558A
Install an M4 cap screw (A) in the tapped hole of the
spool (3). Remove the spool (3) with the spacer (5) and
the spring (2). Remove the M4 cap screw.
JD00555A STEP 12
Remove the flow restriction adaptor (7) and the O-ring
(6).
3
STEP 9
2
6
5
7
JD00559A
Remove the spring (2) and the spacer (5) from the
spool (3).
JD00556A STEP 13
Remove and discard the O-ring (6) and the flow restric-
tion adaptor (7). Repeat steps 9 through 12 for the remaining three
spools.

Copyright ©
8016-11
Inspection Assembly
STEP 1 NOTE: The numbers within brackets in the following
Clean all parts using suitable cleaning solvent.
Immerse valve housing in cleaning solvent for several NOTE: Lubricate all parts with clean hydraulic oil.
minutes to dissolve dirt or other foreign matter inside Ensure that parts are assembled in the same groove as
valve housing. Use low pressure compressed air to they were removed from.
blow out any foreign matter from interior of valve hous-
STEP 1
ing. Dry parts using clean cloths.
STEP 2 3
Inspect springs for cracks, distortion, or evidence of
permanent set. Replace a spring if any of these defects
are observed.
STEP 3
Check the spools for cracks, holes, distortion or other
damage. Check that the spools slide easily in the
groove of the control valve housing. If any defects are 5
observed replace the cushion valve.
STEP 4
JD00559A
Check the plugs, flow restriction adapters, and spring Install the spacer (5) on the spool (3).
guides for damaged threads. Check the ports in flow STEP 2
restriction adapters for foreign matter, chipping, or other
damage. Check spring guides for bent condition.
Replace a defective part.
STEP 5
Check the spacer for chipping, wear and signs of dam-
age. If any of these conditions are seen replace the
2
spacer.
STEP 6 3
Check for damaged threads and signs of internal wear
on the control valve housing. If any defects are seen,
replace the cushion valve. 5
JD00560A
Install the spring (2), the spool (3) and the spacer (5) in
the control valve housing.

Copyright ©
8016-12
STEP 3 STEP 7
11
3
4 13
JD00561A JD00563A
Install the spring (4) in the spool (3). Place the spool (13) in a vice using wooden shims to
protect it and tighten the spring guide (11).
STEP 4
STEP 8
10
11
6 13
7
JD00562A
Install a new O-ring (6) on the flow restriction adaptor JD00564A
(7). Install the flow restriction adaptor in the control Install the spring (10), the spring guide (11) and the
valve housing. spool (13) in the groove of the control valve housing.
STEP 5 STEP 9
Repeat steps 1 through 4 for remaining three spools.
STEP 6 10
11
12
13
JD00565A
Install the spring (10).
JD00554A
Install the spring guide (11) using a new O-ring (12) on
the spool (13).

Copyright ©
8016-13
STEP 10
9
8
JD00566A
Install a new O-ring (9) on the plug (8). Install the plug
and O-ring in the housing.
STEP 11
Repeat steps 6 through 10 for the other spool.
STEP 12
JD00549A
If removed, install the adapters and elbows on the con-
trol valve.

Copyright ©
8016-14
NOTES
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Copyright ©
Section
8017
SAFETY VALVES
8017

Printed in France
Copyright ©
8017-2
TABLE OF CONTENTS
BOOM SAFETY VALVE ................................................................................................................................................. 3
Identifying the ports .................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 3
Installation .................................................................................................................................................................. 3
Disassembly ............................................................................................................................................................... 4
Assembly ................................................................................................................................................................... 6
DIPPER RELIEF VALVE ................................................................................................................................................ 8
Identifying the ports .................................................................................................................................................... 8
Removal ..................................................................................................................................................................... 8
Installation .................................................................................................................................................................. 8
Disassembly ............................................................................................................................................................... 9
Assembly ................................................................................................................................................................. 11

Copyright ©
8017-3
BOOM SAFETY VALVE
Identifying the ports Installation
When installing, use the same procedure in the reverse
order of removal by assembling new seal rings.
2
3 1 For valve adjustment, see Section 8001.
5 6
CD02C001
1 PILOT SPOOL
2 LEAK RETURN
3 HIGH PRESSURE CIRCUIT BYPASS TOWARDS THE OTHER
VALVE
4 VALVE POWER SUPPLY
5 SCREW
6 SAFETY VALVE
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the order
shown.
- Release pressure in the hydraulic circuit (see Section
8000).
Remove the hoses (1), (2) and (3) and plug the unions
and the hoses.
Remove the tube (4) and plug the ports.
Remove the screws (5) and the relief valve (6).
Plug the cylinder port.

Copyright ©
8017-4
Disassembly
12 16 17
13
14 18
15 19
11
2
10 9 8 5 3 4
Remove the spool stop cap (1) and discard the seal (2). CS02J542
Remove the plug (12), discard the seal (16), remove
Remove the screws (3), then the cover (4), discard the
the spring (14) and the check valve (15) and mark their
seal (5) and remove the springs (6) and (7).
positions.
Remove the washer (8) and the spring seat (9).
Remove the plug (16), discard the seal (17), remove
Remove the spool (10).
the spring (18) and the check valve (19) by marking
their positions.
Remove the valve (11).

Copyright ©
8017-5
7
17 12 11 8 4
16 2
15
3
14 9
13 10 5 6
CS02J543
Remove the plug (1), the setting screw (2) and discard
the seal (3).
Remove the spring (4) and the check valve (5).
Remove the body (6) and discard the seal (7).
Remove the spring seat (8), discard the seal (9) and the
back up ring (10).
Remove the spring (11).
Extract the check valve (12) from the sleeve (15),
discard the seal (13) and the back up ring (14).
Discard the seal (16) and the back up ring (17) from the
sleeve (15).

Copyright ©
8017-6
Assembly
7
17 8 4
16 2
12 11
1
15
3
14 5 6
13 9 10
CS02J543
NOTE: When assembling, install new seal rings. Install a seal (7) on the body (6).
Lubricate the body (6) and the inside of the spring seat
Install a seal (16) and a back up ring (17) on the sleeve (8).
(15). Put the body (6) in place.
Install a seal (13) and a back up ring (14) on the check Install the check valve (5) and the spring (4).
valve (12). Install a seal (3) on the screw (2).
Lubricate and install the check valve (12) in the sleeve Install the screw (2) without tightening it too much, the
(15). final tightening will be done with pressure setting.
Install the spring (11). Install the blank nut (1).
Install a seal (9) and a back up ring (10) on the spring
seat (8).
Install the spring seat (8) taking care not to damage the
seal (9) and the back up ring (10).

Copyright ©
8017-7
13 12 16 17 18
19
14
15 11
6
7
2
4
3
10 9
8 5
CS02J542
Install an O-ring (2) on the spool stop cap (1). NOTE: Take care in respecting the position of each
Install the cap (1) on the relief valve. check valve assembly marked during disassembly.
Lubricate and install the spool (10).
Install the washer (8) and the spring seat (9). Install an O-ring (17) on the plug (16).
Install the springs (6) and (7) in the cover (4). Lubricate and install the check valve (19) and the
Install an O-ring (5) on the cover (4). spring (18).
Install the cover (4) using screws (3). Install and tighten the plug (16).
Install the valve (11). Install an O-ring (13) on the plug (12).
Lubricate and install the check valve (15) and the
spring (14).
Install and tighten the plug (12).

Copyright ©
8017-8
DIPPER RELIEF VALVE
Identifying the ports Installation
When installing, use the same procedure in the reverse
order of removal, by assembling new seal rings.
2
3 For valve adjustment, see Section 8001.
1
1 PILOT SPOOL
2 VALVE POWER SUPPLY
3 SPOOL LEAK RETURN
4 VALVE LEAK RETURN
5 SCREW
6 RELIEF VALVE
Removal
NOTE: Before performing any operation on the
machine, carry out the following operations in the order
shown.
- Depressurise the hydraulic circuit (see Section 8000).
Remove the hoses (1), (3) and (4) and plug the unions
and the hoses.
Remove the tube (2), plug the tube and the union.
Remove the screws (5) and the relief valve (6).
Plug the cylinder port.

Copyright ©
8017-9
Disassembly
8 6
1 3 7
2
4 9
10 21
5
16 17
11
14
12
20 19 18 15 13
CS02J541
Remove the screws (1) and the cover (2), discard the
seal (3).
Remove the spring (4) and the check valve (5) after
marking their positions.
Remove the screws (6) and the cover (7), discard the
seal (8).
Remove the spring (9) and the check valve (10) after
marking their positions.
Remove the retaining screws from the spool stop cap
(11), remove it and discard the seal (12).
Remove the screws (13) and remove the cover (14),
discard the seal (15).
Remove the springs (16) and (17).
Remove the seats from the spring (18) and (19).
Remove the spool (20).
Remove the valve (21).

Copyright ©
8017-10
8 7 4
17 12 11
16 2
13
3
15 9 5 6
14 10
CS02J543
Remove the plug (1), the setting screw (2) and discard
the seal (3).
Remove the spring (4) and the check valve (5).
Remove the body (6) and discard the seal (7).
Remove the spring seat (8), discard the seal (9) and the
back up ring (10).
Remove the spring (11).
Extract the check valve (12) from the sleeve (13),
discard the seal (14) and the back up ring (15).
Discard the seal (16) and the back up ring (17) from the
sleeve (13).

Copyright ©
8017-11
Assembly
11 8 7 4
17 12
2
16 1
13
3
15 5 6
14 9 10
CS02J543
NOTE: When assembling, install new seal rings.
Install a seal (16) and a back up ring (17) on the sleeve

(13).
Install a seal (14) and a back up ring (15) on the check
valve (12).
Lubricate and install the check valve (12) in the sleeve
(13).
Install the spring (11).
Install a seal (9) and a back up ring (10) on the spring
seat (8).
Install the spring seat (8) taking care not to damage the
seal (9) or the back up ring (10).
Lubricate the body (6) and the inside of the spring seat
(8).
Put the body (6) in place.
Install the check valve (5) and the spring (4).
Install a seal (3) on the screw (2).
Install the screw (2) without tightening it too much, the
final tightening will be done with pressure setting.
Install the blank nut (1).
Install a seal (7) on the body (6).

Copyright ©
8017-12
3 8 6 7
1
2
9 10
4
21
5
16
17
11
14
12 13
20 19 18 15
CS02J541
Install the valve (21).
Lubricate and install the check valve (5) and the spring
(4) according to the marks made during disassembly,
install the cover (2) equipped with a seal (3). Install the
screws (1).
Lubricate and install the check valve (10) and the
spring (9) according to the marks made during
disassembly, install the cover (7) equipped with a seal
(8). Install the screws (6).
Install a seal (12) on the spool stop cap (11). Install the
retaining screws.
Lubricate and install the spool (20).
Install the spring seats (18) and (19).
Install the springs (16) and (17).
Install a seal (15) on the cover (14).
Install and fasten the cover (14) using screws (13).

Copyright ©
Section
8018
DISASSEMBLY AND REASSEMBLY

OF THE HYDRAULIC SWIVEL
8018

Printed in France
Copyright ©
8018-2
TABLE OF CONTENTS
SPECIAL TORQUE .........................................................................................................................................................2
SPECIAL TOOLS ............................................................................................................................................................3
HYDRAULIC SWIVEL .....................................................................................................................................................4
Description ..................................................................................................................................................................4
Disassembly ...............................................................................................................................................................5
Assembly ....................................................................................................................................................................7
SPECIAL TORQUE
Cover retaining screws (7) ....................................................................................62.7 to 72.5 Nm (46.24 to 53.47 lbf-ft)
Thrust plate retaining screws (9)...........................................................................31.4 to 37.3 Nm (23.16 to 27.51 lbf-ft)

Copyright ©
8018-3
SPECIAL TOOLS
Jig for pushing out axle
M16-M20 FULLY THREADED BOLT

F
SCREW
M16-M20 FEMALE G
D A
COVER (6)
E FITTING SIZE C
A 30 - 40 mm (1.18 - 1.57 in) E 20 mm (0.79 in)

B 20 mm (0.79 in) F 350 - 400 mm (13.78 - 15.75 in)
C 20 mm (0.79 in) G 7 x 25 mm (0.27 x 0.98 in)
D 5 mm (0.197 in)

Copyright ©
8018-4
HYDRAULIC SWIVEL
Description
1 PIVOT 7 SCREW *
2 "V" SEAL 8 LOCTITE
3 O-RING 9 SCREW *
4 PAKING RING
10 THRUST PLATE
5 ROTOR 11 O-RING
6 COVER
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Copyright ©
8018-5
NOTE: For removing the hydraulic swivel, refer to Sec- STEP 3
tion 8006.
Disassembly
Always handle the components carefully. Never force,
hit or drop components. Avoid any contamination by
dust, water or foreign bodies. Work in a clean area with
clean tools. Always remove the pivot (inner component)
and the bushing (outer component) using a press.
STEP 1
Remove the screws (9) and the thrust plate (10).

STEP 4
Remove the screws (7) and the cover (6).

STEP 2
Push out the axle (1) from the rotor (5) using a jig.
STEP 5
Remove and discard the O-ring (11).
Remove the "V" seal (2) from the pivot (inner compo-
nent) (1) and discard it.

Copyright ©
8018-6
STEP 6
Remove the O-ring (3) and the sealing rings (4) from
inside the bushing (outer component) (5). Discard the
sealing rings and the O-ring.

Copyright ©
8018-7
Assembly STEP 3
Clean all the components. Polish any scratches or
rough areas with an oil stone. Use seals, O-rings and
new sealing rings. Take the same precautions as during
removal.
STEP 1
Check the proper installation of the O-ring and the seal-

ing rings using a mirror. Apply hydraulic fluid, make
sure that the components are not protruding, twisted,
etc.
Clean the bushing (outer component) with a cleaning

solvent or low pressure compressed air.
STEP 2
Set one packing rings (4) in each groove up to the sec-

ond from the top.
Set the O-ring (3) in the top groove.

Copyright ©
8018-8
STEP 4 STEP 7
Install a new "V" seal (2) on the pivot (inner component) Install the O-ring (11).
(1) and coat it with clean hydraulic oil.
STEP 8
STEP 5
Install the cover (6) and the screws (7). Tighten the
Insert the pivot (inner component) (1) in the bushing screws to torque (see page 2).
(outer component) (5).
NOTE: Do not cut through the "V" seal, or graze it.
STEP 6
Install the thrust plate (10) and the screws (9).

Copyright ©
Section
8019
DISASSEMBLY AND REASSEMBLY

OF THE SWING HYDRAULIC MOTOR
8019

Printed in France
Copyright ©
8019-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3
TORQUE SETTINGS ...................................................................................................................................................... 3
SPECIAL TOOLS ............................................................................................................................................................ 3
HYDRAULIC SWING MOTOR ........................................................................................................................................ 4
Description .................................................................................................................................................................. 4
Disassembly................................................................................................................................................................ 6
Inspection.................................................................................................................................................................... 9
Maintenance Reference Table .................................................................................................................................. 10
Assembly .................................................................................................................................................................. 11
SECONDARY RELIEF .................................................................................................................................................. 20
Description ................................................................................................................................................................ 20
Disassembly.............................................................................................................................................................. 21
Inspection.................................................................................................................................................................. 21
Assembly .................................................................................................................................................................. 21

Copyright ©
8019-3
SPECIFICATIONS
See Section 1002.
TORQUE SETTINGS
Bypass valve plug (27)........................................................................................................................ 78 Nm (57.53 lbf-ft)
Non return check valve plug (52) .................................................................................................... 137 Nm (101.04 lbf-ft)
Cover screw (49) and (56) .............................................................................................................. 157 Nm (115.79 lbf-ft)
Safety valve (48) ............................................................................................................................. 137 Nm (101.04 lbf-ft)
SPECIAL TOOLS
A B C
E A
B
C
D
Installation jig for brake piston (12)

Press fitting jig for inner ring (2) and taper roller A Ø 190 mm C 50 mm
bearing (4) B Ø 220 mm
A Ø 60 mm C 130 mm
B Ø 55.2 ±0.1 mm D 140 mm
E 15°
A B C
G
H
D
E F
Installation jig for oil seal (3)

A Ø 100 mm E 20 mm
B Ø 81 mm F 155 mm
C Ø 60 ±02 mm G 30°
D 50 - 01 mm H 3 mm

Copyright ©
8019-4
HYDRAULIC SWING MOTOR
Description
1 SLEEVE
2 SNAP RING
3 OIL SEAL
4 BEARING
5 RETAINING WASHER
6 PISTON FACE
7 THRUST PLATE
8 PISTON ASSEMBLY
9 FRICTION DISK
10 STEEL DISK
11 O-RING
12 BRAKE PISTON
13 O-RING
14 SPRING
15 COVER
16 O-RING
17 PLUG
18 PISTON
19 SPRING WASHER
20 TEFLON SEAL
21 BUSHING
22 DISTRIBUTION PLATE
23 BEARING
24 CYLINDER
25 HOUSING
26 SPRING
27 BYPASS VALVE PLUG
28 CHECK VALVE
29 SPRING
30 O-RING
31 BACKUP RING
32 NON-RETURN CHECK VALVE
33 SPRING SEAT
34 CHECK VALVE SEAT
35 CHECK VALVE
36 SPRING
37 O-RING
38 SHIM
39 VALVE HOUSING
40 PISTON
41 O-RING
42 O-RING
43 BACKUP RING
44 PLUG
45 SLEEVE
46 LINER
47 NUT
48 SECONDARY RELIEF ASSEMBLY
49 SCREW
50 BACKUP RING
51 O-RING
52 NON-RETURN CHECK VALVE PLUG
53 SNAP RING
54 RETAINING PIN
55 RETAINING PIN
56 SCREW
A SHOE
B BRAKE PILOT PORT

Copyright ©
8019-5
37 49 30 31 33 32 31 30
48
47
29
41
28
46
45 27
44
42 43
40 39 38 36 35 34 26 52 51 50
21 20 19 15 18 17 16
54
14 55
13 22
12 B
11
23
10
9 53
8 24
7
25
A
6
5 4 3 2 1
CS02J563

Copyright ©
8019-6
Disassembly
STEP 1 STEP 3
48 48 56
49
52
15
26
33
27
D
C
Remove the oil level dipstick (C) and dipstick tube (D).
Remove relief valve assemblies (48) from swing motor.
Remove the by-pass valve assemblies (27), as well as Remove the retaining screws (49) and (56). Remove
the plugs (52), the springs (26) and the non-return the cover (15) from the motor housing.
check valves (33).
Remove and discard all the O-rings of each compo- STEP 4
nent.
53
STEP 2
23
A 22
18
15
CS02C520
Place the cover with the shaft on top and remove the
retaining ring (53) from the shaft.
Remove the needle bearing (23) and the distribution
plate (22).
Remove the pistons (18) from the distribution plate
(22).
To facilitate assembly, put alignment marks (A) on the

cover and motor housing.

Copyright ©
8019-7
STEP 5 STEP 8
NOTE: Protect the housing and the piston surfaces with
rags when you lever the piston out of the housing.
13 13
15 12
A A
12
CS02C521
Remove and discard the large O-ring (13) from the
13
cover (15).
25
STEP 6
21
20
19 Install two M6 screws (A) in tapped holes of the brake

piston (12). Lever these screws and free the brake pis-
15 ton (12) from the housing.
Remove and discard the O-ring (13) from the housing
(25) and the brake piston (12). Remove the two M16
screws (A) from the brake piston.
CS02C522
STEP 9
Remove the bushings (21), the Teflon rings (20) and
the washers (19) from the cover (15). 10
STEP 7
14
25
9
25
Remove the springs (14) from the brake piston (12).
Remove the four friction plates (9) and the four disc
plates (10) from the swing motor housing (25).

Copyright ©
8019-8
STEP 10 STEP 12
24 2
25
CS02C528
Remove the retaining ring (2) from the fluted shaft.

Remove the conical roller bearings and the sleeve (1)
using an antisticking pin puller.
Remove the cylinder assembly (24) from the motor STEP 13

housing (25). NOTE: Mark the location of the pistons on the base
plate and on the cylinder. Pistons must be installed in
STEP 11
same positions during assembly.
4
6
3
7
8
3
24
Remove the bearing (4) from the motor housing.

Position the motor housing in a press. Using a suitable
sleeve or a centring piece, drive the spy joint (3) out
from the housing. Scrap the spy joint (3).
Remove the piston plate (6), the piston assembly (8)
and the base plate (7) from the cylinder (24).

Copyright ©
8019-9
STEP 14 Inspection
6 STEP 1
7
Check the distribution plate sliding surfaces for signs of
seizing or wear. If there is evidence of seizing or wear,
the plate should be replaced.
STEP 2
Check for wear of the pistons. Replace the motor if the
depth of any shoe sliding surface is less than 0.45 mm,
8 if the shoe surfaces are seriously damaged or if a pis-
ton assembly shows any sign of seizing. There should
be no wear of the external surfaces of the piston
assemblies.
CS02C530
Slip the piston plate (6) out of the sliding surfaces of the STEP 3
piston assemblies (8), while ensuring that it does not
get damaged. Remove the pistons from the base plate Check for signs of seizing or wear on the piston plate
(7). sliding surface. The plate should be replaced if there is
evidence of seizing or wear.
STEP 15
STEP 4
Check for signs of seizing, wear or damage on the cyl-
5 inder piston bores. The motor should be replaced if
there is evidence of seizing or if the piston bores are
damaged.
Inspect the needle bearing and tapered roller bearing
for damage. The bearings should be replaced if any
damage is found, or after 3000 hours of operation.
24
CS02C531
Remove the backup washer (5) from the fluted shaft.

Copyright ©
8019-10
Maintenance Reference Table
Table 1
Part name Locations to be in-
Reference valves Measuring instru- Instructions for repair
spected and mea-
(tolerance limits) ments and remedies
sured
Piston assembly (8) Roughness on Surface roughness Repair with paper
0.8 S
shoe sliding face gauge lap.
Groove depth in Replace with new
0.45 mm or more Micrometer
shoe sliding section ones.
Looseness on the
ball joint section be- Replace with new
0.4 mm or less Dial gauge
tween piston and ones.
shoe
Almost no wear. If scratches or seizure are found, replace with new
Piston diameter
ones.
Piston face (7) Surface roughness
Surface roughness 0.8 S Lap
gauge
Cylinder (24) Roughness on the Surface roughness
0.4 S Lap
edge gauge
Piston hole Almost no wear. If scratches or seizure are found, replace the motor.
Distribution plate (22) Surface roughness
Surface roughness 0.8 S Lap
gauge
Piston assembly (8) Clearance between
Micrometer
Cylinder (24) piston diameter and 0.04 mm or less Motor replacement
cylinder bore Air micrometer
Table 2
Part name Inspection and Maintenance Reference
Taper roller bearing (4) Replace bearings with new ones every 3,000 hours even if they function normally.
Needle bearing (23) Additionally, always replace bearings when reassembling, even if it's within 3,000
hours.
Spy joint (3) If damage is found on the lip, replace it with a new one.
Additionally, replace seals with new ones every 3,000 hours even if they function
normally with no leaking.
Additionally, always replace seals when reassembling, even if it's within 3,000
hours.
O-rings (11), (13), (16), (30), If damage is found on O-ring, replace it with a new one.
(37), (41), (42) and (51) Additionally, replace rings with new ones every 3,000 hours even if they function
normally with no leaking.
Additionally, always replace rings when reassembling, even if it's within 3,000
hours.

Copyright ©
8019-11
Assembly
STEP 1 STEP 3
5 7
SPHERICAL
24
24
CS02C532
Apply grease (No. 2 EP lithium grease) on the spherical CS02C534
portion of the cylinder shaft that is in contact with the Apply clean hydraulic fluid on the cylinder (24) bores.
retaining washer (5) and install the retaining washer Install the piston assemblies (8) and the thrust plate (7)
(5). in the barrel (24). Be sure that the pistons are installed
in the same bores as they were removed from.
STEP 2
STEP 4
6
7
CS02C533
24
Apply clean hydraulic fluid on the sliding surface of the
piston assemblies (8). Install the piston assemblies (8)
in the ports of the base plate (7).
CS02C535
Apply clean hydraulic fluid on the sliding surfaces of the
piston assemblies (A) and install the piston plate (6).

Copyright ©
8019-12
STEP 5 STEP 7
PRESS-FITTING JIG
A
4
(INNER)
24
CS02C536
Install a new taper roller bearing inner cage (4) on the
barrel shaft (9).
STEP 6
Before installation, apply grease on the lip of the oil seal
PRESS-FITTING JIG (3). Position housing in a press. Apply Loctite 504 to the
periphery of the lip seal. Install and centre the oil seal
1 (3) in the bore of the housing. With a suitable sleeve
(A), fit the oil seal (3) in the bore of the housing.
2 NOTE: Pay attention to the fitting directions of the oil

seal (3).
LOCTITE APPLIED
TAPER ROLLER BEARING SIDE
4
CYLINDER OUTPUT SHAFT SIDE
24
STEP 8
4
(OUTER RING)
CS02C537
Apply a thin coat of Loctite 515 or 518 where the sleeve
(1) is installed on the cylinder shaft. Fit the sleeve (1) on
the shaft and install the snap ring (2).
25
Install a new bearing outer cage (4) in the housing (25).

Copyright ©
8019-13
STEP 9 STEP 11
CYLINDER END FACE
13
24 12
11
HOUSING END FACE
25
25
Apply grease on the new O-rings (11) and (13); install

the O-ring (11) in the housing (25) and the O-ring (13)
on the brake piston (12).
STEP 12
REINFORCING JIG
A
B
(B) 40 to 50 mm (1.57 in to 1.96 in)

Install the housing (25) on shims (A). 12
Carefully install the barrel assembly (24) in the housing
(25). Be careful when installing the cylinder assembly
not to damage the splines on the shaft.
STEP 10
25
10
Apply clean hydraulic fluid on the periphery of the brake

piston (12). Push the brake piston (12) into the housing
9 (25).
25
Apply clean hydraulic fluid to both faces of the friction

disks (9) and the steel disks (10). First, install a steel
disk then a friction disk, then a steel disk, a friction disk,
then a steel disk, a friction disk, finally the last steel disk
and the last friction disk.
Copyright ©
8019-14
STEP 13
PORTS A AND B SIDE
V SHAPED GROOVE
14
25 ROUND SHAPED GROOVE

RELIEF SIDE
STEP 15
53
Install the springs (14) in the brake piston (12) in their

original locations. 23
STEP 14
22
18
21 15
20
J7CB20C-26
19 Install the new needle bearing inner race (23) on the
shaft and install the retaining ring (53).
54
STEP 16
13
15
J7CB20C-28
Install the spring washers (19) in the cover (15). Apply
No. 2 EP lithium grease on the bushings (21), the new
Teflon rings (20) and in the cover (15). Install a Teflon
ring on each of the bushings. Install the bushings with
seals in their holes in the cover.
Apply No. 2 EP lithium grease on the pistons and install 15
the pistons (18) in the distribution plate (22). Be sure
that the pistons are installed in same bore as they were J7CB20C-30
removed from. Install the pistons and the distribution Install a new, greased O-ring (13) on the cover (15).
plate (22) on the cover (15), positioning the plate hole
on the stop dowel (54).
NOTE: Pay attention to the installation directions for the
distribution plate (22) on the cover (24), which were
marked before disassembly.

Copyright ©
8019-15
STEP 17 STEP 19
25 56
49
15
25
LOCTITE 504
Apply Loctite 504 to the mating surfaces of the motor

housing (25) and the cover (15).
STEP 18 Install the retaining screws (49), (56) and tighten to a
torque of 157 Nm.
STEP 20
48 48
15
52
55
26 26
25
33
27
D
C
Carefully install the cover (15) and the distribution plate
(22) on the housing, making sure that the distribution
plate and bushings do not fall off the cover. Align the
motor and cover marks, engage the stop dowel (55) in Install the oil level dipstick (C) and dipstick tube (D).
the brake piston orifice (12). Install the relief valve assemblies (48) on the swing
motor.
Install the by-pass valve assemblies (27) and the plugs
(52), the springs (26) and the non-return check valves
(33).
Install new O-rings on each component.

Copyright ©
8019-16
STEP 21
PORT P
15
25
Open the entry and exit ports and apply pilot pressure
of 2.9 to 4.9 MPa to the brake relief port.
Then make sure that the output shaft can be smoothly
rotated, one turn or more, with torque of 30 to 40 Nm
If it does not rotate properly, it is suspected that assem-
bly is not completed correctly.
Disassemble once again and readjust it.
Make sure that drain port is released.
NOTE: Ensure that the set pressure on the relief valve
(48) indicates a normal pressure after the hydraulic
motor is installed onto this machine.

Copyright ©
8019-17
TROUBLESHOOTING
Described below are measures to be taken when any abnormalities or malfunctions are found while the hydraulic motor
is used.
Details on disassembling/inspection and reassembling are also described later but careful handling is absolutely
needed to avoid any damage to the sliding parts of the motor while conducting these procedures.
Table 1
Symptom Cause Exterior inspection Remedy Repairs
Does not Motor's internal Measure drain output. If motor supply input is equal See Table 2.
rotate breakage to the drain output, there is
high possibility of breakage
in sliding section. Disassem-
bling/inspection is required.
Motor's internal Open the inlet and outlet If the output shaft does not Replace dam-
breakage ports on the motor and apply rotate smoothly with the aged parts or
pilot pressure of 2.9 to 4.9 torque stated to the left, motor assembly.
MPa to the brake relief port. there is high possibility of
Then attempt to rotate the internal breakage. Disas-
output shaft with torque of 30 sembling/inspection is
to 40 Nm. required.
Incorrect settings Measure load pressure with Reset to specified set pres-
at relief valve in pressure gauge. sure.
the circuit
Excessive Wear or damage Measure drain output. If the drain output is more See Table 2.
slippage in the sliding part than 2.5 L / min., the leakage
of the motor and in is too high. Disassembling/
the high pressure inspection is required.
seal section
Oil temperature is Measure oil temperature. Lower the oil temperature.
too high and there
is excessive inter-
nal leakage inside
the motor
Lack of Wear or seizure of Open the inlet and outlet If the output shaft does not Inspect parts (a) to
torque the motor sliding ports on the motor and apply rotate smoothly with the (e) listed in Table
section pilot pressure of 2.9 to 4.9 torque stated to the left, 2, and also the
Abnormal
MPa to the brake relief port. there is high possibility of bearings. Change
noises
Then attempt to rotate the internal breakage. Disas- them if any abnor-
output shaft with a torque of sembling/inspection is mality is found.
approx. 30 to 40 N•m. required.
Incorrect settings Measure load pressure with Reset to specified set pres-
at relief valve in pressure gauge. sure.
the circuit

Copyright ©
8019-18
Symptom Cause Exterior inspection Remedy Repairs

Lack of Motor's internal Check whether there are any If any foreign metal sub- Repair or replace
torque breakage foreign metal substances in stances are found, there is damaged parts.
the motor oil drain and drain high possibility of motor's
Abnormal Motor assembly
filters. internal breakage. Disas-
noises replacement.
sembling/inspection is
(cont.) required.
A lot of air is Check the oil in the tank and Bleed air completely.
mixed in the oil motor case.
Looseness on Looseness on piping fix- Fasten them with proper
tightening sections tures. tightening torque.
Check for looseness on the
fixture mounting bolts, motor
mounting bolts and bolts on
the motor.
Abnormal Seizure of motor's Check for foreign metal sub- If any foreign metal sub- Repair or replace
heat sliding and rotat- stances in the motor oil drain stances are found or the out- damaged parts.
ing sections and drain filters. Apply pilot put shaft does not rotate
Motor assembly
pressure of 2.9 to 4.9 MPa to smoothly with the torque
replacement.
the brake relief port and above, there is a high possi-
attempt to rotate the output bility of internal breakage.
shaft with torque of 30 to 40 Disassembling/inspection is
Nm. required.
Oil leak- O-ring is dam- Replace O-rings.
age from aged.
mating
Oil seal surface is Repair or replace
faces
damaged. seal surfaces.
Loose bolts Check for loose bolts. Fasten them with proper
tightening torque.
Oil leak- Wear or damage Replace oil seal.
age from on the lips of oil
oil seal. seal
Wear or damage Repair or replace
on seal sections of motor assembly.
shaft
Abnormal pres- Check the internal pressure Internal pressure in the case Replace oil seal.
sure in the case and drain output in the case. should be 0.3 MPa or less.
Repair or replace
If drain output is too large, damaged parts.
disassembly/inspection is
Motor assembly
required.
replacement.

Copyright ©
8019-19
Table 2
Letter Parts to be inspected Repairs
a Wear in the sliding part of the distribution plate (22) Repair or replace parts.
b Damage in the sliding section of the piston plate (6) Repair parts or replace the motor.
c Damage in the sliding section of the piston assembly (8) Repair parts or replace the motor.
d Wear in piston outer diameter of the piston assembly (8) Repair parts or replace the motor.
e Wear in piston hole of the cylinder (24) Replace motor.
f Damage in Teflon ring (20) Replace parts.

Copyright ©
8019-20
SECONDARY RELIEF
Description
38 41 47
40
44
34 35 36 37 39 45 46 43 42
CS02C552
34 SPRING SEAT 41 O-RING
35 CHECK VALVE 42 BACK-UP RING
36 SPRING 43 O-RING
37 O-RING 44 PLUG
38 SHIM 45 SLEEVE
39 VALVE BODY 46 LINER
40 PISTON 47 NUT

Copyright ©
8019-21
Disassembly Inspection
STEP 1 NOTE: Individual relief valve assembly parts cannot
be replaced. If a relief valve assembly fails to operate
Remove the nut (47), the plug (44), discard the properly for any reason other than dirt or foreign mat-
seal (43) and the back up ring (42). ter, the entire assembly must be replaced.
STEP 2
Assembly
Remove the sleeve (45) and the piston (40).
STEP 3 steps refer to the schematic on page 15.
Remove the liner (46), the shim (38) and discard the NOTE: When installing, install new seal rings.
O-ring (41).
STEP 1
STEP 4
Install an O-ring (37) on the valve body (39).
Remove the spring (36), the check valve (35) and the
spring seat (34). STEP 2
STEP 5 Install the spring seat (34) in the valve body (39).
Remove and discard the O-ring from the valve STEP 3

body (39). Oil the inside of the spring seat (34). Install the check
valve (35) in the spring seat (34).
STEP 4
Install the spring (36) on the valve body (39).
STEP 5
Install an O-ring (41) on the liner (46). Install a shim
(38) on the spring (36).
STEP 6
Install the liner (46) in the valve body (39), taking care
not to damage the O-ring (41).
STEP 7
Install the piston (40) in the sleeve (45). Install the
sleeve (45) in the liner (46).
STEP 8
Install a back up ring (42) and an O-ring (43) on the
plug (44). Install the plug (44) in the liner (46).
STEP 9
Install the blank nut (47).

Copyright ©
8019-22
NOTES
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Copyright ©
Section
8020
HYDRAULIC FUNCTIONS
8020

Printed in France
Copyright ©
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS...................................................................................................................................... 3
List of functions ................................................................................................................................................... 3
TRAVEL CIRCUITS ................................................................................................................................................ 6
1. High-speed Travel Circuit................................................................................................................................ 6
2. Low Speed Travel Circuit ................................................................................................................................ 8
3. Straight Travel Circuit.................................................................................................................................... 10
SWING CIRCUITS ................................................................................................................................................ 12
1. Swing Parking Circuit (Lever in Neutral / Swing Locked).............................................................................. 12
2. Swing Parking Circuit (Brake Released) ....................................................................................................... 14
3. Swing Push Digging ...................................................................................................................................... 16
ARM CIRCUITS .................................................................................................................................................... 18
1. Arm Out Circuit ............................................................................................................................................. 18
2. Arm-In Load Holding ..................................................................................................................................... 20
3. Arm-In Circuit ................................................................................................................................................ 22
BOOM CIRCUITS ................................................................................................................................................. 24
1. Boom-Up Circuit (Single) .............................................................................................................................. 24
2. Boom-Up Circuit (Combined) ........................................................................................................................ 26
3. Boom-Down Load Holding ............................................................................................................................ 28
4. Boom-Down Circuit ....................................................................................................................................... 30
BACKUP CIRCUITS.............................................................................................................................................. 32
1. Combined Circuit (Breaker Circuit) ............................................................................................................... 32
2. Combined Circuit (High Speed Confluence Circuit) ...................................................................................... 34

Copyright ©
8020-3
HYDRAULIC FUNCTIONS
List of functions
Functions Description Pages
Travel Circuits
1) High speeds can be achieved by setting the two-level inclinatory angle of the
travel motor to the smaller angle side.
High speed travel
2) Load pressure applied to the travel motor automatically changes the speed to Page 6
circuit
the lower speed.
3) Travel load pressure does not regulate the controller.
Low speed travel Low speeds can be achieved by setting the two-level inclinatory angle of the travel
Page 8
circuit motor to the larger angle side.
Straight travel Maintains machine's straight travel when attachment or swing operations are
Page 10
circuit performed during its travel.
Swing Circuits
1) When the swing lever is in neutral, the swing parking is activated and the swing
is fully held.
2) When the swing lever is operated, the parking brake is released by signals from
the pressure switch.
Swing parking 3) When the swing lever is in neutral, the parking brake is released by load
Page 12
circuit pressure generated by attachment operation.
4) The parking brake starts to operate 5 seconds after the swing lever comes in
neutral and after the load pressure has become lower than the specified values.
5) When the swing lock switch is turned on, the parking brake starts to operate.
At the same time, pilot pressure works on both ends of the swing spool.
When swing and arm operation are conducted simultaneously, swing pushing
Swing push
function can be obtained by the swing override (arm parallel tandem) throttle Page 16
digging
valve integrated in the control valve.
Vibration The anti reverse valve attached to the swing motor reduces swingbacks that occur
-
swingback when the swing stops.
Arm Circuits
Switching between arm (1) and (2) spools makes the hydraulic oil flows merge,
Arm-out circuit Page 18
achieving faster speed.
Arm-in load Regeneration within the boom spool is used to increase speed and prevent cavi-
Page 20
holding tation.
Arm-in circuit High pressure is suppressed with the bleed-off circuit and tilting is mitigated. Page 22
Boom Circuits
1) Switching between boom (1) and (2) spools makes hydraulic oil flows merge,
achieving faster speed.
Boom-up circuit 2) When the arm is operated with the boom simultaneously, the flow volume to the Page 24
arm side is secured through the swing override (arm parallel tandem) variable
throttle valve.
1) The load holding valve that is integrated in the control valve reduces the natural
Boom-down load drop of the boom. Page 28
holding 2) Boom-down pilot pressure enables boom-down operation by releasing the load
holding valve.
1) The regenerative circuit in the boom (1) spool works to improve the boom's
speed. It also prevents negative pressure from occurring.
2) Boom (2) does not operate. Page 30
Boom-down circuit
3) The bleed-off circuit in the spool reduces extra vibrations when the boom is
lowered.

Copyright ©
8020-4
Backup Circuits
1) Backup circuit section is provided at control valve.
Combined circuit Page 32
2) Switching over the spool in the control valve initiates internal confluence.
Others
A cushion valve with heat circuit is attached to the pilot line to reduce shocks when
Cushion -
the arm or boom movement stops.
Through the engine load ratio and circuit pressure, the main relief pressure will be
Auto power boost -
raised from 31.4 MPa to 34.3 MPa.
This is designed to reduce power consumption by minimizing the flow of the
Negative control -
discharge from the hydraulic pump when operating with no load.

Copyright ©
8020-5
This page has been left blank intentionally

Copyright ©
8020-6
Travel Circuits
1. High-speed Travel Circuit
With high speed travel, high speeds can be achieved by setting the two-level inclinatory angle of the travel motor to
the smaller angle side. The circuit has a travel motor that automatically switches over to lower speed by utilizing load
pressure on the travel motor when traveling at high speed.
Discharged oil from the hydraulic pump A1 enters the port P1 of control valve while discharged oil from the hydraulic
pump A2 enters the port P2 of control valve. Each flow goes into the travel motor by switching between the right and
left travel spools. By these flows, the machine travels forward and backward.
By operating the travel mode switch, electric signals are sent to the controller, and from the controller, electric signals
are sent to the solenoid valve for 2-speed (high speed) travel in the 6-way solenoid valve.
By the switchover of the solenoid valve, the original pilot pressure (3.9 MPa) from port C1 on the 6-way
solenoid valve enters port P of right and left travel motors via the rotating joint to set the inclinatory angle
of the travel motor to the smaller angle side, which enables high speeds.
pb6/B6. RH forward travel

pa6/A6. RH reverse travel
pa1/A1. LH forward travel
pb1/B1. LH reverse travel
10. Main hydraulic pump
15. Main control valve
21. Travel motors
25/26. Boom cylinders
52. 6 solenoid valve bank
108. Straight travel valve
A1. Controller
C1. Travel 2nd speed pilot
S2. Travel mode switch
Y2. Pilot pressure solenoid valve
Y4. 2 stage travel solenoid valve
Legend
Pressure Line
Pilot Pressure Line
Drain line
Tank line
Pilot tank line
Electric line

Copyright ©
8020-7
High Speed Travel Circuit
Boom cylinder
T1 T2
26 25
VA VB
VB VA
Travel
B6
(Right)
P P A6
21 Travel motor 21 pb6
Travel B1 pa6
(Left) A1
Switch panel pb1
pa1 Straight travel valve 108
S2 TRAVEL
P
P1 P2 Control valve 15
2-speed travel Lever lock
T Y2
C1
A1 Controller
P
Y4
A1 A2 A3
52 6-way solenoid valve

Hydraulic pump
10
330.1.03.03.23A2

Copyright ©
8020-8
2. Low Speed Travel Circuit
The two-level inclinatory angle in the travel motor is set to the larger angle side. When the travel status is set to high
speed and the key switch is turned off and turned on again, the speed setting will always return to low speed.
Discharged oil from the hydraulic pump A1 enters the port P1 of control valve while discharged oil from the hydraulic
pump A2 enters the port P2 of control valve. Each flow goes into the travel motor by switching between the right and
left travel spools. By these flows, the machine travels forward and backward.
The solenoid valve for high speed travel is turned off and the oil in port P of the travel motor enters the tank line and
establishes a connection. As a result, the inclinatory angle of the travel motor is set to the larger angle side.

pa1/A1. LH forward travel
pb1/B1. LH reverse travel
21. Travel motors
52. 6 solenoid valve bank
A1. Controller

Copyright ©
8020-9
Low Speed Travel Circuit
Boom cylinder
T1 T2
26 25
VA VB
VB VA
Travel
B6
(Right)
P P A6
Travel motor pb6
21 21
Travel B1 pa6
(Left) A1
Switch panel pb1
S2 TRAVEL
P
2-speed travel Lever lock
T Y2
C1
A1 Controller
P
Y4
A1 A2 A3

Hydraulic pump
10
330.1.03.03.23B2

Copyright ©
8020-10
3. Straight Travel Circuit
As an example, we describe the operation where travel and boom up are operated at the same time.
The pilot oil pressure enters from port PP of the control valve and communicates with the tank side via passages of
travel spool and spools for attachments (boom, arm, bucket and swing). When travel and boom-up operations are per-
formed simultaneously, all circuits, which have been communicating with the tank, will be shut off by spools. This
makes pilot pressure oil entered from the port PP to lose where to flow and original pressure (3.9 MPa) switches over
the straight travel selector valve. The pressure works to the pilot chamber in straight travel valve allowing the valve to
be switched over.
As the result of the switchover of the straight travel valve, the pressurized oil in the control valve P1 drives the right
and left travel motors and the pressurized oil in the control valve P2 drives the attachments. The right and left pres-
sures become equal because one pump drives both the right and left motors. This realizes straight travel. Additionally,
extra hydraulic oil from P2 is supplied via the check with travel confluence restriction to the travel side, and speed
reduction is minimized. The same theory applies and the circuits operate the same way when upper actuators other
than boom and travel are operated at the same time.

pb1/B1. LH forward travel
pa1/A1. LH reverse travel
21. Travel motors
52. 6 Solenoid valve bank
A1. Computer / Controller

Copyright ©
8020-11
Straight Travel Circuit
Boom cylinder
T1 T2
26 25
VA VB
Pb3 A7
VB VA
B7
)
Pa3 pb7
pa7 Travel
B6 (Right)
A6
P Travel motor P pb6
Travel
21 21 (Left) B1 pa6
A1
Switch panel pb1
TRAVEL
S2
2-speed travel Lever lock P1 PP P2
valve 15
T Y2
C1
Controller
A1 P
Y4
A1 A2 A3

10 Hydraulic pump
330.1.03.03.23C2

Copyright ©
8020-12
Swing Circuits
1. Swing Parking Circuit (Lever in Neutral / Swing Locked)
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve becomes turned on (24 V
input) and the swing parking brake is activated.
When the swing lock switch is on, even if the swing pressure switch or attachment pressure switch is turned on, the
swing lock switch overrides and the parking brake remains unreleased. Since pressure oil out of the port C5 of 6-way
solenoid valve works on both sides of the swing spool while the swing is being locked, the spool in the control valve
will not be switched over even if the swing control lever is engaged.
pb2/B2. LH swing
pa2/A2. RH swing
22. Swing motor
27. Arm cylinder
54. Swing control valve
A1. Controller
B22. Swing pilot pressure switch
B26. Upper pilot pressure switch
B42. Pump pressure sensor P1
C2. Swing brake pilot
C5. Swing shut-off pilot
S8. Swing brake switch
Y1. Swing pilot shut-off solenoid valve
Y3. Swing brake solenoid valve

Copyright ©
8020-13
Swing parking circuit (Lever in neutral / Swing locked)
22
Swing motor
27
Arm cylinder
pb2
pa2
Shuttle Remote control valve 54

valve 2S 3S 1S
Pressure B44
sensor
Y2
Swing B42
T pressure 3 1
switch Pressure
sensor Attachment 15
B22 pressure B26
switch
C2 Y3
Switch panel
Swing brake swing lock
S8 A1 A2 A3
C5
Hydraulic pump
Y1
6-way solenoid valve Controller 10
52
A1
330.1.03.04.24A2

Copyright ©
8020-14
2. Swing Parking Circuit (Brake Released)
When the swing pressure switch is turned on by operating the lever, output to the swing brake solenoid valve from the
controller is turned off and the swing parking brake is released by pilot pressure. Also, in order to prevent brake drag-
ging caused by swing lateral force that is generated when digging attachments are moved with the swing lever being
in neutral, a mechanism which senses main pressure and releases the parking brake is introduced. Signals from the
pressure sensor on port pr1 or port pr2 of the control valve enter the controller. When either pressure reaches 15
MPa, the output to swing brake solenoid valve from the controller is turned off. This releases the swing parking brake.
When the pressure switch for attachments is kept off for more than 5 seconds, the swing pressure switch will be
turned off. Then 5 seconds after the pressure of the control valve pr1 or pr2 becomes 15 MPa or less, the solenoid
valve turns on and the swing parking brake starts operating. When the pressure on G4 or G5 becomes 15 MPa or
more, the swing brake is released. However, if the attachment switch was kept off for more than 5 seconds, the swing
parking brake works. (When traveling)
Swing Pressure received on

Swing brake Swing motor
Key switch pressure pr1 or pr2
solenoid valve parking brake
switch pressure sensor
OFF OFF 0 OFF Operates
15 MPa or less ON Operates
OFF Released
OFF Turns on 5 seconds
15 MPa or more after attachment
ON Operates
pressure switch
is turned OFF.
15 MPa or less OFF Released
ON
15 MPa or more OFF Released
pb2/B2. LH swing
pa2/A2. RH swing
22. Swing motor
27. Arm cylinder
A1. Controller
Y2. Pilot pressure solenoid valve (blue band)
Y3. Swing brake solenoid valve (pink band)

Copyright ©
8020-15
Swing Parking Circuit (Brake Released)
22
Swing motor
A B T1 Pc5
27
Arm cylinder
pc4
B2
A2 pb2
pa2
Remote control valve
2S 54
Shuttle
valve
Pressure
sensor B44
S2 S3
Y2
Lever lock 3 1 B42 P1 PP PA
P P2
Control valve
Swing Pressure
pressure sensor Attachment 15
switch pressure B26
switch
B22
P
C2 Y3
Switch panel
S8 A1 A2 A3
Hydraulic pump
52
A1
330.1.03.04.24B2

Copyright ©
8020-16
3. Swing Push Digging
The swing pilot pressure is supplied to port pc4 via the shuttle valve and enables the swing priority variable restriction
to be held to the right-hand side. Putting restriction on the parallel circuit secures swing force for enforced digging
operation with raised swing pressure even when the arm and swing are operated at the same time.
pb2/B2. LH swing
pa2/A2. RH swing
22. Swing motor
27. Arm cylinder
A1. Computer / Controller
Y2. Pilot pressure solenoid valve (blue band)
Y3. Swing brake solenoid valve (pink band)

Copyright ©
8020-17
Swing Push Digging
22
Swing motor
A B
Arm cylinder
pc1
B5
27 A5
pb5
pa5-1 pb9
pa5-2
pc4 pa9
B2
pb2 A2
pa2
Shuttle 2S Remote control valve

valve 1S 54
Pressure
sensor B44
S2 S3
Y2
Lever lock 2 4 3 1 B42
2 P1 P2
Swing Control valve
Pressure
pressure sensor Attachment 15
switch pressure B26
switch
6
B22
P
C2 Y3
Switch panel
A1 A2 A3
S8
Hydraulic pump
52
A1
330.1.03.04.24C2

Copyright ©
8020-18
Arm Circuits
1. Arm Out Circuit
Oil discharged from hydraulic pump A1 is supplied to the arm (1) spool through the center bypass oil passage in the
control valve. Oil discharged from hydraulic pump A2 is also supplied to the arm (2) spool through the parallel oil pas-
sage, and merges at the downstream of the arm (1) spool, then flows into the rod side of the arm cylinder via the load
holding valve. Oil returning from the bottom returns to the tank oil passage via the arm (1) and (2) spools.
pa5/A5. Retracting the arm (dipper) (Arm 1)

pb5/B5. Extending the arm (dipper)(Arm 1)
pa9. Retracting the arm (dipper) (Arm 2)
pb9. Extending the arm (dipper) (Arm 2)
27. Arm (Dipper) cylinder
54. Arm (Dipper) control lever
57. Boom and arm (dipper) control shock absorber

Copyright ©
8020-19
Arm Out circuit
T2 Boom cylinder
27 26 25
B5
A5
Arm pb5
cylinder
pa5-1 pb9
pa5-2
pa9
15
P1 P2 Control valve
P Cushion valve C D
57 A1 A2 A3
54
2
4
Remote control valve
Hydraulic pump
T B
10
330.1.03.06.23A2

Copyright ©
8020-20
2. Arm-In Load Holding
When the arm is in neutral, oil on the arm cylinder rod side is sealed by the load holding valve check. This mechanism
reduces internal leakage from the main spool.
When the arm-in is operated, the pilot pressure enters port pa5 of the control valve and moves arm (1) spool to the
arm-in side. Also, the pilot pressure separated from port pa5 enters port pc1 and moves the load holding valve spool
to the right. Through this mechanism, the oil in the spring chamber of the load holding valve check is connected to the
tank line passing the load holding valve spool. As a result, the pressure on the spring chamber decreases and the
load holding valve check is released. The hydraulic oil in the rod of the arm cylinder is returned to the tank line, the
arm cylinder extends and the arm moves in.


Copyright ©
8020-21
Arm-In Load Holding
T1 Boom cylinder
DR1'
pc1
26 25
27 B5
A5
Arm pb5
cylinder
ARM
pa5-1 pb9
DR1' pa5-2
Detail pa9
DR1
Load holding
valve spool
pc1
Load holding
valve check
B5
Arm(2)
Arm(1)
Remote control valve P Cushion valve C D

54 57 A1 A2 A3
4
2
T A Hydraulic pump
10
330.1.03.06.23B2

Copyright ©
8020-22
3. Arm-In Circuit
For arm-in operation, pilot pressure is supplied to port pa5 and pa9 of the control valve and the arm spool
moves to the arm-in side.
At the same time, the arm load holding valve is released by the pilot pressure, and the discharged oil on
the cylinder rod side is restricted by the forced regenerative release valve. This forces the returned oil to be
regenerated into the cylinder bottom side via the check within arm (1) spool, securing the arm speeds
required for floor digging work. When the load pressure rises on the cylinder bottom side, the forced regen-
erative release valve switches over to the large diameter restriction side. As a result, the orifice for return
becomes large and returned oil on the rod side stops recycling.


Copyright ©
8020-23
Arm-In Circuit
T1 Boom cylinder
pc1 26 25
27 B5
A5
Arm pb5
cylinder
pa5-1 pb9
pa5-2
pa9
Detail
Load holding
B5 valve check
H/V
A5
pb5
Forced regenerative
release valve
Remote control valve P Cushion valve C D

A1 A2 A3
54 57
4
2
T A Hydraulic pump
10
330.1.03.06.23C2

Copyright ©
8020-24
Boom Circuits
1. Boom-Up Circuit (Single)
Oil discharged from hydraulic pump A1 is supplied to the boom (2) spool from the parallel oil passage via
the control valve and merges at the downstream of the boom (1) spool. Oil discharged from hydraulic pump
A2 merges with the discharged oil from the boom (2) via the boom (1) spool through the parallel oil pas-
sage and flows into the bottom side of the boom cylinder via the holding valve.
pb3. Lowering the boom (Boom 2)

pa3. Raising the boom (Boom 2)
28. Bucket cylinder
53. Boom control lever

Copyright ©
8020-25
Boom-Up Circuit (Single)
p
pc5 Boom cylinder
26 25
27
Arm
cylinder
A7
pb3 B7
pa3 pb7
pa7
Remote control valve Cushion valve G H

A1 A2 A3
53 57
2
4
Hydraulic pump
E T
10
330.1.03.07.23A2

Copyright ©
8020-26
2. Boom-Up Circuit (Combined)
When floor digging operation is performed, the boom-up pilot pressure, which is supplied to port pc5, releases the
restriction on flow to the arm by moving the swing priority variable restriction to the left. This makes the arm move
smoothly.

53. Boom and bucket control lever

Copyright ©
8020-27
Boom-Up Circuit (Combined)
T1 p
pc5 Boom cylinder
pc1
26 25
27 B5
Arm A5
cylinder pb5
pa5-1 pb9
pa5-2
pa9
A7
pb3
B7
pa3 pb7
pa7
Remote control valve Cushion valve G H C D

A1 A2 A3
53 57
2
4
Hydraulic pump
E T A
10
330.1.03.07.23B2

Copyright ©
8020-28
3. Boom-Down Load Holding
When the boom is in neutral, oil on the boom cylinder bottom side is sealed by the load holding valve
check. This mechanism reduces internal leakage from the main spool. For boom-down operation, the pilot
pressure enters port pb7 of the control valve and moves the spool of the control valve to the boom-down
side. Also, the pilot pressure enters port pc2 and moves the load holding valve spool to the left. Through
this mechanism, the oil in the spring chamber of the load holding valve check passes the load holding
valve spool creating a connection to the tank. Consequently, the pressure on the spring chamber
decreases and the load holding valve check is released. The hydraulic oil at the bottom side of the boom
cylinder is returned to the tank line, the rod of the boom cylinder shrinks, and the boom is lowered.
pb7/A7. Lowering the boom (Boom 1)

pa7/B7. Raising the boom (Boom 1)

Copyright ©
8020-29
Boom-Down Load Holding
T2 Boom cylinder
27 26 25
Arm
cylinder
DR2''
pc2
A7
) B7
pb7
pa7 Detail
Load holding DR2'
valve spool
DR2
pc2
Load holding A7
valve check
Boom(2) Boom(1)
P2 Control valve 15
Remote control valve Cushion valve

P G H
53 57 A2 A3
4
2
Hydraulic pump
F T
10
330.1.03.07.23C2

Copyright ©
8020-30
4. Boom-Down Circuit
For boom-down operation, pilot pressure is supplied at port pb7 of the control valve, and the boom spool moves to the
boom-down side. At the same time, the pilot pressure opens the boom load holding valve and partially regenerates
the discharged oil from the bottom side of boom cylinder at the rod side via the check in the spool. (The lower the load
pressure of the cylinder rod side, the more the regenerated volume will be.)
When the boom is moved down as quickly as possible and the spool is at full stroke, negative pressure is generated
by bleed-off oil passage in the center bypass. High pressure generation is coutrolled, and vibration of the body is
reduced. Since the lack of oil is to be supplemented in the regenerative circuit, engine output can be effectively used.
pb7/A7. Lowering the boom (Boom 1)

pa7/B7. Raising the boom (Boom 1)

Copyright ©
8020-31
Boom-Down Circuit
T2 Boom cylinder
26 25
27
Arm
cylinder
DR2'
pc2
A7
(1) B7
pb7
pa7
Load holding
Detail valve check
A7
H/V
B7
pb7
P2 15
Control valve T2
P2 Bleed-off
Cushion valve G H
Remote control valve A2 A3
P 57
53
4
2
Hydraulic pump
F T
10
330.1.03.07.23D2

Copyright ©
8020-32
Backup Circuits
1. Combined Circuit (Breaker Circuit)
Through remote control operation, the pilot pressure that is supplied to port pb4 of the control valve switches the
backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the breaker.
The pilot pressure operates the pressure switch at the same time. When the change-over switch in the cab is turned
to breaker mode, the controller directs the engine controller by signal from pressure switch so that the speed can
match the previously set engine speed.
Return oil from the breaker passes by way of 3-direction valve, and oil exceeding the set pressure flows from the stop
valve via the relief valve to return to the hydraulic oil tank.
pb4/B4. Breaker/Crusher circuit

pa4/A4. Crusher Circuit
72. Control pedal
76. 3-way selector
78. Return filter
83. Shut-off valve
A1. Controller
B25. Breaker pilot pressure switch
S14. Breaker/Crusher Switch
W4. Breaker safety valve
Y9. Breaker/Crusher two flow solenoid valve

Copyright ©
8020-33
Combined Circuit (Breaker Circuit)
78
Filter
76
3-direction valve
1
83
2
83 Stop valve W4
B4
Relief valve
83 pb4
pa4
72
P T
1 2
Pressure S1 P1
B25 switch Control valve 15
A1 A2
P T Y9
Shuttle
valve
S2 A
B1 B2 Solenoid
valve S14 Change-over switch
2
A1 A2 A3
Controller 1
Hydraulic pump
A1 10

Copyright ©
8020-34
2. Combined Circuit (High Speed Confluence Circuit)
Through remote control operation, the pilot pressure that is supplied to port pa4 (or pb4) of the control valve switches
the backup spool. This allows the discharged oil from the hydraulic pump A1 to flow into the end attachment.
Turning the change-over switch in the cab to crusher (2) energizes the solenoid valve so that the valve is switched
over.
Pilot pressure divided via remote control valve is fed in the port pa10 by way of solenoid valve.
This changes over the spool to block the center-bypass circuit.
The blocked discharge oil of hydraulic pump A2 flows by way of merging passage to be combined together with the
discharged oil out of hydaulic pump A1 at upper flow course of the spare spool.
pb4/B4. Breaker/Crusher circuit

pa4/A4. Crusher Circuit
72. Control pedal
76. 3-way selector
78. Return filter
83. Shut-off valve
A1. Controller
B25. Breaker pilot pressure switch
S14. Breaker/Crusher Switch
W4. Breaker safety valve
Y9. Breaker/Crusher two flow solenoid valve

Copyright ©
8020-35
Combined Circuit (High Speed Confluence Circuit)
78 T1
Filter
pa10
76
3-direction valve
83
2 3
83 Stop valve W4 B4
Relief valve A4
83 ppb4
pa4
72
1 T 2
Pressure S1 P1 P2
B25 switch Control valve 15
A1 A2
P T Y9
Shuttle
valve
B1 S2 B2 A Solenoid
valve S14 Change-over switch
2
A1 A2 A3
Controller 1
Hydraulic pump
A1 10
330.1.03.09.17B2

Copyright ©
8020-36
NOTES
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Copyright ©
8021
Section
8021
TRAVEL HYDRAULIC MOTOR

ASSEMBLY AND DISASSEMBLY

Printed in France
Copyright ©
8021-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
SPECIAL TORQUES ..................................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................... 3
TRAVEL MOTOR ........................................................................................................................................................... 5

Disassembly ............................................................................................................................................................... 7
Assembly ................................................................................................................................................................... 9
BEARING MEASUREMENT ........................................................................................................................................ 12
INSPECTION ............................................................................................................................................................... 13
OVERLOAD RELIEF VALVE ....................................................................................................................................... 16

Disassembly ............................................................................................................................................................. 16
TROUBLESHOOTING ................................................................................................................................................. 17
SPECIFICATIONS
See Section 1002.
SPECIAL TORQUES
Screw (56) ........................................................................................................324±32.4 Nm (238.97 lbf-ft)±(23.90 lbf-ft)
Pilot valve plug (35) ............................................................................................. 49 - 58.8 Nm (36.14 lbf-ft - 43.37 lbf-ft)
Overload relief valve (57) ................................................................................... 98.1 - 118 Nm (72.35 lbf-ft - 87.03 lbf-ft)
Plug (29) ......................................................................................................... 441 - 446 Nm (325.26 lbf-ft - 228.95 lbf-ft)
Plug (42) ......................................................................................................................................... 14.7 Nm (10.84 lbf-ft)
Plug (38) ......................................................................................................................................... 29.4 Nm (21.68 lbf-ft)
Plug (60).......................................................................................................................................... 98.1 Nm (72.35 lbf-ft)

Copyright ©
8021-3
SPECIAL TOOLS
C B A
D
E
C B E
F
D
CRPH06D001A CRPH06D006A
Mount metal (2 pieces) Jig for inserting oil seal
A 160 mm (6.30 in) D 100 mm (3.94 in) A 100 mm (3.94 in) D Ø 90 mm (3.54 in)
B 70 mm (2.75 in) E 37 mm (1.46 in) B 7.7 mm (0.30 in) E more than10 mm (0.40
C 20 mm (0.79 in) in)
C Ø 67.5 mm (2.66 in) F R 0. 5 (0.01 in)
H A
A
F B C
G C B
D
E
D
CRPH06D002A
Jig for pulling out brake piston (2 pieces)
CRPH06D004A
A 12 mm E 100 mm (3.94 in)
Jig for inserting rear bearing
(0.47 in)
A 120 mm (4.72 in) C Ø 42 mm (1.65 in)
B Ø 24 mm F Ø 60 mm (2.36 in)
B Ø 36 mm (1.42 in) D 3 mm (0.12 in)
(0.94 in)
C Ø 40 mm G Ø 6.5 mm (0.26 in)
(1.57 in)
D 20 mm H Hex.socket head bolt 2-M6 x 100
(0.79 in)

Copyright ©
8021-4
E
F C
F E
D B
A
CRPH06D005A
Guide pin for rear cover (2 pieces)
A 100 mm (3.94 in) D M 18
A B C D
B 32 mm (1.26 in) E R2
C 25 mm (0.98 in) F 10°
J
I
K
L
CRPH06D006B
Jig for inserting brake piston
A Ø 280 mm G 2 - M 18 x 35
(11.02 in)
B P. C.D. 251 mm H 2 - 20 drill hole
(9.88 in)
C Ø 215 mm I 15 mm (0.59 in)
(8.46 in)
D Ø 195 mm J 50 mm (1.97 in)
(7.68 in)
E 21 mm (0.83 in) K 10 - plain washer
Ø 18 mm (0.71 in)
F 10 mm (0.39 in) L 2 - M18 x 50

Copyright ©
8021-5
TRAVEL MOTOR
Description
48 49 47 46 43
55 24 53 25 44 45 42
5 8
6
2
7 52
9
51
58
59 38
4 39
3 54
10
11 13
1 16 12 15 14 17 20 22 23 50 21 56
18
31 19 33 32 34 35 36
36
37
48 57
61 60
29
30
28
27
26 40 41 42
43
330.7.02.02.37A1

Copyright ©
8021-6
1 CASING 31 PILOT VALVE SPOOL
2 PLUG 32 PIN
3 OIL SEAL 33 SPRING HOLDER
4 CIRCULAR SNAP RING 34 SPRING
5 EXPANDER PLUG 35 PILOT VALVE PLUG
6 INCLINED PISTON 36 O-RING
7 PISTON SEAL 37 CONNECTOR
8 STEEL BALL 38 PLUG
9 SHAFT 39 O-RING
10 BEARING 40 RESTRICTOR (BRAKE VALVE)
11 PIVOT 41 RESTRICTOR SPRING (BRAKE VALVE)
12 SHOE PLATE 42 PLUG
13 CYLINDER BLOCK 43 O-RING
14 CYLINDER SPRING 44 CHECK VALVE
15 SPRING HOLDER 45 CHECK VALVE SPRING
16 BALL JOINT 46 RESTRICTOR (0.6)
17 SHOE RETAINER 47 O-RING
18 PISTON ASSEMBLY 48 RESTRICTOR (0.8)
19 SEPARATOR PLATE 49 O-RING
20 FRICTION PLATE 50 O-RING
21 BRAKE PISTON 51 BEARING
22 O-RING (SMALL) 52 SHIM
23 O-RING (LARGE) 53 PARALLEL PIN
24 REAR COVER 54 VALVE PLATE
25 PLUG 55 BRAKE SPRING
26 SPOOL ASSEMBLY 56 SCREW
27 SPRING HOLDER 57 OVERLOAD RELIEF VALVE
28 SPRING 58 COUPLING
29 PLUG 59 RETAINING RING
30 O-RING 60 PLUG
61 O-RING

Copyright ©
8021-7
Disassembly 3. Review the sectional drawings prior to disassem-
bling and obtain the parts required according to the
General precautions specific purpose/scope of the job. Do not reuse
1. Hydraulic devices are made of precision compo- seals and O-rings that have been disassembled.
nents in general and structurally have small toler- Also, some parts must be replaced as subassembly
ances. Disassembling/assembling must be done in because those parts are not supplied separately.
a clean area free of dust. Tools and cleaning oil 4. Pistons and cylinders, when they are brand new, do
must also be clean and must be handled with care. not need to be assemblied in a particular order.
2. If devices are removed from the main machine, first When disassembling, however, they need to be
clean the surrounding areas of the port, then plug marked if they are to be used again. Before remov-
the ports and handle with utmost care to keep dust/ ing the pistons from the cylinders, mark them all so
water from entering the inside. they can be put together in the exact order they
were assemblied in originally.
WARNING: Keep hands and fingers away from small gaps or crevices among parts. Lifted loads also require
! extra attention since they may fall on your feet.
NOTE: the numbers in brackets refer to the drawing on STEP 7

page 3.
STEP 1 Guide pin
Remove the plug (29) and O-ring (30).
Hole for releasing 49
STEP 2 brake (left)
Remove spring (28), spring holder (27) and spool 47 55 24
assembly (26).
Put the mating mark on both spool assembly (26) and 52
rear cover (24) so that spool assembly (26) should not
be reversed on re-assembling.
It is impossible to disassemble this spool assembly (26)
further because spool assembly (26) is fixed by adhe-
sive.
STEP 3
Remove plug (42), O-ring (43), check restrictor spring
(41) and restrictor (40).
STEP 4
Remove overload relief valves (57).
When removing overload relief valve (57), valve seat
(57-3) easily comes off, so take great care not to fall
into the rear cover (24) or lose. 13 54 50 51 56
STEP 5
Remove pilot valve plug (35) and then, remove O-ring
(36), pilot valve spring (34), spring holder (33), pilot
330.7.02.02.37D1
valve spool (31) and pin (32). Place the motor with the shaft horizontal, remove Hex.
STEP 6 socket head bolts Ml8 x 50 (56) of rear cover (24) leav-
Remove coupling (58). ing two on diagonally upper and lower position.

Copyright ©
8021-8
STEP 8 STEP 15
Install two guide pins diagonally into rear cover (24).
(Purpose: Prevention of falling rear cover).
STEP 9 19 20
Loosen slowly and simultaneously the remaining two
Hex. socket head bolts Ml8 x 50 (56). 13
STEP 10
Remove rear cover (24) and brake springs (55) taking
care cylinder block (13) is not coming out stuck with
rear cover (24).
18
STEP 11
Keep the cylinder block (13) in its position and remove
the valve plate (54).
Mark the valve plate (54) and the rear cover (24) to dif-
Paper pipe
ferentiate the front from the back at assembly.
STEP 12
Press the cylinder block (13) onto the pressing jig using Matching mark
the removed screw (56) to push out the inner race of
the rear bearing (51).
16 15 17 14
STEP 13
330.7.02.02.37.9
Take a soft material like a sheet of paper and roll it into
a tube to use for marking without scratching parts.
Insert this into the piston (18) hole and mark the cir-
cumference of the cylinder block (13).
STEP 16
Remove the cylinder block (13), the spring bearing (15)
and the cylinder spring (14).
STEP 17
Remove the separator plate (19) and the friction plate
(20).
Place the gear (bearing) extractor inner race of the STEP 18
bearing (51) to remove the bearing. Remove the nine piston assemblies (18), the shoe
retainers (17) and the ball joints (16), all at the same
STEP 14 time.
Hole for releasing brake
NOTE: The procedures above are for the motor as a
single unit, but can also be applied on models with
reduction gears. The disassembling for those can be
conducted in the same manner. The job with theses
models may be easier because there is less vibration
due to larger shafts.
Secure the brake piston (21) with hand and push the
piston (21) out by supplying air through the brake
release oil hole.
WARNING: The procedure requires extra atten-

! tion: the piston may pop out due to the air pres-
sure.

Copyright ©
8021-9
STEP 19 Assembly
General precautions
3 10 1
6 12 1. Clean parts well with cleaning oil and blow dry with
air.
2. Apply clean hydraulic oil to sliding parts prior to
4 assembling.
WARNING: Keep hands and fingers away from

small gaps or crevices among parts. Lifted
! loads also require extra attention since they
11 may fall on your feet.
9 STEP 1
3
330.7.02.02.37I1
Remove the shoe plate (12).
STEP 20 1
Do not remove the inclined piston (6).
In the event that this must come out, secure it by hand,
push out by blowing air into the hole.
STEP 21 CS02B533
The shaft (9) will come out on its own. Apply grease to the outer perimeter of the oil seal (3) as
well as to the inner perimeter of the casing (1). Use jigs
STEP 22 to gently and evenly tap the oil seal (3) into casing (1)
Remove the retaining ring (4) and take out the oil seal without slanting.
(3).
STEP 2
STEP 23
When changing the bearings, inner and outer races are
also to be removed with a bearing puller. Each must be
3 10 1
replaced as an assembly.
6 12
330.7.02.02.37I1
Secure the oil seal (3) with the snap ring (4).

Copyright ©
8021-10
STEP 3 STEP 9
Insert the outer race of the bearing (10) into casing (1) Plastic hammer
and press fit the inner race into the shaft (9).
Heating the inner race to approximately 100°C facili- 1 18 19 20 22 23 56
tates the insertion process here.
STEP 4
Place the shaft (9) into the casing (1). Prior to this pro-
cedure, grease must be applied to the working surface
51
that contacts the seal (3).
STEP 5
Insert the inclined piston (6).
STEP 6
Insert the pivot (11) into the side where the markings
match. Also, if the machine has been in use for a long
time prior to servicing, insert in the direction so the slid-
ing traces on the spherical part of the shoe plate (12)
match the contact traces. 21
STEP 7
17 18 15 13
Jig for inserting
rear bearing Or
Jig for inserting brake piston
10-Plain washer
12 330.7.02.02.37P1
Gently tap and insert the inner race of the rear bearing
(51) into the edge of the shaft (9), see jig for inserting
16 rear bearing on page 3.
9 14 13 STEP 10
1 The separator plates (19) and the friction plates (20)
need to be installed alternately and completely. Start
330.7.02.02.37O1
Apply a liberal amount of grease to the spherical sec- with a separator plate (19) and finish with one also.
tion of the shoe plate (12), then install. STEP 11
STEP 8 Insert the O-rings (22) and (23) into the brake piston
Place the piston assembly (18), shoe retainer (17), ball (21), then install the piston into the casing (1) using the
joint (16), spring (14) into the cylinder block (13) and jig for inserting the brake piston, see on page 3.
insert the whole assembly into the shaft (9). The piston
assembly (18) must be assembled into the original
hole.

Copyright ©
8021-11
STEP 12 STEP 18
Inserting spool assembly (26) to rear cover (24) coin-
49 ciding mating mark made prior to disassembling, and
then assemble spring holder (27) and spring (28).
47 55 24
STEP 19
52 Assemble M 42 plug (29) with O-ring (30), tighten to
the torque specified on page 2.
58
59
13 54 50 51 56
330.7.02.02.37D1
Install two guide pins (B) diagonally on casing (1).(Pur-
pose: Guide for installing rear cover)
Lay down rear cover (24) to mount valve plate (54)
coinciding mating mark made prior to disassembling
and also place brake springs (55) with ample grease to
be attached to rear cover (24) while assembling.
Also set shim (52), outer race of rear bearing (51) and
O-rings (50), (47), (49) on rear cover (24).
STEP 13
Insert rear cover (24) to casing (1) along the guide pin,
and install two Hex. socket head bolts M18 x 50 (56)
diagonally upper and lower position and tight them to
assemble rear cover (24) parallel.
Then, install the rest of Hex. socket head bolts M18 x
50 (56) and remove guide pin and install two the
remainder.
When removing outer race of rear bearing (51), install
shim (52) without fail.
Confirm that O-rings (47), (49), (50) are installed to rear
cover (24).
STEP 14
Assemble coupling (58).
STEP 15
Assemble spring (34), spring holder (33), pilot valve
spool (31) and pin (32) to rear cover (24), and then
install pilot valve plug (35) with O-ring (36), tighten to
the torque specified on page 2.
STEP 16
Assemble overload relief valves (57), tighten to the
torque specified on page 2.
STEP 17
Assemble restrictor (40) and restrictor spring (41) to
rear cover (24), and then install G/18 plug (42) with O-
ring (43), tighten to the torque specified on page 2.

Copyright ©
8021-12
BEARING MEASUREMENT
E S
F
9 10 1 51 52 24
330.7.02.02.37J
This work should be done only when you have changed bearings (10), (51), shaft (9), casing (1) or rear cover (24).
Measure the assembling width «E»
Take care not to incline shaft (9).
Measure the depth «F» of rear cover (24)
Measure them at crossed 4 places on the circuit, then calculate their mean value.
When thickness of shim (52) to be used is placed as «S», the clearance «Y» can be calculated as follows:
Y=F-(E+S)
Select one or two shim (52) so as the clearance «Y» to come to 0-0.1 mm (clearance) on this unit.

Copyright ©
8021-13
INSPECTION
Items to measure and

Criterion and remedy
methods of measurement
1. Sliding surfaces on cylinder block, Table 2. Items and Surface Surface Remedy
valve plate and shoe plate what to be roughness: roughness:
Measure the roughness of the sliding inspected standard acceptable
surfaces of these parts using surface limit
roughness gauge. Surface 0.4 Zµ or 3.0 Zµ or Repair or
roughness of below below replace
cylinder block,
valve plate and
shoe plate
Attention! Lapping is required to repair the surface roughness of
cylinder block and valve plate. (Lapping material: # 1200)
Measure the hardness of the sliding Table 3. Items and Hardness: Hardness: Remedy
surfaces of shoe plate using hardness what to be standard acceptable
meter. inspected limit
Shoe plate HS78 or HS74 Replace
above
2. Clearance between piston and Table 4. Items and Standard Allowable Remedy
cylinder block what to be value value
Measure the outer diameter of piston inspected (in mm)
(in mm)
and the inner diameter of cylinder
using a micrometer at 3 locations at Outer diameter of 0.01 mm 0.05 mm Replace
least in the longitudinal direction. piston d-d1 piston or
Inner diameter of cylinder
The maximum outer diameter is 0.01 mm 0.022 mm
cylinder bore D1- block
represented as d, minimum diameter
as d1, maximum hole diameter as D D
0.037 to 0.065 mm
and minimum diameter as D1. Clearance D-d
0.047 mm
Attention! All 9 pistons must be replaced together if replacement is
necessary.
3. Looseness on piston and shoe Table 5. Items and Standard Allowable Remedy
Hold the shoe on the surface plate what to be dimensions (value in
with jigs and pull out the piston inspected (value in mm)
upwards to measure looseness d of mm)
the piston and shoe.
Looseness of the 0 to 0.1 mm 0.5 mm Replace
crimping area of piston
piston and shoe

Copyright ©
8021-14
Dial gauge
Piston
Jigs
Magnet Shoe
Surface plate
Looseness of crimping area Measurement

330-7-02-02-37T1

4. Negative braking force Table 6. Items and Standard Allowable Remedy
When the assembling is complete, what to be inspected value (in mm) value (in mm)
measure the torque at start of Brake torque 1.171 Nm 1.055 Nm Separator plate
rotation by placing a torque wrench (0.863 lbf-ft) (0.778 lbf-ft) Friction plate
at the end of the output shaft. Spring
Replace all of
the above
Standard of replacing friction and separating plate.
When measuring parking brake torque, it needs to disassemble travelling
unit to motor and reduction gear portion, and it's so hard.
The right allowable value is a standard of replacing friction and separating
plate.
If it is impossible to disassemble travelling unit, refer to the right value.
Standard of replacing friction and separating plate
Measure the total thickness of 6 pieces of friction plate and 7 pieces of
separating plate.
And if the total thickness is below the following allowable value, replace all
separating and friction plates and springs.
Criteria: 33.04 mm (1.30 in)

Allowable Thickness: 31.5 mm (1.24 in)
5. Shaft Usable up to 0.05 mm of wear with steps.
Use a roughness gauge and Attention! Replace the oil seal (3) also when replacing the shaft.
measure the extent of wear on the Attention! The thickness of the shim (52) needs to be adjusted when
seal of the shaft. replacing the shaft.
6. Bearing The bearings (10 and 51) need to be replaced before the hour meter
records 10,000 hours of operation.
Replace bearings.
Attention! Replace the inner and the outer race also when replacing the
bearings.
Attention! The thickness of the shim (52) needs to be adjusted when
replacing the bearings.
7. Spline The spline is reusable up to the 0.3 mm of wear with steps at the contact
Replace parts when the wear of the surface.
spline exceeds the allowable limit.

Copyright ©
8021-15

8. Overload relief valve section Replace as a subassembly every 10,000 hours according to the main
The pressure check and the machine’s hour meter.
adjustment of the overload relief
section cannot be done unless the
applicable test bench is available.

Copyright ©
8021-16
OVERLOAD RELIEF VALVE
Disassembly
NOTE: As a rule, overload relief valve (57) should be handled as one service part. If there are any trouble on overload
relief valve (57), replace as an assembly.
57-3 57-2 57-1 57-12 57-13 57-4 57-9 57-8 57-12 57-10 57-11 57-6 57-7 57-5
CS02B539
NOTE: Valve seat (57-3) is fitted in bore of socket (57-
1) at clearance fit.
When removing overload relief valve (57), valve seat
(57-3) easily comes off, so take great care not to los
NOTE: When assembling overload relief valve (57) to
rear cover (24), apply grease sufficiently on engage-
ment part not to drop valve seat (57-3), tighten to the
torque specified on page 2.
GREASE
CRPH06D015A

Copyright ©
8021-17
TROUBLESHOOTING
1.Hydraulic motor never starts

SYMPTOM CAUSE REMEDY
Pressure never Malfunction of built-in relief valve. Repair or replace relief valve
increases
Pressure increases 1.Parking brake is not released 1.After inspection of clogging, repair or
Clogging of restrictor replace
2.Parking brake is not released 2.Re-install the spool in correct direc-
Spool is installed in wrong direction tion
3.Stuck friction or separating plate of 3.Replace friction and separating plate
parking brake portion
4.Stuck brake piston 4.Repair outer dia. of brake piston or
replace It.
5.Seizure of sliding piston 5.Check, repair or replace piston shoe,
swash plate, cylinder block valve plate
etc.
6.Malfunction of spool: 6.Repair or replace
- Stick between spool and body
- Clogging of restrictor
2.Hydraulic motor rotates weakly
Set pressure of overload valve is Malfunction of spool: Repair or replace
correct, but brake is released - Stick between spool and body
belatedly
Negative brake is released, but High oil viscosity. Raise oil temperature or change the
motor is hard to start hydraulic oil
Negative brake is released, but 1.Negative brake is not completely 1.Check clogging of choke
motor starts weakly released.
Clogging of choke of pressure release
passage
2.Relief valve catches small particles 2.Wash relief valve, check or replace
seat of it
3.Seizure of sliding portion 3.Check, repair or replace sliding por-
tion
3.Drive shaft never rotate up to the set value
Rotation of drive shaft never 1.Shortage of oil coming in 1.Check oil flow or hydraulic circuit to
reaches the set value motor.
2.Large wear or flaw made on shoe, cyl- 2.Check, repair or replace the parts
inder block or valve plate

Copyright ©
8021-18
4.Brake refuses to work

SYMPTOM CAUSE REMEDY
Brake refuses to work Malfunction of negative brake: Check, repair or replace brake piston,
- Worn friction plate. friction plate, spring, etc.
- Broken spring.
Brake works on counter lever Malfunction of spool: Repair or replace or clean up
operation - Stick between spool and body.
- Stick of check valve or that by small
particle.
- Clogging of restrictor.
5.Oil leakage
Oil leakage 1.Loose Hex. socket head bolt or plug 1.Fasten it with given torque
2.O-ring is torn off 2.Replace O-ring
3.Oil leaks inside gear casing 3.Replace oil seal
6.Would not shift from high to low
Would not shift from high to Stick of spool of pilot valve Replace pilot valve assembly.
low
7.Abnormal noise
Abnormal noise appear together Malfunction of spool: Bleed air
with big vibration when brake is - Air is caught inside brake valve
slowly applied or oil is supplied to
Stick between spool and body Repair or replace
other circuits while motor is run-
ning
8.Hunting occurs while descending the slope
Severe hunting while inching Malfunction of spool: Repair or replace
1) Stick between spool and body
1) Restrictor is not seated completely
Interference with parking brake: Repair or replace
1) Permanent set or broken spring

Copyright ©
8022
Section
8022
FAN MOTOR
REMOVAL AND INSTALATION

Printed in France
Copyright ©
8022-2
TABLE OF CONTENTS
FAN MOTOR................................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 4

Copyright ©
8022-3
FAN MOTOR
Description
3
2
1
2
7 6
4 8
10 9
11
12
CRPH06B113G1
1 FAN MOTOR 7 WASHER
2 PILOT VALVE ASSEMBLY 8 VENTILATOR
3 HOSE 9 BOLT
4 HOSE 10 WASHER
5 HUB 11 BOLT
6 BOLT 12 WASHER

Copyright ©
8022-4
Removal STEP 7
STEP 1
CRPH06B114A
Label and disconnect the hoses (4).
JS00163A
Park the machine on hard, flat ground. Lower the STEP 8
attachment to the ground. Label and disconnect the electrical connections to the
pilot valve assembly (2).
STEP 2
Release pressure in the hydraulic system and in the STEP 9
hydraulic reservoir (see Section 8000). Remove the bolt (6) and the washer (7) from the fan
motor (1) and remove the fan motor.
STEP 3
Installation
NOTE: When installing the fan motor on the machine,
1 proceed in the reverse order from that of removal.
operations:
Manual).
tor’s Manual).
leaks.
CT05L063
necessary.
Disconnect the earth cable (-) (1) from the battery.
STEP 4
Refer to section 2001 and remove the radiateur and oil-
cooler assembly.
STEP 5
Remove the bolt (11) and the washer (12) fixing the
ventilator (8) and the hub (5) on the fan motor (1).
STEP 6
Remove the bolt (9) and the washer (10) fixing the
ventilator (8) on the hub (5), then remove the ventilator
and the hub.

Copyright ©
Section
8023
8023
FAN MOTOR

Printed in France
Copyright ©
8023-2
TABLE OF CONTENTS
SPECIFICATIONS ........................................................................................................................................................... 2
PREPARATION BEFORE REMOVAL/INSTALLATION................................................................................................... 2
FAN MOTOR.................................................................................................................................................................... 3
Description ................................................................................................................................................................... 3
REPLACEMENT PROCEDURE FOR THE OIL SEAL..................................................................................................... 4

Disassembly ................................................................................................................................................................. 4
Assembly ..................................................................................................................................................................... 5
REPLACEMENT PROCEDURE FOR THE SUCTION SAFETY VALVE ......................................................................... 6

Disassembly ................................................................................................................................................................. 6
Assembly ..................................................................................................................................................................... 7
REPLACEMENT PROCEDURE FOR THE PILOT VALVE FOR THE REVERSING OPERATIONS .............................. 8
Disassembly ................................................................................................................................................................. 8
Assembly ..................................................................................................................................................................... 8

Copyright ©
8023-3
FAN MOTOR
Description
1 3
4 5 6 7
CRPH06B035G01
1 SNAP RING 6 SAFETY VALVE
2 SPACER 7 O-RING
3 OIL SEAL 8 PILOT VALVE ASSEMBLY
4 PLUG 9 BOLT
5 SPRING

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8023-4
REPLACEMENT PROCEDURE FOR THE OIL SEAL

Disassembly STEP 3
NOTE: Precautions before starting the disassembly 2
work. Before starting the disassembly work, wash the
surfaces of the motor and the shaft so that foreign
substance may not enter into inside of the motor.
STEP 1
CRPH06B020A01
Remove the spacer (2).
STEP 4
3
CRPH06B018A01
Place the motor on the work bench so that its shaft
may be directed upward.
STEP 2
CRPH06B021A01
Using a gimlet type tool (ice pick, etc.), remove the
oil seal (3).
CRPH06B019A01
Using snap ring pliers, remove the snap ring (1).
CRPH06B022A01
WARNING: Be careful not to receive injury to your
fingers by the gimlet type tool (ice pick, etc).

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8023-5
STEP 5 STEP 3
CRPH06B023A01 CRPH06B024A01
Remove the foreign substance remaining in the
seal groove to clean the groove completely.
NOTE: When cleaning, take care that foreign
matter will not enter the bearing.
Assembly
STEP 1
3
A
B
C
CRPH06B025A01
Install the oil seal into the seal groove using a
press-fitting tool.
(A) 5. 2± 0. 1
(B) Ø 26
(C) Ø 44
STEP 4
CRPH06B022A01
After applying grease on the inside surfaces of the
lip of the oil seal (3), install the oil seal into the
shaft. 1
STEP 2
2
CRPH06B019A01
Using snap ring pliers, install the snap ring (1) into
the ring groove.
NOTE: Check and make sure that the snap ring is
CRPH06B020A01
being inserted securely into the ring groove.
Install the spacer (2).

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8023-6
REPLACEMENT PROCEDURE FOR THE SUCTION SAFETY VALVE

Disassembly STEP 2
STEP 1 5
6
4 CRPH06B028A01
CRPH06B026A01
NOTE: Precautions before starting the disassembly 5

work. Before starting the disassembly work, wash the
surfaces of the motor and the neighborhood of the plug 6
so that foreign substance may not enter into inside of
the valve.
Place the motor on the work bench so that its plug
may be directed sideway.
CRPH06B029A01
Remove the spring (5) and the safety valve (6).
STEP 3
CRPH06B027A01
Remove the plug (4).
CRPH06B030A01
Remove the foreign substance remaining on the
safety valve mounting surface to clean the surface
completely.

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8023-7
Assembly STEP 3
STEP 1
5
6
4
CRPH06B026A01
Tightening torque for the plug (4):
CRPH06B027A01 147 to 186.2 Nm (108 ~ 137 lb-ft).
After applying the engine oil, install the safety
valve (6) and spring (5)
STEP 2
CRPH06B031A01
Tighten the plug (4) after setting the O-ring (7) to

the plug.
NOTE: When carrying out the tightening work, fix to
stabilize the motor body using a press machine, etc.

Copyright ©
8023-8
REPLACEMENT PROCEDURE FOR THE PILOT VALVE FOR THE REVERSING

OPERATIONS
Disassembly Assembly
STEP 1 STEP 1
NOTE: Before starting the disassembly work, wash the 10 11 8 12
surfaces of the motor and the neighborhood of the pilot
valve so that foreign substance may not enter into the
motor body side.
CRPH06B034A01
Check the O-rings (10), (11) and (12) are installed
on the new pilot valve (8).
9 STEP 2
CRPH06B032A01
Place the motor on the work bench so that the pilot
valve may be directed sideway.
Remove 4 pcs. of the mounting bolts (9) and
remove the pilot valve (8).
8
STEP 2
CRPH06B032A01
Setting the pilot valve (8) to the motor body, tighten 4
pcs. of the mounting bolts (9) to a torque of 27.5 to 34.3
Nm (20 ~ 25 lb-ft).
CRPH06B033A01
Clean the pilot valve mounting surface completely.

Copyright ©
Section
8024
8024
FAN PUMP
REMOVAL, DISASSEMBLY, ASSEMBLY
AND INSTALLATION

Printed in France
Copyright ©
8024-2
TABLE OF CONTENTS
SPECIAL TOOLS ............................................................................................................................................................. 2
FAN PUMP....................................................................................................................................................................... 3
Description ................................................................................................................................................................... 3
Removal ....................................................................................................................................................................... 4
Disassembly................................................................................................................................................................. 5
Assembly ..................................................................................................................................................................... 6
Installation ..................................................................................................................................................................... 7
SPECIAL TOOLS
CRPH06B047A01
JIG: φ39mm (Outside Dia). x φ29mm (Inside Dia) x

100mm (Length).

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8024-3
FAN PUMP
Description
3
2
CRPH06B037G01
1 SNAP RING
2 OIL SEAL
3 PLATE

Copyright ©
8024-4
FAN PUMP
Removal
STEP 1
JS00163A1
STEP 2
hydraulic reservoir (see section 8000).
STEP 3
1
3
CRPH06B040A01
Label and disconnect the hoses (1) and (2).
Remove the screws (3) fixing the fan pump and remove
the fan pump.

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8024-5
Disassembly STEP 3
NOTE: Before decomposition, please wash the pump

surface and the spline shaft, and make sure that a
forign object should not go into the inside of a pump.
STEP 1
2
CRPH06B043A01
Remove the oil seal (2) using a gimlet (Ice Pick).
NOTE: Don't make a scrath on the shaft surface by a
gimlet. Be careful not injured using a gimlet (Ice Pick).
CRPH06B03A01
STEP 4
Put the pump on a work bench. Which the spline
shaft to be right overhead.
STEP 2
3
1
CRPH06B044A01
CRPH06B042A01
Remove the snap ring (1) using a snap ring plier.
CRPH06B045A01
Remove the plate (3) and take away the rubbish in
the seal housing.

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8024-6
Assembly
STEP 1
CRPH06B050A01
CRPH06B044A01
Clean up the plate (3) and install it in the bottom of
seal housing.
STEP 2
CRPH06B051A01
Install the oil seal (2) using the jig (see special tool
page 2).
STEP 3
CRPH06B048A01
CRPH06B042A01
CRPH06B049A01 Install the snap ring (1) using a snap ring plier.

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8024-7
Installation
NOTE: When installing the fan pump on the machine,
operations:
Manual).
tor’s Manual).
leaks.
necessary.

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8024-8
NOTES
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Copyright ©
Section
8030
HYDRAULIC COMPONENT FUNCTIONS
8030

Printed in France
Copyright ©
8030-2
TABLE OF CONTENTS
HYDRAULIC PUMP ................................................................................................................................................ 3
CONTROL VALVE .................................................................................................................................................. 6
SWING UNIT......................................................................................................................................................... 23
TRAVEL UNIT ....................................................................................................................................................... 28
FAN MOTOR FOR HYDRAULIC DRIVE .............................................................................................................. 40

Copyright ©
8030-3
HYDRAULIC PUMP
Structure and Principle of Operation
This pump couples two pumps placed on the same axis with the 1st gear (114) and distributes the rotational force to
the different axes. The rotational force transmitted from the motor to the front side drive shaft (111) drives the two
pumps and also drives the backup pump installed on the other axis simultaneously.
This pump consists of four major sections: the rotary group that is the main part of the pump governing the rotation,
the swash plate group that adjusts discharge rate, the valve block group that switches between intake and discharge
of oil, and the PTO group that transmits the rotational force from the gear pump drive shaft.
The rotary group is composed of the drive shaft F (111), cylinder block (012), piston shoes (151 and 152), retainer
(153), spherical bush (156) and cylinder spring (157).
Both ends of the drive shaft are supported by bearings (123 and 124).
The shoe forms a spherical joint crimped by a piston and contains a pocket area in order to reduce the thrust force
generated by the loading pressure and to balance the oil pressure so that it slides lightly on the shoe plate (211). The
subgroup of the piston shoe is pressed on the shoe plate by the cylinder spring via the retainer and spherical bushing
in order to facilitate its smooth movement on the shoe plate. The cylinder block is also pressed on the valve plate
(313) by a cylinder spring. The swash plate group consists of the swash plate (212), shoe plate (211), swash plate
support (251), tilting bush (214), tilting pin (531), and servo piston (532). The swash plate is supported on the swash
plate support by the cylindrical part formed on the opposite side of the shoe sliding side.
The hydraulic force, which is controlled by the regulator, is directed into the hydraulic compartment located on both
sides of the servo piston. This causes the servo piston to move back and forth. The movement of the servo piston
makes the swash plate swing on the swash plate support via the spherical part of the leaning pin and changes the
angle of incline (α).
The valve block group consists of the valve block (312), valve plate (313) and valve plate pin (885). The valve plate,
which has two claw-shaped ports, is installed on the valve block. It supplies oil to and recovers oil from the cylinder
block.
Oil that is switched by the valve plate enters the external piping through the valve block.
The PTO group consists of the 1st gear (114), 2nd gear (117) and 3rd gear (118). The 2nd and 3rd gears are sup-
ported by bearings (126 and 125) and are installed on the valve block.
When the drive shaft is driven by the motor (electric motor, engine, etc.), the cylinder block rotates simultaneously via
the spline connection. When the swash plate is inclined, the piston located inside the cylinder block moves back and
forth with respect to the cylinder as it rotates with the cylinder block. Specifically, when the cylinder block rotates one
full turn, the piston moves away from the valve plate (oil is drawn in) during the first 180 degrees and moves towards
the valve plate (oil is discharged) during the remaining 180 degrees. When the angle of the swash plate is zero, the
piston does not move and oil is not discharged.
The rotation of the drive shaft is led to the 1st gear (114), transmitted to the 3rd gear (118) through the 2nd gear
(117) and drives the backup pump connected to the 3rd gear.

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8030-4
Hydraulic pump drawing

Copyright ©
8030-5
Description
No. PART NAME QTY. CONSTITUENT PART(QTY)
04 GEAR PUMP 1ST ZX15LPRZ2
05 PTO ASS'Y 1ST
011 PISTON ASS'Y 2ST 151(9PC), 152(9PC)
013 CYLINDER(R) ASS'Y 1ST 141(1PC), 313(1PC)
014 CYLINDER(L) ASS'Y 1ST 141(1PC), 314(1PC)
030 SWASH PLATE ASS'Y 2ST 212(1PC), 214(1PC)
041 CHECK VALVE 1 ASS'Y 2ST 541(1PC), 543(1PC), 545(1PC)
042 CHECK VALVE 3 ASS'Y 2ST 541(1PC), 544(1PC), 545(1PC)
PROPORTINAL REDUCING
079 1ST KDRDE5KR-V3-V
VALVE ASS'Y
NO. PARTNAME QTY NO. PARTNAME QTY NO. PARTNAME QTY

111 DRIVE SHAFT(F) 1 401 HEX SOCKET HEAD BOLT 8 728 O-RING 4
113 DRIVE SHAFT(R) 1 406 HEX SOCKET HEAD BOLT 8 732 O-RING 2
114 GEAR 1ST 1 466 PLUG 2 774 OIL SEAL 1
123 ROLLER BEARING 2 468 PLUG 4 789 BACKUP RING 2
124 NEEDLE BEARING 2 490 PLUG 27 792 BACKUP RING 2
127 BEARING SPACER 3 492 PLUG 12 808 NUT 4
012 CYLINDER BLOCK 2 531 TILTING PIN 2 824 STOP RING 2
151 PISTON 18 532 SERVO PISTON 2 885 VALVE PLATE PIN 2
152 SHOE 18 534 STOPPER(L) 2 886 SPRING PIN 4
153 RETAINER 2 535 STOPPER(S) 2 901 EYE BOLT 2
156 SPHERICAL BUSH 2 541 SEAT 4 953 SET SCREW 2
157 CYLINDER SPRING 18 543 STOPPER 1 2 954 SET SCREW 2
211 SHOE PLATE 2 544 STOPPER 2 2 981 NAME PLATE 1
212 SWASH PLATE 2 545 STEEL BALL 4 983 PIN 2
214 TILTING BUSH 2 548 FEED BACK PIN 2
SWASH PLATE
251 2 702 O-RING 2
SUPPORT
261 SEAL COVER(F) 1 710 O-RING 2
263 SEAL COVER(R) 1 714 O-RING 1
271 PUMP CASING 2 717 O-RING 2
312 VALVE BLOCK 1 719 O-RING 2
313 VALVE PLATE(R) 1 724 O-RING 16
314 VALVE PLATE(L) 1 725 O-RING 6

Copyright ©
8030-6
Internal structure drawing of PTO
Description
No. PART NAME QTY.
115 IDLER SHAFT 1
117 GEAR 2ND 1
118 GEAR 3RD 1
125 BALL BEARING 2
126 ROLLER BEARING 1
128 BEARING SPACER 2
262 COVER 1
326 GEAR CASE 1
435 HEX SOCKET HEAD BOLT 8
468 PLUG 1
710 O-RING 1
728 O-RING 1
825 SNAP RING 1
826 SNAP RING 1
827 SNAP RING 1
886 PIN 2

Copyright ©
8030-7
CONTROL VALVE
Operation
1. Operation with all spools in neutral position
1) Neutral passage (Figures 1 and 2)
Oil supplied from Port P1 enters the tank passage Ta from neutral passage L1, passing the restriction Lc1
on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5.
Oil supplied from Port P2 passes the tank passage Ta through neutral passage R1, passing the restriction
Rc1 on the low pressure relief, and returns to Ports T1, T2, T3, T4 and T5.
Pressures in the pressure chambers L2 and R2 located in the upstream of the low pressure relief valve
are directed to the pump through Ports ps1 and ps2 and control the delivery volumes of pumps P1 and
P2.
In addition, if a large amount of extra oil flows into the neutral passage, the low pressure relief mechanism
functions to prevent pressures on Ports ps1 and ps2 from increasing abnormally.
2) Regulator operation explanation diagram
Oil supplied from port PP goes into port PT through throttle [Lc3]. It also flows into the tank passage [Ta]
through the land [Rc3], passing through the land [Lc4] and passage (5).
Part of the oil supplied from port PP goes into port PA through throttle [Lc5]. It also flows into the tank
passage [Ta] through the boom 1 spool land [Rc4], passing the passages [L4], (8) and [R4].
The oil that has passed through throttle [Lc6] flows into the tank passage [Ta] through the land [Lc7]. It
also passes through passage (4) and flows into the tank passage [Ta] through the travel spool land [Rc5].
[fig. 1]
NTROL VALVE

Copyright ©
8030-8

Copyright ©
8030-9
Single operation
1. Travel spool switching (Figures 3 and 4)
When switching the travel spool by adding pressure through the pilot port Pb1 (Pa1) in travel (Section 1),
the oil supplied from port P1 flows into port B1 (A1) passing through the neck part of the spool via neutral
passage [L1]. The returning oil passes through the neck part of the spool via port A1 (B1) and returns to
the tank passage [Ta]. When switching the travel spool by adding pressure through pilot port Pb6 (Pa6) in
travel (Section 6), the oil supplied from port P2 flows into port B6 (A6) passing through the neck part of
the spool or passage [S6-1] via neutral passage [R1]. At this moment, because pressures on parallel
passages [R3] and [S6-1] are equal, the poppet [S6-2] does not open. The returning oil passes through
the neck part of the spool via port A6 (B6) and returns to the tank passage [Ta]. When switching only one
side of the spool in travel (Section 1 or 6), land [Lc4] or [Rc3] closes. Since the flow of oil supplied from
port PP to the tank passage is shut off, the pressure on port PT increases.
fig.3
fig.4

Copyright ©
8030-10
2. Swing spool switching [Fig. 5]
When switching the swing spool by adding pressure through pilot port Pb2 (Pa2) in swing (Section 2), the
neutral passage [L1] closes. Oil supplied from port P1 passes from parallel passage [L3] through load
check valve [S2-1], passage [S2-2] and the neck part of the spool and flows into port B2 (A2). The
returning oil passes through the neck part of the spool via port A2 (B2) and returns to the tank passage
[Ta].
fig.5

Copyright ©
8030-11
3. Boom spool switching
1) Neutral Position [Fig. 6]
This valve has an anti-drift valve installed on the cylinder bottom side of boom 1. In the neutral position,
the poppet [AD1] is firmly seated by the pressure on port A7 that is directed to the spring chamber [AD5]
through the passage [AD2], spool [AD3] and passage [AD4].
2) Boom-up (2-pump confluence) [Fig. 7]
When switching the boom 1 spool by adding pressure through pilot port Pa7 in boom 1 (Section 7), the
neutral passage [R1] closes. Oil supplied from port P2 passes through the parallel passage [R3], the load
check valve [S7-1] and the neck part of the spool and flows into port A7. When switching the boom 2 spool
by also adding pressure through pilot port Pa3 in boom 2 (Section 3), the neutral passage [L1] closes. Oil
supplied from port P1 passes through the parallel passage [L3], the load check valve [S3-1], the neck part
of the spool and passage (6), and merges and flows into port A7. The returning oil passes through the
neck part of the spool via port B7 and returns to the tank passage [Ta].
3) Boom-down (regeneration) [Fig. 8]
When switching the boom 1 spool by adding pressure through pilot port Pb7 in boom 1 (Section 7), the
neutral passage [R1] closes. Oil supplied from port P2 passes through the parallel passage [R3], the load
check valve [S7-1] and the neck part of the spool and flows into port B7. When switching the spool [AD3]
in the anti-drift valve by adding pressure to port pc2 and reducing the pressure in spring chamber [AD5] at
the same time, the poppet [AD1] opens and the returning oil from port A7 returns to tank passage [Ta].
Part of the returning oil pushes open the poppet [S7-3] in boom 1 spool, passes through the passage [S7-
2] and merges into port B7 to prevent cavitation on the cylinder rod side.
fig.6

Copyright ©
8030-12
.
fig.7
fig.8

Copyright ©
8030-13
4. Backup spool switching [Fig. 9]
When switching the backup spool by adding pressure through pilot port Pb4 (Pa4) in backup (Section 4),
the neutral passage [L1] closes. Oil supplied from port P1 passes through the load check valve [S4-1], the
passage [S4-2] and the neck part of the spool through the parallel passage [L3] and flows into port B4
(A4). When switching the neutral cut spool [R] at the same time by adding pressure through port Pa
(Fig. 1), the oil supplied from port P2 passes through passage (11) and poppet [S4-3] to merge and flow
into passage [S4-2]. The returning oil passes through the neck part of the spool via port A4 (B4) and
returns to the tank passage [Ta].
5. Bucket spool switching [Fig. 10]

When switching the bucket spool by adding pressure through pilot port Pb8 (Pa8) in bucket (Section 8),
the neutral passage [R1] closes. Oil supplied from port P2 passes through the load check valve [S8-1], the
passage [S8-2] and the neck part of the spool through the parallel passage [R3] and flows into port B8
(A8). The returning oil passes through the neck part of the spool via port A8 (B8) and returns to the tank
passage [Ta].
fig.9
fig.10

Copyright ©
8030-14
6. Arm spool switching
1) Dump (2-pump confluence) [Fig. 11]
When switching the arm 1 spool by adding pressure through pilot port Pb5 in arm 1 (Section 5), the oil
supplied from port P1 flows into port B5 passing through the load check valve [S5-1], the passage [S5-2]
and the neck part of the spool via the neutral passage [L1]. When switching the arm 2 spool by also
adding pressure through pilot port Pb9 in arm 2 (Section 9), the oil supplied from port P2 passes through
the load check valve [S9-1], the passage [S9-2], the neck part of the spool and passage (10) via the
neutral passage [R1] to merge and flow into port B5. The returning oil passes through the neck part of the
spool via port A5 and returns to the tank passage [Ta].
fig.11

Copyright ©
8030-15
2) Crowd (2-pump confluence) [Fig. 12]
When switching the arm 1 spool by adding pressure through pilot port Pa5 in arm 1 (Section 5), the oil
supplied from port P1 flows into port A5 passing through the load check valve [S5-1], the passage [S5-2]
and the neck part of the spool via the neutral passage [L1]. When switching the arm 2 spool by also
adding pressure through pilot port Pa9 in arm 2 (Section 9), the oil supplied from port P2 passes through
the load check valve [S9-1], the passage [S9-2], the neck part of the spool and passage (9) via the neutral
passage [R1] to merge and flow into port A5. When switching the spool [AD3] in the anti-drift valve by
adding pressure to port pc1 and reducing the pressure in the spring chamber [AD5] at the same time, the
poppet [AD1] opens and the returning oil from port B5 passes through the neck part of the spool, the
passage [S5-3] and the arm variable regenerative throttle [Lc8] to return to tank passage [Ta]. Part of the
returning oil pushes open the poppet [S5-4] in arm 1 spool, passes through the passage [S5-2] and
merges into port A5 to accelerate the cylinder speeds. It also prevents the cavitation on the bottom side.
3) Variable regeneration (during crowding) [Fig. 13]
During arm crowding, the spool [S5-6] strokes according to the pressure at the passage [S5-2], which was
directed through the passage [S5-5], so the opening of arm variable regenerative throttle [Lc8] changes
accordingly. If the pressure at the passage [S5-2] is high, the stroke of spool [S5-6] increases and the
opening of throttle [Lc8] becomes larger. On the other hand, if the pressure at the passage [S5-2] is low,
the stroke of spool [S5-6] decreases and the opening of throttle [Lc8] becomes smaller. Thus, the
regenerating flow varies according to the bottom pressure on the arm cylinder.
fig.12
Arm variable
regenerative
throttle
fig.13

Copyright ©
8030-16
7. Neutral cut spool switching [Fig. 14]
This valve has a neutral cut spool installed at the lowest stream of the neutral passage [R1] (at the upper
stream of the low-pressure relief valve).
When switching the neutral cut spool [R] by adding pressure to port Pa10, the neutral passage [R1]
closes.
Oil supplied from port P2 passes through passage (11), poppet [S4-3] (Fig. 10) and merges and flows into
passage [S4-2] in backup (Section 4).
8. Parallel throttle for arm [Fig. 14]

This valve’s parallel circuit for the arm has throttle valves installed in both arm 1 (Section 5) and arm 2
(Section 9). Consequently, the arm speeds are kept from slowing down even in combined operations.
The parallel circuit in arm 2 (Section 9) is connected with the passage [S9-2] (Fig. 12) after being
restricted by throttle [Rc6] at the end of poppet [S9-3] through parallel passage [R3].
The parallel circuit in arm 1 (Section 5) pushes open the poppet [S5-8] through parallel passage [L3] and
is connected with passage [S5-2] (Fig. 12) after being restricted by throttle [Lc9] in the parallel variable
throttle spool. The degree of restriction for throttle [Lc9] can be changed by adding pressure onto pilot
ports Pc4 and Pc5.
Arm parallel variable throttle
Arm parallel throttle
Neutral cut spool
fig.14

Copyright ©
8030-17
9. Relief valve
1) Main relief valve (Fig. 15)
Oil supplied from port P1 passes through the poppet [LP], and oil supplied from port P2 passes through
the poppet [RP] and passage (3). The two flows of oil are thus directed to the main relief valve. The
operation of the main relief valve regulates the maximum pressure on the P1 and P2 sides of the pump.
2) Overload relief valve
In each cylinder port of boom 1, arm 1 and bucket, an overload relief valve is installed to prevent an
abnormal boost of pressure on the actuator due to external force.
This relief valve also prevents cavitations by drawing oil in from the tank when pressure on the cylinder
port becomes negative.
fig.15

Copyright ©
8030-18
Combined Operations
1. Added operation with travel (Fig. 16)
If a task other than travel takes place during travel right/travel left movement (during forward/reverse or
pivot turning), or if travel right/travel left movement takes place while a task other than travel is being
performed, the oil supplied from port PP is shut off from the tank passage [Ta] at the signal land section
(other than travel) which has switched over to lands [Lc4], [Lc7], [Rc3] and [Rc5]. As the result, the
pressure in the signal passage will rise up to the set relief pressure, which is the source of oil pressure for
signals. A rise in signal pressure switches the straight travel spool. The pressures on port PT and PA also
increase. Once the straight travel spool is switched over, oil supplied from port P1 flows from the neutral
passage [L1] into travel (Section 1). It also passes through passage (2), the neck part of the straight travel
spool and neutral passage [R1] and flows into travel (Section 6). Oil supplied from port P2 passes through
the neck part of the straight travel spool and passage (1) and flows into the parallel passage [L3]. If the
negative pressure on sections other than travel is higher than the negative pressure on travel (Section 6),
part of oil supplied from port P2 pushes open the poppet [S6-2] and passes through the throttle at the end
of the poppet and merges in passage [S6-1]. Since travels (Sections 1 and 6) are achieved with oil
supplied from port P1 and tasks other than travel are achieved with oil supplied from port 2, the straight
travel is maintained during combined operation during travel right/left movement or combined operation
with other machines.
fig.16

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8030-19
Anti-drift Valve
This anti-drift valve is attached on the cylinder port of the arm rod (bottom side of boom) to prevent a
natural drop of the arm (boom) cylinder.
In neutral (Fig. 17), pressure on the cylinder port passes through the neck of spool [AD3] via passage
[AD2] and is directed to the spring chamber [AD5] through passage [AD4].
The force of the spring and the pressure differential in the poppet areas firmly seats poppet [AD1].
During arm dump (boom-up) (Fig. 18), oil supplied from the pump pushes open the poppet [AD1] and
flows into the cylinder port.
During arm crowding (boom-down) (Fig. 19), pressure is applied to pc1 (pc2) to switch over spool [AD3],
directing oil from the spring chamber [AD5] into the drain port DR1 (DR2) via passage [AD6] to open the
poppet [AD1]. As a result, oil returning from the cylinder port flows into the tank passage [Ta].
fig.17
AD3 (With spool switched over)
fig.18
fig.19

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8030-20
Relief Valve
1. Operation of the main relief valve
[1] This relief valve is integrated between the
neutral passage “HP” and low pressure pas-
sage “LP”, and oil passes the orifice in the
poppet (C) and fills the internal space (D).
The sleeve (E) and main poppet (C) act on
different areas (A and B). They are firmly
seated.
[2] If the pressure in the neutral passage “HP”

reaches the set spring force of the pilot pop-
pet, the pilot poppet (F) opens.
The oil flows around the poppet and drilled
hole (G) and is directed into the low pressure
passage “LP”.
[3] Since the pilot poppet has been opened, the

pressure in (D) reduces and the main poppet
(C) opens. As a result, the oil flows directly
into the passage “LP”.
Boost operation
When applying pressure to the pilot port PH,
the piston (H) moves to the set position by
plug (I). Due to this, the pilot spring force ris-
es and the pressure in “HP” rises.

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8030-21
2. Operation of the overload relief valve
[1] This relief valve is integrated between the cyl-
inder port “HP” and low pressure passage
“LP”, and oil passes the orifice in the piston
(C) and fills the internal space (G).
The sleeve (K) and main poppet (D) act on
the different areas (A) and (B). They are firm-
ly seated.
[2] When the pressure in the cylinder port “HP”

reaches the set spring force of the pilot pop-
pet, the pilot poppet (E) opens.
The oil flows around the poppet and drilled
hole (H) and is directed into the low pressure
passage “LP”.
[3] Since the pilot poppet (E) has been opened,

a flow passing orifice (I) in the piston (C) is
generated. This flow produces a differential
pressure between the passage “HP” and the
backside of the piston (C). This moves the
piston (C) until it seats on the poppet (E).
[4] The oil flow from the passage “HP” to the

backside of the poppet (D) is only through
the poppet (D), annular space in the piston
(C) and the orifice (F). As a result, the differ-
ential pressure increases. Due to this, the
poppet (D) opens, and the oil flows directly
into the passage “LP”.

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8030-22
3. Draw-in-oil feature of the overload relief valve
[1] This relief valve has an anti-void unit incor-
K
porated. This unit supplies oil to the cylinder
port “HP” when cavitation takes place.
B
When the pressure in the cylinder port “HP”
is lower than the low pressure side “LP”, the
differential pressure between (A) and (B)
opens the sleeve (K). As a result, oil enters
A
the cylinder port “HP” through the low pres-

sure side “LP” and this prevents cavitation.
4. Function of low-pressure relief valve

[1] When oil doesn't flow
[2] Neutral spool

Oil from a neutral passage “HP” flows to a
flow low-pressure passage “LP” in signal
orifice “A”.
The pressure of the signal port “4Ps(5Ps)”
goes up by signal orifice “A”.
[3] Function of low pressure relief

The poppet “B” opens, and when it be-
comes pressure set with spring “C” when
excessive oil flows to a neutral passage
“HP”, it flows directly to “LP” and oil from a
neutral passage “HP” prevents the abnor-
mality pressure being generated.

Copyright ©
8030-23
SWING UNIT
Configuration of Components
Swash plate type axial piston motor
Mechanical brake
Makeup valve
Relief valve
Bypass valve
NOTE: Numbers in parentheses in the following text correspond to the circled numbers in the Internal structural
drawings.
Structure of Hydraulic Motor
The rotary component group is composed of a drive shaft integrated type cylinder [27] and nine piston
assembly [8] arranged in the cylinder [27]. Additionally, both ends of the cylinder [27] are supported with
bearings [4] and [25]. Piston assembly [8] are guided by return plates [6] and spring bearings [7] so that
they can slide on the cam plates [5] smoothly.
The balance plate [24] is pressed against the end face of cylinder [27] by the force of coned disc spring
[17] and hydraulic pressure acting on the bushing [15].
Mechanical brakes [9], [10], [11] and [14] that are used as parking brakes are installed between the
circumference of cylinder [27] and the housing [28].
Also, a relief valve [31] as cushion and makeup valves [35], [36] and [39] for preventing cavitation are built
in the cover section [29]. In order to prevent swinging-back when swing operation is stopped, a bypass
valve [43] is integrated into the cover [29].
Operational Description of Hydraulic Motor
Hydraulic oil supplied from the pump via the control and other valves enters from port A (or port B) on the
cover [29] and is discharged from port B (or port A). Oil leaked from gaps in each sliding part is returned
to the tank through the drain port "a" on the cover [29].
The pressurized oil supplied to port A is supplied to the piston hole "f" in the cylinder [27], passing the
following components in order: passage "b" in the cover [29], passage "c" on the bushing [15] section on
the cover [29], passage "d" on the balance plate [24] which has a crescent-shaped port switching between
supply and discharge every 180° per one motor turn, as well as, passage "e" on the cylinder [27].
The oil pressure acts on piston assembly [8], resulting in piston assembly [8] being pressed to the cam
plate [5] via the shoe section. Because the sliding face of the shoe on cam plate [5] is inclined at a given
angle, the pressing force on the piston assembly [8] to which the oil pressure pushes, is transformed into
a force that slides the shoe on the swash plate. Because the spherical shoe section of piston assembly [8]
is connected so that it works as a universal joint, the shoe's sliding force on the swash plate is transferred
to the motor output shaft as a turning force via the piston assembly [8] and cylinder assembly [27].
As mentioned above, each piston assembly [8] receives the pressurized oil while it travels the stroke from
the top dead center to the bottom dead center of the incline plane and transforms it into a turning force to
revolve cylinder assembly [27] and discharges oil while it travels the stroke from the bottom dead center to
the top dead center. The discharge route is the reverse of the supply route described above and the oil is
discharged from port B.
The hydraulic motor operates in the manner as described above. Its output torque and the number of
revolutions are determined according to the hydraulic force and the volume of oil supplied respectively.

Copyright ©
8030-24
Operational Description of Mechanical Brake
Friction plate [9] is connected to the circumference of cylinder assembly [27] via spline. Also, the
counterpart plate [10] is connected to the housing [28]. When the pressure in the mechanical brake
release chamber is zero, the cylinder assembly [27] (output shaft) is locked and will not turn as a result of
the brake piston [11] pressing the counterpart plate [10] and friction plate [9] through the spring force [14].
In the opposite manner, when the oil pressure of 2.9 to 4.9 MPa is reached on the brake release chamber,
the brake piston [11] overcomes the force and moves until it hits the end face of the cover [29], creating
space between friction plate [9] and counterpart plate [10]. As a result, the mechanical brake turns to a
released status.
Operational Description of Make-up Valve
1. Half-braking condition (a state where relief valve [31] is not in operation)
When decelerating the swing body through the control valve using the half-lever function after
accelerating the swing body, the supply volume to port A from the pump decreases but it is necessary to
supplement oil when the swing body is rotating at a relatively high speed because the pressure applied to
the "c" section tends to become negative due to motor's pumping action.
However, because the whole volume of oil which flows into "c" section from port A is discharged into
control valve via port B when the pressure on port B is lower than the working pressure of relief valve [31],
the absolutely necessary oil volume at the "c" section is not met with the oil volume from the control valve
alone (as the valve is in the half-lever position, the oil volume is still restricted). To prevent this, makeup
check [39] is provided to supplement "c" section to make up for a lack of oil through the makeup port.
2. Full braking condition (a state where relief valve [31] is in operation)

When changing to the neutral position from condition A by quick lever operation, the swing body is turned
by inertial force even though the oil supply volume from the pump to port A becomes zero. In this case,
relief valve [31] on the port B side operates, and the oil, which blew off the relief, passes oil passages "g"
and "h", presses open the makeup check [39] on port A and is supplemented to the passages "b" and "c".
However, the oil lacks by its volume that which has leaked into the case drain of the motor. To prevent this,
the makeup check [39] is opened from the makeup port and the oil flows into the passages "b" and "c" in
order to prevent cavitation.

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8030-25
Operational Description of Relief Valve
(Internal structural drawing of relief valve)
1. When starting
The hydraulic oil supplied from port A by operating the control valve does not immediately reach the
constant revolution level due to the large inertial force of the swing body. Part of the oil passes oil
passages "g" and "h" via relief valve [31] that works as a safety valve, presses open the check [39] on port
B side and flows into port B.
Oil in port A presses open the poppet [47] by counteracting the force of spring [48], passes passage "g"
via a space between seat [46] and poppet [47] and flows into passage "h".
2. When braking (at time of cushioning)

When the control valve is returned to the neutral position, the return passage for the motor's drain oil
closes. Immediately after this operation, the motor is turned by large inertial force and attempts to suck oil
through port A by pumping action and to discharge it to port B. As a result, the pressure on port B
increases because the return passage in the control valve is closed.
As the increased pressure on port B presses open poppet [47] by counteracting the force of spring [48],
the oil flows into passage "c" by pressing open the makeup check [39] via oil passages "g" and "h" through
port B. In this process, the inertial force of the swing body is absorbed and the swing body comes to a
stop.
Also, in the pressure increasing process above mentioned, the highly pressurized oil that flowed into the
front chamber of poppet [47] enters the piston chamber passing the small hole passage on the central
section of piston [52] via circumferential orifice "j" of poppet [47] and moves piston [52] until it hits the end
face of sleeve [51]. Meanwhile, since poppet [47] is already forcedly opened, the cushion relief begins to
work at relatively low pressure, and then increases to a specified pressure in minimal time. This dual-step
action decreases the impact of motor starts and stops.
Operational Description of Bypass Valve
(Internal structural drawing of bypass valve)
When attempting to stop the swing body after operating the control valve to drive the swing body, braking
pressure is generated on one side of the port as the hydraulic motor, which keeps rotating due to its
inertial force, continues its pumping action.
Suppose that this is port A: This pressurized oil for braking flows into the back chamber of check [60] on
the side A via small holes [a3] and [a2]. As a result, the check [60] on side A moves until it contacts and
presses seat [58] on side A to shut off the bypass passage by pushing check [60] on side B, which is
arranged as a counterpart, to the left in the process of decelerating the swing body. In due course, the
swing body stops once but reverses due to braking pressure. Therefore, the pressure on side B increases
and check [60] on side B attempts to move to the right by pushing check [60] on side A, which is arranged
as a counterpart. However, this movement of check [60] is a little delayed because the oil flow of the back
chamber in check [60] on side A is gently controlled through the action of the flow control valve comprised
of poppet [61] on side A and spring [62] on side A. In the meantime, the pressurized oil of port B flows into
the intermediate chamber via small hole "b1" and bypasses port A side via small hole "a1". Subsequently,
check [60] on side B contacts and presses seat [58] on side B and moves to the position where it can shut
off the bypass passage. As described above, the reverse motion will be prevented without any trapping of
the oil because the pressure is bypassed to port A side in the process of generating reverse pressure on
the port B side.

8030-26
5 6 7 8 9 10 11 12 13 14 31 32
Lep SC4608030-0EN
Relief on port A side Relief on port B side
4
15 30
33
Bottom
3 dead center 34
16 29
Internal Structural Drawing
2
17
a g
1 i
Drain port
18 h
f e c
d Makeup port
19 45 35
b
b
20 44 36
34
43 Top dead 37
Port A center Port B
28 27 26 25 24 23 22 21 42 41 40 39 38
Mechanical brake release chamber
Issued 03-07
Copyright ©
Copyright ©
8030-27
Internal Structural Drawing of Externally Adjusted Shockless Relief Valve
46 47 48 49 50 51 52 53
j
57 56 55 54
Internal Structural Drawing of Bypass Valve
58 59 60 61 62
Port B Port A
b3 b2 b1 a1 a2 a3

Copyright ©
8030-28
TRAVEL UNIT
Structure
Fig.1. Structure drawing of travel motor
SYM PART NAME SYM PART NAME SYM PART NAME

1 CASING 21 D-RING (SMALL DIA.) 41 G1/8 PLUG
2 NPT1/16 PLUG 22 D-RING (BIG DIA.) 42 O-RING 1B P8
3 OIL SEAL 23 REAR COVER 43 CHECK VALVE
4 RETAINING RING IRTW68 24 NPT1/16 PLUG (MEC) 44 CHECK VALVE SPRING
5 SHIFTER PISTON 25 SPOOL ASSY 45 M6 RESTRICTOR (É”0.6)
6 PISTON SEAL 26 SPRING HOLDER 46 O-RING 1B P12.5
7 STEEL BALL 27 SPRING 47 M6 RESTRICTOR (É”0.8)
8 SHAFT 28 M42 PLUG 48 O-RING 1B P15
9 BEARING HR33209J 29 O-RING 1B G40 49 O-RING 215.57 X 2.62
10 PIVOT 30 PILOT VALVE SPOOL 50 BEARING HR32207C
11 SWASH PLATE 31 PIN 51 SHIM
12 CYLINDER BLOCK 32 SPRING HOLDER 52 PARALLEL PIN
13 CYLINDER SPRING 33 SPRING 53 VALVE PLATE
14 SPRING HOLDER 34 G3/8 PILOT VALVE PLUG 54 BRAKE SPRING
15 BALL JOINT 35 O-RING 1B P14 55 HEX. SOCKET HEAD BOLT M18 X 50
16 SHOE RETAINER 36 CONNECTOR 56 OVERLOAD RELIEF VALVE
17 PISTON ASSY 37 G1/4 PLUG 57 COUPLING
18 SEPARATING PLATE 38 O-RING 1B P11 58 RETAINING RING C-TYPE 40
19 FRICTION PLATE 39 RESTRICTOR (BRAKE VALVE) 59 G1/2 PLUG
20 BRAKE PISTON 40 RESTRICTOR SPRING (BRAKE 60 O-RING 1B P18

VALVE)
Table 1. Parts list of travel motor

Copyright ©
8030-29
Brief Explanation of Structure
The motor mainly consists of the following parts:
• Rotary group producing turning force to drive shaft
• Parking brake preventing host machine from self-running during its rest
• Capacity control parts that changes the motor capacity consequently rotating speed
• Overload relief valve that is attached to the rear cover
• Brake valve (counter balance valve) portion that control the hydraulic circuit
1) Rotary Group
The cylinder block [12] is inserted into the spline of shaft [8], both ends of which are supported by
bearings [9], [50]. This cylinder block [12] is pushed toward the rear cover [23] together with valve plate
[53] by cylinder spring [13].
Nine pieces of piston ass’y [17] slide inside the cylinder block [12] along the surface of swash plate [11].
Hydrostatic bearings are provided on the end surface of piston ass’y [17] to reduce the sliding resistance,
and the ends of piston ass'y [17] are pushed toward swash plate [11] by cylinder spring [13] through
spring holder [14], ball joint [15] and shoe retainer [16].
2) Parking brake
Seven pieces of separating plates [18] and six pieces of friction plates [19] are alternately set on the
spline of cylinder block [12] and pushed together by 14 brake springs [54] through brake piston [20].
3) Capacity control portion
They consist of: pivots [10] that support swash plate [11] and slide in two half-spherical recesses in swash
plate [11] : shifter piston [5] that change the angle of swash plate [11] on the pivots [10] : stopper [1-1] of
casing that limits the angle of swash plate [11] : pilot valve portion that leads the oil to shifter piston [5] by
external pilot signal : three check valves [43] that select the maximum pressure from the external pilot
pressure, inlet pressure and outlet pressure of the motor and send it to pilot valve portion.

Copyright ©
8030-30
4) Overload relief valve
This valve is screwed in the motor rear cover [23] and consists of : socket [56-1] that is screwed and fixed
in the rear cover [23] and supports the valve seat [56-3] which metallically seated in the hole of rear cover
[23] : valve [56-2] that contact with valve seat [56-3] by adjusting spring [56-9] and fitted in the hole of
socket [56-1] : coupling piston [56-4] that fitted in the hole of the valve [56-2] and functions also as an oil
passage : piston [56-7] that is inserted in the pilot body [56-6] and : shim [56-8] that adjust the spring
force.
Fig.2. Structure drawing of overload relief valve
SYM PART NAME SYM PART NAME
56-1 SOCKET 56-8 SHIM
56-2 VALVE 56-9 ADJUSTING SPRING
56-3 VALVE SEAT 56-10 O-RING 1B P7
56-4 COUPLING PISTON 56-11 BACK-UP RING T2 P7
56-5 CAP 56-12 O-RING 1B G25
56-6 PILOT BODY 56-13 BACK-UP RING T2 G25
56-7 PISTON •
Table 2. Parts list of overload relief valve

Copyright ©
8030-31
5) Brake valve portion
Spool control pressure : 0.59 to 0.95 MPa
Check valve cracking pressure : 0.015 MPa
Fig.3. Brake valve portion

The brake valve portion mainly consists of the following parts:
1] Spool
By shifting the spool [25], the discharged oil from hydraulic motor is automatically shut off or restricted
according to the condition and give the effect of holding, accelerating, stopping and counterbalance
operations.
2] Check valve (Built in the spool)
This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to
lock oil displacement. Therefore, this valve serves as not only a suction valve but also a holding valve for
hydraulic motor.

Copyright ©
8030-32
Function
Inlet Outlet Direction of rotation (Viewing
port port from rear cover)
VB VA Right (Clockwise)
VA VB Left (Counterclockwise)
Table 3. Direction of rotation
Fig.4. Lacation parts
1. Operation of motor
High pressure oil delivered from hydraulic pump is led to inlet port(VA,VB) that is provided in the brake
valve portion and, through the rear cover [23] and valve plate [53], led to cylinder block [12].
The oil flow and direction of shaft rotation are indicated in Table 3.
Fig.5. (a) Fig.5. (b)

As shown in Fig.5(a), high pressure oil is supplied to the pistons which are on one side of the line Y-Y that
connects upper and lower dead points and produces force F1
F1 = P x A (P : pressure, A : area of piston section)
The swash plate [11] with inclined angle of α divides this force F1 into thrust force F2 and radial force F31-
F34 (or F35). (Fig.5 (b)) This radial force is applied to axis Y-Y as turning force and generate drive torque
of T
T=r1 • F31 + r2 • F32 + r3 • F33 + r4 • F34
(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block [12] to driving shaft [8].

Copyright ©
8030-33
2. Operation of parking brake
Parking brake is released when high pressure oil, selected by the brake valve portion that is connected
directly to the rear cover [23], is applied to the brake piston [20].
Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates [18], inserted into the
casing [1], and friction plates [19], coupled to cylinder block [12] by the outer splines.
When no pressure is activated on the brake piston [20], it is pushed by the brake springs [54] and it
pushes friction plates [19] and separating plates [18] towards casing [1] and generates the friction force
which brakes the rotation of cylinder block [12] and hence the shaft [8].
Fig.6. Parking brake portion

Copyright ©
8030-34
3. Operation of capacity variable mechanism
Fig.7. Operation of capacity variable mechanism

Fig.7 typically shows the capacity variable mechanism.
When high speed pilot line is charged with the pressure PA that overcome the spring [33], the spring [33]
is compressed and spool [30] shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve [43] from inlet and outlet pressure of the motor
and high speed pilot line pressure and pushes shifter piston [5]. As a result, swash plate [11] turns around
the line L which connect the two pivots [10] as shown by dotted lines. The turn stops at the stopper [1-1]
of casing and swash plate [11] keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor rotates
faster, around 1.71 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA , spool [30] is pushed back by the spring [33] and
pressure that pressed the shifter piston [5] is released to the hydraulic tank through restrictor [45].
Here, nine pistons are there and they equally spaced on the swash plate [11]. The force that summed up
those of pistons comes to almost the center of the swash plate [11] as shown. Since the pivots [10] are
off-set by S from the center, the rotating force of product S and the force moves swash plate [11] to the
former position and the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at high
speed mode, the system step down to the low speed automatically. The mechanism is that: pump
pressure (VA or VB) is led to the port PB [Fig.7]. and this pressure activate on pin [31]. When the pressure
at PB exceeds predetermined value, spool [30] returns to the left by the counter-pressure against pin [31]
and the pressure on the shifter piston [5] through port C is released to the tank and the motor comes to
low speed.
When PB goes down, the spool [30] moves to the right and the speed become high.

Copyright ©
8030-35
4. Operation of overload relief valve
Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake
valve and have the following functions:
1] When hydraulic motor starts, keep the driving pressure below predetermined value and while
accelerating, bypasses surplus oil to return line.
2] When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under
the predetermined value to stop the inertial force.
3] To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
purposes, the developed pressure is kept comparatively low for a short period, then keep the line
pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and sprocket
etc. can be smoothly done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective
diameter of valve [56-2] which seats on the valve seat [56-3] and, at the same time, is delivered, via small
hole, to the connecting piston [56-4] located inside the valve [56-2] and the piston bore pressure
increases up to "A" port pressure. The valve [56-2] opposes to adjusting spring [56-9] by the force of the
pressure exerted on the area difference between valve seat's effective diameter and piston bore and keep
the predetermined pressure.
When hydraulically braking, the piston [56-7] is at the left position by the driving pressure, and when "A"
port pressure increases, the pressure is applied also to the piston [56-7] through the small hole in the
valve [56-2] and connecting piston [56-4] moves rightward until it touches the cap [56-5]. In this while, the
valve [56-2] maintains "A" port pressure at comparatively low against the adjusting spring [56-9] force and
exhaust oil to "B" port side. After the piston reached to the plug, the valve acts the same as at starting.
Fig.8. Operation of overload relief valve

Copyright ©
8030-36
5. Operation of brake valve
1) Holding status (see Fig.9)
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring
[27] located on both spool ends holds the spool [25] at central position.
Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB
ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is equal to
the tank pressure and the brake is applied by the springs. Thus, the rotation of the motor is mechanically
prevented.
If external torque is exerted on the motor shaft, the motor would not rotate as usual by this negative
parking brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But, due to oil
leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit and motor rotates
a bit. So, the cavitation tends to occur in the lower pressure side of the closed circuit. Then, the check
valve, built in the spool [25], operates to avoid the cavitation and opens the passage from VA to MA or
from VB to MB. Then the oil equivalent to the leakage is sucked from the tank line to the closed circuit.
Spring Spring
Fig.9. Holding status

Copyright ©
8030-37
2) Accelerating operation (see Fig.10)
When VA and VB ports are connected respectively to pump and tank by operating the control valve,
hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool
[25], and oil flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from pump. At
the same time, the pressure of pilot chamber increases to push and move the spool [25] leftwards,
overcoming the spring [27] force. Thus, the return line from MB to VB opens to rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of relief
valve and high pressure oil is being relieved while the motor gains the rotational speed. As the rotational
speed goes up. the relieved volume decreases, and finally the motor rotates at a fixed speed.
Check valve Check valve

with restrictor with restrictor
Pilot chamber Pilot chamber
Spring
Spring
Fig.10. Accelerating operation

Copyright ©
8030-38
3) Stopping operation (see Fig.11)
Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and
VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool
ends become equal, and the spool [25] returns to the neutral position by spring [27] force. Thus, the
passage from MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here, the motor
functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure
increases. Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last
the motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and
the motor is mechanically stopped.
Spring
Spring
Fig.11. Stopping operation

Copyright ©
8030-39
4) Counterbalance operation (see Fig.12)
Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia
force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor
tends to rotate faster than that matched to the volume of oil supply.
Consequently, the pilot chamber pressure on MB to VB side decreases and the spring [27] force moves
the spool [25] leftwards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side rises due to
increased resistance in the passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber pressure on
VB port increases, and spool [25] moves rightwards to enlarge the area of passage from MA to VA.
Therefore the braking effect becomes smaller and the rotational speed of motor is controlled to
correspond to the volume of supplied oil.
In order to give stable counterbalance operation, the restrictors [39] are set in the pilot chamber to damp
the spool [25] movement.
The parking brake is released during pressure adjusting action of the spool [25].
Check valve Check valve

with restrictor with restrictor
Spring
Spring
Fig.12. Counterbalance operation

Copyright ©
8030-40
FAN MOTOR FOR HYDRAULIC DRIVE

Outside Drawing

Copyright ©
8030-41
Internal Structure Drawing
No. Part Name

1 Output shaft
2 Case
3 Thrust plate
4 Piston assembly
5 Cylinder block
6 Valve plate
7 Retainer guide
8 Retainer shoe
9 Main bearing
10 Sub bearing
11 Oil seal
12 End cover
13 Center spring
14 Spring for suction safety valve
15 Suction safety valve
16 Variable flow control pilot valve
17 Flow control spool
18 Flow control spool spring
19 Main spool
20 Proportional solenoid
21 Filter
22 Forward/reverse changeover pilot valve
23 ON-OFF solenoid

Copyright ©
8030-42
Operation Principle
1. Hydraulic Motor
Function
• The hydraulic motor is called as swash plate
axial piston motor and it converts force of pres-
sure oil transferred from the hydraulic pump
into rotation.
Operation Principle
• Oil flown out of the hydraulic pump is intro-
duced into the cylinder block [5] through the
valve plate [7].
It has been so designed that the oil is to be in-
troduced in the one side area of the line Y-Y
connecting the top dead center to the bottom
dead center in the piston [4] stroke.
• Pressure oil entered in the one side part in the
cylinder block [5] pushes each piston [4] (2 pis-
tons or 3 pistons) to generate force F1. (F1 N=P
MPa x π/4 D2 cm2)
• Although the force works to the thrust plate [2],
the force is divided to F2 and F3 as the thrust
plate [2] is fixed with a certain angle of α°
against the output shaft [1].
• Of the component of a force, the radial force F3
generates each torque of (T=F3 x ri) against the
line Y-Y connecting the top dead center to the
bottom dead center.
• The resultant force of the torque [T= Σ(F3 x ri)]
allows the cylinder block [5] to be rotated via
piston as a turning force.
• Since the cylinder block [5] makes a spline con-
nection with the output shaft, the output shaft
rotates to transfer the torque.

Copyright ©
8030-43
2. Suction Safety Valve (Safety Valve with Suction)
1) Function of Suction
• Negative pressure in the inlet port of motor generates cavitation.
When pressure in the inlet port of the motor becomes negative, the suction valve has a func-
tion preventing cavitation from generating by supplying pressure oil from the outlet port.
2) Function of Safety Valve
Operation
[1] When starting
• When pressure oil flown out of the pump
is supplied to the port P and pressure on
MA side increases to generate staring
torque in the motor, the motor starts rota-
tion.
Oil on MB side of the outlet port of motor
will returns from port T to the tank.
[2] When stopping

• When input speed of the fan pump gets to
0 min-1 due to engine stop, pressure oil
from the pump fails to be supplied to port
P.
Since pressure oil will not be flown in MA
side of the motor, the motor speed is be-
ing slowed down gradually to make it a
stop.
• When motor shaft is rotated by inertia
with pressure oil flowing to port P being
decreased, pressure in the inlet port be-
comes negative.
In such case, the suction safety valve
prevents cavitation from being generated
by supplying pressure oil in port T on the
outlet side to Ma side.

Copyright ©
8030-44
Function
• Discharge pressure of the fan pump may
be raised in such case where the engine
is started.
• In order to protect fan system circuit,
safety valve is installed.
• When discharge pressure goes beyond
the pressure set at the safety valve, the
seat of safety valve opens to allow the oil
to be escaped into the passage to port T
to prevent unusual high pressure from
being generated.

Copyright ©
8030-45
3. Variable Flow Control Valve
Function
It supplies oil discharged out of the pump to
the motor as necessary and allows surplus
oil to return to the tank.
• The motor speed is increasing in proportion to
inflow quantity Q as illustrated in Fig. 1.
The pump rotates at min-1 at inflow of Q1.
In order to aim at noise reduction and loss re-
duction as a function of fan motor, it is neces-
sary to control fan speed for maintaining
necessary constant speed regardless of in-
flow.
A flow control valve is built-in as the function
meeting the requirements mentioned above.
Even when inflow increases from Q0 to Q1, mo-
tor speed keeps constant as to min-1 as il-
lustrated in Fig.1
Operation
• Basic operation of flow control is that pressure
difference in front and rear of the constriction
against the inflow works to the flow control
spring with constricted upstream pressure ap-
plied to side and constricted downstream pres-
sure applied to side of flow control spool.
In Fig. 1, if inflow surpasses Q0, pressure dif-
ference in front and rear of the flow control
spool becomes larger than load at mounting in
flow control spring.
This allows opening P to T to open and surplus
flow in the section marked as is discarded
out of the flow control valve for which the motor
speed is to be kept constant in the range between
and .
• The motor mounts electromagnetic propor-
tional variable flow control valve.
The flow control valve of this type makes it
possible to change continuously the pla-
teau between and as in Fig. 2 to con-
stant speed of the motor in the range
between ’ and ’ altering the command
current.

Copyright ©
8030-46
4. Operation of Forward / Reverse Changeover Valve
[1] When ON-OFF solenoid for changeover valve [2] When ON-OFF solenoid for changeover valve
is demagnetized is magnetized
• When ON-OFF solenoid for changeover valve • When ON-OFF solenoid for changeover valve
[1] is demagnetized, pressure oil from the [1] is magnetized, ON-OFF change over valve
pump is shut off by ON-OFF changeover valve [2] switches over and pressure oil from the
[2] allowing port C to lead to the tank circuit. pump enters in the port C to let it flow into the
• This allows the changeover spool [3] to be chamber D.
pushed to the right by the changeover spool • Pressure oil in the chamber D overcomes the
spring [4] and the motor port MA opens to let changeover spool spring [4] to push the
the pressure oil flow in and as a result the mo- changeover spool [3] to the left.
tor makes forward rotation (CW). This allows the motor port MB to open and
pressure oil flows in and as a result the motor
makes reverse rotation (C.C.W.).

Copyright ©
9002
Section
9002
UPPERSTRUCTURE, TURNTABLE
AND COUNTERWEIGHT

Printed in France
Copyright ©
9002-2
TABLE OF CONTENTS
SPECIAL TORQUE SETTINGS ..................................................................................................................................... 2
SPECIFICATIONS ......................................................................................................................................................... 2
UPPERSTRUCTURE .................................................................................................................................................... 3
Inspection ................................................................................................................................................................... 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 6
COUNTERWEIGHT ..................................................................................................................................................... 10
Description ............................................................................................................................................................... 10
Removal .................................................................................................................................................................... 11
Installation ................................................................................................................................................................. 12

See Section 1002.
SPECIFICATIONS
Weight ................................................................................................................................................... See Section 1002

Copyright ©
9002-3
UPPERSTRUCTURE
Inspection
STEP 1 STEP 5
Checking the turntable
If the upperstructure does not revolve properly or
creaks, this shows that the turntable is worn or dam-
aged. If the upperstructure pauses before revolving,
this shows that the crown wheel of the turntable is dam-
aged. When an operator is working with the machine,
he must pay attention to any unusual noises which
could indicate turntable wear. If the operator hears unu-
sual noises and if the upperstructure pauses before
revolving, he must carry out the following inspection. 1
STEP 2
2
Park the machine on hard, level ground. Lower the
STEP 3
3
Reduce the engine speed to idle for 30 seconds, then
CS02C505
Remove the three screws (1) that fasten the access
STEP 4 door (2) to the machine. Remove the access door (2).
Remove and discard the seal (3) from the access door
(2).
STEP 6
WARNING: If your hand is in the access port of

the crown wheel when the upperstructure is
revolving, you could get seriously injured.
! Before applying grease by hand on the crown
wheel, always check that the bucket or the tool
is placed on the ground and that the engine is
shut down.
Ask an assistant to help you operate the swing mecha-

nism, check for scratches, missing teeth, scaling,
cracks or other damage on the crown wheel using a
1 pocket light. In case of damage, refer to "Removing the
upperstructure" and change the turntable of the upper-
CI00F500 structure.
Remove the screws (1) that attach the lower housing to
the machine and remove the lower housing. STEP 7
Install a new seal (3) on the access door and install the
access door (2) on the machine using screws (1).

Copyright ©
9002-4
STEP 8 STEP 4
Install the lower housing on the machine using screws
and plate washers.
Removal
STEP 1
JS00163A1
STEP 2
STEP 3
1 FUEL TANK LOWER ACCESS PANEL

2 HYDRAULIC RESERVOIR LOWER ACCESS PANEL
Remove the lower access door of the fuel reservoir (1)

located in front and on the right. Place a container
beneath the drain valve of the fuel reservoir. Open the
drain valve and drain the fuel.
NOTE: See Section 1002 for the capacity of the fuel
reservoir.
STEP 5
Remove the lower access plate from the hydraulic res-
Open the left-hand side door. Disconnect the earth ervoir (2). Place a container beneath the drain valve of
cable (1) from the battery. Close the LH side door. the hydraulic reservoir. Open the drain valve and drain
the hydraulic fluid into the container.
NOTE: See Section 1002 for the capacity of the
hydraulic reservoir and the capacity of the entire sys-
tem.
STEP 6
Refer to Section 8006 and remove the hydraulic swivel.

Copyright ©
9002-5
STEP 7 STEP 14
Refer to Section 9003 and remove the bucket, the dip- Remove the screws (3) that attach the turntable to the
per and the boom. undercarriage. Carefully disengage the turntable from
the undercarriage by lifting it. Place the turntable on
STEP 8 suitable supports in order to protect the surfaces of the
Refer to page 10 in this Section and remove the coun- turntable from any damage. Remove the lifting equip-
terweight. ment from the lifting rings and disassemble the lifting
rings from the turntable.
STEP 9
Install lifting rings at the rear of the upperstructure.
Connect a suitable lifting device to these lifting rings
and to the lifting rings located at the front of the upper-
structure, above the boom brackets. Use the total
movement of the lifting device.
NOTE: Refer to specifications on page 2 for the weight
of the upperstructure. Make sure that the lifting equip-
ment has sufficient lifting and support capacity for the
upperstructure.
STEP 10
1 4
CD01K066
Using paint or another marking product, make marks
on the upperstructure, turntable (4) and the undercar-
riage, to facilitate re-assembly of the upperstructure
and the turntable.
STEP 11
Remove the screws (1) as well as the flat washers (2)
of the upperstructure turntable (4).
STEP 12
Carefully disengage the upperstructure from the under-
carriage by lifting it. Place the upperstructure on suita-
ble supports in order to protect the swing reduction
gear pinion from any damage.
STEP 13
Install lifting rings on the turntable (4). Connect suitable
lifting equipment to the lifting rings. Use the total move-
ment of the lifting device.
of the turntable.

Copyright ©
9002-6
Installation
Turntable
2
1
4
1
1 3
CS02C506
1 SCREW
2 FLAT WASHER
3 SCREW
4 TURNTABLE
STEP 1 STEP 3
Clean the surfaces of the undercarriage and the turnta- Position the turntable (4) on the undercarriage. Align
ble. the marks on the turntable (4) and on the undercar-
riage. Remove the lifting equipment and remove the lift-
ing rings from the turntable.
steps refer to the diagram of the turntable.
STEP 2
Install lifting rings on the turntable (4) and connect a
suitable lifting device to these rings. Use the total
movement of the lifting device.
of the turntable.

Copyright ©
9002-7
STEP 4 STEP 10
Refer to Section 9003 and reassemble the boom, the
dipper and the bucket on the machine.
STEP 11
Make sure that the drain valve of the hydraulic reservoir
is closed. For filling the reservoir refer to the chapter
"Filling the reservoir" in the operator’s manual.
NOTE: See Section 1002 for the capacity of the
1 hydraulic reservoir and the capacity of entire system.
4
STEP 12
CD01K066
Coat the screw threads (3) with Loctite 262. Install the
screws (3) to attach the turntable (4) to the undercar-
riage. Tighten the screws (3) to the torques specified on
page 2.
STEP 5
Connect a suitable lifting device to the lifting rings
located in front of the upperstructure, on top of the
boom brackets, as well as to the rings installed on the
upper frame behind the upperstructure.
of the upperstructure. Make sure that the lifting equip-
ment has sufficient lifting and support capacity for the
upperstructure.
NOTE: When the upperstructure is lowered and
touches the turntable and the crown wheel, make sure
that the swing reduction gear pinion engages perfectly
with the teeth on the upperstructure crown wheel.
STEP 6
Carefully install the upperstructure in position on the
turntable. Align the marks on the upperstructure and on
the turntable. Check that the mounting ports of the
upperstructure are aligned with those of the turntable.
STEP 7
Coat the screw threads (1) with Loctite 262. Install the 1 FUEL TANK LOWER ACCESS PANEL
screws (1) with flat washers (2) in the turntable and the 2 HYDRAULIC RESERVOIR LOWER ACCESS PANEL
upperstructure to fasten the upperstructure en position.
Install the access door (2) under the hydraulic reservoir,
Tighten the screws (1) to the torques specified on page
as well as the access door (1) under the fuel reservoir.
2.
STEP 8 STEP 13
Make sure that the drain valves of the fuel and hydrau-
Remove the lifting device then remove the lifting rings.
lic reservoirs are closed, fill the reservoirs (see the
STEP 9 operator’s manual).
Refer to Section 8006 and reassemble the hydraulic NOTE: See Section 1002 for the capacity of the fuel
swivel. reservoir and the hydraulic reservoir.

Copyright ©
9002-8
STEP 14 STEP 17
Apply grease by hand on the crown wheel.
STEP 18
Start the engine and turn the upperstructure by one
eighth of a turn. Shut down the engine.
STEP 19
Apply grease again by hand on the crown wheel.
STEP 20
Repeat the operation until all teeth of the turntable are
properly lubricated.
NOTE: Refer to the specifications on page 2 for the
quantity of grease to be applied.
Open the left-hand side door. Reconnect the earth STEP 21
cable (1) to the battery. Close the LH side door.
STEP 15
Refer to page 10, "Installing the counterweight" and put
the counterweight back in place.
WARNING: If your hand is in the access port of

the crown wheel when the upperstructure is
revolving, you could get seriously injured.
! Before applying grease by hand on the crown
wheel, always check that the bucket or the tool
is placed on the ground and that the engine is
shut down.
CD01K066
STEP 16 Apply grease to the grease fittings on the turntable.

Install a new seal ring.
3
CS02C505
Remove the three screws (1) that fasten the access
door (2) to the upperstructure. Remove the access door
(2). Scrap the seal (3).

Copyright ©
9002-9
STEP 22
Install the access door with the seal, on the machine.
Fasten it in position with the three screws and the lock-
ing washers.
STEP 23
CI00F500
Install the lower housing under the machine using
screws and washers.

Copyright ©
9002-10
COUNTERWEIGHT
Description
09-009-0A
1 COUNTERWEIGHT 4 SHIM
2 SCREW 5 INSULATING MATERIAL
3 WASHER

Copyright ©
9002-11
Removal STEP 3
STEP 1
Attach a suitable lifting device to the lifting rings of the

counterweight (1). Use the total movement of the lifting
device.
weight of the counterweight.
STEP 2
Remove the screws (2) and the flat washers (3) that
fasten the counterweight (1) to the undercarriage.
Raise the counterweight (1) and remove it from the

machine. Place it on flat ground. Remove the lifting
equipment.
STEP 4
Remove the shims (4) from the undercarriage anchor-
age points.
NOTE: Count the number of shims (4), remove them
from each anchorage point. Keep each set of shims (4)
to facilitate reassembly.
STEP 5
Check the state of the insulating material (5) installed
on the counterweight. Change the insulating material if
it is damaged.
Copyright ©
9002-12
Installation STEP 4
STEP 1
Install the screws (2) as well as the flat washers (3) to

attach the counterweight (1). Tighten to the torques
STEP 5
Attach a suitable lifting device to the lifting rings of the
counterweight (1). Remove the lifting device from the lifting rings of the
counterweight (1).
weight of the counterweight.
STEP 2
Install the same number of shims (4) as those removed
in step 4 of removal, at each anchorage point of the
counterweight on the undercarriage.
STEP 3
Move the counterweight (1) into position on the under-

carriage. Align the ports of the counterweight with those
on the undercarriage.

Copyright ©
Section
9003
9003
BOOM, DIPPER AND BUCKET

Printed in France
Copyright ©
9003-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 2
BUCKET.......................................................................................................................................................................... 3
Description .................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 4
Shimming the bucket ................................................................................................................................................. 5
Removal and installation of Bucket Yoke and Connecting rod .................................................................................. 6
DIPPER ........................................................................................................................................................................... 8
Description .................................................................................................................................................................. 8
Removal ..................................................................................................................................................................... 9
Installation .................................................................................................................................................................. 9
BOOM ........................................................................................................................................................................... 11
Description ................................................................................................................................................................ 11
Removal ................................................................................................................................................................... 12
Installation ................................................................................................................................................................ 13
SPECIFICATIONS
See Section 1002

Copyright ©
9003-3
BUCKET
Description
13 14 21
20 23
17
20
16 20
13 17 20
15 10 21
14
19 22
9 15
4
18
18
9 22
12
19
11
6
7
24
2
3 1
24
JS0127B
1 LOCKING PIN 13 CONNECTING ROD
2 PIN 14 GREASE FITTING
3 BUCKET 15 BUSHING
4 YOKE 16 BUSHING
5 LOCKING PIN 17 SHIM
6 PIN 18 DUST SEAL
7 DUST SEAL 19 DUST SEAL
8 GREASE FITTING 20 LINKAGE SEAL
9 NUT 21 LINKAGE SEAL
10 SCREW 22 LINKAGE SEAL
11 PIN 23 LINKAGE SEAL
12 SHIM 24 RETAINING RING

Copyright ©
9003-4
Removal STEP 4
STEP 1
Place the bucket flat on flat, level ground. Operate the
attachment controls so that the dipper/bucket
connecting pin is not under load from the weight of the
dipper. Shut down the engine.
STEP 2
Start the engine, disengage the attachment from the

bucket and save the linkage seals for re-use.
Installation
STEP 1
Make sure the bucket is in a stable position.
Remove the retaining rings and pins. STEP 2
STEP 3
Install the linkage seals on the dipper bushing shoulders.

Change them if necessary. Start the engine. Extend the
Remove the bucket pins. bucket cylinder rod to bring it into its housing. Stop the
engine and remove the starter switch key.

Copyright ©
9003-5
STEP 3 Shimming the bucket
The machine is equipped with a bucket play adjusting
system which eliminates play that develops at the
bucket/dipper linkage due to wear. This system delays
the effects of wear and gives longer life to bushings and
pins.
NOTE: Incorrect adjustment of the play can cause
friction, abnormal noises or excess play and damage
the O-rings.
Adjusting the play
Place the bucket flat, lying on the ground.
1
J
Install the dipper/bucket linkage pin and then install the
retaining pin and ring. Start the engine. Bring the bucket
rod into its housing, stop the engine and remove the
starter switch key.
STEP 4 2
CD00E121
Check the play (J) between the dipper and the bucket
lug. If the play (J) exceeds 4 mm, remove the four
screws and the cap (1), then the shims (2). Use the
shims (2) as a feeler gauge and calculate the number of
shims necessary to eliminate the play (J). Install the
necessary number of new shims. Reinstall the cap (1)
and the four screws.
NOTE: When the screws on the cap (1) are tightened,
the inner bushing moves towards the dipper and the
play is eliminated.
IMPORTANT: It is recommended to maintain a play of
Install the connecting rod/bucket linkage pin and then
about 1.2 mm. If the play is insufficient, it may cause wear
install the retaining pin and ring. Push the seals back into
by friction or seizing.
their housings. Adjust the dipper/bucket shimming. See
"Shimming the backhoe bucket". Grease the linkage pins. IMPORTANT: The inner bushing has a stud which
prevents the bushing from turning. The cap (1) has an
orifice in its inner surface. Make sure that the stud is
inserted in that orifice when the cap is installed (1).

Copyright ©
9003-6
Removal and installation of Bucket STEP 3
Yoke and Connecting rod
Remove the bucket. (For details, see page 4 "Removal
and Installation of Bucket".)
STEP 1
Place the bucket yoke (1) parallel to the ground.

STEP 2
Use the bar hammer (1) and the holding-up bar (2) to
push out the pin (3), and remove the bucket yoke (4).
Remove double nuts (1) and (2), and then pull out bolts
(3) and (4).

Copyright ©
9003-7
STEP 4
Use a bar hammer (1) and the holding-up bar (2) to

push out the pin (3), and remove connecting rod (4) and
(5). If the pin is difficult to pull out, it is being loaded.
When pulling out a pin, take care not to damage the
installed O-ring and dust seal.
When installing parts, clean the pin and pin opening of
each part, and firmly rub them with grease.
NOTE: When installing proceed in the reverse order
from removal. Change linkage seals and bushing, if
necessary.

Copyright ©
9003-8
DIPPER
Description
3
1
2
6
7
10
8
6
13 4
9
7
12
8
11
9 12
JS01274C
1 WASHER 7 BUSHING
2 SCREW 8 BUSHING
3 PIN 9 BUSHING
4 DIPPER 10 SHIM
5 BOOM 11 SEAL
6 DUST SEAL 12 SEAL

Copyright ©
9003-9
Removal STEP 6
STEP 1
Remove the bucket, the connecting rods and the yoke,
see page 4.
STEP 2
Start the engine, retract the dipper cylinder rod and
lower the attachment to the ground. Shut down the
engine.
STEP 3
Remove the bucket cylinder and disconnect the dipper
cylinder rod from the dipper, see Section 8005. Attach
the dipper cylinder rod to the boom.
Use a bar hammer (1) and the holding-up bar (2) to
STEP 4
push out the pin (3) and remove the arm (4). If the pin is
difficult to pull out, it is being loaded. When pulling out a
pin, take care not to damage the installed O-ring and
dust seal. When installing parts, clean the pin and pin
opening of each part, and firmly rub them with grease.
STEP 7
Start the engine, move the machine backwards to
separate the dipper from the boom. Lower the boom to
the ground and shut down the engine.
STEP 8
Lower the dipper to the ground and remove the lifting
equipment from the dipper.
Attach a suitable lifting device to the dipper. Take up STEP 9
any slack on the lifting slings, since the dipper has to be Remove and scrap the dust seals.
supported before lifting.
NOTE: Perform step 10 only if the bushings have to be
STEP 5 changed.
STEP 10
Remove the bushings from the dipper or from the
boom, using a hammer and a suitable drift on the outer
diameter of the bushing.
Installation
NOTE: Perform step 1 only if the bushings have been
removed.
STEP 1
Using a suitable sleeve, install the bushings.
STEP 2
Remove the screw (1). Install new dust seals on the dipper.
STEP 3
Attach a suitable lifting device to the dipper. Move the
dipper into position near the machine.

Copyright ©
9003-10
STEP 4
Start the engine and move the machine forwards so
that the boom is aligned with the dipper. Check the
alignment of the pin bores on the boom and the dipper.
Shut down the engine.
STEP 5
Install the pin (3) and the lock bolt (1).

STEP 6
Using a set of feeler gauges, check that the play
between the boom and the dipper is 4.5 to 5.5 mm . If
necessary, remove the pin (3) and add one or more
shims as required to arrive at the correct clearance.
Install the pin (3).
STEP 7
Remove the lifting device from the dipper.
STEP 8
Connect the dipper cylinder rod to the dipper and install
the bucket cylinder, see Section 8005.
STEP 9
Install the bucket, see page 4.
STEP 10
Bleed the cylinders, see Section 8000.
STEP 11
Grease the linkages.

Copyright ©
9003-11
BOOM
Description
5
7
6
5
4 3
JS01275B
1 WASHER
2 SCREW
3 PIN
4 BOOM
5 SHIM
6 DUST SEAL
7 BUSHING

Copyright ©
9003-12
Removal STEP 7
STEP 1
Remove the dipper, see page 9.
STEP 2
Start the engine and lower the boom to the ground.
Shut down the engine.
STEP 3
Remove the dipper cylinder, see Section 8005. Do not
remove the vacuum pump from the hydraulic reservoir.
STEP 4
Disconnect the boom cylinder rods from the boom, see
section 8005
Wrap a nylon sling (1) around the pin that was installed
STEP 5 in step [4], and fix it with the crane.
STEP 8
Remove the grease nipple (1) and inser a batten (2) to

the root of the boom cylinder.
STEP 6
Remove the lock bolt (1).

STEP 9
Install the pin (1) that was removed in section 8005.

Install the bolt (3) with 2 lock nuts (2) and also install
the securing ring (4).
Use a 24-mm slide hammer (1) to remove the pin (2).

Copyright ©
9003-13
STEP 10 STEP 13
Disconnect all the hoses. Mark the hoses and pipes so Remove and scrap the boom dust seals (6).
that the connectors match at the time of assembly. Use NOTE: Perform step 12 only if the bushings (7) have to
caps or plugs to cover the hoses and pipes to prevent be changed.
the entry of water, dust or dirt. Clean the hoses and
pipes by spraying with a parts cleaner to prevent STEP 14
scratches and prevent dirt from accumulating on the Remove the bushings (7) from the boom, using a
connectors. hammer and a suitable drift on the outer diameter of
the bushing.
STEP 11
Disconnect the boom cylinder rods from the boom, see Installation
Section 8005.
NOTE: Perform step 1 only if the bushings (7) have
NOTE: The numbers in brackets in the following steps been removed.
refer to the drawing on page 11.
STEP 1
STEP 12 Using a suitable sleeve, install the bushings (7) on the
boom.
STEP 2
Install new dust seals (6) on the boom.
STEP 3
Reverse the machine and remove the boom (1).
Attach a suitable lifting device to the boom. Raise the

boom and move it into position, check the alignment of
the boom and chassis orifices.
STEP 4
Install the pin (3) and the lock bolt (1).

Copyright ©
9003-14
STEP 5
Using a set of feeler gauges, check that the play
between the boom and the chassis is 3.5 to 5.5 mm. If
necessary, remove the pin (3) and add one or more
shims (5) as required to arrive at the correct clearance.
Install the pin (3).
STEP 6
Connect the boom cylinder rods to the boom, see
Section 8005.
STEP 7
Start the vacuum pump and remove the plugs from the
hoses. Connect the supply hoses at the bottom of the
boom.
STEP 8
Install the dipper cylinder on the boom, see Section
8005.
STEP 9
Install the dipper and the bucket, see page 8.
STEP 10
Bleed the cylinders, see Section 8000.
STEP 11
Grease the linkages.

Copyright ©
Section
9004
9004
SEAT AND SAFETY BELT

Printed in France
Copyright ©
9004-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................................................................................... 2
OPERATOR'S SEAT ...................................................................................................................................................... 3
Description ................................................................................................................................................................. 3
Removal ..................................................................................................................................................................... 4
Installation .................................................................................................................................................................. 7
SAFETY BELT ............................................................................................................................................................... 8
Removal ..................................................................................................................................................................... 8
Installation .................................................................................................................................................................. 8
SPECIFICATIONS
Weight of the operator's seat.................................................................................................................. 46 kg (101.41 lb)
Lep SM4609004-EN Issued 09-07

Copyright ©
9004-3
OPERATOR'S SEAT
Description
10
9
6
3 5
7
2
CS02A504
1 OPERATOR'S SEAT 6 SHOCK ABSORBER
2 MASK 7 BRACKET
3 BOOT 8 FRONT CONTROL ARM BRACKET
4 RAIL 9 CYLINDER
5 REAR CONTROL ARM BRACKET 10 BULB

Copyright ©
9004-4
Removal STEP 5
STEP 1
CD00G049
Loosen and remove the screw (1) that retains the func-
JS00163A1 tion cancellation lever (2). Remove the lever.
Park the machine on hard, flat ground. Lower the tool to
the ground. STEP 6
STEP 2
STEP 3
Move the operator's seat as far forward as possible.
STEP 4
CD00G050
Loosen and remove the three screws that hold the inner
cab access bar. Remove the access bar.
STEP 7
CD00G048
Lift the boot. Loosen and remove the four screws (1)
from the front portion of the control arm.
2
NOTE: Steps 5 to 7 are to be carried out only for the LH
control arm. 1
CD00G051
Label and disconnect the electrical connectors (1),
remove the compartment control casing assembly (2).

Copyright ©
9004-5
NOTE: For the LH control arm, do not carry out step 8. STEP 11
STEP 8 Lift the upper portion of the control arm and position it
to the side.
STEP 12
CD00G066
Remove the trim then remove the air-conditioning box
using the four screws. Remove the latter.
CD00G117
STEP 9 Loosen and remove the two upper screws as well as
the two lower screws that hold the front portion of the
control arm.
1
1 NOTE: For the RH control arm, do not carry out
steps 13 and 14.
STEP 13
1
1
CD00G052
Loosen and remove the four screws (1) from the rear
portion of the control arm.
STEP 10
CD00G118
Loosen and remove the screws that hold the LH side
portion of the control arm.
CD00G053
Loosen and remove the two screws (1) that hold the
arm angle adjustment lever, then remove the lever.

Copyright ©
9004-6
STEP 14 STEP 16
1 1
1
CD00G058 CD00G120
Loosen from the LH side, the rod (1) that links the func- Loosen and remove the two front retaining screws (1) of
tion cancellation lever to the safety bar (2). the control arm to the front seat bracket.
STEP 15 STEP 17
LH side
2
1
1
1
CD00G121
Loosen and remove the two rear retaining screws (1) of
CD00G059 the control arm to the rear seat bracket.
RH side
CD00G119
Loosen and remove the four screws that fasten the
plate (1) to the bracket (2).

Copyright ©
9004-7
STEP 18 STEP 20
CD00G127 CD00G123
Move the LH control arm (1) on the cab side, keep it in Remove the carpet, loosen then remove the eight
this position using suitable lifting equipment. retaining screws from the seat. Remove the seat from
the cab, with the help of an assistant.
NOTE: For the RH control arm, position it behind the
cab. NOTE: The seat weighs 46 kg (101.41 lb).
To install, proceed in the reverse order from that of
removal.
1
CD00G122
Remove the trim in front of the seat using the four
screws (1).

Copyright ©
9004-8
SAFETY BELT
Removal STEP 4
STEP 1
CD00G125
Loosen and then remove the screw (2) and the washer.
JS00163A1 Remove the inertia-reel.
the ground. Installation
STEP 2 To install, proceed in the reverse order from that of
removal.
STEP 3
CD00G124
Loosen then remove the retaining screw (1) and the
washer. Remove the seat fastener.

Copyright ©
Section
9005
CAB AND CAB EQUIPMENT
9005

Printed in France
Copyright ©
9005-2
TABLE OF CONTENTS
CAB ............................................................................................................................................................................... 3
Removal .................................................................................................................................................................... 3
Installation ................................................................................................................................................................. 6
HEATER ........................................................................................................................................................................ 9
Description ................................................................................................................................................................ 9
Removal .................................................................................................................................................................. 10
Installation ............................................................................................................................................................... 11
WINDSHIELD WIPER MOTOR ................................................................................................................................... 13
Description .............................................................................................................................................................. 13
Removal .................................................................................................................................................................. 14
Installation ............................................................................................................................................................... 15

Copyright ©
9005-3
CAB
Removal STEP 7
Remove the radio, if fitted.
STEP 1
STEP 8
JS00163A
the ground. Remove the trim panel at the rear of the cab, taking
care to disconnect the connector for the cigarette lighter
STEP 2 and the solar radiation detector.
shut down the engine. STEP 9
STEP 3 2
CD00G004
Remove the two electronic boxes (1) and (2), see
Section 4003.
Open the left-hand side doors. Disconnect the earth
cable (1) from the battery. Close the doors.
STEP 4
Fold the operator's seat-back down and move the seat
as far as possible.
STEP 5
Remove the floor mat from the cab.
STEP 6
Remove the thrust bar on the left-hand side of the cab.

Copyright ©
9005-4
STEP 10 STEP 14
4 3
CD00G006
Disconnect the windshield washer pipe and remove the
retaining clip.
STEP 15
Remove the windshield wiper motor, see page 13 in
this section.
STEP 16
Remove the upper right-hand side trim panel and
Remove the relays and the relay retaining plate (3). remove the display.
STEP 11 STEP 17
Remove the controller brackets (4) and (5).
STEP 12
1
1
CD00G005
Remove the screws (1) which fasten the rear ventilation
and remove the two conduits.
STEP 13
Remove the connectors (2) at the rear of the cab.
Remove the pollen filter guard, remove the pollen filter

and remove the pollen filter conduit.

Copyright ©
9005-5
STEP 18 STEP 20
Remove the working light from the top of the cab.

Retract the radio aerial. Install suitable lifting rings on
the top of the cab. Install lifting equipment.
STEP 19
Remove the screws and washers which fasten the cab
to the frame.
NOTE: Keep away from the cab while it is being
lowered. Make sure that the cab is not damaged during
lifting or lowering. Room for manoeuvre is very limited
at the rear, on the sides and inside the cab.
Using the lifting equipment, carefully raise the cab until

it is completely away from the machine, then lower it to
the ground.

Copyright ©
9005-6
Installation
NOTE: Keep away from the cab while it is being
lowered. Make sure that the cab is not damaged during
lifting or lowering. Room for manoeuvre is very limited
at the rear, on the sides and inside the cab.
STEP 1
Install suitable lifting rings on the top of the cab. Using

suitable lifting equipment, raise the cab. Guide the cab
so that it is correctly aligned with the mounting studs
and orifices in the upperstructure frame.
STEP 2
Install the screws and washers which fasten the cab to
the frame.
STEP 3
Install the working light on the top of the cab.
STEP 4
Install the windshield wiper motor, see page 13 in this
section.

Copyright ©
9005-7
STEP 5 STEP 9
Use the screws to install the display and connect it to
the electrical harness.
STEP 6
1
Install the electronic control box support brackets.
2 STEP 10
Connect the electrical harnesses together.
STEP 11
Install the pollen filter and the pollen filter conduit.

Using screws (1), fasten the pollen filter housing (2) to
the cab.
STEP 7
Reconnect the blower motor conduit to the ventilation
conduit at the front of the cab. Reconnect the ventilation
conduit at the rear of the cab.
CD00G004
STEP 8 Install the relays and the two controllers, see Section
4003.
.
CD00G006
Connect the windshield washer pipes together and
attach the retaining clip.
Install the trim panel at the rear of the cab, taking care
to reconnect the cigarette lighter connector and the
solar radiation detector.

Copyright ©
9005-8
STEP 12
Install the radio, if fitted.
STEP 13
Install the access bar, using screws and washers.
STEP 14
Install the floor mat.
STEP 15
Open the left-hand side doors. Reconnect the battery

cable (1) to the battery. Close the doors.

Copyright ©
9005-9
HEATER
Description
12
3
1
10 4
6
11
7
2
CS02C514
1 CAB REAR VENTILATION CONDUIT 7 HEATER HOSE
2 CAB LOWER VENTILATION CONDUIT 8 RETAINING CLIP
3 PLUG 9 UNION
4 POLLEN FILTER 10 UNION
5 CONDUIT 11 HEATER ASSEMBLY
6 SCREW 12 CONTROL BLOCK

Copyright ©
9005-10
Removal STEP 5
STEP 1
WARNING: Boiling cooling fluid can spurt out
when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the
system has cooled down and then turn the cap
slightly and wait for all the pressure to be
! released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
maintenance of the cooling system, refer to the
maintenance instructions.
Make sure that the radiator has cooled down and

remove the radiator cap.
JS00163A
Park the machine on hard, flat ground. Lower the tool to STEP 6
the ground. Use a container of suitable capacity and drain the oil-
cooler (see Section 2001).
STEP 2
Reduce the engine speed to idle for 30 seconds, then STEP 7
shut down the engine. Remove the operator's seat from the cab (see Section
9004).
STEP 3
STEP 8

cable (1) from the battery. Close the doors. Install the trim panel at the rear of the cab, taking care
STEP 4 to disconnect the connector for the cigarette lighter and
Raise the engine hood and lock it in the raised position. the solar radiation detector.
STEP 9
Disconnect the electric blower supply harness.

Copyright ©
9005-11
NOTE: The numbers within brackets refer to the NOTE: The numbers within brackets refer to the
schematic on page 9. schematic on page 9.
STEP 1
Install the heater in the cab, using the screws (6), brake
washers and flat washers.
8
STEP 2
7 7
4
CD00G044
Unscrew the hose clips (8) and disconnect the heater
hoses (7).
STEP 11
Remove the ventilation conduits (1) and (2) from the
cab.
STEP 12
Install the conduit (5), the pollen filter (4) and the pollen
filter guard.
STEP 3
Install the heater ventilation conduits (1) and (2).
STEP 4
4
8
Remove the pollen filter guard, remove the filter (4) and
remove the conduit (5). 7 7
STEP 13
Remove the screws (6) that secure the heater to the CD00G044
cab. Remove the heater from the cab. Install the heater hoses (7) and tighten the retaining
clips (8).

Copyright ©
9005-12
STEP 5 STEP 10
Connect the blower supply electrical harness.
Start the engine and run it at idle speed for one minute.
STEP 6 Shut down the engine.
STEP 11
Add cooling fluid according to requirement in the
expansion reservoir.
WARNING: Boiling cooling fluid can spurt out

when the radiator cap is removed. To remove
the cap, proceed as follows: Wait until the
system has cooled down and then turn the cap
slightly and wait for all the pressure to be
! released. You can be seriously scalded if the
radiator cap or expansion reservoir cap is
removed too quickly. For checking and
maintenance of the cooling system, refer to the
maintenance instructions.
Install the trim panel at the rear of the cab, taking care
to reconnect the cigarette lighter connector and the
solar radiation detector. STEP 12
Start the engine and run it at maximum speed until it
STEP 7 reaches normal working temperature.
Install the operator's seat in the cab (see Section
9004). STEP 13
STEP 8 shut down the engine.
Pour suitable cooling fluid in the radiator (see Section
2001). STEP 14
Let the oil-cooler cool.
STEP 9
STEP 15
When the radiator feels cold, remove the caps from the
radiator and the expansion reservoir. Top up if
necessary.
STEP 16
Close the left-hand side doors.
Open the left-hand side doors. Reconnect the earth

cable (1). Close the doors.

Copyright ©
9005-13
WINDSHIELD WIPER MOTOR
Description
11
9
8 10
1
7
6
3 5
CI00G502
1 PROTECTIVE FLAP 7 FLAT WASHER
2 WINDSHIELD WIPER ARM 8 PLASTIC SUPPORT
3 NUT 9 SCREW
4 WINDSHIELD WIPER MOTOR 10 ELECTRICAL HARNESS
5 RUBBER CAP 11 SCREW
6 NUT

Copyright ©
9005-14
Removal STEP 6
STEP 1 Note the position of the windshield wiper arm (2).
Remove the windshield wiper arm (2) from the
windshield wiper motor (4) by pulling it off the
windshield wiper motor shaft.
STEP 7
Remove the rubber cap (5).
STEP 8
Remove the nuts (6), washer (7) and plastic support (8)
from the windshield wiper motor shaft.
STEP 9
JS00163A
the ground.
STEP 2
STEP 3
CD00G133
Remove the upper right-hand trim.
STEP 10
A
cable (1) from the battery. Close the doors. A
STEP 4
NOTE: The numbers within brackets refer to the
schematic on page 13.
From the front of the cab, raise the protective flap (1)
CD00G134
located on the lower portion of the windshield wiper
Remove the lower front trim inside the cab, by the
arm (2).
screw(s) (A).
STEP 5 STEP 11
Remove the nut (3). Disconnect the electrical harness (10) from the
windshield wiper motor (4).
STEP 12
Remove the screws (9) and (11) from the windshield
wiper motor. Remove the windshield wiper motor.

Copyright ©
9005-15
Installation STEP 8
NOTE: The numbers within brackets refer to the Turn back the flap (1) located on the lower portion of
schematic on page 13. the windshield wiper arm (2).
STEP 1 STEP 9
Place the windshield wiper motor (4) in position on the
cab bracket. Connect the windshield wiper motor
connector (4) to the electrical harness (10).
STEP 2
Install the windshield wiper motor (4) on the cab pillar,
using the screws (9) and (11).
STEP 3
Open the left-hand side doors. Connect the earth cable

(1). Close the doors.
STEP 10
Switch on the windshield wiper motor and check that
everything is working correctly.
CD00G134
Install the right-hand front trims in the cab using the
screws.
STEP 4
Install the support (8), washer (7) and the two nuts (6).
Tighten the nuts.
STEP 5
Install the rubber cap (5).
STEP 6
Install the windshield wiper arm (2) on the windshield
wiper motor shaft (4), positioning the windshield wiper
arm (2) in the same position as was noted at
disassembly.
STEP 7
Install the nut (3) on the windshield wiper motor shaft.
Tighten the nut.

Copyright ©
9005-16
NOTES
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Copyright ©
Section
9007
AIR CONDITIONER
9007

Printed in France
Copyright ©
9007-2
TABLE OF CONTENTS
SPECIFICATIONS ........................................................................................................................................................... 2
SPECIAL TORQUE.......................................................................................................................................................... 3
AIR CONDITIONER ......................................................................................................................................................... 4

Description ................................................................................................................................................................... 4
Disassembly and assembly .......................................................................................................................................... 5
SPECIFICATIONS
Capacity of the system ............................................................................................................................... 1.350 ± 0.05 kg
Type of cooler ................................................................................................................................................ HFC (R) 134a
Receiver dryer max. setting pressure of the system with full gas load................................................................. 3.14 Mpa
Table 1
Replacement part Oil level adjustment

Compressor Measure the oil volume in compressor that is removed.
Remove all the oil except that remaining in the compressor that was
removed from the brand new compressor.
Example:
If 30 cc of oil remains in the removed compressor
(for a SD7H13WM7359 compressor), remove 105 cc from the brand new
compressor.
(135 cc - 30 cc = 105 cc)
Evaporator Refill 40 cc.
Condenser Refill 40 cc.
Receiver dryer Refill 20 cc.
NOTE: The oil type is different according to

compressors. Refer to the nameplate attached to the
compressor, which has indications for the oil type.
NOTE: Before starting the operation, stop the engine
and turn off the power for air conditioner related
devices. Avoid water or dust from entering the
refrigerating circuits. In addition, do not leave the piping
unattached from the machine. Avoid conducting piping
removal or fitting work under rainy conditions. When the
work is completed, check that the faulty parts have
been fully repaired by running the air conditioner.

Copyright ©
9007-3
SPECIAL TORQUE
Table 2
Pipe fastening section Tightening torque N•m

1 D hose and compressor (M8 bolt) 20 to 30
2 S hose and compressor (M8 bolt) 20 to 30
3 D hose and condenser (1/2 inch nut) 20 to 25
4 Condenser and L hose (L pipe) (8 mm nut) 12 to 15
5 L hose (L pipe) and receiver dryer (M 6 bolt) 8 to 12
6 S hose, L hose and expansion valve 8 to 12
(M6 x P1.25)
Table 3
Category Type Nominal diameter Pitch Tightening torque
(mm) (mm) N•m
Bolt 7T M6 1.0 8 to 12
M8 1.25 20 to 30
M10 (air conditioning unit mounting - 17 to 19
section)
M10 1.25 40 to 54
M10 1.5 37 to 51
9T M8 1.25 24 to 36
M10 1.25 56 to 76
M10 1.5 53 to 72
Nut Pipe 8 mm 1.5 12 to 15
diameter
1/2 inch 1.5 20 to 25
5/8 inch 1.5 30 to 35
NOTE: About oil capacity for compressors

SD7H13WM7359 X1 Series compressors are filled with
135 cc of oil (SP-10). Low oil level may cause it to seize
up at high speeds and reduce durability while excessive
oil may reduce its cooling performance. While the air
conditioning is running, the oil is distributed in the
refrigerating circuits. Therefore, the oil level must be
adjusted following the instructions in table 1 when cha
nging parts.

Copyright ©
9007-4
AIR CONDITIONER
Description
2
1 3 4
8
10
11
CRPH06B065H01
1 BLOWER MOTOR RELAY 7 HEATER CORE
2 CONTROLLER 8 MODE SWITCH-OVER MOTOR ACTUATOR
3 INSIDE AIR FILTER 9 SCREW
4 INSIDE/OUTSIDE AIR SWITCH-OVER MOTOR ACTUATOR 10 INTAKE CASE
5 BLOWER CASE 11 SCREW
6 AIR MIX MOTOR ACTUATOR

Copyright ©
9005-5
Disassembly and assembly STEP 5
IMPORTANT: Service work on air-conditioning circuits
must be carried out by approved service engineers.
1
NOTE: Never attempt to service the air conditioning 2
system unless you are completely familiar with air
conditioning and the safety precautions which must be
followed when handling liquid refrigerant. Liquid 4
refrigerant can cause severe and painful frostbite.
Contact your dealer, who is experienced in servicing
and handling of refrigerants.
NOTE: When fastening the piping connection for
refrigerating circuits, apply special oil (SP-10) to O- 3
rings and fasten the connecting parts using tightening
CRPH06B067A01
torque specified in Table 2, page 3. Further, tighten Drain the cooling water, detach the heat hose and then
screws and bolts using torque specified in Table 3, remove the 2 screws (4) (5 x 16).
page 3. Remove the pipe clamp (2) and the AHC bracket (3),
STEP 1 and then pull out the heat core (1).
Remove the inside air filter (3), and remove the 4 STEP 6
screws (3) (5 x 14) to remove the intake case (10)
(see page 4).
1
STEP 2
Remove the blower case (5) by removing the 3 screws
(11) (5 x 14) that mount the blower case to the unit
case (see page 4).
STEP 3
1
2
2
CRPH06B068A01
3 Remove the rod D (1) from the rod holder (2) mounted
5 on the lever of the mode motor actuator.
6 4
CRPH06B066A01
After removing the cooling hose (5), remove the 3
bolts (4) (5 x 16) fitted under the blower case (1) and
pull out the blower motor (2).
NOTE: Do not remove the fan from the blower motor.
STEP 4
Remove the 2 screws (6) (4 x 14) under the blower
case (1) and pull out the blower controller (3).
NOTE: Do not disassemble the blower controller.

Copyright ©
9007-6
STEP 7 STEP 9
1 A 3 2
32
3 B
5
4
4
1
CRPH06B069A01
Remove the motor actuator mounted on the lower unit
case (5) and the upper unit case (1) by removing 3
screws.
Remove the 11 mounting screws (5 x 16) from the
lower unit case (5) and the upper unit case (1).
Pull upward the upper unit case (1).
WARNING: Paying attention not to have evaporation
sensor cords caught by the case.
5
STEP 8 CRPH06B071B01
Installing the evaporation sensor:

2 NOTE: Attach the evaporation sensor to the holder,
7
place the tip of the holder and sensor in place as shown
in the figure above.
3 (1) Insert sensor holder into 13th and 14th
columns.
(2) Insert sensor holder into 5th and 6th columns.
6 (3) 3RD column.
(4) Ensure no unnecessary looseness.
(5) Do not allow tip of the thermistor to extrude
4 from tube to the left.
CRPH06B070A01
Pull out the evaporator (2) with its heat insulating
material attached from the lower unit case.
Pull out the evaporation sensor (4) with its sensor
holder attached from the evaporator.
Remove the 2 hexagon bolts (6) (M5x40) from the
evaporator, and then, remove the expansion valve (3)
from evaporator.
Install O-rings (7) (5/8 and 1/2 NFO rings) onto a new
evaporator and then fit the expansion valve.
NOTE: Special care should be taken while installing to
avoid O-ring engagement. Do not reuse O-rings. Install
O-rings with bare hands.

Copyright ©
9005-7
STEP 10 STEP 12
Replacement of the inside/outside air
switch-over motor actuator:
c F
CRPH06B072A01 E
Remove the rod clamp (C) interlocking the mode motor
actuator and mode cam by pushing to the direction of
ARROW. CRPH06B074A01
Remove 3 mounting screws from the motor actuator Remove the screw fixing the motor actuator with its
and remove the motor actuator with its rod clamp and lever (E) attached, and remove the motor actuator.
lever attached from the unit. Remove the lever from the motor actuator. Install a new
Remove the rod clamp and lever. Then, install them on motor actuator in the reverse order of the disassembly.
a new motor actuator in the reverse order of the
disassembly.
STEP 11
Replacement of the air mix motor actuator:
CRPH06B073A01
Remove the rod (B) from the lever by pushing the rod
clamp (A), which is attached on the lever of the motor
actuator, to the direction of ARROW.
Remove the 3 mounting screws from the motor
actuator, and remove the motor actuator with its rod
clamp and lever attached from the unit.
Remove the rod clamp and lever from the motor
actuator. Install a new motor actuator in the reverse
order of the disassembly.

Copyright ©
9007-8
NOTES
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Copyright ©
22 27 K1 K2
D MA MB D ITEM DESCRIPTION PRESSURE SETTINGS
A= MAIN RELIEF (STANDARD) 31.4 MPa / 314 Bar / 4554 PSI

26 25 A= MAIN RELIEF (BOOST) 34.3 MPa / 343 Bar / 4974 PSI
B45
P
* 30 B= BOOM RAISING PORT SECONDARY RELIEF 36.3 MPa / 363 Bar / 5264 PSI
29 * 29 *
B1/B2 = RELIEF ON BOOM HBCV 39.2 MPa / 392 Bar / 5685 PSI
*
REG
REG
VA VB
D1 28 83 C= BOOM LOWERING PORT SECONDARY RELIEF 36.3 MPa / 363 Bar / 5264 PSI
D= DIPPER OUT PORT SECONDARY RELIEF 36.3 MPa / 363 Bar / 5264 PSI
P2
VB D1 = RELIEF ON DIPPER HBCV 39.2 MPa / 392 Bar /5685 PSI
AU Dr
VA B1 B2 E= DIPPER IN PORT SECONDARY RELIEF 36.3 MPa / 363 Bar / 5264 PSI
P3 P2 P2 P3
T1 L1 L2 F= BUCKET OPEN PORT SECONDARY RELIEF 36.3 MPa / 363 Bar / 5264 PSI
G= BUCKET CLOSE PORT SECONDARY RELIEF 36.3 MPa / 363 Bar / 5264 PSI
T1 T1 H= PILOT PRESSURE RELIEF 3.9 MPa / 39 Bar / 565 PSI
I= RIGHT-HAND SWING PORT SECONDARY RELIEF 29.3 MPa / 293 Bar / 4250 PSI
Pil J= LEFT-HAND SWING PORT SECONDARY RELIEF 29.3 MPa / 293 Bar / 4250 PSI
T2
K1/K2 = TRAVEL FORWARD PORT SECONDARY RELIEF 35.8 ±7.8 MPa / 358 Bar / 5511 PSI
P MB MA P
L1/L2 = TRAVEL REVERSE PORT SECONDARY RELIEF xxx MPa / xxx Bar / xxx PSI
Pil Pil
T2 T2 N1/N2 = NEGATIVE CONTROL RELIEF 3.38 MPa / 33.8 Bar / 490.2 PSI
P1
15 21 23 23 21 Q= RELIEF VALVE BLOCK COUNTERWEIGHT 27.5 MPa / 275 Bar / 3988 PSI
Pa9 W1/W2 = CRUSHER OPTION SECONDARY RELIEF VALVE xxx MPa / xxx Bar / xxx PSI
J I GB
P1 P1
Z= MAIN RELIEF VALVE FAN 25 MPa / 250 Bar / 2626 PSI
GA 51 = ACCUMULATOR PRECHARGE 1.5 MPa / 15 Bar / 212 PSI
MU
D C
16 B A ITEM DESCRIPTION
Dr P
15
A B Pb7-2 1. HYDRAULIC RESERVOIR
2. BREATHER
RIGHT 4. BY-PASS VALVE
LEFT LEFT FORWARD RIGHT FORWARD 5. SCREEN FILTER
LEFT REVERSE RIGHT REVERSE 6. RETURN FILTER
10. MAIN HYDRAULIC PUMP
15. MAIN CONTROL VALVE
16. HYDRAULIC SWIVEL
1.8 21. TRAVEL MOTOR
22. SWING MOTOR
23. TRAVEL MOTOR BRAKE
42
0.18 MPa
1,8 bar
0.3 MPa
3 bar
O 73 25. RIGHT BOOM CYLINDER
26 psi T1 43.5 psi 26. LEFT BOOM CYLINDER
PS1 T6 T3 Pc5 T2 T4 T5 Ps2
15 27. DIPPER CYLINDER
HYDRAULIC SCHEMATIC
B1 A1 28. BUCKET CYLINDER
29. BOOM SAFETY VALVE (OPTIONAL)
*
A
DR1' *91 71
SECOND OPTION
P
30.
31.
DIPPER SAFETY VALVE (OPTIONAL)
DIPPER LOAD HOLDING VALVE
N2
CX460 EXCAVATOR
41 DR1
32. BOOM LOAD HOLDING VALVE
41. FILTER (ULTRA-CLEAN)
Pa10 Y9 42. OIL COOLER
73 121 A
T T
Pc1 31 N1 D E 30 43. RETURN MANIFOLD
Pil 51. ACCUMULATOR
10µ
2 B5
B9 52. 6 SOLENOID VALVE BANK
OUT
ARM (1) ARM (2)
A9
15 * * 53. BOOM & BUCKET CONTROL LEVER
A5
Pb9 57 Pa5-2 B28 B24 R 54. SWING & DIPPER CONTROL LEVER
OUT 55. TRAVEL CONTROL PEDAL
B
IN Pa9 57. BOOM & DIPPER CONTROL SHOCK ABSORBER
1 P 2 58. PILOT AND RETURN SYSTEM MANIFOLD
0.004 MPa A Pb5 T
0.07 MPa 59. FILTER
0.58 psi
10.15 psi Pa5-1 60. PILOT SYSTEM MANIFOLD
0.7 bar
0,04 bar
ON IN F G 71. SECOND OPTION CONTROL VALVE
B8 58 72. CONTROL PEDAL (OPTIONAL)
15 Pa5-2
T4 73. SECOND OPTION CONTROL VALVE
OPEN A8
43 Pa9
BUCKET
* 58 Pa1 P T Pb1 76. 3-WAY SELECTOR (OPTIONAL)
Pb8 P5 78. RETURN FILTER (OPTIONAL)
Pa8
85 79. CONTROL SHUTTLE BLOCK (OPTIONAL)
D9 PC4
0.127 MPa T D8 83 B4
90 * CLOSE
DR2' 43
D7
81.
82.
SWING SHUTTLE BLOCK
PILOT CIRCUIT FILTER
18.4 psi DR2 83. SHUT-OFF VALVE (OPTIONAL)
10µ A
1.27 bar 76 A4 OPTION 85. HAND/FOOT CONTROL PILOT FILTER
150 MESH
D7 15 3 B C 32 PC2 42 86. PILOT FILTER BY-PASS VALVE
DR2'
D6 79
B1
Pb4 *91 A7 43
A 90.
91.
HYDRAULIC BREAKER VERSION PLUG
SAFETY VALVE VERSION PLUG
D3 D1 120. HYDRAULIC PUMP FOR COOLING HYDRAULIC CIRCUIT
79 Pa4 B7 52 51 121. COOLING HYDRAULIC MOTOR
B2 DOWN B22. SWING PILOT PRESSURE SWITCH
D2 BOOM (1)
Pb7-1 B23. BREAKER / CRUSHER PILOT PRESSURE SWITCH
A3 B T
D1 52 B3 Pb7-2 29 B24. SECOND OPTION PILOT CIRCUIT 2 PRESSURE SWITCH
5 1 4 6 T 15
BOOM (2)
Pa7-1 Pil
C1
1.5 MPa
60 82 B25. BREAKER PILOT PRESSURE SWITCH
T1 Pa7-2 Pb3 212 psi B26. UPPER PILOT PRESSURE SWITCH (YELLOW BAND)
UP Pa7-2 15 bar
15 B27. TRAVEL PILOT PRESSURE SWITCH
Pa3
B6 Pa3 Y2 B28. SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
TRAVEL Y4 P3
B42. PUMP PRESSURE SENSOR (P1)
B2 FORWARD A6 10 µ B43. PRESSURE SENSOR (NEGA-CONT)
P P0 P B44. PUMP PRESSURE SENSOR (P2) (BLUE BAND)
A2 LEFT SWING *W1 W2
* BACKWARD
Pb6
55
4
C3 0.02 MPa
B45.
M3.
OVERLOAD INDICATOR PRESSURE SWITCH
PRESSURE TEST POINT
Pb2 2.5 C2 2.9 psi
Pa6 Y1. SWING PILOT SHUT-OFF SOLENOID VALVE (GREEN BAND)
55 0.2 bar 0.103 MPa
Pa2 RIGHT 3 Y3 14.5 psi
1 bar
Y2. PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
2.5 Y5 Y3.
Y4.
SWING BRAKE SOLENOID VALVE (PINK BAND)
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
* 78 B1
P1 P2 Y5.
Y6.
POWER-UP SOLENIOD VALVE (YELLOW BAND)
CUSHION CONTROL SOLENOID VALVE (LIGHT GREEN BAND)
FORWARD
TRAVEL
C5 C4 86 Y7. MAIN PUMP PROPORTIONAL SOLENOID
A1 Y9. CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
55
42 T T 2 Y6 Y31.
Y32.
COOLING HYDRAULIC MOTOR SOLENOID VALVE
PROPORTIONAL SOLENOID FOR COOLING HYDRAULIC MOTOR
A 10µ
Pb1
BACKWARD B44 Y1
55 Pa1
1
* 76 Pr2
Pr1 A
1 B42
2 15 P1 P2
PT ON 2.0 MPa PP PA PH P3
3 A4
20 bar
290 psi ON 1.2 MPa
B27 12 bar
83 * OFF 1.4 MPa

14 bar
203 psi
174 psi
OFF 0.8 MPa
B26 8 bar
116 psi
A 15
B4
71 71 B43
P T
LEGEND
P1 PUMP
P4 P5 T4 T5
72 * 55 P2 PUMP
OPTION
58 1 PILOT SYSTEM PUMP
P3 P2 P1 T3 T2 T1 E
Y7
TRAVEL (LEFT) TRAVEL (RIGHT)
81 A3 A2
10 RETURN TO RESERVOIR
85 LEAK-OFF-RETURN
P P 2S 3S 1S FORWARD BACKWARD BACKWARD FORWARD
UP
54 85 53 PILOT SYSTEM CIRCUIT
G
T T (FRONT) (REAR)
1 T 2 COMPONENT BOUNDARY
H
S2 S3 S1
DOWN *B25 P
HOSE
Y31 PIPING CONNECTION

F
85
* 42
A
PIPING CROSS-OVER
IN
ARM
OUT LEFT
SWING
RIGHT DOWN
BOOM
UP
BUCKET
OPEN CLOSE T
R
* 79
* Pi1 Pi2
3 1 1
3
B22 A1 S1 A2
T 41 COMPONENT ITEM NO.
3 B B23
ON 0.5 MPa 1 2 3 T 4 COMPONENT NUMBER
ON 1.2 MPa
2 4 2 4
59 72.6 psi 174 psi B1 S2 B2
5 bar 12 bar 182 cm3 182 cm3 Dr
OFF 0.3 MPa 40.2 cm3 ISUZU
OUT OFF 0.8 MPa 15 15 P 40 cm3 15
85 85 D 43.5 psi
85 6UZ1X
M
116 psi Pb4
5a4 Pa4 Pb1
3 bar 8 bar
270.0 Kw CONNECTION ITEM NO
C IN P T
P 1950 tr/mn
15 15 15 15 15
Pb9
*
Pa1 Pb1 Pa6 Pb6
A4
a3
* OPTION ITEM NO
A Y9 Tc
H A3
57 15
A Pa10 121 43 M3
S
T Z 120 15 cm3 15 cm3
CX460 EXCAVATOR
Y32 B4 B3
HYDRAULIC SCHEMATIC
Number 87574463A
Copyright ©
A1 COMPUTER
A2 ENGINE CONTROLLER
BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)
FUSE C (20A) A4 WIPER CONTROLLER
1 65A 60A
A6 BLOWER CONTROLLER
F21
5R 210 8R 207 8R 207 2 8R 207 F23 1 F24 1 1 F27 A9 AIR CONDITIONER CONTROLLER
3R 211 2
CN.20
2 2
2
1
2
1
2
1
B1 COOLANT TEMPERATURE SENSOR
58L
8R 100
1
2
1 2 3 4 5 6
3R 212 58L CN-A 58L
FUSE B (20A) FUSE A (20A)
3R 213 8R 207 B2 HYDRAULIC OIL TEMPERATURE SENSOR
CN.26
CN.C4 CN.C5
91-A
CN.C1
5WR 003
ALTERNATOR
B3 FUEL TEMPERATURE SENSOR
F15 LAMP (HOUSE,BOOM)

1.25YR 208 1.25YR 208
COMPUTER POWER
F25 1 1 E
ENGINE PRE-HEAT
5B 797 24V 50A
F22
9 10 11 12 13 14 15 16 17 18
B5 EVA SENSOR
ELEC.FUEL PUMP
FUEL FEED PUMP
1.25WR 209 1 BrR 544
5 6 7 8
2 2
CIGAR LIGHTER
8R 203
F18 WIPER,WASHER
M5
2
1
2
1
AIR COND. FAN
COMPRESSOR
1.25R 206 2 BrW 545 CN-A CN-A 5R 002 B6 AIR INTAKE TEMPERATURE SENSOR
LUBRICATOR
LOCK LEVER
CONVERTER
F10 OPTION LINE
EST CONNECTOR
K7
HORN CTWT
COMPUTER
F16 LAMP(CAB)
AIR COND.
3
CAB SEAT
OPTIONAL 206,208,209 CN.C3 (BLUE TAPE) B21 ENGINE OIL PRESSURE SWITCH
F13 AIR COND.

CN.C2
CONTROL
REMOVAL
RELAY BATTERY
BACK UP
CN.22
BEACON
KEY SW.
SDL
POWER 4 1.25WR 209 1.25GR 205 IC
(GATE)
1.25LR 204
B22 SWING PILOT PRESSURE SWITCH
DC/DC
MAIN
REGULATOR
5 1.25R 206 1.25RW 202 020,030 020,030
X5 B23 BREAKER / CRUSHER PILOT PRESSURE
BrW 545
1 2 3 4
BrR 544
206,208,209
6 60R 200 60R 201 60R 001 G2
X3 SWITCH
F19
F17
F14
F20
F11
F12
M8 M8 1 R
F3
F7
F9
F6
F2
F5
F8
F4
F1
1.25G 020
15A
15A
15A
20A
20A
30A
20A
30A
10A
15A
10A
10A
20A
10A
15A
20A
10A
20A
CN.T1
5A
1P-M
5A
1.25LgR 540 K8 B24 SECOND OPTION PILOT CIRCUIT 2
1
D 1.25RY 225 1.25Br 030 2
E C A B C D E F G H J M10 M10 M10 M10
M4 1.25G 020 RELAY SAFETY L PRESSURE SWITCH
0.85OR 385
VW 280
- + - +
2WR 050
VR 240
R 221
BrW 260
LR 250
2LR 310
F A B
0.85GW 290
1.25RW 220
2Gr 330
0.85YW 270
1.25W 320
1.25LW 340
1.25O 300
0.85VR 370
1.25V 256
0.85BrW 230
1.25LgR 350
0.85BrR 360
J 1.25R 206 1 1.25R 206 WR 541 B 5WR 003 B25 BREAKER PILOT PRESSURE SWITCH
PW 255
G
1.25W 322
P 592
CN.C9
PL 593
1 2
0.85BG 637
0.85PG 598
0.85OR 375
0.85RY 225
60B 799
58X
1.25LgR 540 1.25LgR 540 M4
0.85B 704
812,813,458,459 2 0.85GrR 010 3 S B26 UPPER PILOT PRESSURE SWITCH
0.85GR 231
R 222
1.25W 325
DEUTSCH 645,745 WR 541 3 WR 541 1.25BrR 543 2 R
(YELLOW BAND)
R 223
HD14 ADDITIONAL 0.5mF
BrR 543 4 1.25BrR 543 B 759 B 759 1 E 5Y 004 8R 100 B
CN.Z2 CONTROL CONNECTOR 1 B27 TRAVEL PILOT PRESSURE SWITCH
K32 0.85GrR 010 5 0.85GrR 010
12V 12V
1.25Br 030 C M6
1
CN-A B28 SECOND OPTION PILOT CIRCUIT 1
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
WL 812 GR 831 0.85GR 831
CN.T2
1 6
1P-F
CN.C0
CN.T3
R 225
CN-A
HYDRAULIC FAN
G1 PRESSURE SWITCH
2 3
1
1.25RY 225 WV 813 2 W 820 7 W 820 STARTER MOTOR
1
0.85BG 637 OW 458 3 OW 546 8 OW 546 B 779 60R 001 M10 B B42 PUMP PRESSURE SENSOR (P1)
M
CN.13
592,593,598 OG 459 4 VW 800 9 0.85VW 800 8R 100 B43 PRESSURE SENSOR (NEGA-CONT)
SDL
P1 MONITOR DISPLAY ASSY 0.85VR 900 10 0.85VR 900 BG 641 3LR 060 5Y 004 M5 C
M1 B44 PUMP PRESSURE SENSOR (P2)
0.85BG 660
0.85BG 630
0.85WY 400 0.85WY 400
1 2 3 4
11 BG 650
0.85BL 661
(BLUE BAND)
0.85WL 410 0.85WL 410
1 2 3 4
12 BG 651
BG 652
PANEL;SWITCH (L)
P2
CN.28
PWB B45 OVERLOAD INDICATOR PRESSURE
K30 K31
SDL
Br 556
CN.5 CN.6 0.85YL 411 13 0.85YL 411 BG 670
S2 24V 7.0kw SWITCH (EUROPE)
TRAVEL MODE 0.85L 412 14 0.85L 412 2BG 600
ILLUMINATION REFUEL PUMP PUMP STOP
1 2 B47 BOOST PRESSURE SENSOR
630,652,660,661
1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 IGN 1 1.25W IGN 1.25W 1 1.25W 322 0.85PL 417 15 0.85PL 417 2B 700 3LR 060 1 5BW
S3 WORK MODE 3 5
5
1
2
3
4
9 10 11 12 13 14 15 16 27 28 29 30 31 32 33 34 35 36
B+ 2 R B+ R 2 R 221 4 0.85BG 645 0.85BW 420 16 0.85BW 420 GLOW PLUG B48 AMBIENT AIR (BAROMETRIC) PRESSURE
CN-A
CN.S2
2 3
CN.A6
M8 M8 SENSOR
1
AMP 040 MULTI LOCK TRAVEL MODE 3 BrG TRAVEL MODE BrG 3 BrG 441 0.85B 745 WV 930 17 WV 930
58Y
RW 557
GR 831
S4 AUTO MODE
3LR 060
YR 830
2BG 600
B 722
B 759
540,541
010,543
2B 700
1
WORK MODE 4 VY WORK MODE VY 4 VY 440 CN.35 BW 720 18 BW 720
GND (G1) AUTO/MANUAL SELECT SW. R1 EGR MOTOR B49 CRANKSHAFT POSITION SENSOR
SOFT/HARD 5 WG SOFT/HARD WG 5 WG 446 VR 912 1
COMPUTER B50 CAMSHAFT POSITION SENSOR
CN-A
CN.B4
BEACON 6 VG BEACON VG 6 VG 447 WASHER GW 329 2 S61 U
B51 BOOST TEMPERATURE SENSOR
2
1
CN.5 S5 (SOFT/HARD)
7 7
WV 930 1
L 913 3 V M M15 B52 COMMON RAIL PRESSURE SENSOR
A1 AUTO MODE 8 OG AUTO MODE OG 8 OG 442 772,830 M W
FILTER
POWER 24V 10 1.25LgR 351 BZ STOP 9 YG BZ STOP YG 9 YG 443
BW 720 2 M4 1 4 2 1 4 2 B53 EXHAUST GAS RECIRCULATION VALVE
5V 5
4
1
2
5
3
4
1
2
5
3
5
2 1.25LgR 350 S6
(BEACON) RXD 10 PW RXD PW 10 PW 583 3 3 0.75WB 870 8 0.75WR(U) POSITION SENSOR
B61 SUNLOAD SENSOR
OW 546
CONTROL 24V 4 1.25W 320 11 PL TXD PL 11 PL 584 (BLUE TAPE) 24V 0.75GB 871 0.75WB(V)
0.85BrR 916
7
VR 912
VR 917
TXD
B 750
B 751
2LR 915
L 913
2GrR 330
OW 546
CN.S3 CN.S4 EGR POSITION SENSOR
12 1.25W 321 GND SWING LOCK 12 LY SWING LOCK LY 12 LY 444 1.25WR 209 1 1.25WR 209
AUTO STOP ALARM
0.75YB 872 6 0.75WL(W) B81 HORN
GND 1.25BG 600 WORKING LAMP WR WORKING LAMP WR WR 531 1.25YR 208 2 1.25YR 208 8R 100
1 13 13 0.75B 877 5 0.75LW(GND)
GND B82 REFUEL PUMP STOP ALARM
GND 9 1.25BG 601 ENG.STOP 14 BrR ENG.STOP BrR 14 BrR 530 2LR 060 3 3LR 060 3LR 060 0.85BrR 916 0.75WG 873 4 0.75GB(U)
PANEL;SWITCH (R) U E1 WORKING LIGHT (UPPERSTRUCTURE)
GND 3 P3 S7
WASHER 15 GrR WASHER GrR 15 GrR 520 2Gr 330 4 2GrR 330 330,546 0.85B 749
B82 0.75G 874 3 0.75GW(V)
V B53 E2 WORKING LIGHT (ATTACHMENT)
GND 11 BZ STOP 16 WIPER(INT) LR 16 LR 521 1.25GR 394 5 1.25GR 394 010,540,541,543 0.75YG 875 2 0.75GY(W)
W E3 WORKING LIGHT (CAB)
SINGLE CHIP CPU GND 5 17 WIPER(CNT) YR 17 YR 522 B 734 B 734 1.25O 300 6 1.25O 300 24V 0.75R 876 1 0.75RL(VCC)
CN.E0
S8 VCC
E4 CAB LIGHT
GND 13 SWING LOCK WIPER(INT) 18 LR WINDOW L/SW. VR 18 VR 523 1.25B 700 7 2B 700
LOCK
PUMP OUT 14 YR 940 WIPER(CNT) 19 YR ALTERNATOR BrW 19 BrW 545 1.25BG 600 8 2BG 600 0.85GR 831 1 E51 CIGARETTE LIGHTER
S9 Y2
DL090
SUMITOMO
330,546
PWM PUMP RET 6 BY 941 ENG.STOP WINDOW L/SW. 20 VR GND 1.25BG 20 1.25BG 602 602,603,604,636,645,664 0.85B 760 2 LEVER E52 AIR CONDITIONER
5 6 7 8
1 2 3 4
COMMONRAIL
CN.A4
0.75GR 396
1.25B 730
NO USE 16 ALTERNATOR 21 BrW 0.85B 704 0.85B 704 1.25BG 602 (BLUE TAPE) G1 BATTERY
S10 PRESS. SENSOR
CN.E2
REFUEL PUMP
HYD.FAN MOTOR 15 YG 942 WORKING LAMP GND 22 1.25BG 0.85B 745 0.85B 745 BG 603 2GrR 330 1 2GrR 330 G2 ALTERNATOR
BG
D/A SWING BRAKE
PWM HYD.FAN MOTOR 7 BO 943 0.85BG 604 0.85VW 800 1 OW 546 3 OW 546 2LR 915 1
CN.P4
S11 2R M H1 AUDIBLE WARNING DEVICE
ROOM LAMP
Y3
VR 524
8 bit
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
E4 M14
1
2
2 STAGE RELIEF 8 YW 802 WIPER BG 636 0.85B 762 2 CONTROL 2B 748 2 2B 748 2B 748 2 2B
B52
2 3 4
6 7 8
H2 TRAVEL ALARM
603,604
R 225
CN.21
1.25B 700
PROTECT 0.85BG 645 (PINK TAPE)
S12 K2 RELAY-GLOW PLUG
CN.T8
58M
CN.E1
1
58X
CN.S1
1 2
24VB WASHER 0.85BrR 0.85BrR 360
1 2
6 BG 664
58X
RW 557
3
2 WR 24V
2 STAGE K3 RELAY-HORN
CN.P0
1
5
GrR 14 GrR 520 0.85LW 801 1
1 2 3
4 5 6
SDL
CN.9
Y4 CRANK ANGLE (MPU)
M
GND LR 12 LR 521 0.85B 761 TRAVEL K5 RELAY-ROTARY LIGHT
MT090
SUMITOMO
2
CN.T6
SENSOR
1.25BG 600
1 2
OW 546 YR YR 522 K6 RELAY-AIR CONDITIONER CONDENSER
1 2 3 4 5
REFUEL PUMP 17 13 (RED TAPE)
24V,10W
CN.E3
18 GW 810 VR 3 VR 523 1 1.25B 700 0.75R 471
BEACON LCD GR 983 1
12 L(5V) FAN
2 STAGE -
B49
CN.P9
1 2 3
WARNING BUZZER 19 W 820 5V 4.7k 0.85GR 11 0.85GR 896 2 B 710 0.85YW 802 1 0.75W 481 13 0.75Br(COM-SIG)
S53
CN.P8
Y5 B 757 K7 RELAY BATTERY
B 702
2
91A
1 2
CONDENSER
SDL
1.25B 701
ENG.STOP 21 WR 501 VW 2 VW 525 3 B 711 0.85B 763 RELIEF 0.75G 491 LW(GND) +
2 14
HYD.FAN REVERSE 22 RW 558
P4 LIMIT SW. (DOOR) WR 1 WR 390
JOINT
4 B 713 0.75G 950
K8 RELAY SAFETY
CONNECTOR (YELLOW TAPE) 0.85B 756 1 1 Y
M9 K10 RELAY-WORKING LIGHT
CN.E4
SWING BRAKE 27 VW 800 LW 7 LW 972 5 B 715 M 0.75L 951 VW
630,641,650,651,652,654,660,,661,670,681
FPC GR 982 2 2
1 B 2 VW G(MRE) SENSOR
2 STAGE TRAVEL 28 LW 801 BL 8 BL 973 6 B 725 0.85LgW 803 1
SOFT
BW 688 3 0.75B (UPPERSTRUCTURE/ATTACHMENT)
3 VW 1 BG(B) Y6
CN.T5
K11 RELAY-WORKING LIGHT (CAB)
1 2
LgW 803 BZ. YW YW 970 HARD 0.75G 955
58X
CUSHION 29 9 0.85B 764 2 18 OB(GND) GND
2 3
4 5 6 7 8
2 B50
B 722
24V
HIGH DUMP 30 OR 811 BY 10 BY 971 0.75L 953 5 T K17 BLOWER OFF RELAY
CN.P3
(LIGHT GREEN)
710,711 713,715,725
DUAL SWITCH
B 722
SDL
CN.E5
SWING SHUT-OFF 31 BrW 804 WV 4 WV 930 E51 0.75R 954 19 Y(VCC) K30 REFUEL PUMP RELAY
SWING WR 980 2 S52 VCC
SPARE1(PNP) 32 WL 812
H1 BW 5 BW 720 0.85BrW 804 1
Y1 1.25W 981
BL 686 6 0.75BW K31 REFUEL PUMP STOP RELAY
090
SUMITOMO
HOURMETER LIGHTER 24V,5A 1
WV 813
SPARE2(PNP) 20
S54 0.85B 765 2 4
BW 721
WV 931
SHUT OFF
K32 RELAY, HYDRAULIC FAN
CN.B9
1.25B 701
WATER TEMP.
B1
1 2
VARIABLE ISC 23 LIMIT SW. (F-WINDOW) 0.85BrW 230 0.75WR 484
B 715 (GREEN TAPE) 7 0.75RB(WT)
P5 WR WR SENSOR K33 MAIN RELAY
B 702
1
MAGNET CLUTCH 0.75WL 483
7 8 9 10 11 12 13 14
SWITCHED DROP 36 Y8 15 0.75BR(BT)
4 5 6
1 VR VW 2 VW t° C M1 STARTER MOTOR
ISC3 24 0.75RG 477 8
BG(B) VR VR 1.25W 981 1 0.75RW(5V)
3 3
M3 WIPER MOTOR
2BG 600
2B 700
CN.14
0.75GR 487
758,759
26 16
SDL
ISC2 0.75L(BP-SIG)
2 BG(B) 4 BG(B)
M4 WASHER MOTOR
CN.C8
33 0.75BR 497
SWP
DECR 17 0.75RL(GND)
CN.U5
1.25BG 600
0.85BG 637
1 2 3
CN.15
1
BL(SPK:L-) 5 BL
SDL
1 2 3
INCR 34 0.75RY 478 9 0.75WB(5V) M5 MOTOR (AIR CHANGING)
LW(SPK:L+) LW BOOST TEMP.
A/C CONT. 25 GY 566
6
0.85RY 834 1 0.75YB 488 10 0.75LY(OP-SIG) B51 M6 AIR VENT DIRECTION CONTROL MOTOR
1 2 3
CN.B7
1 2 3
BY(SPK:R-) BY SENSOR
CN.P7
7 DC/DC(24V/12V) CONVERTER
SWP
91A
35 0.85B 771 2 0.75BY 498 11 0.75BY(GND)
PROTECT NO USE M7 MOTOR ACT (AIR-MIX)
0.85B 756
YW(SPK:R+) 8 YW TO LUBLICATOR t° C
2 3
4 5 6 7 8
1.25W 325 VW 280 1 VW 280 20
2B 748
1 M8 BLOWER MOTOR
TECH2 CONNECTOR
CN.25
X4
SDL
SWP
1 2
WR 571 R 223 2 R 223 1.25O 331 2 OW 301 1
CN.6 2 MEMORY CLEAR2
X7 M9 AIR CONDITIONER CONDENSER FAN
10
11
12
13
14
15
16
LG 570 B 702 3 B 702 VW 280 6 24V IN (MAIN) LW 801 1 0.85LW 801 2B 758 VR 841 2
1
2
3
4
5
6
7
8
9
7 8 9 10 11 12 13
24V 5V 3
4 5 6
MOTOR
DL040
SUMITOMO
MT090 CN.U9
SUMITOMO
1
17
13
P 585 R 223 2 24V IN (BACKUP) YW 802 2 0.85YW 802 OW 894 VW 842 3
9
5
1
4 1
CN.A2
BG 633 PB 590 1 BY BOOST PRESS.
AMP MIC
1 2
X24
18
14
10
CN.T4
M14 FUEL FEED PUMP MOTOR
6
2
CN.P1
B 702 GND
58X
PG 586 5 LgW 803 3 0.85LgW 803 B 777 2
2 1
5
0.85B 771
PG 588
19
15
11
YW SENSOR
B47
BP 634
2
B 734
7
3
16 15 14 13 12 11 10 9 R
BP 587 RS232C PB 589 0.85YR 281 1 12V OUT(MAIN) BrW 804 4 0.85BrW 804 M15 EXHAUST GAS RECIRCULATION MOTOR
20
16
12
6
8
4
1 2 3
M20
CN.U8
8 7 6 5 4 3 2 1
SWP
12V OUT(BACKUP)
1 2
7 0.85RW 282 3 GW 810 5 GW 810 M20 ELECTRIC FUEL PUMP
(KWP2000)
BrR 543
OPTION
BG 620 12V OUTPUT 0.85BY 729 4 GND OR 811 6 1.25O 895 OW 300 1
CN.P5
8 CN.71
CN-B
WIPER CONTROLER
1
Y9 P1 INSTRUMENT PANEL
1
2
7 SHUT OFF BrR 840 7 BrR 840 1.25B 778 2 BrR 840 2 2SPEED
OPT.SW (OPT.2SPEED)
ELE.FUEL PUMP P2 SWITCH PANEL (LEFT-HAND)
B 734 VR 841 8 VR 841 1.25O 300 1.25O 300 1 OW 300
0.85YR 283
0.85BY 727
WIPER SW.IN(INT) 11 LR P3 SWITCH PANEL (RIGHT-HAND)
CN.G0
SWP
BrR 840 1.25O 895 BrR 840
1 2
633,634,635 1 VW 842 9 VW 842 1.25O 895 BrR 840 BrR 840 2
1 BL WIPER SW.IN(CNT) 12 YR U1 OIL PRESS.
P4 MONITOR DISPLAY
4 5 6 7
1
575,588,589,592,593 BP 690 2 Br 556 10 Br 556 G 464 G 464 3 G 464
S63 0.85B 771 B 767 SENSOR
CN.70
L 2 LW WASHER SW. IN 13 GrR
B21 P5 HOURMETER
PA
CN.11
BrG 460 3 0.85GR 890 11 0.85BrR 890 BrG 461 BrG 461 4
12V
2 3
0.85BrY 575 0.85BG 635 WASHER CONT.(+) 2 WV
X23 PA
WASHER CONT.(-) BW
0.85LR 901 12 0.85LR 901 LY 435 LY 435 5 LY 435 BREAKER&CRUSHER PILOT PRESS. P6 AIR CONDITIONER CONTROL PANEL
CN. 62
V REF 3
CN-A
R1 GLOW PLUG
2 3
0.85PG 598 MEMORY CLEAR1

5 6 7 8 9
WR 980 13 WR 980 BG 655 6 BG 655
CN.P6
BG 655
CN-B
ACCESSORY SOCKET
1
CN.1 1 2 3 4 POWER (24V) IN 1 0.85BrR

OPT.SW (MULTI)
1
2
1KΩ 100Ω 1KΩ GR 982 14 GR 982 LY 435 2 R3 THROTTLE VOLUME

GND 10 1.25B
X8
4 5 6
1 2 3
CN.B1
SWP
0.85VG 469
X15 B23
BG 656
G 464
THERMO SENSOR(O) 0.85OL 415 0.85BG 621 BrR 840
6 X9 1
W1 WINDOW CONTROL 9
GrR 893 15 GrR 893 BG 655 1 R4 THERMISTOR INNER TEMPERATURE
603,604
A GND 13 0.85BO 425 BP 690 2 YR 940 16 0.85YR 940 B 752
0.85GL 413
0.85BG 621 IMMOBILIZER S14 A4 REV. SIG. 7 VW
B 772 FUEL LEAKAGE R5 FUEL SENSOR
FUEL SENSOR 14 BrG 460 3 ANTENNA BY 941 17 0.85BY 941 B3
WR 391
YW 970
LW 972
BY 971
STOP SIG. VR S1 KEY SWITCH

BL 973
8
CN. 63
TEMP. SENSOR
R 222
B 710
CN-A
SPARE11(A/D) 15 YG 942 18 YG 942 GW 810 GW 810 1 1.25OW 300 1

2 3
CN.G1
(RED TAPE)
MT090
SUMITOMO
WINDOW LIMIT SW.
1
1 2
4
090
0.85WY 400 HBCV WARNING SWITCH S2 TRAVEL MODE SWITCH
CN.16
A Vcc 3 BO 943 19 BY 943 B 767 2 BrR 840 2 0.75Y 485 1 0.75YG(FT) t °C
1 2
WIPER MOTOR(CW) GW
B752,772
5
CN. 65
GND (G2)
435,461,464,895
BREAKER PILOT PRESS. S3 WORK MODE SWITCH
CN-A
P1 SIG 1 0.85WL 410 20 3 0.75RW(PCV1)

2 3
WG 448 1 RW 558 RW 558 G 464 G 464 0.75P 864 2
CN.B6
1
WIPER MOTOR(CCW) GR
8
3
9
4
6
2
1
7
5
SWP
1 2
0.85YL 411 HYD.FAN SW.
P2 SIG 9 0.85BG 604 2
S13 0.85B 760 BrG 461 4 BrG 461 0.75W 866 3 0.75RB(PCV2) S4 AUTO MODE SWITCH
N1 SIG 0.85L 412 YG 451 5
10 3 1 WV 931 1 LY 435 LY 435 LY 435 2 4 S5 CUSHION CONTROL SWITCH
4 5 6
1 2 3
CN.P2
CN-A
A GND 2 0.85BW 420 BG 606 2

RADIO AM/FM STEREO 24V,2A
BW 721
M6
BG 655 6 BG 655 BG 655 B25 0.75GR 396 5 0.75RL(PCV1)
SUPPLY PUMP
10 11 12 13 14 15 16 17 18 19 20
2
(BLUE TAPE)
S64 E3 1 S6 ROTARY LIGHT SWITCH
5 6 7 8 9
0.85LY 470 VALVE (PCV1)
Y33
CN.Q1
5V THROTTLE UPPER PILOT PRESS.
CN-A
11 BP 690 3 W 820 W 820 2
H2 6
S7 AUDIBLE ALARM CUT OUT SWITCH
2
1
BG 656
G 464
SIG THROTTLE VOL 4 0.85LG 480 BG 606 B 752 B 752
(YELLOW TAPE) WIPER MOTOR M3 LAMP (CAB)1 1
S8 SWING BRAKE SWITCH
A GND 5 0.85BL 490 LG 430 2 B26
CN.24
GR TRAVEL ALARM
3 S9 ENGINE EMERGENCY STOP SWITCH
DL090
SUMITOMO
0.85PL 417
SDL
OVER LOAD WARNING 12
4 5 6
1 2 3
BG 650 1
CN.C7
A/D 0.85GR 24V,107dB
CN.A5
GW 1 0.85GR 894 1
SWP
1
1 2
S10 WORKING LIGHT SWITCH
CN.60
10 bit KEY SW. 7 LgR 542 HORN SWITCH 2ND-OPTION LINE PILOT PRESS.
1 2
58W
0.85B 0.85B 743 24V 70W

S51 M 5 1.25B 2 2
1 2 3 4
SUPPLY PUMP
SPARE12(CMP) 16 S15 1 LW 532 (YELLOW TAPE) S11 WIPER SWITCH
3 2 1
14 13 12 11 10 9 8 7
GrG 445 1 6 VR VALVE (PCV2)
CN.C5
5V BATT.CHARGE BrR 543 B 713
8 2 S12 WASHER SWITCH
090
0.85LR 901 0.85LR 901 G 464 2 G 464 G 464 2
1 2
5V
BG 605 2
3 VW 842
4 VW
B81 B24 Y34
CN.Q0
VR 240 BG 656 BG 656 BG 656
CN.19
1 S13 OVERLOAD SWITCH
CN-A
1 1
SDL
3 2
2
1
LAMP (CAB)2
CN. 64
10V YR 830 4 B 714 0.85B 754

CN-A
2 0.85VR 900
S14 BREAKER / CRUSHER SWITCH
2BG 600
2 3
CN.G2
2B 700
758,759
1
BG 657
G 465
HORN (RIGHT)
SWP
1 2
6 5 4
5V
CN.M0
S25 B81
1.25BG 600
S15 HORN SWITCH
1 2
090
B 710
LIMIT SWITCH (GATE) 24V 0.85GR 892 24V,333Hz 115dB

1 0.85B 753 TRAVEL PILOT PRESS. 1.25RG 850 1 1.25W(INJECTOR POWER1)
1 2 3 4
CN. 2 S16 ONE TOUCH IDLE

CN.61
24V 70W
SDL
TXD RS232C 222,391,710,970,971,972,973 0.85B 742 2 G 464 2 G 464 1.25RW 851 2 1.25R(INJECTOR POWER2)
SCI S18 COUNTERWEIGHT REMOVAL MAIN SWITCH
RXD DRIVER & SPARE13(CMP) 23 S1 240,448 HORN (LEFT) YG 431 2 BG 656 1 BG 656 2ND-OPTION LINE PILOT PRESS. 3
RECIEVER P 585 R3 KEY SWITCH VR 240 VR 240 24V,303Hz,115dB CYLINDER #1 S19 COUNTERWEIGHT RAISING/ LOWERING
CN.Q2
27 1
CN-A
B 754 BG 651 1 4
Tx
B27
WR 391
LAMP (HOUSE)
2
1
Rx 21 CONNECTION YR 830 2 YR 830 830,840,842 G 465 2 0.75GW 854 5 0.75L (INJECTOR ORDER1) SWITCH
PG 586
20 BP 587
THROTTLE VOL.
CAB SEAT HEAT
OFF ACC
BrG 460 3 BrG 460 E3 B28 0.75WL 857 0.75LR(INJECTOR ORDER4)
SG
X6 B G1 G2 ACC M ST 0.85LgR 891 1 BG 657 1 6
CYLINDER #6 S20 COUNTERWEIGHT ARM
E1
CN.C6
1
2
28 LG 570 ON BrR 840 4 BrR 840 BrG 460 0.85B 741 2 24V 70W 0.75GB 855 7 0.75LY(INJECTOR ORDER2)
090
SW. TO ACCESS RAISING/LOWERING SWITCH
1 2
HEAT
CN.M1
WR 571 VW 842 VW 842 0.75G 856 0.75LW(INJECTOR ORDER3)
22
S16 5 BrG 461 (RED TAPE) 8
1 2
PROTECT
CN.B5
ST
090
0.85GR 231
S21 OPTIONAL SWITCH (RIGHT)
CN-A
OFF
0.85BrR 890
CYLINDER #5
B 716
25 PW 583 WG 448 6 WG 448 0.75GR(INJECTOR ORDER5)
2
1
TXD SERIAL OUTPUT 1 2 0.75WB 858 9
603,604,636
3
2
1
S25 OPTIONAL SWITCH (LEFT)

1 2 3 4
SCI PL 584 ACC LW 532 LW 532 0.75WR 859 0.75GB(INJECTOR ORDER6)

RXD SERIAL INPUT 19 7 10
CN.53
SWP PRESS. SENSOR (P1)

SDL
ONE TOUCH IDLE S51 HYDRAULIC FUNCTION CANCELLATION

GND 26 CN. 54 ON GrG 445 8 GrG 445 K33 SWING PILOT PRESS. 11
0.85Y
0.85B
0.85L
CYLINDER #3
TA INPUT 24 ST
YG 451 9 YL 451 0.85BrR 890 1 0.85BrR 890 1 0.85WY 400 2 12 LEVER SWITCH
COUNTER 1/4
GND 17 1 G 450 B 713 10 B 713 MAIN
0.85B 740 2 0.85B 740 2 24V 70W E2 BrY 432 2 0.85WL 410 3 B42 S52 AIR CONDITIONING COMPRESSOR
18 2 BG 603 0.85BG 604 11 0.85BG 604 0.85BG 604 3 BG 652 1 B22 0.85BW 420 1 CYLINDER #2 CLUTCH SWITCH
1
2
3
TA GND 0.85BrR 897
DL090
SUMITOMO
9 10 11 12
5 6 7 8
1 2 3 4
LR 251 1 1 2 3 3 VR 841 12 603,636 0.85B 744 4 S53 DOOR LIMIT SWITCH
CN.A3
WR 541
CN-A
HW090
SUMITOMO
CN.F0
4 5 6 LAMP (BOOM) 1
WR 390
WR 391
CN.D0
4
2
5
3
6
1
B 711
0.85LY 470
0.85BL 490
2
1
0.85L 480
B 717 2 4 13
S54 FRONT WINDOW LIMIT SWITCH
1 2
CYLINDER #4
S21
3
CN.B0
3 2 1 CN-A
MT090
SUMITOMO
090
14
1 2
1.25RW 220
0.85GrR 010
1.25LgR 540
SDL S55 RESERVE TANK LOW SWITCH
CN.B2
CN. 55
WR 390
CN. 52
1 2
58X
3 4
1 2
CN. 50 PRESS. SENSOR (P2)
CN. 3 0.85BrR 897 1 S61 REFUEL PUMP SWITCH
0.85GrR 010
IMMOBILIZER 31 0.85VG 469

0.85B 744 2 24V 70W E2 0.85Y 401 2 S62 AIR CLEANER SENSOR
PACKARD
LgR 542
2LR 310
394,540
1 2 B44 AIR INTAKE TEMP. SENSOR

S63 DOUBLE ACTING SWITCH (OPTIONAL)
CN-A
CN.U7
CN.A7
OVER LOAD 32 1.25RW 220 1 1.25RW 220 0.85YL 411 3
1 2
3 5
5
1
2
3
4
2
1
BOOM UP PILOT 33 VY 434 WR 390 2 WR 390 LAMP (BOOM) 2 0.85BY 421 1 S64 COOLING HYDRAULIC MOTOR SWITCH
AIR CONDITIONER 4
34 3 1.25LgR 540 (BLUE TAPE) t °C
SPARE16(SW.) 1.25LgR 540 0.85BO 492 1 U1 DC-DC (24V-12V) CONVERTER
60B 798
2LR 310
HW090
SUMITOMO
E52
BG 636
YR 552
1.25GR 394
1.25BG 600
CN.30 B6
CN.D1
2ND OPT.PILOT 35 G 464 THERMISTOR (INNER TEMP.) EVA-SENSOR 0.85GrR 010 4 0.85GrR 010 0.85YR 940 PUMP 0.75OL 482 2
1 W1 ANTENNA
1 2
3
BZ. STOP 36 YG 443 G 450 5 G 450 0.85BY 941 2 CONT. Y7
WR 541
PRESS. SENSOR X2 ROTARY LIGHT CONNECTOR

LgR 503
GrR 504
B5 M12
0.85LgR 502
1.25GR 394
GrG 445 R4 VR 841
2B 758
HIGH DUMP 37 VR 841 16 BG 636
CN.D4
B 759
B 767
(NEGA_CON-1:FRONT PUMP) X3 OPTIONAL POWER CONNECTOR
SWP
1 2
1 2 3
BrG 460 0.85LY 470
1
2
1
2
38 6
AMP
BREAKER MODE 0.85LY 470
CN.A8
2LR 310
41 7 0.85LG 480 X4 ENGINE TEST POINT CONNECTOR
300,840,841,842,980,982
TEST 0.85L 480 GrR 893 0.85LY 402 2 BARO SENSOR
7 CONTROL AMP A9 X2
0.85OB
0.85GY
0.85OB
TO BEACON
B43 X5 CONTROLLER TEST POINT CONNECTOR
0.85LY
CHECK 42 0.85BL 490 8 0.85BL 490 YR 552 B 734 B 755 0.85L 412 3
630,641,660,661,670
1 2 1 2 10
ENG.STOP 43 BrR 530 CONTROL PANEL 0.85GR 231 15 0.85GR 231 B 775 B 775 0.85BL 422 1 0.85Y 476 1 X6 CAB SEATCOMPRESSOR MOTOR
1.25BG 600
0.85LY
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7
CN. S3 CN. S2 4
SOFT/HARD 44 WG 446 4 B 711 17 B 711 0.85B 740 0.85YL 486 3 B48 CONNECTOR
HW090
SUMITOMO
0.85GY 3
9 10 11 12 13 14 15 16 17 18
LY 444 BG 603 BG 603 0.85BY 496

5 6 7 8
CN.D2
SWING LOCK 45 7 18
P6 0.85B 741 2 X7 LUBRICATOR CONNECTOR
1 2
0.85OB 18
3
SPARE19(SW.) 46 OW 458 A6 2 0.85LB 0.85LB 1
8 YR 560 9 YR 560
GLOW BEACON CONDENSER FAN
0.85B 744
R5 X8 RADIO CONNECTOR
SPARE20(SW.) 47 OG 459 1 BY 561 10 BY 561 0.85B 753 0.85B 753 PRESS. SENSOR (HBCV)
1 2B 14 FUEL SENSOR X9 ANTI-THEFT SYSTEM CONNECTOR
CN. S0
SPARE24(SW.) 48 2 PL 562 11 PL 562 0.85B 754 0.85B 754

2L 19 X15 ACCESSORY SOCKET
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
CN. S1
BLOWER AMP 3
I/O NO USE 40 3 PW 563 12 PW 563 2B 700 0.85BG 660 1 0.85LY 407 1 0.85LY 407 2
1 2 3 4
20
B45 X23 CLEAR MEMORY 1
CN. S9
CAN H 29 0.85P 580 6 WL 564 13 WL 564 2BG 600 0.85GL 413 2 0.85PL 417 2 0.85WG 417 3
8 9 10 11 12 13 14
2 3
0.85L 2
1
CAN CAN L 39 0.85PL 581

0.85YW
5 BW 565 14 BW 565
K2 K5 K6 300,464,630,670,810,840,841,842,980,982 0.85BG 427 3 0.85BG 427 1 X24 CLEAR MEMORY 2
CN.B3
5
SWP
AMP 070 MULTI LOCK
1 2
CAN GND 30 BLOWER MOTOR 19 630,670 Y1 SWING PILOT SHUT-OFF SOLENOID VALVE
CN.23
2L 0.85BrW
10 11 12 13 14 15 16 17 18 19 20
2 6
2 3
4 5 6 7 8
P 592
HW090
SUMITOMO
SDL
5 6 7 8 9
PL 593
CN.R1
1 2 3
20 (GREEN BAND)
SWP
CN. 51
CN.R0
M8 M 1 2R 0.85RB 16 15 0.85R
1 2
1 2 3 4 5
400,410,411,412,417,420
3
0.85O 17 17 0.85G Y2 PILOT PRESSURE SOLENOID VALVE
413,415,418,425,430,431,432,435,437,461,464,895
CN. S8
B61 (BLUE BAND)

CN. 10
0.85W
5
1
2
3
4
21 18
5
1
2
3
4
5
1
2
3
4
1
1 2 1 2
1
2
1 2
SDL
BLOWER-OFF RELAY AIR CLEANER SENSOR

CN. 4 22 16 0.85B 3 5 3 5 3 5 Y3 SWING BRAKE SOLENOID VALVE
DEUTSCH
1 WL 564
WR 555
PW 819
4 4
2WR 050
4
GR 982
RESERVE TANK LSW.

B 728
BrW 260
B 725
LR 250
CN.H1
LgR 503
2LR 060
GrR 893
2R HYDRAULIC MOTOR (FAN)

BrR 506
1 26 2 (PINK BAND)
1 2
1 2 3 4
AIR CLEANER 49 L 418 2 BW 565 0.85L 418 1

SPARE21(SW.) 50
4 0.85BrR 0.85BrR 15 3 0.85WR
CN.31 CN.37 CN.36 LG 430 1 LG 430 0.85BG 641 1 0.85BL 661 2 S62 Y4 2 STAGE TRAVEL SOLENOID VALVE
CN. 12
K17
SDL
0.85WG 0.85WR
1 2
3 0.85RG 30 4
TRAVEL PILOT 51 YG 431
2WG
SUNLOAD SENSOR
YG 431 2 YG 431 1.25YG 944 1 0.85GrR 437 2 S55 (RED BAND)
2 0.85WL 13 6
CN.T9
SWP
BEACON VG 447 BrY 432 BrY 432
1 2
52 3 YG 942 1 1.25BY 945 2
Y32 Y5 POWER-UP SOLENOID VALVE
CN.B8
0.85LgW 25 11 0.85WG
SWP
1 2
L/M MODE OR 455 0.85R PW 563 L 418 0.85L 418
CN. S7
53 4 060,503,893,982 4 BY 943 2 (YELLOW BAND)

1 2
3 4
0.85YL 9 7 HYD.OIL TEMP SENSOR

AUTO MODE 54 OG 442 0.85G 5 PL 562 050,250,260,819 LY 435 5 LY 435 RW 558 3
BREAKER PILOT LY 435
0.85Br 29 12 0.85GW
0.85W BY 561 GrG 437 0.85GrG 437
Y6 CUSHION CONTROL SOLENOID VALVE
55 6 B 725 6 B 775 4 1.25RW 559 1 R
5 0.85YR 0.85LW 12 13 0.85GW (LIGHT GREEN BAND)
WORK MODE 56 VY 440
M7 1 0.85RG 0.85LgB 24 8
0.85B 7 YR 560 BrG 461 7 BrG 461 1.25B 776 2 Y Y31 0.85BO 425 1 t °C
B2 F1 FUSE 20A ; ENGINE CONTROLLER Y7 MAIN PUMP PROPORTIONAL SOLENOID
WR 555
CN.H0
12 3 4 5
COOLANT GrG 437 VW 525 G 464 G 464

BrR 506
57 16 8 0.85OL 415
58X
(LIMIT SW.DOOR) 0.85O 2

1 2
3 4
0.85WL 0.85YR F2 FUSE 5A ; COMPUTER CONTROL INSTRUMENT PANEL AND
CN.H2
2 0.85YG 8 10
CN. S4
HORN LAMP (HOUSE,BOOM) LAMP(CAB) Y8 AIR CONDITIONER MAGNET CLUTCH
58X
M
HYD.FAN REVERSE YL 451 (LIMIT SW.WINDOW) 0.85YW VR 524 0.85GL 413 0.85GL 413
1 2
58 15 9
WARNING CHG. 59 WG 448
3 0.85LgW 0.85RY 28 9 0.85YB
(WATER TEMP.SIG) 0.85BrW 14 GY 566 0.85OL 415 10 0.85OL 415
DIAGNOSTIC TEST SOCKET Y9 CRUSHER/BREAKER OPTION TWO FLOW
CN.D3
AMP
4 0.85YL 0.85LR 11 1 0.85Y F3 FUSE 20A ; COMPUTER POWER
1 2
SPARE23(SW.) 60
23 14
(RECIEVER DRYER) 0.85GW 17 WR 980 0.85BO 425 11 0.85BO 425 SOLENOID VALVE
0.85LgR F4 FUSE 10A ; HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
1 2 3
SWP
SWING PILOT 61 BrY 432 (ILLUMINATION) 0.85RB 3 0.85GR 567 VY 434 12
MOTOR-ACT (AIR-MIX) 0.85GB 27 5 0.85BR Y12 COUNTERWEIGHT RAISING SOLENOID
UPPER PILOT LG 430 (MAIN POWER) 2WG 1.25LW 340
K10 K11 OR 455 OR 455 F5 FUSE 10A ; AIR CONDITIONER CONDENSER FAN
62 9
K3 13
VALVE
1 2 3
RB 856 F6 FUSE 10A ; ROTARY LIGHT
SWP
G 854
0.85BR
ONE-TOUCH IDLE 63 G 450 (COMP.POWER) 0.85WG 8 0.85YW 270 PW 255 14 PW 255 3 3

TRAVEL MODE 64 BrG 441
5 0.85YB
(GND) 2B 1 1.25B 701 1.25V 256 15 1.25O 895
S19 1 RG 855 S20 1 RW 857
F7 FUSE 30A ; FUEL FILLER PUMP Y13 COUNTERWEIGHT LOWERING
M6 1 0.85Br R 853 SOLENOID VALVE
58X
1 2
2 R 852 2
1 2 3 4 5
I/O 2 WR 555 WR 501 16 WR 501 F8 FUSE 20A ; FUEL FEED PUMP

0.85BR
0.85BR
0.85WG
0.85WG
2 0.85LW
418,430,431,432,434,435,437,455,464,580,581
Y14 COUNTERWEIGHT ARM RAISING

CN. S5
10 0.85LgR 502 17 0.85LgR 502 F9 FUSE 30A ; GLOW PLUG

3 0.85LgB
5
1
2
3
4
5
1
2
3
5
1
2
3
4
4
RAM 11 GrR 504 18 GrR 504 RG 855

CTWT
F10 FUSE 20A ; LUBRICATOR (OPTION) CONNECTOR SOLENOID VALVE
4 0.85YG
2kbyte
Y12
290,370,385,896
12 1 2 1 2 1 2 BrR 506 19 BrR 506 R 853 B 772 RAISE

F11 FUSE 10A ; BACK-UP Y15 COUNTERWEIGHT ARM LOWERING
WR 535
LW 532
0.85GW 290
0.85GW 291
0.85OR 385
0.85OR 386
0.85GR 896
0.85VR 900
0.85VR 370
0.85VR 371
13 3 5 3 5 3 5 YR 552 20 YR 552
MOTOR-ACT (MODE) 4 4 4
(YELLOW TAPE) F12 FUSE 20A ; KEY SWITCH SOLENOID VALVE
0.85GR 890
5 6 7 8
1 2 3 4
0.85GR 567
WR 531
18 0.85P 580 21 P 580

CN.U6
F13 FUSE 20A ; HEATER / AIR CONDITIONER Y31 COOLING HYDRAULIC MOTOR SOLENOID
SWP
255,256,413,415,425,501,589
10 11 12 13 14 15 16 17 18
0.85PL 581 PL 581 CTWT

1 2 3 4 5 6 7 8 9
CN.32 CN.33 CN.34 22 G 854

0.85Y F14 FUSE 5A ; AIR CONDITIONER COMPRESSOR VALVE
AMP NEW SCCS
5
1.25BG 600
E2PROM
FLASH
0.85LR 901 CTWT REMOVAL MAIN SW B 774 LOWER Y13
M5 1 0.85RY F15 FUSE 15A ; WORKING LIGHT (UPPERSTRUCTURE/ATTACHMENT) Y32 PROPORTIONAL SOLENOID FOR COOLING
1 2 3 4 5
CN. 28
MEMORY (GREEN TAPE)

0.85LR
58X
1 2
8kbyte 2 F16 FUSE 15A ; WORKING LIGHT (CAB) AND OPTION CONNECTOR HYDRAULIC MOTOR
CN. S6
2Mbyte
M
1 R 852
633,634,635,637
461,501 502,504
1
1.25BG 600
3 0.85LgR
531,532,567 890,900,901 2 O 455 2 F17 FUSE 10A ; DC-DC (24V-12V) CONVERTER Y33 SUPPLY PUMP VALVE (PCV1)
506,552 895
4 0.85GB
B 772 3 B 772 P 255 3
S18 F18 FUSE 15A ; WIPER AND WASHER Y34 SUPPLY PUMP VALVE (PCV2)
58X
1 2
CN. 1 CN. 2 CN. 3 CN. 4 MOTOR-ACT (AIR-CHG.) 0.75G 955 BG 670 4 BG 670 RY 858 4 F19 FUSE 15A ; HORN
0.75L 953 ARM
Br 556 5 Br 556 BG 670 5 RW 857 F20 FUSE 15A ; CIGARETTE LIGHTER AND CAB SEAT COMPRESSOR
1 2 3 4 5 6 7 8 17 18 19 20 21 22 29 30 31 32 33 34 35 36 37 38 49 50 51 52 53 54 55 56 0.75R 954 0.85RY 834 6 RY 858 Br 556 6 B 773 TOP
Y14 ADJUSTMENT
0.75GR 396
9 10 11 12 13 14 15 16 23 24 25 26 27 28 39 40 41 42 43 44 45 46 47 48 57 58 59 60 61 62 63 64
OR 455 7 O 455 (BLEUE TAPE) F21 FUSE BOX
AMP 040 MULTI LOCK 8
PW 255 P 255 F22 FUSE 20A ; MAIN FUSE FOR F11 AND F12 CIRCUITS
4 5 6
1 2 3
CN. A0 CN. A1 ARM

RB 856
SWP
AMP HYBRID I/O Y15 F23 FUSE 65A ; MAIN FUSE FOR F3 TO F10 AND F13 TO F20 CIRCUITS
B 775 BOTTOM
4 5 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 F24 FUSE 20A ; MAIN FUSE FOR F2 CIRCUIT
0.85LgR 502
106 107 108 109 110 111 112 113 119 120 121
0.85BrY 575
0.75WG 873
0.75WR 484
1.25GR 394
1.25GR 395
0.75GW 854
0.85BG 630
0.85BG 631
0.85BG 632
0.75RG 477
0.75GR 487
0.75WR 859
1.25RW 851
0.75YG 875
0.85BW 689
0.75WB 870
0.75WB 858
0.75WL 483
0.75WL 857
1.25RG 850
0.75RY 478
0.75GB 871
0.75GB 855
0.85BY 496
0.75YB 488
0.75OL 482
0.75BY 498
0.75BR 497
0.75YB 872
0.85YL 486
(RED TAPE)
0.85BL 687
0.75W 866
0.75W 867
0.75W 479
0.75W 481
F25 FUSE 20A ; MAIN FUSE FOR F1CIRCUITS

0.75G 874
0.75G 491
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 98 99 100 101 102 103 104 105

1.25B 730
1.25B 731
1.25B 732
0.75R 471
58X
0.75Y 485
1 2
0.75G 950
0.75G 856
0.85Y 476
0.75L 953
0.75P 864
0.75P 865
0.75L 951
3
BrR 506
117 118
GrR 504
WR 501
YR 552
PG 588
PL 581
YR 553
PB 589
BL 956
BL 957
BL 956
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 90 91 92 93 94 95 96 97
F27 FUSE 60A ; SAFETY RELAY
P 580
1 2 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 82 83 84 85 86 87 88 89 114 115 116
CN. A0 CN. A1
101
100
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
12
13
15
16
22
23
26
27
28
33
35
36
43
62
81
10
11
14
17
18
37
19
20
21
24
25
29
30
31
32
34
38
39
40
41
42
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
83
84
85
86
88
89
95
96
97
91
92
93
94
87
82
90
98
99
9
1
3
4
2
5
6
7
8
TABLE OF COLOR SYMBOLS LEGENDE

CONNECTED NOT CONNECTED
SYMBOL COLOR SYMBOL COLOR
IA-ACCEL PSTN1
PG-SIGNAL(GND)
PG-SIGNAL(GND)
PG-CASE(GND)
CC-KW2000
OS-MAIN RELAY
IS-IGKEY(START)
IS-MODE MAP1
IS-IGKEY(ON)
IA-INTAKE TEMP
OF-TACHO
IS-MODE MAP0
IS-MEMORY CLEAR
IA-COMMON.R PRESS
IA-COMMON.R PRESS
PG-POWER(GND)
PG-POWER(GND)
PG-POWER(GND)
SG-5VRT2(BARO)
SP-5V2(BARO)
OS-GLOW LAMP
IS-IDLE DOWN SW
SG-5VRT5(COMMO.R)
OS-BOOST LAMP
IA-BOOST TEMP
OS-PCV1
IF-G(REM) ANGLE
OS-GLOW RELAY
OS-OIL P. LAMP
PS-+B
PS-+B
OS-DIAG LAMP
SP-5V1(ACCEL)
OS-PCV1
IS-IDLE MANU SW
IS-DIAG
IS-ENG STOP SW
SG-SLD1
OS-MAIN RELAY
IA-BARO
OS-STARTER RELAY
IF-CRANK+
SG-5VRT4(BOOST P)
SG-5VRT1(ACCEL)
CC-CAN-H
CC-CAN-L
IS-EGR PSTN2 V
OP-COM2
OP-COM1
IF-SPD
IS-MODE MAP2
SG-SLD5
OS-INJECTION5
OS-INJECTION6
OS-INJECTION3

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Copyright ©

CX460 TIER 3 CRAWLER EXCAVATOR

Copyright © 2007 CNH France S.A.

MEMBERSHIP ACCOUNT HOLDERS CAN

EXPLORE AVAILABLE PLANS

DIVISION/SECTION SECTION N° REFERENCE N°

Lep SM460TOC-0EN Issued 09-07

SAFETY, GENERAL INFORMATION

Copyright © 2006 CNH France S.A.

Lep 7-27691EN Issued 02-06

Lep 7-27691EN Issued 02-06

To prevent injury always follow the Warning, Caution

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

Lep 7-27691EN Issued 02-06

WARNING: When the battery electrolyte is

WARNING: Use suitable floor (service)

Lep 7-27691EN Issued 02-06

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Lep 7-27691EN Issued 02-06

SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

Copyright © 2007 CNH France S.A.

TYPE, SERIAL NUMBER

FLUIDS AND LUBRICANTS ............................................................................................................................................ 6

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 22

DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................27

SHIMS FOR ADJUSTING ATTACHMENT GAPS ..........................................................................................................32

SPECIAL TORQUE SETTINGS......................................................................................................................................33

MACHINE OVERALL DIMENSIONS ..............................................................................................................................36

Lep SC4601002-0EN Issued 03-07

Lep SC4601002-0EN Issued 03-07

(1) Type .......................................................................................................................................................................

Serial numbers of the components

Lep SC4601002-0EN Issued 03-07

Transmission component oil

Lep SC4601002-0EN Issued 03-07

Oil viscosity / Oil range

1) With mineral base

Lep SC4601002-0EN Issued 03-07

Applicable Standard Recommendation

JIS (Japanese Industrial Standard) NO.2

DIN (Deutsche Industrie Normen) DIN 51601

SAE (Society of Automotive Engineers)

Based on SAE-J-313C NO. 2-D

Based on BS/2869-197 Class A-1

Lep SC4601002-0EN Issued 03-07

Lep SC4601002-0EN Issued 03-07

Plastic and resin parts

Lep SC4601002-0EN Issued 03-07

Complete machine dimensions

Main body dimensions

Lep SC4601002-0EN Issued 03-07

Capacity of coolant and lubricants

Hydraulic oil filter

Lep SC4601002-0EN Issued 03-07

Horn: electric horn (x2)

Lep SC4601002-0EN Issued 03-07

Lep SC4601002-0EN Issued 03-07

Lep SC4601002-0EN Issued 03-07

Travel lower body

Lep SC4601002-0EN Issued 03-07