Lbx130x2 Service Manual

Table of Contens SH120
Table of Contens
130 X2 Service Text Table of Contents

Main Body Section
Specifications
Overall
1. Main Data
2. Performance
3. Main Body Dimensions
4. Engine
5. Cooling System
6. Upper Side Work System
7. Operating Device
8. Swing Unit
9. Travel Lower Body
10. Dozer Blade
Hydraulic Equipment
1. Hydraulic Device
2. Control Valve, Cylinder
Capacities, Filters
1. Coolant and Oil Capacities
2. Hydraulic Oil Filters
3. Fuel Filter
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator
Lifting Capacities
Overall View
Overall View (130X2)
1. Standard Arm (2.50 m)
2. Long Arm (3.01 m)
Overall View (130X2(Blade))
Work Range Diagram
Work Range Diagram (130X2 )
Work Range Diagram (130X2 (Blade))
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Table of Contents 130 X2 Service Text
Summary Section
Main Equipment Table
Lower Component
1. Travel Unit
2. Take-up Roller
3. Upper Roller
4. Lower Roller
5. Recoil Spring
6. Shoe
Upper Component
1. Swing Unit
Engine-related
1. Engine
2. Muffler
3. Air Cleaner (double element)
4. Radiator
Hydraulic Device
1. Hydraulic pump
2. Pump P-Q Diagram
Control-related
1. Control Valve
2. Solenoid Valve (4 stack)
3. Remote Control Valve (left/right, travel operations)
4. Remote Control Valve Characteristic Diagram
5. Cushion Valve (heat circuit, with shuttle valve)
6. Selector Valve (option)
7. Center Joint
Backhoe Attachment
1. Cylinder
2. Attachments
Equipment Layout Diagram
Main Equipment Layout
Consumable Part Layout
Standard Machine Option List
List of Optional Components
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Hydraulics Section
Hydraulic Equipment Layout
Overall View
Pump Chamber Hydraulic Equipment Layout
Swing Body Center Section Hydraulic Equipment Layout
Housing Left Side Hydraulic Equipment Layout
Layout of Hydraulic Equipment in Cab
Port Diagram
Pump
1. Hydraulic Pump (standard model)
2. Hydraulic Pump (blade model)
Valves
1. Control Valve
2. Control Valve (blade model)
3. 4 Stack Solenoid Valve
5. Remote Control Valves (upper, travel)
6. Cushion Valve
7. 2-way Selector Valve (Option for North America)
8. 4-way Selector Valve (Option for Export, Europe)
9. Direction Valve/Shut-off Valve
10. HBCV (Option for Export, Europe)
Manifolds
1. Manifold Under Cab
2. Manifold (accumulator section)
3. Manifold (hydraulic oil tank section)
Motors
1. Swing Motor
2. Travel Motor
3. Center Joint
Pilot Hose Connection Diagram
Pilot P and T Lines
Pilot Control Line
Pilot Control Line (2-way selector valve) (Option for North America)
Pilot Control Line (4-way selector valve) (Option for Export, Europe)
Blade Line
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Function List
Function Table
Explanation of New Functions
1. Swing Relief Cut Control
2. Option Line Flow Adjustment Control
3. Multi Purpose Circuit (breaker ÅÃ crusher) One-touch Switching Control
4. Bucket-close Regenerative Circuit
Explanation of Hydraulic Circuit and Operations (standard model)
Travel Circuit
Travel Low-speed Circuit
Travel High-speed Circuit
Straight Travel Circuit (with/without HBCV)
Swing Circuit
Swing Relief Cut-off Control Circuit
Swing Priority Circuit (with/without HBCV)
Swing Brake Circuit
Swing Parking Circuit (lever in neutral)
Swing Parking Circuit (brake release)
Swing Parking Circuit (machine stop)
Boom Circuit
Boom-up Circuit (single operation)
Boom-up Circuit (single operation) (with HBCV) (Option for Export, Europe)
Boom-up Circuit (compound boom up + arm in) (with/without HBCV)
Boom-down Regenerative Circuit
Boom-down Regenerative Circuit (with HBCV) (Option for Export, Europe)
Boom-down Tilting Prevention Circuit (with/without HBCV)
Boom-down Load Hold Valve Circuit (with/without HBCV)
Arm Circuit
Arm-out Circuit (with/without HBCV)
Arm-in Forced Regenerative Circuit (with/without HBCV)
Arm-in Load Hold Valve Circuit (with HBCV) (Option for Export, Europe)
Arm-in Load Hold Valve Circuit (without HBCV)
Bucket Circuit
Bucket-open Circuit
Bucket-close Regenerative Circuit
Negative Control Circuit
Negative Control Circuit (bucket close)
Horsepower Boost Circuit
Arm-in Horsepower Boost Circuit (with/without HBCV)
Travel Horsepower Boost Circuit
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Other Circuits
Cushion Circuit (arm-out operation)
Cushion Circuit (arm-out operation stopped)
Cushion Circuit (arm-out Å® arm-in operation)
Heat Circuit (lever in neutral)
Auto Pressure Boost Circuit (bucket close)
Explanation of Hydraulic Circuit and Operations (option)
Option Circuits
Breaker Circuit (single operation)
Shuttle Circuit (hydraulic fork)
Multi Purpose Circuit (breaker Q control)
Multi Purpose Circuit (2 pumps flow crusher)
2nd Option Circuit (hydraulic rotation fork)
Blade Circuit (blade-up Circuit)
Blade Circuit (blade-down Circuit)
Main Equipment Structure and Operation Explanation
Pump
1. Hydraulic Pump
2. Regulator
3. Gear Pump
Motor
1. Travel Motor
2. Swing Motor
Valve
1. Control Valve
2. 4 Stack Solenoid Valve Operation Explanation
3. Upper Pilot Valve (remote control valve)
4. Travel Pilot Valve (remote control valve)
5. Cushion Valve
6. Direction Valve (3 direction)
7. HBCV Holding Control Valve (Option for Export/Europe)
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Electrics Section
Work Mode Select Switch
The Throttle Volume and Work Mode Select Switch are Linked!!
Computer Connection Method
Monitor Changes
Pilot Pressure Switch Changed to Pressure Sensor
Pump Electromagnetization Proportional Valve
1. Horsepower Control Proportional Valve
2. P1 Flow Control Proportional Valve
System Control for Energy Saving
1. Reduced Fuel Consumption Through Transient Load Reduction Control
2. Reduced Fuel Consumption Through Swing Relief Cut Control
Electrical Equipment Layout Diagram
Overall View
1. Main Unit Right Side Layout Diagram (radiator chamber)
2. Engine Section Layout Diagram
3. Main Unit Left Side Layout Diagram (pump chamber)
4. Main Unit Center Section Layout Diagram
5. Cab Layout Diagram
6 Layout Around Operator's Seat
Stand Alone Parts Diagram
Main Equipment Structural Diagrams
Connection Connector Pin Layout
1. Computer A
2. Monitor
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Electrical Circuit Diagram
Overall View
1. Sequence Circuit Diagram
Block Diagram
1. Computer A
2. ECM
3. Monitor Display
4. Air Conditioner
5. Lever Lock
6. Horn
7. Working Light
8. Option
9. Others
10. Electrical Symbol List
Electrical Connector Wiring Diagram
Wire Harness
1. Main Frame Harness
2. Cab Main Harness
3. Cab Sub Harness
4. In-Cab Harness
5. Engine Harness
6. Console Right Harness
7. Console Left Harness
Electrical Parts and Wiring Assembly Diagram
Main Frame
Cab
Explanation of Functions and Operations
Explanation of Electrical Functions
Engine Speed Control
1. Throttle Control
2. Idling Control (auto/one-touch)
3. Idling Start
4. Idle Up
5. Auto warm up
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Engine Start/Stop Control
1. Engine Start/Stop Judgment
2. Power-cut Delay
3. Engine Emergency Stop
4. Neutral Start
Pump Control
1. Work Mode Control
2. Pump Horsepower Boost Control
3. Pump Horsepower Cut Control
Swing
1. Swing Brake
2. Swing Free Swing (Option for North America)
3. Swing Lock (for maintenance)
4. Swing Relief Cut
Travel
1. Travel Speed Switchover
2. Travel Alarm
Valve Control
1. Lever Lock
2. Solenoid Sticking Prevention
3. Pressure Boost Control
Monitor Control
1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge)
Accessories
1. Horn
2. Working light
3. Wiper and Washer
4. Room Lamp
5. Radio Mute
Others
1. Anti-theft
2. Battery Save Function
3. Alternator Power Generation Detection
4. Overload Alarm (Option for Europe)
Options
1. Option Line Control
3. Feed Pump Automatic Stop
4. Return Filter Clogging Detected
5. Beacon (Option for Europe)
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Table of Contents
Service Support
Screen Operations
1. Screen Shift
Screen Display List
1. CHK (status display) Screen List
2. DIAG (trouble diagnosis) Screen
3. HR (usage log) Screen List
4. CFG (setting change) Screen
5. CAL (troubleshooting support) Screen
6. Check the Monitor Switch (self-diagnosis function)
7. Option Flow Setting
8. Anti-theft Setting
9. Model Setting
10. Engine Screen Information
Screen Display Details
1. Message Display List
Trouble Display
1. Diagnostic Trouble Code Display
2. Main Unit Diagnostic Trouble Code List
3. Diagnostic Trouble Code (monitor display)
4. Sensor Trouble Operation Table
5. EPF (Engine Protection Feature)
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Engine Section
Engine Summary
Main Data Table (changes from model 3)
Overall Appearance Diagram
Sensor and Auxiliary Equipment Layout (left)
Sensor and Auxiliary Equipment Layout (rear)
Engine System Diagram
Fuel System Diagram
Detailed Parts Diagrams
1. ECM (engine control module)
2. Supply Pump/SCV (suction control valve)
3. Common Rail
4. Common Rail Pressure Sensor/Pressure Limiter
5. Injector
6. Engine Coolant Temperature Sensor
7. Engine Oil Pressure Sensor
8. Cam Position Sensor (CMP sensor)
9. Crank Position Sensor (CKP sensor)
10. Atmospheric Pressure Sensor
11. Suction Air Temperature Sensor
12. Boost Pressure Sensor
13. Boost Temperature Sensor
14. Charge Fuel Pump
15. EGR Cooler
16. EGR Valve
Engine Control Summary
Explanation of Engine Terms
Function Explanation Table
Explanation of Engine Structure
Technology for Exhaust Gases
1. Common Rail System
2. Multi Stage Fuel Injection (multiple injection)
3. Inter Cooler
4. EGR (Exhaust Gas Recirculation)
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Explanation of Engine Operation
Engine Overall
1. Comparison of 4BG1T and 4JJ1
Fuel Unit
1. Common Rail System Summary
2. Change Points for Injection Method (governor, common rail)
3. Explanation of Injector Operation
4. Explanation of Supply Pump Operation
5. Supply Pump Disassembly Diagram
6. Pressure Limiter
7. Cautions for Maintenance
Explanation of Engine Control
1. Fuel Injection Quantity Correction
2. Starting Q Correction
3. Preheat Control (QOS quick on start)
4. Atmospheric Pressure Correction (high altitude correction)
5. Control for Overheating
6. Control for Boost Temperature Rise
7. Control for Engine Oil Pressure Drop
8. Start Control (coolant temperature monitoring)
9. Long Cranking Control
10. Starting Control for Reduced Number of Cylinders
11. Normal Stop (key switch OFF operation)
Engine Maintenance Standards
Engine Information Screen
Monitor Operation Method
Engine Information (Q resistance, QR code, engine serial number) Copying Method
Rewriting Injector QR Codes
When Replacing Computer A at the Same Time
Engine Information Acquisition Timing
Redoing Engine Information Acquisition
Trouble Display
Engine Equipment Table
Exhaust Gas 3rd Accessory Electrical Parts Compatibility (Isuzu part number)
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Exhaust Gas Regulations
Features of Materials Subject to Exhaust Gas Regulation
Exhaust Gas Regulation Values
Cautions for Fuel Used
Engine Fuel and Maintenance of Fuel Filters
1. Fuel to be applied
2. Maintenance of fuel filters
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Air Conditioner Section
Changes from Model 3
Change List
Layout Diagram
Air Conditioner Overall Diagram
1. Frame
2. Cab
Air Conditioner Circuit Diagram
Explanation of Control
1. Air Mix Motor Actuator Control
2. Blow Mode Motor Actuator Control
3. Refresh/Recirculate Switch Motor Actuator Control
4. Blower Amp Control
5. Compressor Clutch Control
6. COOLMAX Control and HOTMAX Control
7. Trouble Detection and Control after Trouble Detected
8. Monitor Mode
9. Door Switch Control
10. Inside Air Filter Clogging Detection Control
Actuator Inspection
Air Mix Motor Actuator Inspection
Refresh / Recirculate Motor Actuator Inspection
Mode Motor Actuator Inspection
Self-diagnosis Function With Panel Display
Trouble Display and Self-check Procedure
1. Trouble Display Position
2. Explanation of Trouble Display
3. Explanation of Monitor Mode
Part Function and OK / NG Judgment
Control Panel and Control Unit
Blower Amp
Relay
Air Mix Actuator
Refresh / Recirculate Actuator
Blow Mode Actuator
Evaporator Sensor
Dual Pressure Switch
Solar Radiation Sensor
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New Machine Performance Section
New Machine Performance
Performance Evaluation Check Sheet
Performance Evaluation Recording Sheet
New Machine Performance Judgment Standards
Reference Values (130)
Measurement Method and Main Unit Posture
Engine Speed
Pressure in Each Section
Cylinder Falling Amount
Attachment Speed
Swing Speed
Swing (180Åã) Brake Angle
Travel Speed
Off Travel Amount
Travel Sprocket Speed
Shoe Tension Amount
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount
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Maintenance Section
Pressure Measurement and Adjustment Procedures
Procedures for Pressure Measurement from the Monitor Display
1. Pressure Measurement Method
2. Operating Method
Procedures for Measuring Hydraulic Oil Temperature from the Monitor Display
1. Hydraulic Oil Temperature Measurement Method
2. Operating Method
Procedures for Pressure Measurement by Installing Pressure Gauge
1. Preparations
2. Items to Prepare
Pressure Measuring Ports
Control Valve
1. Location of Relief Valves
Pressure Measurement Preparations
1. Main Pressure Measurement
2. Pilot Pressure Measurement
3. Negative Control Pressure Measurement
Pressure Adjustment
1. Main Pressure Adjustment
2. Pilot Pressure Adjustment
Hydraulic Pump Flow Measurement Procedure
Procedures for Flow Measurement from the Flow Meter Installation
1. Preparations
2. Items to Prepare
Work Preparations
Flow Measurement
Drain Volume Measurement Procedure
Preparations
Travel Motor Drain Volume Measurement
Swing Motor Drain Volume Measurement
Air Bleed Procedure
Hydraulic Pump
Travel Motor
Swing Motor
HBCV(for Export, Europe)
1. Boom Cylinder HBCV
2. Arm Cylinder HBCV
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Procedures for Replacing Consumable Parts
Air Conditioner Belt and Fan Belt Replacement
1. Air Conditioner Belt Replacement
2. Fan Belt Replacement
Fuel Main Filter Replacement
1. Filter Replacement
2. Air Bleeding
Engine Oil Filter and Engine Oil Replacement
1. Engine Oil Replacement
2. Engine Oil Filter Replacement
Radiator Coolant Replacement
Air Cleaner Cleaning and Replacement
Hydraulic Oil Filter Replacement
1. Return Filter Replacement
2. Suction Filter Replacement
3. Air Breather Element Replacement
4. Pilot Oil Filter Replacement
5. Hydraulic Oil Replacement
Others
1. Coolant Filling
2. Washer Fluid Filling
Periodic Maintenance Procedures
Maintenance Every 250 Hours
1. Battery Inspection and Replacement
Maintenance after First 250 Hours for New Machine/Every 1000 Hours from Then on
1. Swing Reduction Gear Oil Replacement
2. Gear Oil Filling
Replace the Flange Packing at the Bottom of the Fuel Tank
Bolt Size and Torque Table
Bolt and Nut Tightening
Retightening Torque Table
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Data Section
Main Unit Weight
Divided Weight (standard specifications)
Stand Alone Part Weight
Shoe Weight (per side)
Arm Weight
Interchangeability
Interchangeability
1. Main Part Interchangeability Table (130X2)
Attachment Installation Methods
Attachment Dimensions
Paint Colors
Paint Colors
Unit Conversion Ratio
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Specifications SH120
Specifications
Specifications
Overall
1. Main Data
Model name 130X2 130X2 (Blade)
Operating weight 27800 lb (12610 kg) 29500 lb (13381 kg)
Engine output 95 HP/2000 rpm
Heaped 0.62 m3 (0.81 yd3)

Bucket capacity
Leveled 0.46 m3 (0.60 yd3)
2. Performance
130X2 130X2 (Blade)
Swing speed 14.3 rpm
Low speed 2.1 mph (3.38 km)/h
Travel speed
High speed 3.5 mph (5.6 km)/h
Maximum pulling force 25900 lbf (115 kN)
Grade ability 70 % (35°)
Ground pressure
600 mm grouser shoe 4.9 PSI (0.034 MPa) 5.9 PSI (0.041 MPa)
3. Main Body Dimensions

130X2 130X2 (Blade)
Main body length 153 in. (3880 mm)
Main body width 102 in. (2590 mm)
Upper swing body width 101.6 in. (2580 mm)
Cab width 39.4 in. (1000 mm)
Main body height 113.4 in. (2880 mm)
Swing radius (rear end) 83.8 in. (2130 mm)
Swing body rear end distance 83.8 in. (2130 mm)
Swing body rear section bottom
35 in. (895 mm)
height
Distance between tumblers 110 in. (2790 mm)
Overall track length 138 in. (3500 mm)
Overall track width 102 in. (2590 mm)
Distance between tracks 78 in. (1990 mm)
Track shoe width 23.6 in. (600 mm) (options 27.6 in. (700 mm))
18 in. (460 mm) 14.9 in. (380 mm)
Minimum ground clearance
(to bottom of lower frame) (to bottom of Blade)
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Specifications
4. Engine
130X2/130X2 (Blade)
Name Isuzu 4JJ1X diesel engine
4-cycle, water cooled, overhead camshaft, vertical in-line, direct injection
Model
type (electronic control), with turbocharger
Number of cylinders - bore x stroke 4- ø 3.76 in. (95.5 mm) x 4.13 in. (105 mm)
Total stroke volume 183 cu in. (2.99 L)
Maximum torque 265 lbf•ft (30 N•m) at 1600 rpm min.
Fuel consumption ratio 227.6 g/kW•h max.
Starter 24 V 4.0 kW Reduction type
Charging generator 24 V 50 A AC type
Battery 12 V 92 Ah/5 Hr x2
5. Cooling System
130X2/130X2 (Blade)
Fan type ø 21.7 in (550 mm) X 8 Intake
Radiator
Fin type Wavy
Fin pitch 0.138 in. (3.5 mm)
Oil cooler
Fin type Wavy
Inter cooler
Fin type Triangular straight
Fuel cooler
Fin type Wavy
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Specifications
6. Upper Side Work System
130X2/130X2 (Blade)
Model Backhoe attachment
Components, dimensions, working
dimensions
Bucket capacity Heaped 0.65 yd3 0.5 m3 (Leveled 0.48 yd3 (0.37 m3))
Boom length 182.3 in. (4630 mm)
Arm type Standard 0.98 in. (2.50 mm) Long 0.118 in. (3.01 mm)
Arm length 121.5 in. (3086 mm) 142 in. (3605 mm)
Maximum digging radius 327.2 in. (8310 mm) 345.3 in (8770 mm)
Maximum digging radius at
321.6 in. (8170 mm) 340.2 in. (8640 mm)
ground line
Maximum digging depth 218 in. (5540 mm) 238.2 in. (6050 mm)
Maximum vertical straight wall
194.8 in. (4950 mm) 210.6 in. (5350 mm)
digging depth
Maximum digging height 345.3 in. (8770 mm) 356.3 in. (9050 mm)
Maximum dump height 252 in. (6390 mm) 263 in. (6680 mm)
Minimum swing radius at front 92 in. (2340 mm) 105 in. (2660 mm)
Height for minimum swing radius
258.3 in. (6560 mm) 259.4 in. (6590 mm)
at front
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Specifications
7. Operating Device
130X2/130X2 (Blade)
Operator's seat
Position Left side
Adjustable forward and back and up and down, reclining mechanism, with
Structure
seat suspension
Cab Sealed steel type, Front surface reinforced glass
Levers and pedals
For travel use Lever and pedal type (hydraulic pilot type) x2
For operating machine use Lever type (hydraulic pilot type) x2
Instruments and switches
Work mode select switch 3 modes (SP, H, A)
Travel mode select switch Low-speed/high-speed switch type
One-touch idle Knob switch type
Engine emergency stop Switch type
Monitor device
Machine status display (full dot
liquid crystal)
Work mode select status SP/H/A
Instrument (full dot liquid crystal
except for hour meter)
Fuel gauge Bar graph indicator
Engine coolant temperature
Bar graph indicator
gauge
Hydraulic oil temperature gauge Bar graph indicator
Hour meter Digital type
Machine status and warning alarms (full dot liquid crystal and warning alarm) * has warning alarm
Overheat * Battery charge * Faulty electrical system *
Refill fuel * Engine oil pressure * Refill coolant *
Engine preheat Auto warm up Air cleaner
Anti-theft device triggered Faulty engine system * Engine emergency stop *
Illumination equipment
Working light Cab top: 24 V 70 W x1
Boom up: 24 V 70 W x1
Interior light 24 V 10 W x1
Horn Electric horn x2
Wiper with intermittent function, window washer, air conditioner, clock, rear
Others
view mirrors (left and right) 1 each
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Specifications
8. Swing Unit
130X2/130X2 (Blade)
Swing circle Swing bearing type (with inner gear)
Swing hydraulic motor Fixed displacement piston motor x1
Reduction gear Planetary gear 2-stage reduction gear
Swing parking brake Mechanical lock (operational lever linkage type)
9. Travel Lower Body

130X2/130X2 (Blade)
Travel hydraulic motor Variable displacement piston motor x2
Reduction gear Planetary gear 2-stage reduction gear
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) 43
Shoe width 23.6 in (600 mm) (options 27.6 in. (700 mm))
Grouser height 0.8 in (20 mm)
Link pitch 6.6 in (171.5 mm)
Roller
Number of upper rollers
x1
(per side)
Number of lower rollers (per side) x 7
Track belt tension adjuster Grease cylinder type (with cushion spring)
10.Dozer Blade
130X2 130X2 (Blade)
Width of Blade - 102 in. (2590 mm)
Height of Blade - 22.4 in. (570 mm)
Max. lift above ground - 15.0 in. (380 mm)
Min. drop below ground - 14.6 in. (370 mm)
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Specifications
Hydraulic Equipment
1. Hydraulic Device
130X2/130X2 (Blade)
Hydraulic pump drive type Direct engine link (no transmission)
Hydraulic pump
Double variable displacement piston pump x1
Model
Gear pump x1
Piston pump 2 x 34.1 gpm (129 L)
Discharge volume
Gear pump 5.8 gpm
Pump control method Simultaneous output full-horsepower control
Set pressure of main relief valve 4970 PSI (34.3 MPa) (5620 PSI (38.7 MPa) for boost)
Set pressure of overload relief 4685 PSI (32.3 MPa) (boom down)
valve 5540 PSI (38.2 MPa) (other)
2. Control Valve, Cylinder

130X2 130X2 (Blade)
Control valve
Quadruple spool
Model One-piece type x1
Quintuple spool
Operating method Hydraulic pilot type: travel, swing, and operating machine
Cylinder Number of cylinders x tube bore - Rod diameter - Stroke
Boom cylinder 2 x ø 4.1 in. (105 mm) - ø 2.7 in. (70 mm) - 38 in. (961 mm)
Arm cylinder 1 x ø 4.5 in. (115 mm) - ø 3.1 in. (80 mm) - 44 in. (1108 mm)
Bucket cylinder 1 x ø 3.7 in. (95 mm) - ø 2.5 in. (65 mm) - 35 in. (881 mm)
- 2 x ø 3.9 in. (100 mm) - ø 2.6 in.
Blade cylinder
(70 mm) - 8 in. (203 mm)
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Specifications
Capacities, Filters
1. Coolant and Oil Capacities
130X2/130X2 (Blade)
Coolant 3.9 gal (14.8 L)
Fuel 69 gal (261.2 L)
Engine lubricating oil 4.5 gal (17.0 L)
Travel reduction gear lubricating oil
0.6 gal (2.3 L)
(one side)
Swing reduction gear lubricating oil 0.6 gal (2.3 L)
Hydraulic oil 41 gal (155.0 L)
Hydraulic oil tank regulation amount 22 gal (83.3 L)
2. Hydraulic Oil Filters

130X2/130X2 (Blade)
Suction filter (inside tank) 105 µm
Return filter (inside tank) 6 µm
Pilot line filter (inside housing) 8 µm
3. Fuel Filter
130X2/130X2 (Blade)
Main filter 4 µm
Pre-filter 10 µm
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Specifications
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Lifting Capacity SH120
Lifting Capacity
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator
Discuss the procedures in advance
[1] Operators and those who handle rigging must be trained for those spe-
cific purposes.
[2] Use a sling that is sturdy enough. Also, use a device designed to prevent
loads from falling.
Take measures to ensure safe operation

[1] Specify signals to be used for lifting [2] Work on a level surface. (Working [3] If you are on a slope, level out the
loads and designate a signal person on a slope can cause the machine to footing before starting to work.
for the entire course of operation. overturn and fall.)
[4] Do not allow anyone to be under the [5] Do not lift a load exceeding the rated [6] The wire ropes and the chains for
suspended load or at other danger- capacity. (The machine can over- rigging must be sturdy enough and
ous areas. turn and jeopardize the safety of be free of disfigurement and corro-
workers.) sion.
Use wire ropes with safety factor 6 or greater.

Use lifting chains with safety factor 5 or greater.
Caution
[1] The operators must be trained specifically.
[2] The weight of the loads and the rigging equipment combined must not exceed the maximum load
value.
[3] During the crane operations, lower the engine speed (mode A) and keep working at low engine
speed.
[4] Be extra careful while carrying out the swing operations. Move the machine slowly.
[5] Do not leave the cab while you are suspending a load.
[6] Do not travel any distance while you are suspending a load.
[7] Sling the load in such a manner that the wire rope and the ring do not get detached from the
hook.
[8] If the bucket hook, or the rigging equipment gets damaged during operation, stop the procedure
and make necessary repairs.
[9] Please contact our authorized service shops when you wish to have hooks attached to your
bucket.
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Lifting Capacity
Lifting Capacities (Standard Arm)
Type of machine: 130X2 L: 8.21 ft (2.5 m) Arm length
Arm: Standard arm R: Reach from swing center
Shoe: 600 Grouser shoe H: Bucket hook height
Bucket: 0.65 yd3 (0.50 m3) W: Lifting capacity
We: Frontal rating load
Ws: Lateral rating load
MAX: Rating load at height point H and

at maximum working reach
(Maximum working reach: 25.366 ft) (Units; Ib)

Max.
R 20 ft 15 ft 10 ft 5 ft
H W R (ft)
We 3450 * 16.73
25 ft
Ws 3450 * 16.73
We 2950 * 21.89
20 ft
Ws 2950 * 21.89
We 2750 * 24.72 6050 6200 *
15 ft
Ws 2750 * 24.72 4300 6200 *
We 2750 * 26.13 5900 8000 * 10150 *
10 ft
Ws 2500 26.13 4200 6850 10150 *
We 2900 * 26.39 5650 9050 16650 *
5 ft
Ws 2400 26.39 3950 6300 11900
We 3250 * 25.53 5400 8550 17100 5900 *
0 ft
Ws 2500 25.53 3750 5850 10900 5900 *
We 3900 * 23.41 5300 8350 17000 11350 *
-5 ft
Ws 2850 23.41 3600 5650 10800 11350 *
We 5300 * 19.53 5350 8350 17200 18050 *
-10 ft
Ws 3950 19.53 3700 5650 11000 18050 *
We 8200 * 13700 *
-15 ft
Ws 6000 11450
*Hydraulic pressure factor: 87.0%. Without asterisk: Stability factor: 75.0%
NST-02-02-006LX 2
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Lifting Capacity
Lifting Capacities (Long Arm)
Type of machine: 130X2 L: 9.87 ft (3.0 m) Arm length
Arm: Long arm R: Reach from swing center


Max.
R 25 ft 20 ft 15 ft 10 ft 5 ft
H W R (ft)
We 3300 * 19.22
25 ft
Ws 3300 * 19.22
We 2900 * 23.74
20 ft
Ws 2900 * 23.74
We 2750 * 26.35 5700 *
15 ft
Ws 2600 26.35 4500
We 2750 * 27.67 4000 6050 7000 *
10 ft
Ws 2300 27.67 2800 4300 6950
We 2900 * 27.91 3900 5750 9250 14300 *
5 ft
Ws 2200 27.91 2700 4050 6450 12400
We 3250 * 27.10 3800 5450 8650 17300 6100 *
0 ft
Ws 2250 27.10 2600 3750 5900 11050 6100 *
We 3750 25.13 5300 8300 16850 10650 *
-5 ft
Ws 2550 25.13 3600 5650 10700 10650 *
We 4800 21.63 5300 8300 17000 15400 *
-10 ft
Ws 3300 21.63 3600 5600 10800 15400 *
We 8500 15750 * 24300 *
-15 ft
Ws 5800 11150 24300 *
3 NST-02-02-006LX
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Lifting Capacity
Lifting Capacities (Standard Arm)
Type of machine: 130X2 (Blade) L: 8.21 ft (2.5 m) Arm length
Arm: Standard arm R: Reach from swing center


Max.
R 20 ft 15 ft 10 ft 5 ft
H W R (ft)
We 3450 * 16.73
25 ft
Ws 3450 * 16.73
We 2950 * 21.89
20 ft
Ws 2950 * 21.89
We 2750 * 24.72 6150 6200 *
15 ft
Ws 2750 * 24.72 4600 6200 *
We 2750 * 26.13 6000 8000 * 10150 *
10 ft
Ws 2700 26.13 4450 7250 10150 *
We 2900 * 26.39 5750 9200 16650 *
5 ft
Ws 2600 26.39 4200 6700 12650
We 3250 * 25.53 5500 8700 17300 5900 *
0 ft
Ws 2700 25.53 4000 6250 11650 5900 *
We 3900 * 23.41 5400 8450 17250 11350 *
-5 ft
Ws 3100 23.41 3900 6050 11500 11350 *
We 5300 * 19.53 5450 8500 17450 18050 *
-10 ft
Ws 4250 19.53 3950 6100 11700 18050 *
We 8200 * 13700 *
-15 ft
Ws 6400 12100
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Lifting Capacity
Lifting Capacities (Long Arm)
Type of machine: 130X2 (Blade) L: 9.87 ft (3.0 m) Arm length
Arm: Long arm R: Reach from swing center


Max.
R 25 ft 20 ft 15 ft 10 ft 5 ft
H W R (ft)
We 3300 * 19.22
25 ft
Ws 3300 * 19.22
We 2900 * 23.74
20 ft
Ws 2900 * 23.74
We 2750 * 26.35 5700 *
15 ft
Ws 2750 * 26.35 4750
We 2750 * 27.67 4100 6150 7000 *
10 ft
Ws 2500 27.67 3000 4600 7000 *
We 2900 * 27.91 4000 5850 9350 14300 *
5 ft
Ws 2350 27.91 2900 4300 6850 13100
We 3250 * 27.10 3850 5550 8800 17600 6100 *
0 ft
Ws 2450 27.10 2800 4050 6350 11800 6100 *
We 3800 * 25.13 5400 8450 17150 10650 *
-5 ft
Ws 2750 25.13 3900 6050 11400 10650 *
We 4900 21.63 5400 8450 17250 15400 *
-10 ft
Ws 3550 21.63 3900 6000 11500 15400 *
We 8650 15750 * 24300 *
-15 ft
Ws 6200 11900 24300 *
5 NST-02-02-006LX
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Lifting Capacity
NST-02-02-006LX 6
Overall View SH130
Overall View
Overall View
Overall View (130X2)
1. Standard Arm 98.4 in. (2.50 m)
Note: 1. Numbers are subject to change without notice due to design change or other reason.
Note: 2. The figures give values that include the shoe lug height 0.8 in. (20 mm).
2. Long Arm 118.5 in.(3.01 m)

1 NST-02-03-008LX
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Overall View
Overall View (130X2 (Blade))
2. Long Arm 118.5 in. (3.01 m)

NST-02-03-008LX 2
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Work Range Diagram SH130
Work Range Diagram
Work Range Diagram

Work Range Diagram (130X2)
Note: 2. The figures give values that include the shoe lug height (20 mm).
1 NST-02-04-008LX
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Work Range Diagram
2. Long Arm 118.5 in. (3.01 m)
Note: 2. The figures give values that include the shoe lug height 0.8 in (20 mm).
NST-02-04-008LX 2
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Work Range Diagram
Work Range Diagram (130X2 (Blade))
Note: 2. The figures give values that include the shoe lug height 0.8 (20 mm).
3 NST-02-04-008LX
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Work Range Diagram
2. Long Arm 118.5 in. (3.01 m)
NST-02-04-008LX 4
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Main Equipment Table SH120

Lower Component
1. Travel Unit
130X2/130X2 (Blade)
Part No. KNA10520
Manufacturer Nabtesco Corporation
Motor type Variable displacement piston motor
Automatic 2nd-speed switchover with parking brake
Intake amount 44.9/74.3 cm3/rev
Operating pressure 4975 PSI (34.3 MPa)
Operating flow 34.1 Gal./min (129.3 L)
Brake torque 8187 lbf•ft min. (including reduction gear)
Relief valve set pressure 5410 PSI (37.3 MPa)
Automatic 2nd-speed switchover
3626 - 3916 PSI (25-27 MPa)
pressure
Reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 54.0
Dry weight 320 lb (145 kg)
2. Take-up Roller
130X2/130X2 (Blade)
Part No. KNA11040
Weight 144 lb (65.3 kg)
3. Upper Roller
130X2/130X2 (Blade)
Part No. KMA1275
4. Lower Roller
130X2/130X2 (Blade)
Part No. KNA10600
1 NST-03-01-009LX
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5. Recoil Spring
130X2/130X2 (Blade)
Item Part No. Weight lb (kg)
Yoke KNA10900 33 9 (14.9)
Sems B M16 x 50 105R016Y050R 1 (0.45)
Threaded rod KNA10910 34 (15.4)
Groove height N M42 165R042HSN 2 (0.9)
SP pin 8 x 70 338W080Z070B 0.2 (0.09)
Recoil spring KNA10530 70 (31.8)
Grease cylinder assembly KNA0338 32 (14.5)
Sems B M16 x 50 105R016Y050R 0.2 (0.009)
Assembly Total 172 (78.0)
Mounting length of spring 16.5 in (419.1 mm)
6. Shoe
130X2/130X2 (Blade)
Part No. Weight or quantity
600 grouser KNA10620 1757 lb (797 kg)
Link KNA10690 1 set
Shoe KNA0632 x 43
Bolt KNA0396 x 172
Nut KNA0397 x 172
700 grouser KNA10630 2088 lb (947.1 kg)
Link KNA10690 1 set
Shoe KNA0632 x 43
Bolt KNA0396 x 172
Nut KNA0397 x 172
NST-03-01-009LX 2
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Upper Component
1. Swing Unit
130X2/130X2 (Blade)
Swing motor assembly
Part No. KNC10010
Swing motor
Part No. -
Manufacturer TOSHIBA MACHINE CO., LTD.
Motor type Fixed displacement piston motor
With parking brake
Intake amount 65 cm3/rev
Operating pressure 4047 PSI (28 MPa)
Operating flow 34.1 gpm (129 L)
Mechanical brake torque 248 lbf•ft min. (28 N•m)
Brake off pressure 421 PSI max. (3 MPa)
Relief valve set pressure 4047 PSI (28 MPa)
Swing reduction gear
Part No. -
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 17.03
Dry weight 218 lb (98.9 kg)
Turntable bearing
Part No. KMB10410
Number of teeth 98
Counterweight
Part No. KNB10810
Weight 4784 lb (2170 kg)
3 NST-03-01-009LX
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Engine-related
1. Engine
130X2/130X2 (Blade)
Part No. KNH10490
Engine model name Isuzu 4JJ1X diesel engine
4-cycle, water cooled, overhead camshaft, vertical in-line, direct injection
Engine type
type (electronic control)
Number of cylinders - bore - stroke 4 - φ3.76 in. - 4.13 in. (95.5 - 105 mm)
Total displacement 183 cu•in (3.0 L)
Compression ratio 17.5
Rated output 95 HP/2000 rpm
Maximum torque 265 lbf•ft/about 1600 rpm (30 N•m)
Fuel consumption ratio 227.6 g/kW•h max.
Engine dry weight About 705 lb (320 kg)
Engine dimension L 36.5 - W 29.9 - H 3.5 in (927 x 759.5 x 89 mm)
Oil pan All direction 0.61 rad, inclinable
Cooling fan É”21.7 in (551 mm - suction type - 8 vanes, plastic
With bell mouth-type fan guide
Pulley ratio 0.95 (reduction)
Charging generator 24 V 50 A AC type
Starter motor 24 V 4 kW reduction type
Coolant capacity 1.6 gal (6.0 L)
Oil pan capacity Max.: 3.9 gal (14.8 L) Min.: 2.9 gal (11.0 L) (not including oil filter)
Direction of rotation Right (as seen from fan)
2. Muffler
130X2/130X2 (Blade)
Part No. KLH10140
Manufacturer SANKEI GIKEN KOGYO CO., LTD.
Model φ9.8 in x 25.6 in (249 x 650 mm)
3. Air Cleaner (double element)

130X2/130X2 (Blade)
Part No. KLH10150
Manufacturer Nippon Donaldson, Ltd.
Element (outer) KLH10550
Element (inner) KLH10560
NST-03-01-009LX 4
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4. Radiator
130X2/130X2 (Blade)
Part No. KNH10450
Manufacturer TOKYO RADIATOR MFG. CO., LTD.
Oil cooler Weight 34 lb (15.4 kg)
Oil capacity 1.7 gal (6.4 L)
Radiator Weight 22 lb (10 kg)
Coolant capacity 1.5 gal (5.7 L)
Air cooler Weight 10 lb (4.5 kg)
Capacity -
Fuel cooler Weight 2 lb (0.9 kg)
Capacity 0.05 gal 0.2 L)
Total weight 161 lb (73 kg)
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Hydraulic Device
1. Hydraulic pump
130X2 130X2 (Blade)
Part No. KNJ11850 KNJ11860
Manufacturer Kawasaki Precision Machinery Ltd.
Main pump
Pump type Double variable displacement piston pump
Displacement capacity 65 x 2 cm3/rev
Operating pressure Rated 4970 PSI (36.3 MPa)
Maximum 5260 PSI (36.3 MPa)
Input revolution speed 2000 rpm
Maximum discharge flow 34.1 Gal/min (129 L) x 2 (at 2000 rpm)
Pilot pump
Pump type Gear pump
Displacement capacity 10 cm3/rev
Operating pressure 569 PSI (4 MPa)
Maximum discharge flow 5.8 Gal/min (22 L) (at 2000 rpm)
Control method Hydraulic simultaneous constant output control
Maximum flow adjustment control through external commands
(negative control)
Setting horsepower adjustment control through external command milli-
amp
Dry weight 179 lb (81.2 kg)
Blade pump
Part No. - KNJ10650
Pump type - Gear pump
Displacement capacity - 28.2 cm3/rev
Operating pressure - 2988 PSI (20.6 MPa)
Maximum discharge flow - 15.9 Gal/min (60.2 L)
Dry weight - 9.7 lb (4.4 kg)
NST-03-01-009LX 6
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2. Pump P-Q Diagram
7 NST-03-01-009LX
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Control-related
1. Control Valve
130X2 130X2 (Blade)
Part No. KNJ14640 KNJ14650
Maximum flow 34.1 Gal (0.29 L)/m (at 2000 rpm)
Overload set pressure 4685 PSI (32.3 MPa) boom down
5540 PSI (38.2 MPa) other
- 3408 PSI (23.5 MPa)
Main relief set pressure 4975 PSI (34.3 MPa)
(at boosting) 5265 PSI (36.3 MPa)
Foot relief set pressure 370 PSI (2.6 MPa)
Function Straight travel circuit
Boom up/arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice (for arm operation)
2 pumps flow
Weight 353 lb (160 kg) 388 lb (176.0 kg)
With supplied valve
2. Solenoid Valve (4 stack)

130X2/130X2 (Blade)
Part No. KHJ15450
Manufacturer YUKEN KOGYO CO., LTD.
Valve specifications
Maximum flow P → B 6.6 Gal. (25 L)/min other 1.3 Gal. (5.0 L)/min
Rated pressure 653 PSI (4.5 MPa)
Port size P.T.B port G3/8
C1, C2, C3 ports G1/4
Solenoid specifications
Operating voltage 20 - 32 V DC
Power consumption 17 W max.
NST-03-01-009LX 8
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3. Remote Control Valve (left/right, travel operations)
4. Valve for left/right operations
130X2/130X2 (Blade)
Part No. KHJ13270
Operating pressure 569 PSI ( 4.1MPa)
Secondary pressure 93 - 355 PSI (0.6 - 2.4 MPa) primary short type
Operating angle 1, 3 ports 19°
2, 4 ports 25°
5. Valve for travel operation

130X2/130X2 (Blade)
Part No. KRJ5803
Operating pressure 569 PSI (4.0 MPa)
Secondary pressure 93 - 355 PSI (0.6 - 2.4 MPa) primary short type
Operating angle 12.4°
9 NST-03-01-009LX
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6. Remote Control Valve Characteristic Diagram
7. Operation remote control valve control diagram
8. Travel remote control valve control diagram
NST-03-01-009LX 10
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9. Cushion Valve (heat circuit, with shuttle valve)
130X2/130X2 (Blade)
Part No. KNJ14440
Manufacturer YANAGISAWA SEIKI MFG. CO., LTD.
Port size G3/8 (A-P ports)
G1/4 (R-V ports)
10.Selector Valve (option)

130X2/130X2 (Blade)
2WAY
Part No. KHJ12080
Manufacturer Nishina Industrial Co., Ltd.
Rated flow 6.6 gpm (25.0 L)
Operating method I: ISO
D: Deere
Port size G3/8
11 NST-03-01-009LX
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11.Center Joint
130X2 130X2 (Blade)
Part No. KRA11190 KRA12010
Operating pressure High pressure passage High pressure passage
(ABCD) 4975 PSI (34.3 MPa) (ABCD) 4975 PSI 34.3 MPA)
2987 PSI (20.6
(EF)
MPa)
Drain port (E) 73 PSI (0.5 MPa) Drain port (G) 73 PSI (0.5 MPa
Pilot port (F) 566 PSI (3.9 MPa) Pilot port (H) 566 PSI (3.9 MPa)
Flow High pressure passage High pressure passage
55.3 Gal. (209.3 L)/
(ABCD) 61.8 Gal. (234 L)/min (ABCD)
min
21.2 Gal. (80.3 L)/
(EF)
min
Drain port (E) 2.6 Gal. (9.8 L)/min Drain port (G) 2.6 Gal. (9.8 L)/min
Pilot port (F) 5.5 Gal. (21.0 L)/min Pilot port (H) 5.2 Gal. (19.6 L)/min
Port A Forward right G3/4 Forward right G3/4
Port B Forward left G3/4 Forward left G3/4
Port C Backward right G3/4 Backward right G3/4
Port D Backward left G3/4 Backward left G3/4
Port E Drain port G1/2 Blade up G1/2
Port F Pilot port G1/4 Blade down G1/2
Port G Drain port G1/2
Port H Pilot port G1/4
Weight 65 lb (29.5 kg) 118 lb (53.5 kg)
NST-03-01-009LX 12
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Backhoe Attachment
1. Cylinder
Boom cylinder 130X2/130X2 (Blade)
Part No. KNV14330 (R)
Part No. KNV14340 (L)
Manufacturer KYB Corporation
Cylinder bore φ4.1 in (104 mm)
Rod diameter φ2.8 in (71 mm)
Maximum retracted length 57.6 in (1463 mm)
Stroke 37.8 in (960 mm)
Arm cylinder 130X2/130X2 (Blade)

Part No. KNV14350
Rod diameter φ3.2 in (81.3 mm)
Maximum retracted length 63.7 in (1618 mm)
Stroke 43.6 in (1107.4 mm)
Bucket cylinder 130X2/130X2 (Blade)

Part No. KNV12540
Rod diameter φ2.6 in (66 mm)
Maximum retracted length 54.1 in (1374.1 mm)
Stroke 34.7 in (881.4 mm)
Weight 201 lb (91.2 mm)
Blade cylinder 130X2 130X2 (Blade)

Part No. - KNV1219 (R)
- KNV1220 (L)
Manufacturer - KYB Corporation
Cylinder bore - φ3.9 in (99.0 mm)
Rod diameter - φ2.7 in (68.6 mm)
Maximum retracted length - 23 in (584.2 mm)
Stroke - 7.92 in (201.2 mm)
Weight - 99 lb (45.0 kg)
13 NST-03-01-009LX
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2. Attachments
（1）
Bucket type
● Standard bucket
◎ General digging (specific gravity 2.0 ton/m3 max.)
○ Light digging (specific gravity 1.6 ton/m3 max.)
△ For loading only (specific gravity 1.2 ton/m3 max.)
× Do not use
Bucket capacity (m3) 0.37 0.45 0.5 0.55 0.65

Standard arm 98.4 in (2.5 m) ◎ ◎ ● ○ △
Long arm 118.5 in (3.01 m) ● ○ × × ×
NST-03-01-009LX 14
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Equipment Layout Diagram SH130

Main Equipment Layout
1 Engine 7 Swing motor 13 Fuel tank

2 Radiator 8 Front idler 14 Arm cylinder
3 Reserve tank 9 Bucket 15 Boom cylinder
4 Boom 10 Arm 16 Travel motor
5 Battery 11 Hydraulic pump 17 Tool box
6 Air cleaner 12 Hydraulic oil tank 18 Bucket cylinder
1 NST-03-02-006E
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Consumable Part Layout
1 Fuel tank 6 Hydraulic oil tank 11 Air conditioner outside air filter
2 Pilot filter 7 Return filter 12 Washer tank
3 Fuel prefilter 8 Tank air breather 13 Battery
4 Engine oil filter 9 Suction filter 14 Reserve tank
5 Fuel filter 10 Air cleaner
NST-03-02-006E 2
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Standard Machine Option List SH130

List of Optional Components
◎ : Standard ● : Option
130X2
Spec. Models Remarks
/130X2 (Blade)
600G shoe ◎ With seal, without hole
700G shoe ● With seal, without hole
Link chain rubber crawler (500) ●
Lower under cover ◎
Track guard (double) ●
Free swing ●
Air conditioner (Auto) ◎
AM/FM radio (Hi) ◎
DC-DC converter ◎
Feed pump ●
Air conditioner and cool box ◎
Rear view mirror (forward right) ◎
Rear view mirror (cab) ◎
Front guard, mesh (lower)
(with cab seating) ●
Front guard, mesh (full)

(with cab seating) ● Mesh type guard
OPG Level 1 (with cab seating) ● FB strengthened guard

OPG Level 2 (with cab seating) ● FB strengthened guard
Head guard, FOPS Level 2 ●
Rain deflector ●
Sunroof polycarbonate ◎
Cab top light ●
KAB seat ◎
KAB seat (air suspension) ●
Sunvisor ●
Sun shade ◎
Quick change (2-way) ●
(pedal) ●
Breaker circuit + Strengthened bucket linkage
(SW) ●
(pedal) ● + Strengthened bucket linkage,
Multi purpose circuit
(SW) ● strengthened boom, arm
Shuttle circuit
(thumb line tube, 2 pumps flow) ● + Strengthened bucket linkage
+ Strengthened bucket linkage,

Multi purpose + 2nd option (pedal) ● strengthened boom, arm
Att reinforcement plate ●
1 NST-03-03-009LX
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◎ : Standard ● : Option
130X2
Spec. Models Remarks
/130X2 (Blade)
Strengthened boom and arm ●
Strengthened boom ●
STD arm (2.50 m) ◎
Long arm (3.01 m) ●
LLC (50 %) ◎
NST-03-03-009LX 2
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Hydraulic Equipment Layout SH130

Overall View
1 Left side housing

2 Swing body center section
3 Pump chamber
4 Hydraulic oil tank
5 Fuel tank
1 NST-04-01-008E
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Pump Chamber Hydraulic Equipment Layout
1 Hydraulic pump 7 P1 pressure sensor

2 Accumulator 8 Pilot pump
3 Pilot filter 9 Horsepower control electromagnetic proportional valve
4 4 stack solenoid valve 10 N2 pressure sensor
5 N1 pressure sensor 11 Hydraulic oil temperature sensor
6 P2 pressure sensor
NST-04-01-008E 2
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Swing Body Center Section Hydraulic Equipment Layout
1 Swing motor
2 Center joint
3 Control valve
3 NST-04-01-008E
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Housing Left Side Hydraulic Equipment Layout
1 Cushion valve (with heat circuit)

2 Swing pilot pressure sensor
3 Oil cooler
NST-04-01-008E 4
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Layout of Hydraulic Equipment in Cab
1 Travel remote control valve

2 Upper operation remote control valve
5 NST-04-01-008E
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NST-04-01-008E 6
Main Equipment Structure and Operation Explanation SH120

Pump
1. Hydraulic Pump
(1)Structure and operation explanation
This pump has a structure with 2 pumps positioned on the same shaft coupled with the 1st gear
(116) and rotation force is distributed to different shafts by the gear structure. The 2 pumps are
driven by transmitting the rotation of the power source to the front side drive shaft (111). Auxiliary
pumps installed on different shafts can also be driven at the same time.
The pump can be roughly divided into the rotary group, which is the main part of the pump rotat-
ing, the swash plate group, which changes the discharge flow, the valve block group, which
switches between oil suction and discharge, and the PTO group that transmits the gear pump
drive shaft.
The rotary group is made up of drive shafts (111 and 113), cylinder block (141), piston shoes
(151and 152), holder plate (153), sphere bushing (156), bearing spacer (127), and cylinder
spring (157). The drive shaft is supported at both ends with bearings (123 and 124). The shoe is
caulked to the piston and forms the spherical joint, reduces the thrust force generated by the load
pressure, and has a pocket section for balancing the pressure for sliding lightly on the shoe plate
(211). The piston shoe sub-group is pressed against the shoe plate by the cylinder spring via the
holder plate and spherical bushing so that it can slide smoothly on the shoe plate. Also, in the
same way, the cylinder block is pressed against the valve plates (313 and 314) by the cylinder
spring.
The swash plate group comprises the swash plate (212), shoe plate, swash plate support board
(251), tilting bushing (214), tilting pin (531), and servo piston (532). The swash plate is supported
by the swash plate support board at the cylindrically shaped section formed by the opposite side
of the shoe sliding surface. By leading the hydraulic pressure force controlled by the regulator
into the hydraulic pressure chambers on both sides of the servo piston, the servo piston moves
left and right. This moves the swash plate back and forth on the swash plate support board via
the tilting pin spherical section and changes the tilting angle (?).
The valve block group comprises the valve block (312), valve plates (313 and 314), and spring
pin (886). The valve plate, which has two hook-shaped ports, is installed on the valve block. Its
function is to feed oil to the cylinder block and recover it from the cylinder block. The oil switched
by the valve plate is connected through the valve block to the outside pipes.
The PTO group comprises the 1st gear, 2nd gear (117), and 3rd gear (118). The 2nd and 3rd
gear are supported by their respective bearings (125 and 126) and can install the valve block.
Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block is
also rotated at the same time via the spline coupling. When the swash plate tilts, the piston
located at the center of the cylinder block moves reciprocally relative to the cylinder while turning
with the cylinder block. Therefore, if looking at one piston while the cylinder block turns one rota-
tion, the piston moves away from the valve plate (oil intake stroke) for 180 ° of the cylinder block
rotation, then moves toward the valve plate (oil discharge stroke) for the remaining 180°. When
the swash plate tilting angle (?) is 0, the piston subassemblies (151 and 152) do not move
through a stroke and oil is not discharged.
Also, at the same time, the drive shaft rotation is taken out by the 1st gear and transmitted
through the 2nd gear to the 3rd gear to drive the pilot gear pump coupled with the 3rd gear.
1 NST-04-02-004E
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(2)Hydraulic pump internal structure diagram Code Part name Q'ty
111 Drive shaft (F) 1
113 Drive shaft (R) 1
116 1st gear 1
123 Cylinder roller bearing 2
124 Needle roller bearing 2
127 Bearing spacer 2
141 Cylinder block 2
151 Piston 18
152 Shoe 18
153 Holder plate 2
156 Spherical bushing 2
157 Cylinder spring 12
211 Shoe plate 2
212 Swash plate 2
214 Tilting bushing 2
251 Swash plate support board 2
255 Rotation lock pin 2
256 Set spring 2
261 Seal cover (F) 1
271 Pump casing (F) 1
272 Pump casing (R) 1
312 Valve block 1
313 Valve plate (R) 1
314 Valve plate (L) 1
326 Cover 1
401 Hexagon socket head bolt 2
466 ROH plug 2
467 ROH plug 2
468 ROH plug 4
490 Insert plug 9
531 Tilting pin 2
532 Servo piston 2
533 Q min. plug 2
534 Stopper (L) 2
535 Stopper (S) 2
548 Feedback pin 2
702 O-ring 2
710 O-ring 1
711 O-ring 1
717 O-ring 2
723 O-ring 6
724 O-ring 12
727 O-ring 4
732 O-ring 4
733 O-ring 2
1 Right rotation valve plate 774 Oil seal 1
2 Left rotation valve plate 789 Backup ring 2
792 Backup ring 2
Component part number 806 Hexagon nut 2
Code Part name Q'ty
(quantities) or model
808 Hexagon nut 2
04 Gear pump 1 set ZX10L7RZ1-07A-V 824 Stop ring 2
011 Piston subassembly 2 sets 151 (9PC), 152 (9PC) 886 Spring pin 4
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC) 901 Eyebolt 2
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC) 953 Hexagon socket head stop screw 2
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC) 954 Stop screw 2
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC) 981 Nameplate 1
983 Striking pin 2
2 NST-04-02-004E
2
Blade Code Part name Q'ty
111 Drive shaft (F) 1
113 Drive shaft (R) 1
116 1st gear 1
123 Cylinder roller bearing 2
124 Needle roller bearing 2
141 Cylinder block 2
151 Piston 18
152 Shoe 18
153 Holder plate 2
156 Spherical bushing 2
157 Cylinder spring 12
211 Shoe plate 2
212 Swash plate 2
214 Tilting bushing 2
251 Swash plate support board 2
255 Rotation lock pin 2
256 Set spring 2
261 Seal cover (F) 1
271 Pump casing (F) 1
272 Pump casing (R) 1
312 Valve block 1
313 Valve plate (R) 1
314 Valve plate (L) 1
466 ROH plug 2
467 ROH plug 2
468 ROH plug 4
490 Insert plug 9
531 Tilting pin 2
532 Servo piston 2
533 Q min. plug 2
534 Stopper (L) 2
535 Stopper (S) 2
548 Feedback pin 2
702 O-ring 2
710 O-ring 1
711 O-ring 1
717 O-ring 2
723 O-ring 6
724 O-ring 12
727 O-ring 4
732 O-ring 4
733 O-ring 2
774 Oil seal 1
1 Right rotation valve plate 789 Backup ring 2
2 Left rotation valve plate 792 Backup ring 2
806 Hexagon nut 2
Component part number 808 Hexagon nut 2
Code Part name Q'ty
(quantities) or model
824 Stop ring 2
04 Gear pump 1 set ZX10L7RZ1-07A-V 886 Spring pin 4
05 PTO ASSY 1 set For the Machine with Blade 901 Eyebolt 2
011 Piston subassembly 2 sets 151 (9PC), 152 (9PC) 953 Hexagon socket head stop screw 2
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC) 954 Stop screw 2
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC) 981 Nameplate 1
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC) 983 Striking pin 2
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC)
3 NST-04-02-004E
3
(3)PTO internal structure diagram (for the machine with Blade)
No. PART NAME QTY. Tightening torque

No. PART NAME
115 IDLER SHAFT 1 (N•m)
117 GEAR 2ND 1 415, 435 M10 33
118 GEAR 3RD 1 468 G3/4 74
125 BALL BEARING 2
126 ROLLER BEARING 1
128 BEARING SPACER 2
262 COVER 2
326 GEAR CASE 1
414 HEX SOCKET HEAD BOLT 4
435 FLANGE SOCKET 4
468 PLUG 1
710 O-RING 1
711 O-RING 1
728 O-RING 1
825 SNAP RING 1
826 SNAP RING 1
885 SPRING PIN 1
886 PIN 2
4 NST-04-02-004E
4
2. Regulator
(1)Regulator operation explanation
[1] Flow control
• Operation explanation (See the regulator operation explanation diagram.)
1) Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the figure
below.
1. Flow reduction operation
When the pilot pressure Pi increases, the pilot pis-
ton (643) moves in the direction of R and stops at
the location where the pilot spring (646) force and
hydraulic pressure force balance each other. The
pin (875) fixed to the lever (2) (613) is bonded to the
grooved section of the pilot piston (643). Therefore,
as the pilot piston (643) moves, the lever (2) rotates
with the B section (fixed by the fulcrum plug (614)
and pin (875)) as the fulcrum. The pin (897) fixed to
the feedback lever (611) protrudes into the large opening (C section) of the lever (2)
(613). Therefore, as the lever (2) (613) is rotated, the pin (897) moves in the direction of
R. The pin (548) fixed to the tilting pin (531) that shakes the swash plate (212) is
bonded to the 2-side width section (D section) of the feedback lever (611). Therefore, as
the pin (897) moves, the feedback lever (611) rotates with the D section as the fulcrum.
The spool (652) is coupled to the feedback lever (611) via the pin (8polm7o
When the spool (652) moves, the discharge pressure P1 is led to the servo piston large-
bore chamber via the spool and CI port. The discharge pressure P1 is always led to the
servo piston small-bore chamber. As a result, the servo piston is moved in the direction
of R due to the surface area difference and reduces the flow.
When the servo piston (532) moves in the direction of R, the D section also moves in
the direction of R. A return spring (654) is mounted on the spool (652), and a force pull-
ing the spool in the direction of L is constantly used. Therefore, the pin (897) is pressed
into the large opening (C section) of the lever (2) (613). Consequently, the feedback
lever (611) rotates with the C section as the fulcrum in accordance with the movement
of the D section, and the spool (652) moves in the direction of L. This movement causes
the open section between the sleeve (651) and the spool (652) to begin to close and the
servo piston (532) stops at the point where the open section fully closes.
2. Flow increase operation
As the pilot pressure Pi decreases, the pilot piston (643) moves in the direction of L due
to the force of the pilot spring (646), and the lever (2) (613) rotates with the B section as
the fulcrum. The pin (897) is pressed in the large opening (C section) of lever (2) (613)
by the return spring (654) via the spool (652), pin (874), and feedback lever (611), so
accompanying rotation of lever (2) (613), the feedback lever (611) rotates with the D
section as the support point and the spool (652) moves in the direction of L.
When the spool (652) moves, the CI port opens to the tank port, so the pressure in the
large-bore chamber of the servo piston drains out, the servo piston (532) is moved in
the direction of L by the discharge pressure P1 of the small-bore section and the flow
increases.olm
The D section also moves in the direction of L in accordance with the movement of the
servo piston (532), the feedback lever (611) rotates with section C as the fulcrum, and
the spool (652) moves in the direction of R. This operation continues until the opening
of the spool (652) and sleeve (651) closes and stops when the opening is completely
closed.
NST-04-02-004E 5
5
3. High-pressure selection function
The pilot pressure Pi, which serves as the KR76-9Y2C-V flow control signal, is the
pressure for which high pressure is selected from amongst Pi and proportional valve
secondary pressure Pi1 via the shuttle valve.
The power shift pressure Pf, which serves as the KR76-9YOC-V power shift control sig-
nal, is the pressure for which high pressure is selected from amongst P2 and Pi2 via the
shuttle valve.
[2] Horsepower control
1) Horsepower control
As the load pressure increases, the pump tilting angle decreases and the overload of the
engine is prevented as in the figure below. This regulator uses the simultaneous full-horse-
power control method. Therefore, the tilting angles (displacement volume) of the 2 pumps
are controlled to the same value as indicated in the equation below.
Tin=P1 x q/2?+P2 x q/2?=(P1+P2) x q/2?
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(For detailed operation of each part, see the Flow control)
1. Overload prevention operation
When the self pump discharge pressure P1 or
the counterpart pump discharge pressure P2
rises, since P1 and P2 operate on the stepped
section of the compensation piston (621), the
compensation rod (623) is pressed in the
direction of R and moves to the location where
the force of the outer spring (625) and inner
spring (626) balance out the hydraulic pres-
sure force. The movement of the compensa-
tion rod (623) is transmitted to the lever (1)
(612) via the pin (875), and the lever (1) (612)
rotates around the pin (875) (E section) fixed
to the casing A (601). The pin (897) fixed to the feedback lever (611) protrudes into the
large opening (F section) of the lever (1) (612). Therefore, as the lever (1) (612) is
rotated, the feedback lever (611) rotates with section D as the fulcrum, and the spool
(652) moves in the direction of R.
When the spool (652) moves, the discharge pressure P1 is led to the large-diameter
section of the servo piston via the CI port, the servo piston (532) is moved in the direc-
tion of R, and the pump discharge flow is decreased to prevent overload of the power
source.
The movement of the servo piston (532) is transmitted to the feedback lever (611) via
the D section, the feedback lever (611) rotates with section F as the fulcrum, and the
spool (652) moves in the direction of L. The spool (652) moves until the open section
between the spool (652) and sleeve (651) closes, and then the spool (652) stops at the
point the open section fully closes.
6 NST-04-02-004E
6
2. Flow return operation
If the self pump discharge pressure P1 or the counterpart pump discharge pressure P2
decreases, the compensation rod (623) is pressed back by the outer spring (625) and
the inner spring (626) and lever (1) (612) rotates about the E section. The feedback
lever (611) rotates with the D section as the fulcrum accompanying the rotation of the
lever (1) (612), and the spool (652) moves in the direction of L. Consequently, the Cl
port opens into the tank port, the pressure in the servo piston large-diameter section
bleeds, the servo piston (532) moves in the direction of L, and the pump discharge flow
increases.
The servo piston (532) movement is transmitted to the spool (652) by the feedback
structure and the operation continues until the opening between the spool (652) and
sleeve (651) is closed.
[3] Low tilting (low flow) command priority mechanism
As above, the flow control and the horsepower control tilting command is transmitted to the
feedback lever (611) and spool (652) via the large opening (C and F sections) of lever (1)
(612) and lever (2) (613). However, because the C and F sections have a structure in which
a pin (?5) projects into a large hole (?9), the pin (897) only comes in contact with the lever of
the side in which tilting is smaller. The pin (897) does not come in contact with the ?9 hole
for the lever on the side that has the larger tilting command state and the pin is free. This
type of mechanical selection method gives priority to flow control and horsepower control
commands with low tilting.
[4] Power shift control (decreased horsepower control)
Use the power shift pressure Pf to arbitrarily control the pump set horsepower as in the fig-
ure on the right.
As the power shift pressure Pf increases, the compensation rod (623) moves in the direction
of R via the pin (898) and the compensation piston (621). Therefore, the pump tilting angle
decreases and the horsepower setting decreases as described in the overload prevention
operation for horsepower control. By contrast, as the power shift pressure Pf decreases, the
horsepower setting increases.
NST-04-02-004E 7
7
(2)Regulator operation explanation diagram
Leads to Cl port servo piston

large-core chamber
Right direction
Left direction
Front side hydraulic circuit diagram Rear side hydraulic circuit diagram
(KR76-9Y0C-V) (KR76-9Y2C-V)
P1 P2
8 NST-04-02-004E
8
(3)Front side regulator internal structure diagrams
Part Component part number

Part name Q'ty
number (quantities) and model
Electromagnetic proportional pressure
079 1 set KDRDE5K-31/30C50-102
reducing valve
Tightening
Code Screw size
torque (N•m)
412, 413 M8 29
418 M5 6.9
436, 438 M6 12
466 G1/4 36
467 G3/8 74
496 NPTF 1/16 8.8
614 M14 x 1.5 27
630 M30 x 1.5 160
801 M8 16
802 M10 19
1 Front side regulator

2 Rear side regulator
Code Part name Q'ty Code Part name Q'ty

- Regulator subassembly 1 set 645 Adjusting ring Q 1
412 Hexagon socket head bolt 2 646 Pilot spring 1
413 Hexagon socket head bolt 2 651 Sleeve 1
418 Hexagon socket head bolt 2 652 Spool 1
436 Hexagon socket head bolt 5 653 Spring seating 1
438 Hexagon socket head bolt 4 654 Return spring 1
466 ROH plug 1 655 Set spring 1
467 ROH plug 2 708 O-ring 1
496 Insert plug 15 724 O-ring 7
545 Steel ball 1 726 O-ring 2
546 Seat 1 1 727 O-ring 2
547 Seat 2 1 728 O-ring 1
601 Casing A 1 730 O-ring 2
611 Feedback lever 1 732 O-ring 1
612 Lever (1) 1 734 O-ring 1
613 Lever (2) 1 753 O-ring 2
614 Fulcrum plug 1 755 O-ring 1
615 Adjusting plug 1 757 O-ring 1
616 Loosening prevention plug 2 765 O-ring 1
621 Compensation piston 1 766 O-ring 1
622 Piston case 1 777 O-ring 1
623 Compensation rod 1 801 Hexagon nut 1
624 Spring seating C 1 802 Hexagon nut 1
625 Outer spring 1 814 Stop ring 1
626 Inner spring 1 836 Stop ring 1
627 Adjusting ring C 1 874 Pin 1
628 Adjusting screw C 1 875 Pin 4
629 Cover C 1 887 Pin 1
630 Lock nut 1 897 Pin 1
631 Pf sleeve 1 898 Pin 1
641 Pilot cover A 1 924 Hexagon socket head stop screw 1
643 Pilot piston 1
644 Spring seating Q 1
9 NST-04-02-004E
9
(4)Rear side regulator internal structure diagram
Part Component part number

Part name Q'ty
number (quantities) and model
079 1 set KDRDE5KR-20/40C13-203A
reducing valve
Tightening
Code Screw size
torque (N•m)
412, 413 M8 29
436, 438, 439 M6 12
466 G1/4 36
467 G3/8 74
496, 497 NPTF 1/16 8.8
614 M14 x 1.5 27
630 M30 x 1.5 160
801 M8 16
802 M10 19

- Regulator subassembly 1 set 645 Adjusting ring Q 1
439 Hexagon socket head bolt 4 654 Return spring 1
466 ROH plug 2 655 Set spring 1
467 ROH plug 2 656 Valve casing 1
496 Insert plug 8 708 O-ring 1
546 Seat 1 1 726 O-ring 2
547 Seat 2 1 727 O-ring 2
601 Casing B 1 728 O-ring 1
612 Lever (1) 1 732 O-ring 1
613 Lever (2) 1 734 O-ring 1
623 Compensation rod 1 777 O-ring 1
625 Outer spring 1 802 Hexagon nut 1
627 Adjusting ring C 1 836 Stop ring 1
629 Cover C 1 875 Pin 4
641 Pilot cover B 1 898 Pin 1
643 Pilot piston 1 924 Hexagon socket head stop screw 1
644 Spring seating Q 1
10 NST-04-02-004E
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3. Gear Pump
(1)Gear pump internal structure diagram
1 Suction port G3/4 Tightening torque: 54.6 lb-ft (74 N•m)

2 Discharge port G3/4 Tightening torque: 37 lb-ft (53 N•m)
Component part number

Code Part name Q'ty
(quantities) and model
307 (1PC), 308 (1PC), 351 (1PC)
350 Gear case subassembly 1 set
353 (1PC), 354 (1PC), 361 (1PC)

To main pump 307 Poppet 1 361 Front case 1
308 Seat 1 433 Hexagon socket head bolt 2
309 Ring 1 434 Hexagon socket head bolt 2
310 Spring 1 435 Hexagon socket head bolt 4
Tightening torque 311 Adjusting screw 1 466 VP plug 1
Code Screw size
lb-ft (N•m)
312 Lock nut 1 700 Angle ring 1
312 M14 x 1.5 21.1 (29)
351 Gear case 1 710 O-ring 1
433, 434
M8 12.5 (17) 353 Drive gear 1 725 O-ring 1
435
354 Driven gear 1 732 O-ring 1
466 G1/4 12 (16)
355 Filter 1 850 Locking ring 1
(2)Structure and operation explanation

Structure
The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear
(353), driven gear (354) pair and the relief valve for setting the discharge pressure are installed.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309),
adjusting screw (311), and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted on
the front case (361).
Operation
Oil suctioned in from suction port B3 is discharged from discharge port A3 by the drive and driven
gears.
The discharge oil is held at the set pressure of 565.7 PSI (3.9 MPa) by the relief valve.
Unnecessary discharge oil is drained from the drain port via the relief valve.
11 NST-04-02-004E
11
Motor
1. Travel Motor
(1)Travel motor operation explanation
1) Structural diagram
Figure 1 Motor structural diagram
Automatic 2nd-speed type

Figure 2 Hydraulic circuit diagram
1 Double counter balance valve 4 Parking brake

2 Crossover relief valve 5 Piston motor
3 2nd-speed switching mechanism 6 Reduction gear
NST-04-02-004E 12
12
2) Operation explanation
a) Functions
[1] Function of hydraulic motor
The hydraulic motor in this machine is referred to as a swash plate-type axial piston
motor. It functions to convert hydraulic power sent from the pump to rotational movement.
[2] Function of brake valve
1) The brake valve's function is to allow for smooth braking and stopping by controlling
inertial force from the main unit that can make the travel motor rotate when the travel
motor is stopped.
2) Function of check valve for preventing hydraulic motor cavitation
3) The check valve opens the port for releasing the parking brake during travel motor oper-
ation and closes the port when the travel motor is stopped.
[3] Function of parking brake
The parking brake functions to prevent rolling and slipping using a friction plate-type
brake mechanism when the power shovel is parked or stopped on an incline. The parking
brake is one component of the hydraulic motor.
[4] Function of high and low 2-speed switching mechanism
Functioning of the switchover valve and control piston makes the swash plate tilting angle
change and the hydraulic motor piston stroke volume change, which enables switching
between high-speed low torque rotation and low-speed high torque rotation.
[5] Function of reduction gear
This reduction gear comprises a 2-speed planetary gear mechanism and functions to
reduce high-speed rotational movement from the hydraulic motor and to convert low-
speed large torque to produce hub (1) (case) rotation.
13 NST-04-02-004E
13
b) Operation principle, operation explanation
[1] Hydraulic motor
The pressurized oil from the hydraulic
motor enters the rear flange (301) of the
motor, passes through the brake valve
mechanism, and is guided from the tim-
ing plate (109) to inside the cylinder
block (104). The structure is such that
the pressurized oil is led only to one side
of the Y1 - Y2 line connecting top dead
center and bottom dead center of the
piston (105) stroke. The pressurized oil
that has entered one side of the cylinder
block pushes each piston (4 or 5), which
produces force (FN = P PSI (MPa) x A
cm2). This force is used by the swash
plate (103). However, because the
swash plate is fixed to the shaft (102) at
an angle (?°) to the axis line, the force is
divided into component forces (F2, F3).
The radial force of these two component
forces (F3) produces each torque (T =
F3 x ri) between Y1 - Y2. The combined
force of this torque [T = ?(F3 x ri)] is the
rotational force that works through the
piston to rotate the cylinder block. This
cylinder block spline couples with the
shaft, so torque is transmitted when the
shaft rotates.
NST-04-02-004E 14
14
[2] Brake valve
1) During normal operation
When pressurized oil is fed from the A port, the pressurized oil opens the valve (327),
enters the C port on the suction side of the hydraulic motor, and rotates the hydraulic
motor.
At the same time, the pressurized oil enters the a chamber from the orifice (329) to pro-
duce force by acting on the end surface of the spool (323). The spool is slid from a neu-
tral state to the left by the force of the spring (328).
If the spool is slid, a gap (path) with the rear flange (301) is formed by the spool groove.
Due to this path, oil returns to the tank side through the hydraulic motor D port return
path and the B port path, which allows for the hydraulic motor to rotate.
Additionally, pressurized oil enters the E port through the spool sliding. Pressurized oil
that enters the E port makes the parking brake piston (112) operate to release the park-
ing brake.
(For details, see the "Parking brake" operation explanation on p. 136.

When pressurized oil is fed from the B port, the left-right movement of the spool and
valve are reversed and reverse rotation occurs.
15 NST-04-02-004E
15
2) Stopping operation (brake operation)
If the supply of pressurized oil from the A port stops during travelling, the pressurized oil
force pushing the spool (323) disappears, and the spool returns from the left side to a
neutral position due to the force of the spring (328) acting on the washer (325).
At this time, the oil inside the a chamber passes through the orifice (329) to exit through
the A port. However, narrowing of the orifice produces back pressure and controls the
spools return speed.
At the same time, inertial force is rotating the hydraulic motor even though the pressur-
ized oil has stopped. As a result, the hydraulic motor return oil passes from the D port
through the gap (path) between the spool groove and the rear flange to return to the B
port.
When the spool has returned completely to a neutral position, the hydraulic motor
return-side path formed by the spool is cut off and the hydraulic motor stops.
During operation, this brake valve perform metering the hydraulic motor return-side
path through controlling the spool sliding speed and the shape of the spool groove. It
also produces back pressure to allow for smooth stopping of the hydraulic motor when
inertial force is acting on the motor.
At the same time, when the brake is applied to stop the hydraulic motor, rotation contin-
ues and the pump operates to suction oil even if inertial force is used to stop the supply
of pressurized oil.
However, because the path on the suction side is cut off by the spool, oil cannot be
resupplied and cavitation will occur.
At this time, the valve (327) operates with just a small amount of negative pressure
being applied, and the oil path formed by the A port-side circuit and the C port of the
motor suction area opens. This prevents the cavitation effect in the hydraulic motor.
Additionally, when pressurized oil is fed from the B port, left-right operation of each of
the aforementioned parts is reversed and the hydraulic motor stops.
NST-04-02-004E 16
16
3) Self-travel prevention function
If the hydraulic motor is rotated by an external force during normal operation, self-travel
will occur.
For example, this occurs when going down a sharp incline when using as the power
shovel travel motor.
The following explains the mechanism for preventing this phenomenon.
The hydraulic motor is being rotated by an external force during normal operation. The
pressure of the hydraulic oil (A port or B port) being fed is reduced.
If the pressure approaches a state where self-travel begins, the spool (323) begins to
move to a central neutral position.
The area of the hydraulic oil path from the D port to the B port of the exit-side of the
hydraulic motor is reduced, according to the amount of movement of the spool.
The flow amount of the hydraulic oil discharged from the D port to the B port is also
restricted.
At the same time, the D port pressure (back pressure) is raised.
In this way, by controlling the hydraulic motor exit port flow amount and pressure, the
self-travel phenomenon is prevented.
17 NST-04-02-004E
17
c) Parking brake
[1] During travel
If the pressurized oil is fed from the brake valve, this causes the spool of the hydraulic
motor brake valve to operate and the path to the parking brake opens. The pressurized oil
is led to the cylinder chamber a comprising the spindle (2) and piston (112) in the reduc-
tion gear section.
If the pressurized oil exceeds 110.2 PSI (0.76 MPa), the spring (113) force is overcome,
and the piston is moved to the rear flange (301) side. The movement of this piston makes
the force pushing on the the counterpart plate (116) and friction plate (115) disappear.
Movement of the friction plate embedded in the cylinder block (104) of the hydraulic motor
is free and the brake force going to the cylinder block is released.
[2] During stopping
If the pressurized oil from the brake valve is cut off and the pressure within cylinder cham-
ber a falls below 110.2 PSI (0.76 MPa), the piston is forced to return by the spring force.
This spring force presses the counterpart plate and friction plate, which are free and are
being pressed by the piston, against the spindle. The frictional force produced by the
plates being pressed against the spindle stops the rotational force of the cylinder block
and applies 152.0 lbf•ft (206 N•m) of braking torque to the hydraulic motor shaft.
Additionally, this operation is smooth due to oil being controlled in the appropriate oil
path.
NST-04-02-004E 18
18
d) Relief mechanism operation explanation
[1] Starting
The pressurized oil fed from the pump is led from the A port to the C port.
The C port is connected to the hydraulic motor and the pressurized oil that enters the C
port contributes to the rotational force of the hydraulic motor.
At this time, the valve (202a) inside relief valve "A" does not open due to the action of
pressurized oil.
The valve (202b) in relief valve "B" is opened by the pressurized oil from the C port when
a prescribed pressure is exceed and the pressurized oil is led to the D port.
The pressurized oil from the C port passes through the valve (202b) orifice e, the sleeve
(203b) orifice f and the orifice (384), and is led to the chamber y.
The piston (381) moves in the direction of the arrow to the stroke end due to the pressur-
ized oil led to the chamber.
When the piston has moved to the stroke end, the pressure between the valve (202b) ori-
fice e and sleeve (203b) orifice f increases.
Due to the raised pressure of the pressurized oil, the opening pressure of relief valve "B"
exceeds the shovel's system pressure and the valve (202b) closes.
The C port pressure is raised by the action of relief valve "A" or "B" and this applies rota-
tional force to the motor.
19 NST-04-02-004E
19
C port pressure during the aforementioned operation
However, because the machine is in the stopped position just before this, the valve (202b)
of the relief valve "B" does not open when the piston has reached the stroke end.
For this reason, the pressure acting on the C port is as follows.
As explained above, the pressure of the C port during starting changes depending on the
position of the piston.
* When the pressurized oil fed from the pump is led from the B port to the D port, the
operation principle of relief valves "A" and "B" explained above are switched..
NST-04-02-004E 20
20
[2] During stopping
The hydraulic motor is rotated by a supply of pressurized oil going from the A port to the
C port. If the supply of pressurized oil to the A port is cut off, the counterbalance valve will
return to neutral.
If the counterbalance valve returns to neutral, the exit-side D port is cut off and pressure
increases in the D port due to the hydraulic motor only being rotated according to the
amount of inertia.
The pressurized oil inside the D port passes through the valve (202a) orifice c, the sleeve
(203a) orifice d and the orifice (384) of relief valve "A" to chamber x.
The piston (381) moves in the direction of the arrow to the stroke end due to the pressur-
ized oil led to chamber x.
While the piston is moving, pressure in chamber x does not rise.
Because of this, the valve (202a) of relief valve "A" is pushed open by the D port pressur-
ized oil and this pressurized oil flows from the D port to the low-pressure side C port.
The D port pressure is controlled through relief provided by relief valve "A" and cavitation
is prevented through oil being fed to the C port.
If the piston reaches the stroke end, the pressure between chamber x, the valve (202a)
orifice c and the sleeve (203a) orifice d rises and the valve (202a) closes.
In this case, the relief valve "A" provides relief at a pressure exceeding the shovel's sys-
tem pressure and stops the hydraulic motor.
21 NST-04-02-004E
21
Diagram showing pressure status in hydraulic motor (D port) when pressurized oil supply
stops as previously stated
The pressure while the piston is moving is commonly referred to as "Relief primary pres-
sure (low pressure)".
The pressure after the piston has finished moving is commonly referred to as "Relief sec-
ondary pressure (high pressure)".
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e) Automatic 2-speed switchover mechanism explanation
[1] During low speed mode
When pilot pressure is not being fed from the P port, the valve (363) is pushed upwards
by the spring (366) force or by pressurized oil from the A port or B port.
Port C pressurized oil is cut off and the oil in chamber w goes to the drain (motor case)
through the valve.
Accordingly, the swash plate (103) moves to its maximum angle ?1, the hydraulic motor
stroke volume rises to the maximum, and low-speed rotation begins.
[2] During high speed mode

When pilot pressure has been fed from the P port, this pressure overcomes the spring
(366) force and pressurized oil from the A port or B port and the valve (363) is pushed
downwards and the C port pressurized oil passes through the valve to the chamber w.
The piston (161) is pushed upwards and held until the swash plate (103) touches the sur-
face x.
At this time, the swash plate moves to its minimum tilting angle ?2 , the hydraulic motor
stroke volume lowers to the minimum, and high-speed rotation begins.
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[3] Operation explanation of automatic switchover from high-speed operation to low-speed
operation
If the load increases during high-speed operation, pressurized oil in the A port and B port
also increases. If a stipulated pressure is reached, this overcomes the P port pilot pres-
sure and the valve (363) is pushed upwards.
The oil in chamber w goes to the drain (motor case) through the valve.
At this time, the swash plate (103) touches the spindle surface y, moves to its maximum
tilting angle ?1 and is held there, and low-speed rotation begins.
f) Reduction gear operation explanation

The rotational movement of the hydraulic motor shaft is transmitted to the 1st-stage sun gear
1 (4) spline coupled with the shaft (102).
At this time, the 1st-stage planetary gear 1 (5) is meshed with the sun gear 1, and the plane-
tary gear 1 meshes with the hub (1) while rotating and rotates in orbit around the hub. This
orbital movement rotates the 2nd-stage sun gear 2 (8) coupled to carrier 1 (3) and carrier 1
fixed to the planetary gear 1.
This rotation is transmitted to the hub (ring gear) through the 2nd-stage planetary gear 2 (9) fit
into the carrier 2 (7) that is spline coupled with the spindle (2), and this becomes the reduction
gear output rotation.
(Rotation is also transmitted from the 1st-stage planetary gear 1)
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(2)Travel motor internal structure diagram
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(3)Travel motor part table
1 Hub 1 162 Shoe 1
2 Spindle 1 167 Pivot 2
3 Carrier 1 1 171 Parallel pin 2
4 Sun gear 1 1 185 Spring 1
5 Planetary gear 1 3 201 Valve seat 2
6 Carrier pin 1 3 202 Valve 2
7 Carrier 2 1 203 Sleeve 2
8 Sun gear 2 1 204 Collar 2
9 Planetary gear 2 3 205 Plug 2
10 Carrier pin 2 3 206 Spring 2
11 Thrust washer 1 6 207 O-ring 2
12 Thrust washer 2 6 208 Backup ring 4
13 Thrust plate 1 209 O-ring 2
14 Cover 1 210 Backup ring 4
15 Coupling 1 211 O-ring 2
16 Parallel pin 1 3 212 O-ring 2
17 Parallel pin 2 3 213 Shim 2
22 Lock washer 2 301 Rear flange 1
23 Shim 1 323 Spool 1
24 Ball bearing 2 324 Plug 2
27 Needle roller bearing 3 325 Washer 2
28 Needle roller bearing 3 326 Plug 2
29 Floating seal 2 327 Valve 2
30 Plug 3 328 Spring 2
31 O-ring 3 329 Orifice 2
32 O-ring 1 330 Spring 2
33 O-ring 2 331 O-ring 2
34 Parallel pin 2 336 O-ring 2
35 Hexagon socket head bolt 12 341 Parallel pin 1
36 Snap ring 1 343 Hexagon socket head bolt 10
102 Shaft 1 352 Plug 3
103 Swash plate 1 353 Steel ball 2
104 Cylinder block 1 354 Hexagon socket head plug 5
105 Piston 9 357 Plug 1
106 Shoe 9 358 O-ring 3
107 Retainer plate 1 359 O-ring 1
108 Thrust ball 1 363 Spool 1
109 Timing plate 1 366 Spring 1
110 Washer 1 376 Orifice 1
112 Piston 1 377 Filter 1
113 Spring 10 378 Steel ball 1
114 Spring 1 379 Plug 1
115 Friction plate 3 380 Plug 2
116 Counterpart plate 4 381 Piston 1
132 Oil seal 1 383 O-ring 2
139 O-ring 1 396 Hexagon socket head plug 2
145 Snap ring 1 398 Hexagon socket head plug 8
149 Ball bearing 1 399 Nameplate 1
150 Ball bearing 1
151 Roller 3
161 Piston 1
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2. Swing Motor
(1)Swing motor operation explanation
1) Hydraulic motor section
As the figure below shows, when the high-pressure oil passes through the valve plate (1)
intake-side port (a) and flows into the cylinder, the hydraulic pressure operates on the piston
and a force F is generated in the axial direction. This force F is divided into 2 vectors, a force
F1 perpendicular to the swash plate (3) via the shoe (2) and a force F2 perpendicular to the
shaft. This force F2 is transmitted to the cylinder block (4) via the piston, generating a rota-
tional couple around the output shaft.
9 pistons are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the
output shaft by multiple pistons linked with the high-pressure oil intake-side port.
When the oil in and out directions are reversed, the rotation of the output shaft also reverses.
The theoretical output torque T lbf•ft (N•m) is given by the following equation.
1 Valve plate
2 Shoe
3 Swash plate
4 Cylinder block
5 Piston
6 Drive shaft
Figure 1 Motor section operation explanation diagram
2) Valve casing section

[1] Anti-cavitation check valve section
Because the system using this type of motor does not have a valve with a counter-balance
function, the motor sometimes rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil
shortfall.
1 M port
Figure 2 Hydraulic circuit diagram 2 Control valve
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3) Brake section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate
(743) is constrained for circumferential rotation by the arc groove cut into the casing E (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is
pressed to the casing (301) by the brake spring (712) via the separator (743) and the brake
piston (702), friction force is generated between the friction plate and casing and between the
separator plate and the brake piston. The drive shaft is constrained and braked by this friction
force.
On the other hand, when brake release pressure is applied to the oil chamber formed between
the brake piston and the casing and the hydraulic pressure overcomes the spring force, the
brake piston moves, the force pressing the friction plate against the casing disappears, and
the brake is released.
Figure 3 Brake operation diagram
1 Oil chamber
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4) Relief valve operation explanation (Relief valve model: KRD22EK10)
[1] Operation explanation for when the relief valve is pressurized
In the case where the P port is pressurized with the tank pressure, the P and R ports are
initially at the tank pressure and the valve status is as shown in Figure 4 (1).
At the pressure where there is balance between the hydraulic pressure determined by the
product of the pressure P and the pressurized area A1 of the plunger (6) on the one hand and
the hydraulic pressure determined by the spring (2) load FSP and plunger pressurized area
A2 and the g chamber pressure Pg on the other hand, the relief valve starts to operate.
After that, the g chamber pressure rises and the piston (4) starts its stroke. Accompanying this
movement, the load on the spring increases.
Through the operation above, the relief pressure P is increased from P1 to Ps in the pressure
boost time t1.
This process is explained below in terms of the relationship between the movement state of
the parts in Figures 4-(2)-(4) and the relief pressure.
1) State shown in Figure 4-(2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via the
orifice m in the plunger (6).
When the hydraulic pressure operating on the plunger increases and reaches the pressure
at which it balances the spring (2) load FSP, the relief valve carries out the relief operation at
pressure P1.
The relationship at this time is expressed by the following equation.
P1 x A1 = FSP1 + Pg1 x A2 FSP1: Initial set load for the spring
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (4). When
this hydraulic pressure force becomes larger than the load on the spring (2), the piston starts
to move to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug (9) is
discharged into the g chamber via the orifice n set up on the piston while the piston moves to
the left, so the h chamber functions as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting plug
end section and the relief pressure P rises smoothly.
When the piston (4) reaches the adjusting plug (9) end section, it does not move farther to
the left, so the constant relief state is reached and the relief pressure is held at P2.
Through the processes (1)-(4) above, the relief pressure varies as in Figure 5.
[2] Operation explanation for when the relief valve is depressurized
In the case where the P port pressure falls,
the P port pressure and the g chamber pressure fall together to the tank pressure when the
pressurization of the P port ends. Through this, the plunger (6) which was open moves to the
left and is seated in the adjustment plug (9). At the same time, the piston (4) also is moved to
the right by the spring (2) and returns to the state in Figure 4-(1).
NST-04-02-004E 29
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Figure 4 Relief valve operation explanation diagram
1 Orifice m 6 Plunger
2 Spring 7 Orifice n
3 h chamber 8 g chamber
4 Piston 9 Adjusting plug
5 A1 pressurized area
Figure 5 Boosted pressure characteristics
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(2)Swing motor internal diagram
Code Part name Code Part name

1 INNER RING 22 BALANCE PLATE
2 OIL SEAL 23 NEEDLE BEARING
3 TAPERED ROLLER BEARING 24 SNAP RING
4 LEVEL GAUGE ASSY 25 CYLINDER
5 BACKING SPRING 26 HOUSING
6 CAM PLATE 27 PLUG
7 RETURN PLATE 28 CAP
8 PISTON ASSY 29 BACK-UP RING
9 LINING PLATE 30 O-RING
10 PLATE 31 O-RING
11 O-RING 32 COVER
12 PISTON 33 PARALLEL PIN
13 O-RING 34 RELIEF ASSY
14 SPRING 35 O-RING
15 TEFLON RING 36 HEXAGON SOCKET BOLT
16 PISTON 37 CHECK
17 CAP 38 SPRING
18 O-RING 39 CAP
19 SCROWAVE 40 BACK-UP RING
20 TEFLON RING 41 PLUG
21 BUSH
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(3)Swing reduction gear internal structure diagram
Code Part name Code Part name

1 PINION SHAFT 13 HOLDER 1 ASSY
2 PLATE 14 HOLDER 2 ASSY
3 TAPERED ROLLER BEARING 15 SHAFT 2
4 GEAR CASE 16 HOLDER 2
5 PLUG 17 BUSH 2
6 OIL SEAL 18 SPUR GEAR 5
7 TAPERED ROLLER BEARING 19 THRUST PLATE 2
8 COLLAR 20 SPRING PIN
9 RING GEAR 21 PARALLEL PIN
10 SPUR GEAR 4 22 PLUG
11 HEXAGON SOCKET BOLT 23 PLUG
12 SUN GEAR
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Valve
1. Control Valve
Appearance diagram
1 Valve installation tap
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Blade
1 Valve installation tap
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Cross-section structural diagram (BKT-side valve)
Ball check in cover 1 Main plunger section

2 Foot relief valve
Ball check in cover
3 Main relief valve
4 Overload relief valve
5 Center bypass valve
AM regeneration check valve
BM back pressure check valve
8 Load hold valve
9 BM regeneration check valve
10 Check valve
1 Plug 11 Check valve
Valve alignment surface 2 Bushing
12 Check valve
3 Cover
4 Housing Check valve
5 Steel ball
14 Check valve
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Cross-section structural diagram (SW-side valve)
Part numbers lower than #15 are common with the BKT side valve.
Ball check in cover
1 Main plunger section

Ball check in cover 2 Foot relief valve
8 Load hold valve
10 Check valve
15 Swing priority valve
16 Check valve
1 Plug 5 Steel ball AM regeneration valve
17
2 Cover 6 Cap
3 O-ring 7 Orifice 18 Check valve
4 Housing 8 Travel signal switchover spool Check valve
19
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Structural diagram (each section)
(1) Main plunger
BKT Plunger
BM-1 Plunger
Code Name Q'ty Code Name Q'ty
1 Plunger 1 6 O-ring 1
2 Spring guide 2 7 Spacer 1
3 Spring 1 8 Spring 1
4 Plunger cap 1 9 Check valve 1
5 Cap 1
(Note)
1.BM-1, BKT plunger: There is a check valve incorporated at one end.
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(2) Foot relief valve

1 Poppet 1 4 Sleeve 4
3 Spring 1 6 Cap 1
(3) Main relief valve

1 Sleeve 1 10 Adjusting screw 1
2 Main poppet 1 11 O-ring 1
3 O-ring 1 12 Backup ring 1
4 Pilot poppet 1 13 O-ring 1
5 Spring 1 14 Piston 1
6 Cap 1 15 Pilot seat 1
7 Hexagon nut 1 16 O-ring 1
8 Sleeve 1 17 Spring 1
9 Hexagon nut 1 18 Orifice 1
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(4) Overload relief valve (AM, BM, BKT)

2 Pilot seat 1 12 Spring 1
4 Cap 1 14 Backup ring 1
5 Hexagon nut 1 15 Piston 1
6 Adjusting screw 1 16 O-ring 1
7 Spring receiver 1 17 Backup ring 1
8 O-ring 1 18 Main seat 1
9 Spring 1 19 Main poppet 1
(5) Center bypass valve

1 Cap 1 3 Spring 1
2 O-ring 1 4 Spool 1
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(6) Arm regeneration check valve

1 Cap 1 3 Spring 1
2 O-ring 1 4 Check valve 1
(7) Boom back pressure check valve

1 Cap 1 3 O-ring 1
2 Spring 1 4 Check valve 1
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(8) Load hold valve(AM, BM)

1 Cap 1 11 O-ring 1
2 O-ring 1 12 Cap 1
3 Piston 1 13 Cover 1
4 Backup ring 1 14 O-ring 1
6 Sleeve 1 16 Poppet 1
7 Backup ring 1 17 Cap 2
9 Poppet 1 19 Spring 1
10 Spring 1 20 Spacer 1
(9) Boom regeneration check valve

1 Cap 1 4 Spring 1
3 Spacer 1
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(10) Check valve (SW, BM-2, OPT, others)

1 Cap 1 4 Check valve 1
2 Backup ring 1 5 Spring 1
3 O-ring 1
(11) Check valve (different cap orifice diameter) (AM-2)

(12) Check valve (different cap orifice diameter) (BKT)
(13) Check valve (different cap orifice diameter) (BM-1)
(18) Check valve (different cap orifice diameter) (AM-1)

4 Nylon tip 1
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(14) Check valve (TL)

4 Nylon tip 1 8 Cap 1
(15) Swing priority valve

1 Cap 1 7 Cap 1
2 O-ring 1 8 Cap 2
3 Manifold 1 9 O-ring 2
4 Spool 1 10 Spool 1
6 O-ring 1
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(16) Check valve

2 Seat 1 5 Check valve 1
(17) Arm regeneration valve

1 Piston 1 6 O-ring 1
2 Sleeve 1 7 Cap 1
3 Spool 1 8 Spring receiver 1
5 Cap 1
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(19) Check valve (TR)

1 Cap 1 4 Nylon tip 1
2 Backup ring 1 5 Check valve 1
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Operation Explanation
Straight Travel Circuit
This circuit is for maintaining straight travel even if there is compound operation of an actuator
other than travel (AM, BM, BKT, SW, OPT-1) during straight travel.
[1] When operating the left and right travel plungers and travelling straight (refer to Figure 4)
The travel signal line is blocked by the plunger switchover and the Ps1 pilot pressure oper-
ates on the straight travel signal switchover spool. This switches the spool and connects
the plunger switching pilot signal path for other than travel and the straight travel switchover
valve pilot chamber. For the sake of neutrality for operations other than travel, the pilot
pressure is not raised, the straight travel switchover valve does not operate, the oil flowing
in from the P1 pump is supplied to TR and the oil flowing in from the P2 pump is supplied to
TL, and the vehicle travels straight.
NST-04-02-004E 46
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[2] When, for example, a swing operation is performed from the straight travel state (refer to
Figure 5)
When the swing plunger is operated, the operation pilot pressure goes through the straight
travel signal switchover spool and enters the straight travel switchover valve pilot chamber.
Therefore, the straight travel switchover plunger switches, the PR port is connected to the
left and right travel plunger feed paths, and the PL port is connected to the left and right
parallel paths.
Accordingly, the oil flowing in from the P1 pump drives the left and right travel motors with
equal speed and the oil flowing in from the P2 pump is fed from the parallel path for the
valve to the swing motor and can drive this motor.
Also, orifice a entering the travel plunger from the PL port-side parallel feed path turns the
excess swing oil to left and right travel, and this prevents sudden changes in vehicle speed.
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Straight travel circuit (Figure 4)
Switching pilot
pressure other than for travel
1 Parallel path
2 Ball check
3 Straight travel signal switchover spool
4 Straight travel switchover valve
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Straight travel circuit (Figure 5)
1 Parallel path
2 Orifice a
4 Straight travel signal switchover spool
5 Ball check
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Swing Priority Circuit
[1] Arm-in and boom (up) operation (see Figure 6)
Through boom-up operation, the plunger switchover pilot pressure operates on the swing
priority valve Pi1 port, spool B is switched, and the degree of opening of the path is
increased.
Because the center bypass path is cut off at upstream boom 2, the oil flowing in from the
P1 pump is fed from the parallel oil path giving priority to arm 1, which has a lighter load.
Because the parallel path is narrowed by orifice C, the oil flowing in from the P2 pump is fed
giving priority to boom 1, and the excess oil flows into arm 2 to avoid a sudden change in
the arm speed.
Arm-in and boom (up) operation
50 NST-04-02-004E
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[2] Arm-in and boom (up) operation, swing operation (see Figure 7)
When a swing operation is performed from an arm-in and boom-up operation (explained on
the previous page), the swing plunger switchover pilot pressure pressurizes the swing prior-
ity valve Pi2 port.
Spool A switches and the boom-up plunger switchover pilot pressure is blocked.
Therefore, spool B switches, the priority valve path is blocked, and the swing drive pressure
is secured.
Arm-in and boom (up) swing operation
NST-04-02-004E 51
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Swing priority circuit (Figure 6)
To parallel path
1 Parallel path
2 Orifice C
3 Spool B
4 Spool A
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Swing priority circuit (Figure 7)
To parallel path
1 Parallel path
2 Orifice C
3 Spool B
4 Spool A
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Explanation of operation of each section (Figure 8)
1 Main relief valve

3 Foot relief valve
4 AM regeneration valve
5 BM regeneration
Load hold valve
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Main Relief Valve
[1] For standard settings [Py pilot signal: OFF]
• Piston D is at the right end due to spring C.
1) The pressurized oil from the pump passes through orifice (2) of main poppet A and enters
chamber (3). d1 > d2, so main poppet A is securely seated.
1 Main poppet A 4 Piston D

2 Pilot poppet B 5 Tank path
3 Spring C
2) When the pressurized oil reaches the pressure set by spring C, pilot poppet B opens and
the oil flows through horizontal hole (4) and into the tank path.
1 Pilot poppet B
2 Spring C
3 Tank path
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3) When the oil flow is formed, a pressure drop is generated across orifice (2). The chamber
(1) pressure x d2 surface area becomes greater than chamber (3) pressure x d1 surface
area, main poppet A opens, the pressurized oil flows in the tank path, and the circuit pres-
sure is controlled to a constant value.
1 Main poppet A
2 Tank path
[2] For high-pressure setting [Py pilot signal: ON]

Piston D moves to the left, spring C set load rises, and the circuit switches to the high-pres-
sure setting state.
1 Spring C
2 Piston D
3 Tank path
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56
Overload Relief Valve
[1] Overload operation
1) The pressurized oil from the cylinder port passes through orifice (2) of piston A and
enters chamber (3). d1 > d2, so main poppet B is securely seated.
1 Main poppet B 4 Tank path

2 Cylinder port 5 Pilot poppet D
3 Piston A 6 Spring C
2) When the oil pressure reaches the pressure set by spring C, pilot poppet D opens and the
oil flows through horizontal hole (4), path (5), and horizontal hole (6), and into the tank
path.
1 Cylinder port
2 Tank path
3 Pilot poppet D
4 Spring C
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3) The oil flow is formed, a pressure drop is generated across orifice (2), and piston A
moves to the right and is seated at the top of pilot poppet D.
The pressurized oil of chamber (1) passes through orifice (7) of piston A, horizontal hole
(4), path (5), and horizontal hole (6), and flows into the tank path.
1 Cylinder port
2 Piston A
3 Tank path
4 Pilot poppet D
4) When a pressure drop is generated across orifice (7) of piston A and chamber (1) pres-
sure x d2 surface area becomes greater than chamber (3) pressure x d1 surface area,
main poppet B opens, the cylinder port pressurized oil flows into the tank path, and the
actuator is protected.
1 Main poppet B
2 Cylinder port
3 Piston A
4 Tank path
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[2] Make-up operation
Because d1 becomes greater than d2, normally the cylinder port pressure is higher than
the tank pressure, so main poppet B is securely seated.
When the cylinder port pressure drops (and approaches negative pressure) and the cylin-
der port pressure becomes less than the tank pressure, main poppet B opens after receiv-
ing tank pressure proportional to the difference in surface areas of d1 and d2, the oil flows
from the tank path to the cylinder port, and this prevents cavitation.
1 Main poppet B
2 Cylinder port
3 Tank path
Foot Relief Valve

[1] Pi3 pilot signal: OFF
• Piston A and spring receiver B are at the right end due to spring C.
1) Because the load on spring C is extremely small, the oil from the center bypass path
opens the poppet and flows into the tank path. [Check valve operation]
1 Poppet
2 Tank path
3 Spring C
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Arm Regeneration
[1] When the alarm plunger is operated to the cloud side, the plunger moves to the right, the
center bypass path is cut off, and the oil from the pump opens the load check valve and is
fed to the cylinder bottom side from the feed path.
1 Load hold valve 5 Spool B

2 Feed path 6 Spring C
3 Center bypass path 7 Tank path
4 Piston A 8 Check valve D
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60
[2] When the bottom side pressure is low [PB < PA]
The rod-side return oil opens the load hold valve poppet and flows through regeneration
valve path (1)-path (2) and into the tank path, but because path (2) is narrowed by the spool
B degree of opening, the pressure rises, check valve D opens, and oil is fed to the bottom
side again from the feed path.

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[3] When the bottom side pressure is high [PB > PA]
The head-side pressurized oil operates on check valve D from the feed path, and check
valve D closes. At the same time, it also operates on piston A of the regeneration switcho-
ver section. When the pressure becomes equal to or greater than the spring C set pres-
sure, it pushes piston A, spool B moves to the right, the path (2) degree of opening
increases, and the rod side return oil flows through path (1)-path (2) and into the tank path.

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62
Boom Regeneration
[1] When the boom plunger is operated to the lower side, the plunger moves to the left, and the
oil from the pump opens the load check valve and is fed to the cylinder rod side from the
feed path.
The bottom side return oil opens the load hold valve poppet and flows through the back
pressure check valve and into the tank path, but the pressure is boosted by the back pres-
sure check valve. Part of it opens check valve A and is regenerated on the rod side and
part of it opens check valve B and flows through the inside of the plunger and into the foot
relief valve through the center bypass path to lower the pump flow.
1 Load hold valve 5 Back pressure check valve

2 Check valve B 6 Tank path
3 Center bypass path 7 Check valve A
4 Feed path
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Load Hold Valve
Explanation is given using the boom load hold valve.
[1] When the plunger is neutral
Because the pilot signal pressure (Ps2) is cut off by the plunger, piston A and poppet B are
at the position in the diagram and path (5) and path (6) are cut off by poppet B.
Because chamber (1) is connected with chamber (2) by orifice (4), the pressure becomes
Pc.
Here, because d1 > d2, poppet D is seated and chamber (2) and chamber (3) are com-
pletely blocked.
Boom 1 PL
1 Piston A 4 Poppet D
2 Check valve C 5 Feed path
3 Poppet B 6 Tank path
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[2] During plunger operation
1) Boom up [Pv ＞ Pc]
The plunger moves to the right and the feed path oil enters chamber (3). Chamber (1) is
connected to chamber (2) via orifice (4), so the pressure becomes Pc, poppet D is
opened by pressure Pv, and the feed path oil is fed to the cylinder bottom side.
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2) Boom down [Pc ＞ Pv]
The plunger moves to the left and chamber (3) is connected to the tank path. The pilot
signal pressure (Ps2) operates on piston A due to the plunger switchover, poppet B is
moved to the right and path (5) and path (6) are linked. Therefore, chamber (1) is con-
nected to the tank path via a path consisting of path (5) - path (6) - check valve C and
goes to low pressure, the pressure Pc operates on the difference in surface area between
d1 and d2, poppet D is opened, and the bottom side return oil flows into the tank path.
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2. 4 Stack Solenoid Valve Operation Explanation
(1)External shape diagram (Figure 1) and configuration diagram (Figure 2)
1 Electromagnetic switch valve

2 Body
(2)Main component parts

This valve is made up of the body and the electromagnetic switch valve.
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(3)Operation explanation
Hydraulic circuit diagram

The pressurized oil fed from the P port feeds pressurized oil to the C1 - C5 ports according to the
excitation or non-excitation of electromagnetic switch valves S1 - S4 resulting from exciting elec-
tromagnetic switch valve SP.
Electromagnetic switch valves S1 and S3 → Oil passing through when valve excited
Electromagnetic switch valve S2 → Oil passing through when valve not excited
Electromagnetic switch valve S4 → Oil passing to C5 when valve excited Oil
passing to C4 when valve not excited
(4)Structural diagram
Normal closed type Solenoid; SP, S1, S3 Normal open type Solenoid; S2
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3. Upper Pilot Valve (remote control valve)
(1) Structure
The structure of the remote control valve is as shown in the assembly cross section diagram.
(page 73). There is a longitudinal axial hole in the casing and the pressure reduction valve is
installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring
(241), return spring (221), spring seating (216), and washer 2 (217). The secondary pressure
setting spring (241) is set so that the secondary pressure calculation is 72.5 - 145.0 PSI (0.5 - 1
MPa) (depending on the model). The spool (201) is pressed against the push rod (212) by the
return spring (221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring
seating goes down at the same time and the secondary pressure setting spring (241) setting is
changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, fur-
thermore, the secondary pressure is taken out from the ports 1, 2, 3, and 4.
(2) Function
[1] Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction,
etc. This is done by operating the pilot valve output pressure on the control valve spool end
section.
In order to satisfy this function, the remote control valve is made up of the following ele-
ments.
1) Inlet port (P) to which the oil is fed from the hydraulic pump
2) Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the
control valve spool end
3) Tank port (T) required for controlling the above output pressure
4) Spool connecting the output port to the inlet port or tank port
5) Mechanical means including a spring operating on the above spool in order to control the
output pressure
[2] Main part functions
The function of the spool (201) is to switch the oil path either to have the hydraulic pressure
fed from the hydraulic pump received by the P port and lead the P port pressurized oil to the
output ports (1, 2, 3, and 4) or to lead the output port pressurized oil to the T port. The out-
put pressure operating on this spool (201) is determined by the secondary pressure setting
spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the
push rod (212) is inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates
to return the push rod (212) in the displacement zero direction regardless of the output pres-
sure and makes the spool (201) neutral return reliable. It also has the effect of a counter-
force spring for giving an operator an appropriate operation feel.
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(3) Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Figure
1) and operation explanation diagrams (Figure 2-Figure 4). Figure 1 is a typical usage example
for the remote control valve.
Figure 1 Remote control valve usage example
1 Pilot valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
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70
[1] When the handle is in neutral (See Figure 2)
The force of the secondary pressure setting spring (241) that determines the remote control
valve output pressure does not operate on the spool (201). Therefore, the spool (201) is
pushed up by the return spring (221) (spring seating (216)) and the output ports (2 and 4)
are connected with the T port. Therefore, the output pressure is the same as the tank pres-
sure.
Figure 2 When the handle is in neutral
[2] When the handle is tilted (See Figure 3)

When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seat-
ing (216)) spool (201) moves down and the oil fed from the pilot pump flows out to the ports
(2 and 4) through the P port and the ports (2 and 4) and pressure is generated.
Figure 3 When the handle is tilted
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[3] When the handle is held (See Figure 4)
When the handle is tilted and the pressure of the ports (2 and 4) rises to a pressure equiva-
lent to the set spring force (241), the hydraulic pressure force and the spring force are in bal-
ance. When the ports (2 and 4) pressure becomes higher than the set pressure, the ports (2
and 4) and the P port close and the ports (2 and 4) and the T port open. When the ports (2
and 4) pressure becomes lower than the set pressure, the ports (2 and 4) and the P port
open and the ports (2 and 4) and the T port close, so the secondary pressure is held con-
stant.
Figure 4 When the handle is held

(secondary pressure at or above set pressure)
1 T port
2 P port
[4] Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top
end section touches the push rod bore bottom section and the output pressure goes into the
state of still being connected with the P port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside
the push rod, when the handle is flipped down beyond a certain angle, the push rod bore
bottom section and the spring touch. That spring force changes the 2nd pressure gradient
and after that the push rod bore bottom section and the spring seating top end section
touch, and the output pressure remains connected to the P port.
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72

101 Casing 1 217 Washer 2 4
151 Plate 1 221-1 Return spring (port 1) 1
201 Spool 4 221-2 Return spring (port 3) 1
211 Plug 4 221-3 Return spring 2
212-1 Push rod 2 241-1 Secondary pressure setting spring 2
212-2 Push rod 2 241-2 Secondary pressure setting spring 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating 1 2 312 Adjusting nut 1
216-2 Spring seating 1 2 501 Bellows 1
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4. Travel Pilot Valve (remote control valve)
(1)Operation
The remote control valve with built-in damper (hereinafter, remote control valve) is a remote con-
trol valve incorporated into the remote control valve main unit as a damping function for prevent-
ing the man-machine system hunting (lever hunting) phenomenon.
Operation of the remote control valve is divided into the 4.-(1)-1) Pressure reduction valve sec-
tion and the 4.-(1)2) Operating section damping mechanism section. The explanations in these
two sections are based on the hydraulic pressure circuit diagram, assembly section diagram, and
damping operation explanation diagram below. The figure below is a typical usage example for
the remote control valve.
1 Remote control valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
1) Pressure reduction valve section

[1] For the neutral state
The spool (301) is pushed up by the return spring (335) via the spring seating (311) and
washer 1 (215) and is in the neutral position shown in the assembly section diagram.
Therefore, since the output port is connected only to port T by the spool switching function,
the pressure at output ports 1 and 2 is the same as the pressure at port T.
[2] When the remote control valve operation section is tilted from the neutral state
In the assembly section diagram, when the cam (420) is rotated clockwise, the port 1 side
push rod (214) is pushed down, the spool moves down via washer 1, the spring seating, the
secondary pressure setting spring (324), washer 2 (217), and washer 3 (313), the port P and
port 1 are connected, and the oil fed from the pilot pump flows to port 1 and generates pres-
sure.
When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting
spring force that has been set by tilting the operation section, the hydraulic pressure on the
spool and the spring force come into balance and the port 1 output pressure is held constant.
The port 2 spool stays in the neutral state and the oil from the control valve is discharged via
port T.
Some specifications are of the type that near the maximum angle of the operation section, a
push rod directly touches the spool top section and forcibly pushes in the spool to connect
port P and the output port so that they have the same pressure.
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2) Operating section damping mechanism section
[1] For the neutral state
The push rod is pushed up by the damping springs (333 and 337) via the piston (224) and is
in the position shown in the assembly section diagram.
[2] When the operation section is tilted from the neutral state
(See Damping operation explanation diagram [1].)
In the assembly section diagram, when the cam is rotated clockwise, the port 1-side push rod
is pushed down and the piston moves down.
At this time, the oil in the damping piston chamber is discharged from the piston metering hole
and the pressure generated at this time generates damping force.
On the other hand, the port 2-side push rod is moved up by the damping spring via the piston.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of
bushings (223) and steel balls (225) and into the damping piston chamber. The oil outside the
piston chamber drains out from the path that leads from the casing top end section to port T.
[3] When the operation section is tilted back from a full tilt
(See Damping operation explanation diagram [2].)
In the assembly section diagram, after the cam is fully tilted clockwise then rotated counter-
clockwise, the port 2 push rod is pushed down and the piston moves down.
At this time, as described above, the oil in the damping piston chamber is discharged from the
piston metering hole and the pressure generated at this time generates damping force.
On the other hand, the port 1 push rod is moved up by the return spring (335) and the damp-
ing spring.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of
bushings and steel balls and into the damping piston chamber. Also, the oil outside the piston
chamber drains out from the path that leads from the casing top end section to the tank port.
In other words, the structure is such that damping force works for either tilt operation, from the
neutral position to the full tilt position or from the full tilt position to the neutral position.
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[1] <Operation when lever is moved through its stroke from the neutral position> [2] <Lever stroke state and operation when lever is moved back>
Neutral
Full stroke 12.5
The oil outside the piston

drains out from the path
that leads from the casing
top edge section to the T
port. ( during operation)
When the lever is moved

through its stroke from neutral When the lever is tilted from
in the ( / ) direction, the neutral in the opposite di-
right (left) piston chamber oil rection, the push rod is
is discharged from the meter- pushed up by the damping The piston chamber oil is
ing hole and damping pres- spring. discharged through the
sure is generated by the pres- ( during operation) metering hole.Damping
sure generated at this time. pressure is generated by
The T line oil is suctioned the pressure generated
into the damper chamber at this time.
through the three ball check ( during operation)
valves.
( during operation)
Oil drains
to T.
Damping operation explanation diagram
1 Push rod 4 Piston chamber

2 Orifice 5 Oil
3 Piston
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(2)Assembly section diagram
Code Part name Q'ty

101 Casing 1
151 Plug 2
201 Cover 2
202 Plug 4
203 Grease cup 4
210 NHU packing 4
212 O-ring 4
214 Push rod 4
215 Washer 1 8
217 Washer 2 4
218 Spring seating 4
221 Locking ring 4
223 Bushing 4
224 Piston 2D085 4
225 Steel ball 12
301 Spool 4
311 Spring seating 4
313 Washer 3 4
324 Secondary pressure spring 4
335 Return spring 4
336 Spring 4
337 Spring 4
412 Bushing 4
413 Camshaft 2
420 Cam 2
Hexagon socket head stop
423 2
screw
471 Locking screw 4
472 Lock nut 4
501 Bellows 2
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5. Cushion Valve
[1] Valve summary
This valve is made up of a shuttle valve section and cushion valve section with a heat circuit.
The cushion valve with a heat circuit is connected between the hydraulic shovel control valve and
the pilot operation valve to reduce body shaking (cushion function) caused by emergency stop
operations by the operator.
This valve is also equipped with a circuit with which the operator can deliberately disable the
cushion function for reverse operations.
The shuttle valve selects the high-pressure signal pressure from two signal pressure systems.
This valve has two circuits.
Figure 1
Figure 2
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[2] Operation explanation
1) Normal operation
The pressurized oil fed from the A port (or C, E, or G port) pushes up the check plunger and is
sent to the B port (or D, F, or H port). The pressurized oil that has passed through the B port
operates on the control valve spool and operates the actuator. The oil pushed out from the con-
trol valve spool passes through the D port (or B, F, or H port) and flows out to the T port.
Figure 3
2) Cushion operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
closed by the pilot operation valve, the pressurized oil that has operated on the control valve
spool is pushed back to the B port (or the D, F, or H port) by the return spring on the spool. The
returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E,
or G port), and is drained from the pilot operation valve. At this time, by passing through the
metering orifice, the pressurized oil holds down the control valve spool speed and reduces
shaking of the body. (Cushion function)
Figure 4
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3) Reverse operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
switched to the C port (or A, E, or G port), the pressurized oil that has operated on the control
valve spool is pushed back to the B port. Because the pushed back oil flows out to the T port
without passing through the check plunger metering orifice, it does not hold down the control
valve spool speed, so the cushion function does not work.
Figure 5
4) Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through
the inside of the reverse operation spool, flows out to the T port, and heats up the inside of the
valve.
When pressurized oil is being fed from the pilot operation valve to the A port (or C, E, or G
port), the oil fed to the R port flows out to the C port (or A, E, or G port) and heats up the circuit
to the pilot operation valve and inside the valve.
Figure 6 Figure 7
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5) Shuttle valve
In the pressure between the I and J ports and the pressure between the K and L ports, the steel
ball is pressed from the high pressure to the low pressure. Through this process, the high-pres-
sure oil is fed to the S port or the Q port. In the same way, oil is fed to the U port at the higher of
the pressures between the M and N ports and between the O and P ports.
Figure 8 Figure 9
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6. Direction Valve (3 direction)
(1)Structure
Z
B T1
T2
DR
PP
A
Z
B T1
Z-Z section
B T1 T2
DR PP
Circuit diagram
Figure 1
1 Cover 5 Body 9 Hexagon socket head bolt

2 Name plate 6 Cover 10 Rivet screw
3 Spool 7 Spring 11 O-ring
4 Spring 8 Hexagon socket head bolt
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This valve switches the direction with the pilot pressure.
[1] When the spool is neutral (PP port no load) Shuttle circuit, 2 pumps flow circuit selected
When the pilot pressure is not fed to the PP port, the spool (3) is held in the neutral position
by the springs (4) and (7), the A and B ports are connected, and pressurized oil in the T1
and T2 ports is cut off by the spool (3). (See Figure 2)
Figure 2
[2] When the spool operates (PP port pressurized) Breaker circuit selected
When pressure is fed to the PP port, force [F] (PP port pressure x spool cross-sectional
area) works on the spool (3) to the left direction. When F becomes larger than the set load
with springs (4) and (7), the spool (3) moves to the left, and the A port is connected with the
T1 and T2 ports.
Also, at this time, the pressurized oil at the B port is cut off by the spool (3). (See Figure 3)
Figure 3
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7. HBCV Holding Control Valve (Option for Export/Europe)
(1)Holding control valve operation explanation
Configuration diagram (Figure 1) and hydraulic circuit diagram (Figure 2)
Figure 1 Configuration diagram
1 Poppet
2 Spool
3 Relief valve
4 Piston (1)
5 Piston (2)
Figure 2 Hydraulic circuit diagram
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(2)Configuration and functions
[1] Poppet
Stops leaks between M.C.V. and cylinder.
Has a load check function.
Note: M.C.V. means main control valve.
[2] Spool
The spool is moved through its stroke by the cylinder operation pilot pressure and controls
the flow from the cylinder to the M.C.V.
Controls the poppet opening and closing when the pilot pressure is high.
[3] Relief valve
Controls the cylinder port maximum pressure.
[4] Piston (1)
Receives the pilot pressure and moves the spool through its stroke.
[5] Piston (2)
For relief, the piston (1) moves the spool through its stroke.
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1) Spool neutral state (Figure 3)
[1] At the spool neutral position (with no pilot pressure applied), leaks from the cylinder are
stopped by the poppet seat section (a), the spool seat section (b), the spool sliding section
seal (c), and the relief valve poppet seat section (d) to prevent natural falling of the cylinder.
Figure 3 Spool neutral state
1 Poppet seat section (a)

2 Spool seat section (b)
3 Spool sliding section seal (c)
4 Relief valve poppet sheet section (d)
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2) When oil flows from the A port to the B port (Figure 4)
(When oil flows from M.C.V. to the cylinder)
[1] The oil flowing in from the A port resists the cylinder pressure and poppet return spring, opens
the poppet, and flows to the B port.
Figure 4 When oil flows from the A port to the B port
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3) When oil flows from the B port to the A port (Figures 5 and 6)
(When oil flows from the cylinder to the M.C.V.)
[1] When the pilot pressure is applied, the pressure in the pilot chamber (e) rises. Because the
pilot line oil flows from the pilot chamber through the orifices (f), (g) and to the drain port, the
air in the pilot line is automatically drained out.
[2] Because of the pilot pressure, piston (1), piston (2), and the spool resist the spool return
spring force and move through their strokes. The return oil from the actuator is discharged
from the B port (cylinder side) through the spool control section (h) and to the A port (M.C.V.
side).
Figure 5 When oil flows from the B port to the A port

(When the pilot pressure is low)
1 Control section (h)

2 Orifice (f)
3 Pilot chamber (e)
4 Orifice (g)
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[3] Furthermore, when the pilot pressure becomes higher, the poppet spring chamber (i) is con-
nected to the A port side through the spool internal path. At this time, the poppet opens
because a pressure difference is generated between the poppet spring chamber and the B
port due to the poppet orifice (j).
Figure 6 When oil flows from the B port to the A port

(When the pilot pressure is high)

2 Orifice (j)
3 Spring chamber (i)
4 Pilot chamber (e)
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4) When an abnormality occurs in the cylinder (Figure 7)
(Relief valve operation status)
[1] If an abnormally high pressure above the set pressure for the relief valve occurs in the cylin-
der, the relief valve opens and pressure is generated in the (k) chamber .
[2] Because of the pressure generated in (k) chamber, piston (1) moves to the plug side and pis-
ton (2) moves to the spool side. Because piston (2) that has moved to the spool side resists
the spool return spring force and pushes the spool, the spool moves through its stroke to open
the path from the B port to the A port and the cylinder oil escapes to the M.C.V. side.
Figure 7 Relief valve operation status

2 (k) Chamber
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Function List SH120
Function List
Function List
Function Table
Åù: New function Å¢: Changed function
Operation
Operation Explanation of functions
explanation
Travel circuit
Low-speed circuit Sets the travel motor 2-stage tilting angle to a large angle to set low speed.
Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
The speed is automatically switched to low speed according to the load pressure
High-speed circuit on the travel motor.
In order to prevent hunting at high speed, if the travel pressure becomes 3740
PSI (25.8 MPa) or higher, the speed is set to low speed.
Straight travel
When there is an attachment or swing operation during traveling, travel is held
circuit
straight without curving.
(Å¢)
Swing circuit
For swing single operation, if swing is started with a sharp lever operation, the
pump flow is reduced with the proportional valve installed on the swing pump
Swing relief
(front side).
cut-off control
Normally, this control eliminates the excess oil discharged from the swing relief
circuit
valve and reduces the horsepower consumption.
(Åù)
When the swing speed rises, the pump discharge pressure falls, so the pump
flow is increased gradually while it is detected with the sensor.
1. Swing pushing is obtained by the swing priority variable orifice built into the
Swing priority control valve.
circuit 2. The swing priority variable orifice also works to secure the arm flow for bed
metering.
Swing brake Suctions in the oil from the make-up line in order to prevent cavitation when
circuit swing stops.
1. When the swing lever is in neutral, swing parking works and is held at 100 %.
2. When there is a swing lever or attachment operation, swing parking is
Swing parking released.
circuit 3. Swing parking works about 5 s after the swing lever is put into neutral.
(Å¢) 4. When an attachment operation is stopped, if there is no swing operation, the
swing parking circuit works about 1 s later.
5. When the engine is stopped, swing parking works.
Boom circuit
1. Single The flow is merged internally by switching the boom (2) spool to raise
the speed.
Boom-up circuit
2. Compound The swing priority variable orifice spool is switched to make
movement in arm-in compound operation smooth.
Boom-down Regeneration within the boom spool is used to increase speed and prevent cavi-
regenerative circuit tation.
Boom-down tilting
High pressure is suppressed with the bleed-off circuit and tilting is mitigated.
prevention circuit
Boom-down load By releasing the load hold valve built into the control valve, boom speed
hold valve circuit becomes faster.
1 NST-04-03-005E
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Function List
Åù: New function Å¢: Changed function
Operation
Operation Explanation of functions
explanation
Arm circuit
Arm-out circuit The flow is merged internally by switching the arm (2) spool to raise the speed.
Arm-in forced The speed for compound operation is raised by the forced regeneration release
regenerative circuit valve in the control valve.
Arm-in load hold The load hold valve built into the control valve is released to make the arm-in
valve circuit operation possible.
Bucket circuit
Bucket-close
regenerative Regeneration within the bucket spool is used to increase speed and prevent cav-
circuit itation.
(Åù)
Negative control circuit
Negative control For no-load operation, this circuit sets the hydraulic pump discharge volume to
circuit minimum to reduce horsepower consumption.
Horsepower boost circuits
Arm-in
horsepower boost Increases the hydraulic pump discharge volume for arm-in operations.
circuit
Travel horsepower
Increases the hydraulic pump discharge volume for travel single operation.
boost circuit
Others
Softens the shock through the work of the cushion valve with heat circuit.
Cushion circuit This circuit is attached to the boom and arm pilot lines.
There is no soft/hard switch.
Auto pressure Boosts the main relief pressure from 4970 PSI (34.3 MPa) to 5260 PSI
boost circuit (36.3 MPa) according to the engine load ratio and circuit pressure.
Option circuits
The main control valve has an option section as standard so that it can support a
Breaker circuit
breaker, crusher or other special attachment.
Option flow
It is possible to set the flow for the breaker, crusher, or other special attachment
adjustment
application by just operating a switch in the cab. Maximum of 5 applications.
(Åù)
Multi purpose
It is possible to switch the circuit between the breaker and the crusher by just
circuit switch
operating a switch in the cab.
(Åù)
2nd option circuit Option valve can be added to the top section of the control valve and a 2nd
(Åù) option line can be installed easily.
This circuit uses an optional valve added to the top of the control valve and a
Blade circuit
blade-dedicated pump
NST-04-03-005E 2
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Function List
1. Swing Relief Cut Control
[1] Model 3 circuit
• When a swing starts, almost all the oil is discharged from the swing relief valve.
1 Foot relief valve

2 Negative control signal
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Function List
[2] Model 5 circuit
• When a swing starts, the flow is reduced with the front side proportional valve and the excess oil
is eliminated.
1 Foot relief valve

2 Negative control signal
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Function List
2. Option Line Flow Adjustment Control
• This control adjusts the set flow to match the breaker, crusher, or other application.
1 Negative control signal 2 Foot relief valve 3 Negative control orifice
5 NST-04-03-005E
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Function List
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6
Function List
3. Multi Purpose Circuit (breaker ÅÃ crusher) One-touch Switching Control
• This control makes it easy to switch the circuit with a rocker switch in the cab.
1 Option line select switch

2 3 positions
3 Computer A
4 3-direction valve
5 Pilot switchover
6 Crusher
7 Breaker
8 Option line switchover solenoid
4. Bucket-close Regenerative Circuit

This circuit speeds up bucket closing.
Bucket-close regenerative circuit used.
1 Bucket cylinder
3 Hydraulic pump
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Function List
NST-04-03-005E 8
Explanation of Hydraulic Circuit and Operations (standard model) SH120

Travel Circuit
As an example, this section explains the forward travel operation.
The travel motor 2-stage tilting angle is a large angle side. Even if the travel switch is set to the high-
speed side, switching the key switch OFF and then ON again always returns the system to this
state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the
control valve 5a1 port and switches the left travel spool to the forward side.
At the same time, the oil is also fed to the 4a1 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve PR (P1) port and the discharge
oil from hydraulic pump A2 enters the control valve PL (P2) port. Each flows to the respective travel
motor and causes forward travel through the left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the
hydraulic oil tank.
The travel high-speed solenoid valve goes OFF, the travel motor P port oil connects with the tank
line and the travel motor revolution tilt angle goes to the large revolution tilt side.
1 Control valve 10 Travel (right)

2 4 stack solenoid valve 11 Travel (left)
3 Travel remote control valve 12 Computer A
4 Travel motor 13 Backward left
5 Hydraulic pump 14 Forward left
6 Console lever lock switch 15 Forward right
7 Travel mode select switch 16 Backward right
8 Check valve 17 Travel high speed
9 Oil cooler 18 Lever lock
NST-04-04-007E 1
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2 NST-04-04-007E
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Travel Circuit
As an example, this section explains the forward travel operation.
Sets the travel motor 2-stage tilting angle to a small angle to set high speed. The travel motor has an
automatic switchover function that switches the speed from high speed to low speed according to
the load pressure on the travel motor.
At the same time, the oil is also fed to the 4a1 port to switch the right travel spool to the forward side.
The return oil from the travel motor goes through the left and right travel spools and returns to the
hydraulic oil tank.
Electrical signals are sent to the computer A by operation of the travel high-speed select switch and
the computer A sends electrical signals to the travel high-speed solenoid valve. Due to the switching
of the travel high-speed solenoid valve, the pilot pressure 570 PSI (3.9 MPa) from the C1 port enters
the left and right travel motor P ports through the center joint and sets the travel motor revolution tilt
angle to a small angle to raise the speed.
1 Control valve 10 Travel (right)

2 4 stack solenoid valve 11 Travel (left)
3 Travel remote control valve 12 Computer A
4 Travel motor 13 Backward left
5 Hydraulic pump 14 Forward left
6 Console lever lock switch 15 Forward right
7 Travel mode select switch 16 Backward right
8 Check valve 17 Travel high speed
9 Oil cooler 18 Lever lock
NST-04-04-007E 3
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4 NST-04-04-007E
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Travel Circuit
Straight Travel Circuit (with/without HBCV)
As an example, this section explains simultaneous forward travel and boom-up operations.
In the same way, the oil is also fed to the 4a1 port to switch the right travel spool to the forward side.
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve
to the control valve 4b21 port and switches the boom (1) spool to the up side.
The pilot pressure oil from the control valve 4b21 port separated internally is fed from the 4b22 port
to the 5a31 port and switches the boom (2) spool to the up side.
In the pilot pressure oil from Ps1, that which passes through the travel spool and is linked to the tank
side is cut off by the travel spool switching. In this way, the pressurized oil from Ps1 switches the
straight travel signal.
The pilot pressure oil separated internally from 4b21 operates on the straight travel valve pilot cham-
ber via the straight travel signal and the straight travel valve is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure. (The pilot
pressure is low for slight upper operation, so the amount of switching of the straight travel spool is
slight to prevent sharp reduction in the travel speed.)
The straight travel being switched makes it possible for the PR (P1) port pressurized oil to drive
travel and for the PL (P2) port pressurized oil to drive the upper. Since the left and right motors are
driven by 1 pump for travel, the left and right motors have the same pressure and straight travel is
possible. Furthermore, the PL (P2) port excess oil is fed to the travel side via the check valve with
travel merge orifice to minimize the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are
operated simultaneously.
1 Travel motor 11 Check valve with travel merge orifice 21 Travel remote control valve
2 Boom (up) 12 Boom (down) 22 Backward left
3 Boom (down) 13 Boom (up) 23 Forward left
4 Cushion valve 14 Travel mode select switch 24 Forward right
5 Remote control valve (boom, bucket) 15 Upper pilot sensor 25 Backward right
6 Control valve 16 Travel high speed 26 Oil cooler
7 Travel (right) 17 Lever lock 27 Check valve
8 Travel (left) 18 Console lever lock switch 28 Boom cylinder
9 Straight travel valve 19 4 stack solenoid valve 29 Computer A
10 Straight travel signal 20 Hydraulic pump 30 Travel pilot pressure sensor
NST-04-04-007E 5
5
Straight Travel Circuit (without HBCV)
6 NST-04-04-007E
6
Straight Travel Circuit (with HBCV) (Option for Export, Europe)
7 NST-04-04-007E
7
Swing Circuit
This control aims for an energy-saving effect by controlling the pump in such a way as to minimize
the excess oil drained from the swing motor relief valve for the starting pressure boost for a swing
single sharp operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input
electrical signals, computer A outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pres-
sure to reduce the hydraulic pump A1 side discharge flow. Also, the input signal from hydraulic
pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge flow.
[1] Swing relief cut-off control is executed when all the conditions below are satisfied.
• Travel non-operation
• Swing single sharp operation or swing + boom-down operation
[2] Swing relief cut-off control ends when a condition below is satisfied.
• When swing operation is stopped
• Travel, boom up, arm out/in, or bucket open/close operation
1 Swing motor 11 Computer A

2 Swing 12 Lever lock
3 Cushion valve 13 Swing brake
4 Right swing 14 4 stack solenoid valve
5 Left swing 15 Console lever lock switch
6 Swing pilot pressure sensor 16 Hydraulic pump
7 Remote control valve (arm, swing) 17 P1 pressure sensor
8 Control valve 18 P1 flow control proportional valve
9 Travel pilot pressure sensor 19 Check valve
10 Upper pilot pressure sensor 20 Oil cooler
NST-04-04-007E 8
8
9 NST-04-04-007E
9
Swing Circuit
Swing Priority Circuit (with/without HBCV)
The swing pilot pressure is fed to the 5b2 port via the cushion valve and holds the swing spool to the
right side. The discharge oil from hydraulic pump A1 enters the control valve PR (P1) port and is fed
from the parallel oil path to the swing spool and arm (1) spool. By metering the parallel oil path to
arm (1), for arm and swing simultaneous operation, the swing pressure is boosted to secure the
swing force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the cush-
ion valve to the control valve 5b2 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the
cushion valve to the control valve 5b52 port and switches the spool to the arm-in side.
The pilot pressure oil from the control valve 5b52 port separated internally is fed from the 5b51 port
to the 4a41 port and switches the arm (2) spool to the in side.
The discharge oil from hydraulic pump A1 enters the control valve PR (P1) port and is fed from the
parallel oil path to the swing spool. Switching the spool lets the oil flow into the swing motor B port
and the right swing operation is carried out.
The discharge oil from hydraulic pump A2 enters the control valve PL (P2) port, is fed from the cen-
ter bypass oil path to the arm (2) spool, and merges upstream of the arm (1) spool. Switching the
spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the orifice on the con-
trol valve PR (P1) port parallel oil path narrows, so the pressure is boosted to secure the swing force
for pressing digging.
The arm cylinder with HBCV holds its stop position even when the arm stops and the engine stops.
1 Swing motor 12 Upper pilot pressure sensor

2 Arm (in) 13 Orifice
3 Arm (out) 14 Arm cylinder
4 Right swing 15 Console lever lock switch
5 Left swing 16 Lever lock
7 Swing pilot pressure sensor 18 4 stack solenoid valve
8 Remote control valve (arm, swing) 19 Oil cooler
9 Computer A 20 Check valve
10 Hydraulic pump 21 Cut valve
11 Control valve
NST-04-04-007E 10
10
Swing Priority Circuit (without HBCV)
11 NST-04-04-007E
11
Swing Priority Circuit (with HBCV) (Option for Export, Europe)
12 NST-04-04-007E
12
Swing Circuit
Swing Brake Circuit
As an example, this section explains the brake circuit operation after the end of a right swing opera-
tion.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure
oil is cut off and the control valve swing spool returns to neutral.
The pressurized oil fed to the swing motor B port from the control valve 5B2 port is cut. At the same
time, the destination location is eliminated for the pressurized oil flowing from the swing motor A port
to the control valve 5A2 port, so the pressure rises to the swing motor relief valve set pressure. The
pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force. In
order to make up the shortfall in the oil volume, oil is supplied from the make-up line connected to
the swing motor Mu port from the control valve R2 port to open the make-up check valve and oil is
suctioned in to prevent cavitation.
1 Swing motor 9 Lever lock

5 Swing pilot pressure sensor 13 Computer A
6 Remote control valve (arm, swing) 14 Control valve
7 Hydraulic pump 15 Oil cooler
8 Check valve 16 Upper pilot pressure sensor
NST-04-04-007E 13
13
Swing Brake Circuit
14 NST-04-04-007E
14
Swing Circuit
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal
from computer A.
The swing motor P port oil goes from the 4 stack solenoid valve C2 port through the swing brake
solenoid, and returns to the hydraulic oil tank to hold the swing parking brake.

7 Check valve 15 Upper pilot pressure sensor
8 Oil cooler 16 Hydraulic pump
NST-04-04-007E 15
15
16 NST-04-04-007E
16
Swing Circuit
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes
ON (24 V input), the pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 72.5 PSI (0.5 MPa) or higher at the pressure sensor
in the swing pilot line, the output from computer A to the swing brake solenoid valve goes OFF, the
swing motor P port pressure rises, the swing parking brake is released, and swing becomes possi-
ble.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to
the control valve 5b2 port via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a
swing operation, the electrical signal output from computer A goes OFF, and the swing brake sole-
noid valve is switched. The pilot pressure oil is fed to the swing motor P port from the swing brake
solenoid valve C2 port to release the swing parking brake.
parallel oil path to the swing spool. Switching the spool lets the oil flow into the swing motor B port
and the right swing operation is carried out.
The pressurized oil from the swing motor A port goes through the swing spool and returns to the
hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve
Px2 port pressure sensor and the swing parking brake continues to be released.
After the swing operation ends, if about 5 s pass with no upper operation, the swing brake solenoid
valve output from computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within
about 5 s, when about 1 s passes after the end of the upper operation, the swing parking brake
works again.
The swing parking brake is also released for upper single operations and when about 1 s passes
after the end of the upper operation, the swing parking brake works again.
Swing pilot pressure Upper pilot pressure Swing brake solenoid Swing motor
Key switch
sensor sensor valve mechanical brake
OFF 0 PSI (0 MPa) 0 PSI (0 MPa) OFF ON
ON 0 PSI (0 MPa) 0 PSI (0 MPa) ON ON
ON 72.5 PSI (0.5 MPa) min. 0 PSI (0 MPa) OFF OFF
ON 0 PSI (0 MPa) 72.5 PSI (0.5 MPa) min. OFF OFF
ON 72.5 PSI (0.5 MPa) min. 72.5 PSI (0.5 MPa) min. OFF OFF
? Pilot pressure sensor judgment standard
・ When the pressure goes above 0.5 MPa {72.5 psi}, the system judges that an operation is
underway.
・ When the pressure goes below 0.3 MPa {43.5 psi}, the system judges that the operation has
ended.
1 Swing motor 10 Swing brake
2 Cushion valve 11 4 stack solenoid valve
3 Right swing 12 Console lever lock switch
4 Left swing 13 Computer A
5 Swing pilot pressure sensor 14 Control valve
6 Remote control valve (arm, swing) 15 Upper pilot pressure sensor
7 Check valve 16 Hydraulic pump
8 Oil cooler 17 Swing
9 Lever lock
NST-04-04-007E 17
17
18 NST-04-04-007E
18
Swing Circuit
When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the
swing brake solenoid C2 port through the lever lock solenoid and returns to the hydraulic oil tank,
holding the swing parking brake hold status.

7 Hydraulic pump 15 Oil cooler
8 Check valve
NST-04-04-007E 19
19
20 NST-04-04-007E
20
Boom Circuit
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cush-
ion valve to the control valve 4b21 port and the boom (1) spool is switched. At the same time, the
pilot pressure oil from the 4b22 port separated in the internal path is fed to the 5a31 port and
switches the boom (2) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve PR (P1) port, is fed from the par-
allel oil path to the boom (2) spool and merges downstream of the boom (1) spool. The discharge oil
from hydraulic pump A2 is fed to the boom (1) spool via the center bypass oil path, merges with the
discharge oil from boom (2), flows through the boom load hold valve check valve and into the boom
cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic
oil tank.
1 Cushion valve 11 Upper pilot pressure sensor

2 Boom (up) 12 Travel pilot pressure sensor
3 Boom (down) 13 Console lever lock switch
4 Boom cylinder 14 Monitor display
5 Remote control valve (boom, bucket) 15 Computer A
6 Lever lock 16 P1 pressure sensor
7 Boost pressure relief 17 P2 pressure sensor
8 4 stack solenoid valve 18 Hydraulic pump
9 Control valve 19 Check valve
10 Boom load hold valve check valve 20 Oil cooler
NST-04-04-007E 21
21
22 NST-04-04-007E
22
Boom Circuit
Boom-up Circuit (single operation) (with HBCV）(Option for Export, Europe)
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cush-
ion valve to the control valve 4b21 port and the boom (1) spool is switched.
allel oil path to the boom (2) spool and merges downstream of the boom (1) spool. The discharge oil
from hydraulic pump A2 is fed to the boom (1) spool via the center bypass oil path, merges with the
discharge oil from boom (2), pushes open the boom load hold valve check valve, pushes open the
holding control valve (HBCV) poppet, flows into the bottom side, and the boom-up operation is car-
ried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic
oil tank.
1 Cushion valve 12 Travel pilot pressure sensor

2 Boom (up) 13 Console lever lock switch
3 Boom (down) 14 Monitor display
4 Boom cylinder 15 Computer A
5 Remote control valve (boom, bucket) 16 P1 pressure sensor
7 Boost pressure relief 18 Hydraulic pump
8 4 stack solenoid valve 19 Check valve
9 Control valve 20 Oil cooler
10 Boom load hold valve check valve 21 Boom HBCV poppet
11 Upper pilot pressure sensor
NST-04-04-007E 23
23
Boom-up Circuit (single operation) (with HBCV) (Option for Export, Europe)
24 NST-04-04-007E
24
Boom Circuit
Boom-up Circuit (compound boom up + arm in) (with/without HBCV)
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the Pi1 port, the swing priority variable ori-
fice is moved to the left side and the restriction on the flow to the arm is ended to smooth the arm
movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is
fed via the cushion valve to the control valve 4b22 port and 5b52 port and switches the boom (1)
and arm (1) spools. At the same time, the pressurized oil separated from the boom (1) side pilot
internal path is fed from the 4b21 port to the 5a31 port and the discharge oil from hydraulic pump A1
enters the control valve PR (P1) port and is fed from the parallel oil path to the boom (2) and arm (1)
spools. Because the swing priority variable orifice spool in the parallel oil path is moved, the restric-
tion on flow to the arm is released and the oil flows through the arm (1) spool and into the arm cylin-
der bottom side. At this time, it merges with the discharge oil from the arm (2) spool downstream of
the arm (1) spool. This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load hold valve check valve and the arm (1)
spool and returns to the hydraulic oil tank.
The discharge oil from hydraulic pump A2 enters the control valve PL (P2) port and is fed from the
parallel oil path to the boom (1) spool. This oil merges with the discharge oil from the boom (2)
downstream of the boom (1) spool. Switching the spool lets the oil flow through the load hold valve
check valve and into the boom cylinder bottom side and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve PL
(P2) port and is fed from the parallel oil path to the boom (1) spool. This oil merges with the dis-
charge oil from the boom (2) downstream of the boom (1) spool. Switching the spool lets the oil flow
through the load hold valve check valve and the HBCV poppet into the boom cylinder bottom side
and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic
oil tank.
1 Boom cylinder 11 4 stack solenoid valve 21 Computer A

2 Arm (in) 12 Control valve 22 P1 pressure sensor
3 Arm (out) 13 Swing priority variable orifice 23 P2 pressure sensor
4 Boom (up) 14 Load hold valve check valve 24 Hydraulic pump
5 Boom (down) 15 Forced regeneration release valve 25 Oil cooler
6 Cushion valve 16 Boom load hold valve check valve 26 Check valve
7 Remote control valve (boom, bucket) 17 Upper pilot pressure sensor 27 Arm cylinder
8 Remote control valve (arm, swing) 18 Travel pilot pressure sensor 28 Arm HBCV check valve
9 Lever lock 19 Console lever lock switch 29 Arm spool
10 Boost pressure relief 20 Monitor display 30 Boom HBCV poppet
NST-04-04-007E 25
25
Boom-up Circuit (compound boom up + arm in) (without HBCV)
26 NST-04-04-007E
26
Boom-up Circuit (compound boom up + arm in) (with HBCV) (Option for Export, Europe)
27 NST-04-04-007E
27
Boom Circuit
Boom-down Regenerative Circuit
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cush-
ion valve to the control valve 4a22 port and switches the boom (1) spool to the down side.
center bypass oil path to the boom (1) spool. Switching the spool lets the oil flow into the boom cyl-
inder rod side and the boom-down operation is carried out.
The pilot pressure oil from the Ps2 port is fed to the load hold valve. This opens the load hold valve
check valve.
The pressurized oil at the boom cylinder bottom side passes through the load hold valve check valve
and pushes open check valve A through the back pressure check valve and is regenerated on the
cylinder rod side. The lower the cylinder rod side load pressure, the greater the volume of regenera-
tion. When the cylinder rod side load pressure becomes high, the check valve is closed and the cyl-
inder bottom return oil goes through the boom spool (1) without regeneration and returns to the
hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, neg-
ative control pressure is generated by the center bypass bleed-off oil path and the pump does not
discharge full flow and because the shortfall is made up for with regeneration, engine output can be
used effectively.
1 Cushion valve 13 Control valve

2 Boom (up) 14 Upper pilot pressure sensor
3 Boom (down) 15 Travel pilot pressure sensor
4 Boom cylinder 16 Console lever lock switch
5 Boom load hold valve check valve 17 Monitor display
6 Bleed-off 18 Computer A
7 Check valve A 19 P1 pressure sensor
8 Back pressure check valve 20 P2 pressure sensor
9 Remote control valve (boom, bucket) 21 Hydraulic pump
10 Lever lock 22 Check valve
11 Boost pressure relief 23 Oil cooler
12 4 stack solenoid valve
NST-04-04-007E 28
28
Boom-down Regenerative circuit
29 NST-04-04-007E
29
Boom Circuit
Boom-down Regenerative Circuit (with HBCV）(Option for Export, Europe)
ion valve to the control valve 4a22 port and switches the boom (1) spool to the down side.
center bypass oil path to the boom (1) spool. Switching the spool lets the oil flow into the boom cyl-
inder rod side and the boom-down operation is carried out.
The pilot pressure oil from the Ps2 port is fed to the load hold valve. This opens the load hold valve
check valve.
The pilot pressure oil from the 4a22 port separated in the internal path flows into the HBCV PL port
and switches the HBCV spool. This opens the HBCV poppet.
The pressurized oil at the boom cylinder bottom side passes through the HBCV poppet and pushes
open check valve A through the back pressure check valve and is regenerated on the cylinder rod
side. The lower the cylinder rod side load pressure, the greater the volume of regeneration. When
the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom
return oil goes through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, neg-
ative control pressure is generated by the center bypass bleed-off oil path and the pump does not
discharge full flow and because the shortfall is made up for with regeneration, engine output can be
used effectively.

2 Boom (up) 15 Travel pilot pressure sensor
3 Boom (down) 16 Console lever lock switch
4 Boom cylinder 17 Monitor display
5 Boom load hold valve check valve 18 Computer A
6 Bleed-off 19 P1 pressure sensor
7 Check valve A 20 P2 pressure sensor
8 Back pressure check valve 21 Hydraulic pump
9 Remote control valve (boom, bucket) 22 Check valve
10 Lever lock 23 Oil cooler
11 Boost pressure relief 24 Boom HBCV spool
12 4 stack solenoid valve 25 Boom HBCV poppet
13 Control valve
NST-04-04-007E 30
30
Boom-down Regenerative Circuit (with HBCV) (Option for Export, Europe)
31 NST-04-04-007E
31
Boom Circuit
Boom-down Tilting Prevention Circuit (with/without HBCV)
By operating the remote control valve all the way to the boom-down side at once, even if the boom
spool goes its full stroke, negative control pressure is generated by the center bypass bleed-off oil
path and the circuit is such that the hydraulic pump does not discharge full flow, so the generation of
high pressure is restrained and main unit tilt is reduced. Since the shortfall in the oil volume is com-
pensated by the regenerative circuit, the engine output can be used effectively.
1 Cushion valve 13 Travel pilot pressure sensor

2 Boom (up) 14 Console lever lock switch
3 Boom (down) 15 Monitor display
4 Boom cylinder 16 Computer A
5 Boom load hold valve check valve 17 P1 pressure sensor
6 Bleed-off 18 P2 pressure sensor
7 Remote control valve (boom, bucket) 19 Hydraulic pump
10 4 stack solenoid valve 22 Boom HBCV spool
11 Control valve 23 Boom HBCV poppet
NST-04-04-007E 32
32
Boom-down Tilting Prevention Circuit (without HBCV)
33 NST-04-04-007E
33
Boom-down Tilting Prevention Circuit (with HBCV) (Option for Export, Europe)
34 NST-04-04-007E
34
Boom Circuit
Boom-down Load Hold Valve Circuit (with/without HBCV)
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bot-
tom side is sealed by the load hold valve check valve, reducing internal leakage from the main spool
and reducing the natural drop of the boom.
ion valve to the control valve 4a22 port and switches the boom spool to the down side.
parallel oil path to the boom (1). Switching the spool lets the oil flow into the boom cylinder rod side
and the boom-down operation is carried out.
The boom cylinder bottom side pressurized oil goes through the load hold valve check valve and the
boom (1) spool and returns to the hydraulic oil tank.
When the circuit has an HBCV, the pilot pressure oil from the 4a22 port separated in the internal
path is fed to the holding control valve (HBCV) and moves the HBCV spool. In this way, the HBCV
poppet spring chamber oil is connected to the tank line through the spool, the spring chamber pres-
sure drops, and the HBCV poppet is opened.
The boom cylinder bottom side pressurized oil goes through the HBCV poppet, load hold valve
check valve and the boom (1) spool and returns to the hydraulic oil tank.
1 Boom cylinder 12 Computer

2 Boom (up) 13 P1 pressure sensor
3 Boom (down) 14 P2 pressure sensor
4 Cushion valve 15 Hydraulic pump
5 Remote control valve (boom, bucket) 16 Oil cooler
7 Boost pressure relief 18 Load hold valve poppet
8 4 stack solenoid valve 19 Load hold valve check valve
9 Control valve 20 Bleed-off
10 Console lever lock switch 21 Boom HBCV spool
11 Monitor display 22 Boom HBCV poppet
NST-04-04-007E 35
35
Boom-down Load Hold Valve Circuit (without HBCV)
36 NST-04-04-007E
36
Boom-down Load Hold Valve Circuit (with HBCV) (Option for Export, Europe)
37 NST-04-04-007E
37
Arm Circuit
Arm-out Circuit (with/without HBCV)
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion
valve to the control valve 5a5 port and 4b4 port and switches the arm (1) and (2) spools to the open
side.
center bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the
control valve PL (P2) port, flows from the center bypass oil path and through the arm (2) down-
stream arm merge oil path and merges downstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load hold valve check valve and into the arm
cylinder rod side, carrying out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load hold valve
check valve to push open the arm cylinder HBCV check valve and flow into the rod side, carrying out
the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the
hydraulic oil tank.
1 Arm (in) 11 Computer A

2 Arm (out) 12 P1 pressure sensor
3 Cushion valve 13 P2 pressure sensor
4 Remote control valve (arm, swing) 14 Hydraulic pump
6 Boost pressure relief 16 Check valve
7 4 stack solenoid valve 17 Arm cylinder
8 Control valve 18 Load hold valve check valve
9 Console lever lock switch 19 Arm HBCV spool
10 Monitor display 20 Boom HBCV poppet
NST-04-04-007E 38
38
Arm-out Circuit (without HBCV)
39 NST-04-04-007E
39
Arm-out Circuit (with HBCV) (Option for Export, Europe)
40 NST-04-04-007E
40
Arm Circuit
Arm-in Forced Regenerative Circuit (with/without HBCV)
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion
valve to the control valve 5b52 port and 4a41 port and switches the arm (1) and (2) spools to the in
side.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation
is carried out.
At the same time, the the pilot pressure oil from the PS2 port operates on the load hold valve poppet
and the poppet opens. In this way, the load hold valve check valve spring chamber oil is connected
to the tank line through the load hold valve poppet, the spring chamber pressure drops, and the load
hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load hold valve check valve and the arm
(1) spool and is metered by the forced regeneration release valve.
When the circuit has an HBCV, the pilot pressure oil separated from the 5b52 port is fed to the hold-
ing control valve (HBCV) PL port and moves the HBCV spool. In this way, the HBCV poppet spring
chamber oil is connected to the tank line through the spool, the spring chamber pressure drops, and
the HBCV poppet is opened. The arm cylinder rod side pressurized oil goes through the HBCV pop-
pet, the load hold valve check valve and the arm (1) spool and is metered by the forced regeneration
release valve. Through this, the return oil pushes open the arm (1) upstream check valve and is forc-
ibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc. When the
cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to
the large metering side and the opening becomes larger. Through this, the upstream check valve is
closed and the cylinder rod side return oil returns to the hydraulic oil tank via the arm spool (1) and
forced regeneration release valve without being regenerated.
1 Arm (in) 13 P2 pressure sensor

2 Arm (out) 14 Hydraulic pump
3 Cushion valve 15 Arm cylinder
4 Remote control valve (arm, swing) 16 Check valve
6 Boost pressure relief 18 Upstream check valve
7 4 stack solenoid valve 19 Load hold valve check valve
8 Control valve 20 Load hold valve poppet
9 Console lever lock switch 21 Forced regeneration release valve
10 Monitor display 22 Arm HBCV spool
11 Computer A 23 Arm HBCV poppet
NST-04-04-007E 41
41
Arm-in Forced Regenerative Circuit (without HBCV)
42 NST-04-04-007E
42
Arm-in Forced Regenerative Circuit (with HBCV) (Option for Export, Europe)
43 NST-04-04-007E
43
Arm Circuit
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is
sealed by the load hold valve check valve, reducing internal leakage from the main spool and reduc-
ing the natural drop of the arm.
side.
is carried out.
At the same time, the pilot pressure oil from the Ps2 port operates on the load hold valve poppet and
the poppet opens. In this way, the load hold valve check valve spring chamber oil is connected to the
tank line through the load hold valve poppet, the spring chamber pressure drops, and the load hold
valve check valve is opened. When the circuit has an HBCV, the pilot pressure oil separated from
the 5b52 port is fed to the holding control valve (HBCV) PL port and moves the HBCV spool. In this
way, the HBCV poppet spring chamber oil is connected to the tank line through the HBCV spool, the
spring chamber pressure drops, and the HBCV poppet is opened.
1 Arm (in) 13 Load hold valve check valve

2 Arm (out) 14 Load hold valve poppet
3 Cushion valve 15 Forced regeneration release valve
4 Remote control valve (arm, swing) 16 Arm cylinder
5 Lever lock 17 Hydraulic pump
7 4 stack solenoid valve 19 Check valve
8 Control valve 20 P1 pressure sensor
9 Upper pilot pressure sensor 21 P2 pressure sensor
10 Console lever lock switch 22 Arm HBCV spool
11 Monitor display 23 Arm HBCV poppet
12 Computer A
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Arm Circuit
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is
sealed by the load hold valve check valve, reducing internal leakage from the main spool and reduc-
ing the natural drop of the arm.
side.
is carried out.
At the same time, the pilot pressure oil from the Ps2 port operates on the load hold valve poppet and
the poppet opens. In this way, the load hold valve check valve spring chamber oil is connected to the
tank line through the load hold valve poppet, the spring chamber pressure drops, and the load hold
valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load hold valve check valve and the arm
(1) spool and returns to the hydraulic oil tank.
1 Arm (in) 12 Computer A

2 Arm (out) 13 Load hold valve check valve
3 Cushion valve 14 Load hold valve poppet
4 Remote control valve (arm, swing) 15 Forced regeneration release valve
5 Lever lock 16 Arm cylinder
7 4 stack solenoid valve 18 Oil cooler
10 Console lever lock switch 21 P2 pressure sensor
11 Monitor display
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Bucket Circuit
Bucket-open Circuit
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cush-
ion valve to the control valve 4b3 port and switches the bucket spool to the open side.
center bypass oil path to the bucket spool. Switching the spool lets the oil flow into the bucket cylin-
der rod side and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the
hydraulic oil tank.

2 Bucket (close) 11 Console lever lock switch
3 Bucket (open) 12 Monitor display
4 Remote control valve (boom, bucket) 13 Computer A
9 Bucket cylinder 18 Oil cooler
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Bucket-open Circuit
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Bucket Circuit
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cush-
ion valve to the control valve 4a3 port and switches the bucket spool to the close side.
parallel oil path to the bucket spool. Switching the spool lets the oil flow into the bucket cylinder bot-
tom and the bucket-close operation is carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cyl-
inder bottom side. The lower the cylinder rod side load pressure, the greater the volume of regener-
ation. When the cylinder rod side load pressure becomes high, the check valve is closed and the
cylinder bottom side return oil goes through the bucket spool without regeneration and returns to the
hydraulic oil tank.
1 Cushion valve 11 Console lever lock switch

2 Bucket (close) 12 Monitor display
3 Bucket (open) 13 Computer A
4 Remote control valve (boom, bucket) 14 P1 pressure sensor
8 Bucket cylinder 18 Check valve
9 Control valve
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When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic
pumps A1 and A2 goes from the control valve PR (P1) and PL (P2) ports through the center bypass
oil path, and through the negative control relief valve, and returns to the hydraulic oil tank.
The negative control pressure oil separated from center bypass oil path is fed from the FR and FL
ports to the hydraulic pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and
the pump discharge flow is reduced.
1 Control valve 8 N1 negative control pressure sensor

2 Upper pilot pressure sensor 9 N2 negative control pressure sensor
3 Travel pilot pressure sensor 10 Horsepower control proportional valve
5 Console lever lock switch 12 P1 flow control proportional valve
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As an example, this section explains the bucket-close operations.
The discharge oil from the hydraulic pump A2 enters the control valve PL(P2) port, is fed to the
bucket spool, flows into the bucket cylinder bottom side because of the spool switching and the
bucket-close operation is carried out.
Because the bucket spool switches and the pressurized oil on the center bypass downstream side is
cut off, the Pi2 pump negative control pressure oil from the FL port is eliminated, the pump tilting
moves to the increase side, and the flow is increased.
Also, the command current to the P1 flow control proportional valve is lowered and the pressurized
oil from the hydraulic pump A3 is cut off, but the negative control pressure is fed from the control
valve FR port to the Pi1 port, moves the pump tilting to the minimum flow side, and the hydraulic
pump A1 discharge volume is reduced.
1 Control valve 10 Console lever lock switch

2 Travel pilot pressure sensor 11 Lever lock
3 Upper pilot pressure sensor 12 4 stack solenoid valve
4 Cushion valve 13 N1 negative control pressure sensor
5 Bucket (close) 14 N2 negative control pressure sensor
6 Bucket (open) 15 P1 flow control proportional valve
7 Bucket cylinder 16 Hydraulic pump
9 Remote control valve (boom, bucket) 18 Oil cooler
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Arm-in Horsepower Boost Circuit (with/without HBCV)
For the arm-in operation, the horsepower boost signal is output to the hydraulic pump horsepower
control proportional valve from computer A by the arm pilot pressure sensor input signal and P1
pressure sensor and P2 pressure sensor input signals.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horse-
power control proportional valve from the computer.
[1] Condition under which the arm-in horsepower boost control is entered
• Arm-in pilot pressure 72.5 PSI (0.5 MPa) or higher (arm-in operation)
• P1 ＋ P2 ≧ 6525 PSI (45 MPa)
[2] Conditions under which the arm-in horsepower boost control is ended
• Arm-in pilot pressure 43.5 PSI (0.3 MPa) or lower (arm-in operation end)
• P1 ＋ P2 ≦ 6525 PSI (45 MPa)
When either occurs
1 Arm (in) 11 Boost pressure relief

2 Arm (out) 12 4 stack solenoid valve
3 Cushion valve 13 Arm cylinder
4 Remote control valve (arm, swing) 14 P1 pressure sensor
5 Control valve 15 P2 pressure sensor
6 Upper pilot pressure sensor 16 Hydraulic pump
7 Travel pilot pressure sensor 17 Horsepower control proportional valve
8 Computer A 18 Oil cooler
10 Console lever lock switch
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Arm-in Horsepower Boost Circuit (without HBCV)
57 NST-04-04-007E
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Arm-in Horsepower Boost Circuit (with HBCV) (Option for Export, Europe)
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For travel single operation, the horsepower boost signal is output to the hydraulic pump horsepower
control proportional valve from computer A by the travel pilot pressure sensor input signal.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horse-
power control proportional valve from computer A.
[1] Conditions under which the travel horsepower boost control is entered
• Travel pilot pressure 72.5 PSI (0.5 MPa) or higher.
• SP mode
[2] Conditions under which the travel horsepower boost control is ended
• Travel pilot pressure 43.5 PSI (0.3 MPa) or lower.
• AUTO mode, H mode
1 Travel motor 8 Control valve

2 Travel remote control valve 9 Travel pilot pressure sensor
4 Console lever lock switch 11 Horsepower control proportional valve
6 Travel mode select switch 13 Check valve
7 Computer A
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Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-
out operation is stopped, and when an arm-out operation is followed by an arm-in operation.
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the
remote control valve 4 port into the cushion valve, pushes up the internal check valve, and is fed to
the control valve 5a5 and 4b4 port.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve 4a41 and 5b52 ports passes from the cushion
valve B port through the cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line returns to the hydraulic oil tank through the cushion
spool from the cushion valve R port, so heat performance is improved.
1 Arm (in) 8 Lever lock

2 Arm (out) 9 4 stack solenoid valve
3 Cushion spool 10 Console lever lock switch
4 Orifice 11 Control valve
5 Check valve 12 Hydraulic pump
6 Cushion valve 13 Oil cooler
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Other Circuits
When the remote control valve arm-out operation lever is returned to neutral, the oil pushed out from
the control valve 5a5 and 4b4 ports flows to the cushion valve D port through the cushion orifice and
returns from the remote control valve to the hydraulic oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the
cushioning is improved.
1 Arm (in) 8 4 stack solenoid valve

2 Arm (out) 9 Control valve
3 Cushion spool 10 Console lever lock switch
4 Orifice 11 Hydraulic pump
5 Cushion valve 12 Check valve
7 Lever lock
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Other Circuits
Cushion Circuit (arm-out → arm-in operation)
When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rat-
tling operation), the pilot pressure oil is fed from the remote control valve 2 port into the cushion
valve A port, pushes up the internal check valve, and reaches the control valve 5b52 port and 4a41
port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the 5a5 port and 4b4 port does not pass through the cushion
orifice, but passes through the cushion spool that has been switched to the right and returns to the
hydraulic oil tank, so response is improved.
1 Arm (in) 8 4 stack solenoid valve

2 Arm (out) 9 Console lever lock switch
3 Cushion spool 10 Control valve
4 Orifice 11 Hydraulic pump
5 Cushion valve 12 Oil cooler
7 Lever lock
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Cushion Circuit (arm-out → arm-in operation)
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Other Circuits
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic
pumps A1 and A2 goes from the control valve PR (P1) and PL (P2) ports through the center bypass
oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve R4 port is fed to the cushion valve R port and returns
through the cushion spool to the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is
raised to improve heat performance.
1 Arm (in) 8 Console lever lock switch

2 Arm (out) 9 Hydraulic pump
3 Cushion valve 10 Check valve
5 Lever lock 12 Boom (up)
6 4 stack solenoid valve 13 Boom (down)
7 Control valve
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Other Circuits
When an attachment is operated, this circuit boosts the control valve main relief set pressure from
4970 PSI (34.3 MPa) to 5260 PSI (36.3 MPa) according to the engine load ratio and hydraulic load
pressure, then ends the pressure boost after 8 s.
As an example, this section explains bucket-close operations.
At the same time, the pressurized oil separated from the pilot internal oil path is detected and the
upper pilot pressure sensor output signal is input to computer A, which judges that there is upper
operation. Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pres-
sure, outputs the ON (24 V) signal to the boost relief solenoid, switches the valve, and the pilot pres-
sure oil is fed to the control valve main relief valve Py port to hold the boost relief set pressure for 8
seconds.
There is no boost for the option circuit and during travel operation.

2 Bucket (close) 11 Console lever lock switch
3 Bucket (open) 12 Monitor display
4 Remote control valve (boom, bucket) 13 Computer
9 Bucket cylinder 18 Oil cooler
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Explanation of Hydraulic Circuit and Operations (option) SH120

Option Circuits
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the
control valve 5b4 port and switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve PR (P1) port through the par-
allel oil path and fed to the option spool. The switching of the spool causes the oil to flow into the
breaker.
The option spool port relief valve pressure becomes the breaker set pressure.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve
is controlled by the output signals from the computer A to adjust the discharge flow.
The return oil from the breaker returns directly to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the mon-
itor display with the ON signal from the breaker switch in the cab, the optimum usage flow can be
selected.
1 Control valve 10 Console lever lock switch

2 Stop valve 11 Lever lock
3 Breaker 12 4 stack solenoid valve
5 Computer A 14 P2 pressure sensor
6 Monitor display 15 P1 flow control proportional valve
7 Breaker switch 16 Hydraulic pump
8 Option remote control valve 17 Check valve
9 Option pilot pressure switch 18 Oil cooler
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Option Circuits
As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the
control valve 5b4 port and switches the option spool to the close side.
allel oil path to the option spool, flows into the hydraulic fork because of the option spool switching
and operates to the close side.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil
tank.
The option spool port relief valve pressure becomes the hydraulic fork set pressure.
1 Control valve 8 4 stack solenoid valve

2 Hydraulic fork 9 Console lever lock switch
3 Stop valve 10 Hydraulic pump
4 Upper pilot pressure sensor 11 Option remote control valve
5 Monitor display 12 Option pilot pressure switch
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Option Circuits
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the
computer A to the option switchover solenoid valve to switch the valve.
The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is
fed to the 3-direction valve PP port and shut-off valve PP port and each valve is switched.
Always switch the 2 pumps flow select switch to the 1 pump side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the
control valve 5b4 port and switches the option spool.
allel oil path and fed to the option spool. Switching the spool lets the oil flow from the shut-off valve
A port through the B port and into the breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve.
The return oil from the breaker returns from the 3-direction valve A port through the T1 port and to
the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the mon-
itor display, the optimum operating flow can be selected.
1 Control valve 10 Option switchover solenoid valve

2 3-direction valve 11 Console lever lock switch
3 Shut-off valve 12 Lever lock
4 Breaker 13 4 stack solenoid valve
5 Option remote control valve 14 Horsepower control proportional valve
6 Option pilot pressure switch 15 P1 flow control proportional valve
7 Multi purpose circuit switch 16 Hydraulic pump
9 Monitor display 18 Oil cooler
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Option Circuits
When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal
(24 V) is output from the computer A to the 2 stack merge solenoid valve to switch the valve.
When the multi purpose circuit switch is flipped to the crusher side, the crusher circuit is formed
without outputting a signal from the computer A to the option switchover solenoid valve and without
switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-
direction valve forms the A ⇔ B circuit.
By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to
the control valve 5b4 port and switches the option spool.
At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the
A2 port and is fed to the control valve a-port and the control valve neutral cut valve is switched.
The discharge oil from hydraulic pump A2 enters the control valve PL (P2) port and goes through
the center bypass oil path and since the neutral cut valve has cut the port to the tank, the oil goes
from the ck1 port via the ck2 port and merges on the upstream side of the option spool.
allel oil path and fed to the option spool. Switching the spool lets the oil flow from the shut-off valve
A port through the B port and into the crusher.
The return oil from the crusher returns from the 3-direction valve A port through the B port and the
option spool and returns to the hydraulic oil tank.
Because the crusher operating flow can be set to 5 levels on the service support screen of the mon-
itor display, the optimum operating flow can be selected.
The option spool port relief valve pressure becomes the crusher set pressure.
1 3-direction valve 12 Control valve

2 Shut-off valve 13 Neutral cut valve
3 Crusher 14 Upper pilot pressure sensor
4 Option switchover solenoid valve 15 Lever lock
5 2 stack merge solenoid valve 16 4 stack solenoid valve
6 Option remote control valve 17 Console lever lock switch
7 Option pilot pressure switch 18 Horsepower control proportional valve
8 Monitor display 19 P1 flow control proportional valve
9 Computer A 20 Hydraulic pump
10 Multi purpose circuit switch 21 Check valve
11 2 pumps flow select switch 22 Oil cooler
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Option Circuits
As an example, this section explains the case in which the hydraulic rotation fork attachment is
used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed
to the control valve 4a5 port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve P3 port, goes through the 2nd
option spool and flows to the hydraulic rotation fork to operate to the right swing side.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the
hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control
valve.
2nd option spool port relief valve pressure becomes the hydraulic rotation fork set pressure.
1 Control valve 9 2nd option pilot pressure switch

2 Stop valve 10 Monitor display
3 Upper pilot pressure sensor 11 Computer A
4 Lever lock 12 4th pump
6 Console lever lock switch 14 Check valve
7 2nd option remote control valve 15 Oil cooler
8 Hydraulic rotation fork
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Option Circuits
By operating the blade remote control valve to the up side, the pilot pressure oil is fed to the control
valve 4a6 port and the blade spool is switched to the up side.
Oil discharged from the 4th hydraulic pump is supplied to the control valve P3 port. Switching the
spool lets the oil flow into the blade cylinder rod-side through the center joint, and this carries out the
blade-up operation.
The blade cylinder bottom-side pressurized oil returns to the hydraulic oil tank through the blade
spool.
1 Control valve 9 Pressure switch

2 Center joint 10 Monitor display
7 Remote control valve 15 Oil cooler
8 Blade cylinder 16 Manihold
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Option Circuits
By operating the blade remote control valve to the down side, the pilot pressure oil is fed to the con-
trol valve 4b6 port and the blade spool is switched to the down side.
Oil discharged from the 4th hydraulic pump is supplied to the control valve P3 port. Switching the
spool lets the oil flow into the bottom side of the blade cylinder through the center joint, and this car-
ries out the blade-down operation.
The blade cylinder rod-side pressurized oil returns to the hydraulic oil tank through the blade spool.
1 Control valve 9 Pressure switch

2 Center joint 10 Monitor display
7 Remote control valve 15 Oil cooler
8 Blade cylinder 16 Manihold
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Port Diagram SH120
Port Diagram
Port Diagram
Pump
1. Hydraulic Pump (standard model)
Port Port name Port size

A1, A2 Discharge port SAE6000PSI 3/4
B1 Suction port SAE2500PSI 2-1/2
Dr1 Drain port G1/2
Proportional valve
P1 G1/4
primary pressure port
P2 P2 port G1/4
Pi1, Pi2 Negative control port G1/4
a1, a2, a5,
Gauge port G1/4
a6
a3 Gauge port G3/8
a4 Gauge port G1/4
Gear pump discharge
A3 G1/2
port
B3 Gear pump suction port G3/4
PH1, PH2 Pressure sensor port G3/8
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Port Diagram
2. Hydraulic Pump (blade model)

A1, A2 Discharge port SAE6000PSI 3/4
B1 Suction port SAE2500PSI 2-1/2
Dr1 Drain port G1/2
Proportional valve
P1 G3/4
primary pressure port
P2 P2 port G1/4
Pi1, Pi2 Negative control port G1/4
a1, a2, a5,
Gauge port G1/4
a6
a3 Gauge port G1/4
a4 Gauge port G1/4
Gear pump discharge
A3 G1/2
port
B3 Gear pump suction port G3/4
PH1, PH2 Pressure sensor port G3/8
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Port Diagram
Valves
1. Control Valve (standard model)
(1)Relief valve
Main relief valve adjustment location details
Main relief valve set pressure

Lo: 4970 PSI at 23.8 Gal (34.3 MPa at 90 L/min)
Hi: 5260 PSI at 22.5 Gal (36.3 MPa at 85 L/min)
1 Arm in 7 Main a (normal use)

2 Arm out 8 Main b (boosted pressure)
3 Bucket open 9 Boosted pressure lock nut
4 Boom up 10 Boosted pressure adjusting screw
5 Bucket close 11 Standard lock nut
6 Boom down 12 Standard pressure adjusting screw
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Port Diagram
Port Port size Port name Port Port size Port name
5b52 G1/4 Arm 1-in pilot line Pi4 G1/4 Negative control power save signal
4a4 G1/4 Arm 2-in pilot line 5A5 3/4 SAE standard pressure Arm-out line
4a3 G1/4 Bucket-close pilot line 5B5 3/4 SAE standard pressure Arm-in line
4a2 G1/4 Boom-down pilot line 5A2 1/2 SAE standard pressure Swing left line
4a1 G1/4 Right travel forward pilot line 5B2 1/2 SAE standard pressure Swing right line
5b4 G1/4 Option pilot line 5A1 3/4 SAE standard pressure Left travel forward line
5b3 G1/4 Boom 2-up pilot line 5B1 3/4 SAE standard pressure Left travel backward line
5b2 G1/4 Right swing pilot line P1 (PR) 3/4 SAE high pressure Pressure line
5b1 G1/4 Left travel backward pilot line
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Port Diagram
5a5 G1/4 Arm 1-out pilot line R1 φ32 Return line
5a4 G1/4 Option pilot line R3 φ34 Return line
5a31 G1/4 Boom 2-up pilot line 4A3 1/2 SAE standard pressure Bucket-close line
5a2 G1/4 Left swing pilot line 4B3 1/2 SAE standard pressure Bucket-open line
5a1 G1/4 Left travel forward pilot line 4A2 1/2 SAE standard pressure Boom-down line
4b4 G1/4 Arm 2-out pilot line 4A1 3/4 SAE standard pressure Right travel forward line
4b3 G1/4 Bucket-open pilot line 4B2 3/4 SAE standard pressure Boom-up line
4b21 G1/4 Boom 1-up pilot line P2 (PL) 3/4 SAE high pressure Pressure line
4b22 G1/4 Boom 1-up pilot line 4B1 3/4 SAE standard pressure Right travel backward line
4b1 G1/4 Right travel backward pilot line
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Port Diagram
2. Control Valve (blade mode)
(1)Relief valve
Main relief valve set pressure

Lo: 4970 PSI at 23.0 Gal (34.3 MPa at 87 L/min)
Hi: 5260 PSI at 21.9 Gal (36.3 MPa at 83 L/min)
1 Arm in 7 Main a (normal use)

2 Arm out 8 Main b (boosted pressure)
3 Bucket open 9 Boosted pressure lock nut
4 Boom up 10 Boosted pressure adjusting screw
5 Bucket close 11 Standard lock nut
6 Boom down 12 Standard pressure adjusting screw
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Port Diagram
5b52 G1/4 Arm 1-in pilot line 5b1 G1/4 Left travel backward pilot line
4a4 G1/4 Arm 2-in pilot line Pi3 G1/4 Negative control power save signal
4a3 G1/4 Bucket-close pilot line 5A5 3/4 SAE standard pressure Arm-out line
4a21 G1/4 Boom-down pilot line 5B5 3/4 SAE standard pressure Arm-in line
4a22 G1/4 Boom-down pilot line 5A2 1/2 SAE standard pressure Swing left line
4a1 G1/4 Right travel forward pilot line 5B2 1/2 SAE standard pressure Swing right line
5b4 G1/4 Option pilot line 5A1 3/4 SAE standard pressure Left travel forward line
5b3 G1/4 Boom 2-up pilot line 5B1 3/4 SAE standard pressure Left travel backward line
5b2 G1/4 Right swing pilot line P1 (PR) 3/4 SAE high pressure Pressure line
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Port Diagram
5a5 G1/4 Arm 1-out pilot line R1 É”32 Return line
5a4 G1/4 Option pilot line R3 É”34 Return line
5a31 G1/4 Boom 2-up pilot line 4A3 1/2 SAE standard pressure Bucket-close line
5a2 G1/4 Left swing pilot line 4B3 1/2 SAE standard pressure Bucket-open line
5a1 G1/4 Left travel forward pilot line 4A2 1/2 SAE standard pressure Boom-down line
4b4 G1/4 Arm 2-out pilot line 4A1 3/4 SAE standard pressure Right travel forward line
4b3 G1/4 Bucket-open pilot line 4B2 3/4 SAE standard pressure Boom-up line
4b21 G1/4 Boom 1-up pilot line P2 (PL) 3/4 SAE high pressure Pressure line
4b22 G1/4 Boom 1-up pilot line 4B1 3/4 SAE standard pressure Right travel backward line
4b1 G1/4 Right travel backward pilot line
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Port Diagram
Port Port size

C3 G1/4
C1 G1/4
Port Port size

B G3/8
T G3/8
View from bottom
Port Port size

C2 G1/4
P G3/8
1 Swing lock
2 Lever lock
3 Boosted pressure
4 Travel high speed
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Port Diagram
B1
A2
B2
T A1
B port side A port side
Port Port size

A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4
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Port Diagram
5. Remote Control Valves (upper, travel)
(1)Remote control valves (left-right)
Right side Left side
Right side Port name Left side Port name Port size
1 Bucket close 1 Swing right G3/8
2 Boom down 2 Arm in G3/8
3 Bucket open 3 Swing left G3/8
4 Boom up 4 Arm out G3/8
P Pressure P Pressure G1/4
T Return T Return G3/8
(2)Remote control valve (travel)

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4
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Port Diagram
6. Cushion Valve
1 Arm in
2 Boom up
3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
11 Swing priority switching pilot line
12 Drain line

E, F Boom up G3/8
G, H Boom down G3/8
O, P Bucket open G3/8
M, N Bucket close G3/8
C, D Arm out G3/8
A, B Arm in G3/8
K, L Swing left G3/8
I, J Swing right G3/8
Q Swing pressure sensor signal G1/4
U Å| G1/4
S Swing priority orifice switch G1/4
V Å| G1/4
T Return G1/4
R Heat circuit G1/4
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12
Port Diagram
7. 2-way Selector Valve (Option for North America)
Remote control valve side Cushion valve side
Port Port name *DEERE type Port size

A Remote control valve side/boom-up G3/8
B Remote control valve side/arm-in port G3/8
C Remote control valve side/boom-down G3/8
D Remote control valve side/arm-out port G3/8
1 Cushion valve side port G3/8
13 NST-04-06-011E
13
Port Diagram
8. 4-way Selector Valve (Option for Export, Europe)
Port Port name *ISO type Port size

A Right remote control valve side port/boom-up G1/4
C Right remote control valve side port/boom-down G1/4
D Right remote control valve side port/bucket-open G1/4
B Right remote control valve side port/bucket-close G1/4
E Left remote control valve side port/arm-out G1/4
G Left remote control valve side port/arm-in G1/4
H Left remote control valve side port/swing-left G1/4
F Left remote control valve side port/swing-right G1/4
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14
Port Diagram
9. Direction Valve/Shut-off Valve
(1)Direction valve
Port Port size

A G1
B G1
T1 G1
T2 G3/4
PP G1/4
DR G1/4
(2)Shut-off valve
Port Port size

A G1
B G1
T G3/4
PP G1/4
DR G1/4
15 NST-04-06-011E
15
Port Diagram
10.HBCV (Option for Export, Europe)
B port opening side
Port Port size Remarks

SAE 6000PSI 3/4 Arm HBCV
A
SAE 6000PSI 3/4 Boom HBCV
SAE 6000PSI 3/4 Arm HBCV
B
SAE 6000PSI 3/4 Boom HBCV
C G1/4
DR G1/4
PL G1/4
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16
Port Diagram
Manifolds
1. Manifold Under Cab
Port Port size
P1 G3/8
P2 G3/8
P3 G3/8
P4 G1/4
P5 G1/4
T1 G3/8
T2 G3/8
T3 G3/8
T4 G1/4
T5 G1/4
2. Manifold (accumulator section)
Port Port size

P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8
17 NST-04-06-011E
17
Port Diagram
3. Manifold (hydraulic oil tank section)
Port Port size

D G1/2
D1 G3/8
D2 G1/4
D5 G1/4
D6 G1/4
T G1/2
T1 G3/8
N2 G1/4
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18
Port Diagram
Motors
1. Swing Motor

Mu Make up G3/4
Dr Drain G3/8
P Brake release Rc1/4
A Left swing G3/4
B Right swing G3/4
GA, GB Pressure measurement G1/4
Au Air bleed port G1/4
AGr Air bleed port for grease-up Rc1/4
Dr
Reduction gear oil drain port Rc3/8
(RG)
SGr Reduction gear grease-up port Rc1/8
19 NST-04-06-011E
19
Port Diagram
2. Travel Motor

A, B Main port G3/4
D Drain port G1/2
P Pilot port G1/4
P1, P2, P3, P4 Pressure detection port Rc1/8
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20
Port Diagram
3. Center Joint
Standard model

A, A' Main port (forward right) G3/4
B, B' Main port (forward left) G3/4
C, C' Main port (backward right) G3/4
D, D' Main port (backward left) G3/4
E, E' Drain port * E (2), E' (1) G1/2
F, F' Pilot port * F (2), F' (1) G1/4
21 NST-04-06-011E
21
Port Diagram
Blade model

A, A' Main port (forward right) G3/4
B, B' Main port (forward left) G3/4
C, C' Main port (backward right) G3/4
D, D' Main port (backward left) G3/4
E, E' Main port (blade up) G1/2
F, F' Main port (blade down) G1/2
G Drain port *G(2) G1/2
H Pilot port *H(2) G1/4
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Pilot Hose Connection Diagram SH120

Pilot P and T Lines
Part name Code Q'ty

Assembly hose (wear resistant rubber hose) 1 1
Nylon hose 2 1
Hydraulic hose 3 1
Nylon hose 4 2
Hydraulic hose 5 1
Hydraulic hose 6 1
Assembly hose (flexible nylon hose) 7 1
Nylon hose 8 1
NST-04-07-012E 1
1
Pilot P and T Lines
1 House frame
3 Hydraulic pump
4 Control valve
A 5 Swing motor
6 Center joint
7 Travel line
8 Cushion valve
9 Boom line
10 Travel line
11 Return and oil cooler line
12 Suction line
2 NST-04-07-012E
2
Pilot Control Line
Part name Code Q'ty

Assembly hose (rubber hose) 1 1
Hydraulic hose 6 1
Nylon hose 7 1
Nylon hose 8 1
Nylon hose 9 1
NST-04-07-012E 3
3
Pilot Control Line
1 Right remote control valve

2 Left remote control valve
3 Platform (left)
4 Control valve
Hose adapter (bulkhead)
5
(pilot P and T)
6 Pressure sensor
7 Pressure sensor
8 Pressure sensor
9 Floor
4 NST-04-07-012E
4
Part name Code Q'ty

Selector valve 4 1
Manifold 5 1
Line assembly (flare) 6 1
Cushion valve 10 1
Line filter 11 1
Nylon hose 14 1
Hydraulic hose 15 1
Nylon hose 16 1
Nylon hose 17 1
NST-04-07-012E 5
5

3 Platform (left)
4 Control valve
5
(pilot P and T)
6 Pressure sensor
7 Pressure sensor
8 Pressure sensor
9 Floor
6 NST-04-07-012E
6
Part name Code Q'ty Part name Code Q'ty

Assembly hose (rubber hose) 1 1 Line assembly (flare) 11 1
Assembly hose (rubber hose) 2 1 Line assembly (flare) 12 1
Assembly hose (flexible nylon hose) 3 1 Line assembly (flare) 13 1
Line assembly (flare) 4 3 Assembly hose (flexible nylon hose) 14 1
Line assembly (flare) 5 1 Assembly hose (flexible nylon hose) 15 1
Line assembly (flare) 6 1 Hydraulic hose 16 1
Line assembly (flare) 7 1 Nylon hose 17 1
NST-04-07-012E 7
7

3 Platform (left)
4 Control valve
5
(pilot P and T)
6 Pressure sensor
7 Pressure sensor
8 Pressure sensor
9 Floor
8 NST-04-07-012E
8
Blade line
Part name Code Q'ty

Switch pressure 1 2
NST-04-07-012E 9
9
Blade line
1 Control valve
2 Center joint
3 Floor
4 Control blade
5 Trim side (upper)
6 Harness wire (cab)
7 Travel line
8 Remote control valve
9 Pilot control line
10 NST-04-07-012E
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Explanation of New Functions SH120

Work Mode Select Switch
The Throttle Volume and Work Mode Select Switch are Linked!!
1 NST-05-00-005E
1
[1] Flow of throttle control
With Model 3, the throttle volume signal is connected directly to the ECU and only the work
mode signal instruction is sent from the main unit computer. With Model 5, the throttle volume
signal first goes to computer A, then the target engine speed instruction is sent from computer
A to the ECM.
1 Throttle volume
2 Computer A
3 CAN communication
4 Engine
5 UART communication
6 Monitor
[2] Pump horsepower control for each mode

If a throttle volume signal is input to computer A, computer A judges the work mode according
to the degree of opening of the throttle volume and controls milli-amp for pump horsepower
control proportional valve to match the work mode.
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2
Control milli-amp * = When the target engine speed is 1500 min-1 {1500 rpm} or less, milli-amp for pump
horsepower control proportional valve is 50 mA.
Volume position (detent position) 1 2 3 4-8 9 - 15
Work mode SP H A
2000 1850 1700 1699 - 1500 1499 - 1050
Engine speed (min-1 {rpm}) {2000} {1850} {1699 - 1500} {1499 - 1050}
{1700}
Model 5 Max High 600 600 531 213 50

Milli-amp for pump
horsepower control Max Low 571 564 491 213 50
proportional valve (mA)
Min 213 213 213 213 50

2 Throttle volume 7 N1 pressure sensor
3 Arm-in pressure sensor 8 N2 pressure sensor
4 Hydraulic pump 9 Pump horsepower control proportional valve
3 NST-05-00-005E
3
Computer Connection Method
[1] Computers and the ECM are connected with CAN communication.
[2] The monitor and computers are connected with serial communication (UART).
1 Monitor
2 Computer A
3 Computer B
4 Computer S
1) Computer A ......... Main unit side computer (standard)

2) Computer B ......... Up to the wiring for connecting the liftcrane computer (OPT) is attached
as standard.
3) Computer S ......... Up to the wiring for connecting the remote support computer (OPT) is
attached as standard.
4) ECM .................... Engine computer
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4
Monitor Changes
1 Horn volume select switch

2 Travel speed select switch
3 Auto idle switch
☆ Changes from Model 3

[1] LCD backlight color change (green → white); no change in number or size of LCD dots
[2] Mounted switch changes
Switch name Model 3 Model 5 Details
Work mode Yes Eliminated Throttle volume link mode switching
Auto mode Yes Eliminated Throttle volume link mode switching
Travel mode Yes Yes
Wiper Yes Yes
Washer Yes Yes
Working light Yes Yes
Swing lock Yes Eliminated
Emergency stop Yes Eliminated Changed to rocker switch
Buzzer stop Yes Eliminated Buzzer changed to auto off
Auto idle No Yes Dedicated switch added
Horn volume No Yes New
[3] Major increase in LCD brightness (Model 3: 6 cd min. → Model 5: 220 cd Typ.)
(The increased brightness creates glare at night, so a light reduction function linked to work-
ing light output was added.)
5 NST-05-00-005E
5
[4] External switch input ports added (5 ports)
1 Monitor
2 Computer A
<Purpose>
Sending the above switch states to the computer A makes it possible to check the opera-
tion of each switch on the service support check screen. Also, since the cumulative opera-
tion time for each switch is stored in the computer A, the time that the front window was
open or closed and the usage log of each option line can be checked on the service sup-
port HR screen.
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6
[5] Output port (wiper, washer, working light, horn volume switching) control method change
1 Monitor display
2 Computer A
<Purpose>
Passing the switch states through the computer A makes the following possible.
1) Checking operation of each switch on the service support CHK screen
2) Checking the usage log for each operation on the service support HR screen
Judging communication errors

If there is an error in UART communication between the monitor and the computer A, the travel
mode select switch and auto idle select switch LEDs flash to indicate the error.
7 NST-05-00-005E
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Pilot Pressure Switch Changed to Pressure Sensor
No. Model 3 Model 5 Change details
1 Upper pressure switch Upper pressure sensor Switch to sensor
2 Travel pressure switch Travel pressure sensor Switch to sensor
3 Swing pressure switch Swing pressure sensor Switch to sensor
4 P1 pressure sensor P1 pressure sensor Parts change (not compatible with Model 3)
5 P2 pressure sensor P2 pressure sensor Parts change (not compatible with Model 3)
6 N1 pressure sensor N1 pressure sensor Parts change (not compatible with Model 3)
7 None N2 pressure sensor New
8 Option pressure switch Option pressure switch No change
[1] Configuration
Pilot pressure sensor and switch sensing points
1 Computer A 6 1st option lever 11 Travel (right) lever

2 Bucket lever 7 Upper pressure sensor 12 2nd option lever
3 Arm lever 8 Swing pressure sensor 13 Travel pressure sensor
4 Boom lever 9 1st option pressure switch 14 2nd option pressure switch
5 Swing lever 10 Travel (left) lever
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8
[2] Pilot pressure sensor characteristics
Relationship between pilot pressure and voltage (rated 725.2 PSI (5 MPa )
[3] Sensor ON/OFF criterion

Option pressure
Upper sensor Arm-in sensor Swing sensor Travel sensor
switch
72.5 PSI 72.5 PSI 72.5 PSI 72.5 PSI 72.5 PSI
ON (0.5 MPa) (0.5 MPa) (0.5 MPa) (0.5 MPa) (0.5 MPa)
OFF 43.5 PSI 43.5 PSI 43.5 PSI 43.5 PSI 43.5 PSI
(0.3 MPa) (0.3 MPa) (0.3 MPa) (0.3 MPa) (0.3 MPa)
[4] Sensor trouble criterion

When 0.25 V < Voltage < 4.75 V, normal; otherwise abnormal
[5] New functions through switch to sensor

Changing the pilot pressure switch to a sensor makes it possible to judge sharp operation of
the operation lever.
Judgment method
When the time to reach the Pu PSI (MPa) pressure is t1 [s] or t2 [s], the shorter time until Pu
(MPa) is reached, the more sharp the operation.
Therefore, operation is sharper with t1 [s] than with t2 [s].
With Model 5 machines, the sharp operation judgment standards ⊿ Pu (MPa) and ⊿ T [s] are
set in the computer A, and if ⊿ Pu (MPa) pressure rise occurs within ⊿ T [s], this is judged to
be sharp operation.
Also, sharp load is judged in the same way using the main pressure sensor.
9 NST-05-00-005E
9
Pump Electromagnetization Proportional Valve
2 electromagnetic proportional valves are mounted on the main pump.
[1] Horsepower control proportional valve
[2] P1 flow control proportional valve (new)
1 Computer A
2 Hydraulic pump
3 P1 flow control proportional valve
6 N1 pressure sensor
8 Horsepower control proportional valve
1. Horsepower Control Proportional Valve

Controls overall flow for the P1 and P2 pumps
<Applications>
1) Pump horsepower boost control
2) Pump horsepower cut control
<Control>
Control milli-amp: 50 mA min. 600 mA max.
Milli-amp increase → Pump flow increase
Milli-amp decrease → Pump flow decrease
2. P1 Flow Control Proportional Valve
Control of the flow for the P1 pump
<Applications>
1) Swing relief cut control
2) Option flow control
<Control>
Control milli-amp: 50 mA min. 740 mA max.
Milli-amp increase → Pump flow decrease
Milli-amp decrease → Pump flow increase
* In order to detect disconnections, the minimum value for the control milli-amp is set to 50 mA.
At 0 mA, computer A judges that the line is disconnected.
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System Control for Energy Saving
Fuel consumption is reduced through the use of 3 new fuel pressure control systems.
[1] Transient load reduction control
[2] Swing relief cut control
1. Reduced Fuel Consumption Through Transient Load Reduction Control
When the lever is operated sharply or there is a sharp high load, the pump control delay reduces the
engine speed.
At this time, the engine side control increases the fuel injection quantity to restore the speed to the
target engine speed, so fuel consumption increases. By using transient load reduction control, when
these conditions occur, the pump torque is reduced to minimize the drop in engine speed and
reduce fuel consumption.
(1)Transient load reduction control
When the conditions below occur, the milli-amp to the pump horsepower control proportional
valve is first lowered to the minimum to reduce the pump torque, then the horsepower is con-
trolled by gradually raising the milli-amps while watching the difference between the actual
engine speed and the target speed and thus reducing the increase in fuel injection quantity.
<Conditions>
1) Sharp lever operation
Judged from sharp rise in the pressure at the upper pressure sensor
2) Operation for high loads and sharp loads
Judged from sharp rise in the pressure at the P1 or P2 pump pressure sensor
11 NST-05-00-005E
11
(2)Pump horsepower boost control
When recovering from transient load reduction control, if milli-amp for pump horsepower control
proportional valve is recovered to the rated milli-amp, the startup speed is delayed, so there is an
impact on operability. In order to compensate for this, when there is sharp lever operation or high
load, the milli-amp to the pump horsepower control proportional valve is set to the maximum milli-
amp for the mode to protect against any drop in the recovery speed.

2 Throttle volume 7 P2 pressure sensor
3 Upper pressure sensor 8 N1 pressure sensor
4 Arm pressure sensor 9 N2 pressure sensor
Horsepower control propor-
5 Hydraulic pump 10
tional valve
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12
2. Reduced Fuel Consumption Through Swing Relief Cut Control
Model 3 swing line
• When the swing starts, high pressure is required, but not flow. On Model 3, the swing starts and at
first almost all the oil flows from the swing relief to the tank, so energy is consumed needlessly.
1 Swing motor
Model 5 swing line

[1] Swing relief cut used
<Purpose>
The swing relief cut control provides relief when the pressure is boosted for the start of the swing
due to sharp swing operation and the drained off excess oil is held to the lowest amount possible.
This provides an energy-saving effect.
<Operation>
For sharp swing operation, when the swing starts, the P1 pump discharge volume is reduced and
only the necessary amount of oil is flowed. When the constant swing is reached, flow is neces-
sary, so the P1 pump discharge volume is increased.
1 Computer A 3 Discharge increased

2 Discharge decreased 4 P1 flow control valve
Caution
The P1 flow control proportional valve Milli-amp (high) ⇒ P1 pump flow (low)
Milli-amp (low) ⇒ P1 pump flow (high)
13 NST-05-00-005E
13
<Control contents>
When the conditions below are all met, computer A judges that this is swing relief cut control,
increases the milli-amp to the P1 flow control proportional valve, and reduces the P1 flow.
After that, while checking the P1 pump discharge pressure, it gradually reduces the output milli-
amp to the P1 flow control valve and raises the P1 pump flow to the constant swing speed.
<Conditions>
1) Sharp swing operation Judged from the swing pilot pressure sensor pres-
sure rise state
2) Within 1 s after start of swing
3) Attachment non-operation That no attachment is operating is judged from the
N2 negative control pressure and P1 pressure sensor.
4) Travel non-operation Travel pressure sensor OFF
5) Option line non-operation Option pressure sensor OFF
1 Computer A 10 Swing 19 P1 pressure sensor

2 Swing remote control valve 11 Travel (left) 20 P2 pressure sensor
3 Swing motor 12 Arm (2) 21 Hydraulic pump
4 Swing pressure sensor 13 Bucket 22 N1 pressure sensor
5 Option pressure switch 14 Boom (1) 23 N2 pressure sensor
6 Arm pressure sensor 15 Travel (right) 24 Discharge increased/decreased
7 Arm (1) 16 Straight travel 25 P1 flow control proportional valve
8 Option 17 Travel pressure sensor
9 Boom (2) 18 Upper pressure sensor
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Electrical Equipment Layout Diagram SH120

Overall View
1 Main unit left side (radiator chamber)

2 Engine
3 Main unit right side (pump chamber)
4 Main unit center section
5 In cab
1 NST-05-01-005E
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1. Main Unit Right Side Layout Diagram (radiator chamber)
Shuttle valve back diagram
Location of fuses
1 Air cleaner sensor 6 Fuse: ECM20A (F4) 11 Safety relay

2 Suction air temperature sensor 7 Fuse: Computer 20A (F5) 12 Battery relay
3 Fusible link 65A (F1) 8 Fuse: GPS15A (F6) 13 Receiver dryer sensor
4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery
5 Fuse: Key 15A (F3) 10 Washer motor
NST-05-01-005E 2
2
2. Engine Section Layout Diagram
1 Engine coolant temperature sensor 7 Starter motor

2 Boost pressure sensor 8 Engine hydraulic pressure sensor
3 Overheat switch 9 Suction control valve
4 Common rail pressure sensor 10 Fuel temperature sensor
5 EGR valve 11 Cam position sensor
6 Boost temperature sensor 12 Crank position sensor
3 NST-05-01-005E
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3. Main Unit Left Side Layout Diagram (pump chamber)
1 Charge fuel pump 8 Travel high speed

2 P1 pressure sensor 9 N1 pressure sensor
3 P2 pressure sensor 10 P1 flow control proportional valve
4 4 stack solenoid valve 11 Horsepower Control Proportional Valve
5 Swing lock 12 N2 pressure sensor
6 Lever lock 13 Oil temperature sensor
7 Boosted pressure
NST-05-01-005E 4
4
4. Main Unit Center Section Layout Diagram
1 Upper pressure sensor

2 Travel pressure sensor
5 NST-05-01-005E
5
5. Cab Layout Diagram
1 Air conditioner solar radiation sensor 7 Monitor display 13 Air conditioner control panel
2 Clock 8 12 V socket 14 Emergency stop switch
3 Cigar lighter 9 Wiper motor 15 Rocker switch
4 Knob 10 Radio 16 Gate lock limit switch
5 Wiper controller 11 Throttle volume
6 Rocker switches (4) 12 Key cylinder
NST-05-01-005E 6
6
No. Name
R1 Main relay
R2 Glow relay
R3 Lamp relay
R4 Lamp relay (CAB)
R5 Horn relay L
R6 Horn relay R
R7 Speaker relay R
R8 Speaker relay L
R9 Room lamp relay
R10 Beacon relay
R11 Starter cut relay
1 Computer A
2 Relay
3 ECM (engine control module)
4 Fuse box
5 Atmospheric pressure sensor
6 TECH II service connector
7 EST service connector
8 Computer A service connector
9 Computer S service connector
7 NST-05-01-005E
7
6. Layout Around Operator's Seat
Right console
Left console
1 Cup holder
2 Key switch
3 Rocker switch space
4 AM/FM radio
5 Tilt lever
6 Throttle volume
7 Ashtray
8 Air conditioner control panel
9 Gate lever
10 Emergency stop switch
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8
Stand Alone Parts Diagram
Name Shape Circuit Remarks
Model
； 24 VDC specifications
Isuzu
Safety relay Part No.
； 182553-0391
Part No.
； AEH0017
Model
； For +24 VDC
Battery relay
Part No.
； KHR1241
Model
； 5.0 kW, 24 V
Starter motor
Isuzu Part No.
； 898045-0270
Model
； 50 A, 24 V
Alternator
Isuzu Part No.
； 898092-1120
Model
； 115E41R
Battery
Part No.
； KHR3943
9 NST-05-01-005E
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Part No.
Washer motor
； KHR2261 (tank + motor)
Model
Fusible link ； 65 A
(F1) Part No.
； KHR1592
Model
Fusible link ； 50 A
(F2) Part No.
； KHR3850
Model
Fuse box (F3,
； 7224-8511(20 A)
F4, F5, F6)
7224-8512 (15 A)
Model
Throttle ； RA30Y2 30SKB1K?K
volume Part. No.
； KHR2751
NST-05-01-005E 10
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Model
； 24 VDC
Starter switch
Part No.
； KHR3270
Fuel level Part No.

sensor ； KHR10670
Model
Charge fuel ； 24 VDC
pump Part No.
； KHH10460
Reserve tank Part No.

limit switch ； KHH0221
11 NST-05-01-005E
11
Vacuum Part No.

sensor ； KHH10330
Isuzu Part No.

Glow plug
； 894390-7775
EGR valve accessory

EGR motor
EGR valve
EGR position
Isuzu Part No.
sensor
； 897381-5602
Common rail accessory

Common rail
Common rail
pressure
Isuzu Part No.
sensor
； 898011-8880
Cam position Isuzu Part No.

sensor ； 897312-1081
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12
Crank position Isuzu Part No.

sensor ； 897312-1081
Oil pressure Isuzu Part No.

sensor ； 897600-4340
Boost
Isuzu Part No.
pressure
； 809373-2691
sensor
Boost
Isuzu Part No.
temperature
； 812146-8300
sensor
Fuel Supply pump accessory part

temperature Supply pump
sensor Isuzu Part No.； 897381-5551
Supply pump accessory part

Suction
Supply pump
control valve
Isuzu Part No.； 897381-5551
13 NST-05-01-005E
13
Isuzu Part No.

Injector
； 898011-6040
Isuzu Part No.

Suction air
； 812146-8300
temperature
Part No.
sensor
； KHH0535
Engine
coolant Isuzu Part No.
temperature ； 897363-9360
sensor
Isuzu Part No.

Atmospheric
； 897217-7780
pressure
Part No.
sensor
； KHH0536
Part No.
Computer A
； KHR10024
Model
； 24 VDC
Relay
Part No.
； KHR3802
NST-05-01-005E 14
14
DC-DC Part No.

converter ； KHR2447
Alarm (feed Part No.

pump) ； KHR4024
Part No.
Feed pump
； KHR12840
Feed pump Part No.

switch ； KHR11520
Model
Lamp (front ； 24 V 70 W
right house) Part No.
； KHR2475
Model
； 24 V 70 W
Lamp (boom)
Part No.
； KHR0957
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15
Model
Lamp ； 24 V 70 W
(cab top) Part No.
； KHR16240
Speakers
Part No.
(R)
； CAP2284
(L)
Model
； SK-0023-001-N0-KK
Monitor
Part No.
display
； KHR10051
KHR15200 (CASE)
Pressure Model
sensor ； 50.0 MPa
(P1) Part No.
(P2) ； KHR10290
Pressure
sensor Model
(N1)
； 5.0 MPa
(N2)
Part No.
(swing)
(upper) ； KHR10300
(travel)
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16
Model
Pressure
； 0.49 MPa
switch (option)
Part No.
(2nd option)
； KHR10820
Pressure Part No.

switch (filter) ； KHR14470
4 stack Part No.

solenoid valve ； KHJ15450
2 stack
solenoid valve Part No.
(knob switch ； KHJ14780
type)
2 stack
Part No.
solenoid valve
； KHJ14000
(pedal type)
17 NST-05-01-005E
17
P1 flow
control Part No.
proportional ； TIP0002128
valve
Horsepower
control Part No.
proportional ； LJ00684
valve
Free swing Part No.

switch ； KHR16140
Model
； KAB 555
KAB seat
Part No.
； KHN12810
Free swing Part No.

solenoid ； KHJ0659
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18
Hydraulic oil
Part No.
temperature
； KHR2433
sensor
Part No.
Clock
； KHR10060
Model
Knob right
； with 2 switches
(with one-
Part No.
touch switch)
； KHJ14460
Knob right Model

(with one- ； with 4 switches
touch switch) Part No.
(short type) ； KHJ16140
Knob left (with Model

horn switch ； with 2 switches
and radio Part No.
mute) ； KHJ14450
19 NST-05-01-005E
19
Knob left Model

(with horn
； with 4 switches
switch and
Part No.
radio mute)
(short type) ； KHJ16150
Basic frequency
； 2560 Hz
Travel alarm
Part No.
； KHR3852
Basic frequency
； 370 Hz
Horn (low)
Part No.
； KHR2427
Basic frequency
； 415 Hz
Horn (high)
Part No.
； KHR2428
Sumitomo Wiring Systems

Part No.
； 6098-0017
Diode
6098-0061
Part No.
； KHP1796
NST-05-01-005E 20
20
Lever lock Part No.

limit switch ； KHR14930
Model
； AM/FM ST (12/24 V)
Radio
Part No.
； KHR15570
Model
Lamp (room ； 24 V, 10 W
lamp) Part No.
； KHN2714
Model
Accessory ； 12 VDC
socket Part No.
； KHR2501
Model
Cigar lighter ； 24 VDC
24 V Part No.
； KHR11210
21 NST-05-01-005E
21
Air conditioner Part No.

unit ； KHR13320
Limit switch
Part No.
(front window)
； KHR2950
(door)
Wiper Part No.

controller ； KHN3392
Part No.
Wiper motor
； KHN16020
Solar radiation Part No.

sensor ； KHR10540
NST-05-01-005E 22
22
Receiver Part No.

dryer (switch) ； KHR13590
Air conditioner
compressor Part No.
(magnetic ； KHR3197
clutch)
Motor actuator
(air mix)
Part No.
(mode)
； KHR13610
(refresh/
recirculate)
Part No.
EVA sensor
； KHR13670
Interior
Part No.
temperature
； KHR13790
sensor
23 NST-05-01-005E
23
Relay
Part No.
(compressor)
； KHR2836
(blower OFF)
Part No.
Blower motor
； KHR2845
Part No.
Blower amp
； KHR13730
Air conditioner Part No.

switch panel ； KHR12510
Option select
switch Part No.
(breaker/ ； KHR14450
crusher)
NST-05-01-005E 24
24
Option select
Part No.
switch
； KHR14060
(breaker)
Option select
Part No.
switch
； KHR15020
(crusher)
2 pumps flow Part No.

select switch ； KHR14460
Emergency Part No.

stop switch ； KHR14050
25 NST-05-01-005E
25
NST-05-01-005E 26
Main Equipment Structural Diagrams SH130

Connection Connector Pin Layout
1. Computer A
1 NST-05-02-002E
1
2. Monitor
NST-05-02-002E 2
2
Electrical Circuit Diagram SH120

Overall View
1. Sequence Circuit Diagram
R101
B G1 G2 ACC M ST
Cigar lighter
R103
R102
F19 HEAT
YR210 B
OFF
YR212 B712 B711 ACC
F4
F3
YR211 YR211 To KAB. SEAT ON
RW120
ST
RG125
Fuel pump
F23
LgR530
GrR009
WR290
PW230 B753 B700
M RW120
RW121
PW231 B754
LgR520 B779
BR
BR
DC / DC converter B600
F7
WR521
F20 OR220 BG609
6 R157 R150 R11
2 Safety relay
R002
F2 WR003
12 V output RY280 R11
CN45 3 GrR010
LR104 S
B750 B700
12 V output WR281 R7 YW970 WR003
YR974 B
R105
CN46 1 R(+) E
Radio BY971
WR282
R(-) BrR523
R
WR291 LR975 R8 LW972
ACC
F5
L(+) Y004
F1
B705 B700 BL973 C
5 R152 L(-)
(ACC)
Accessory socket 12V Back-up
B710
W130
GND
R106
BW706 R001
CN47 4 B Starter motor
Y004
S E
Y904 Y904
WR293 R8
LG832 CLOCK Left knob
Cab light 70 W S / W (mute)
WR292 LG831 LG L852 BG622
R7 4 7
BrR523
R155 R BG
Cab light 70 W 2 5 Alternator
F26 R4 G
GrR185 GrR185 GR903 B R153 R9 YL829 YL 8
3 Br016
Y L
F18 LgR160 LgR
6
B797
Boom light 70 W 1 G015 E
GrR186 R4 WR824 R
Y900 B740 R030 R030
Monitor 2
R155 R155 B
House light 70 W GW Pulverizer Breaker / crusher switch

R3 17 BG OR853
LW180 Y900 L901 B741 LW
16
R9
R9
Breaker
F16 OPT 2nd speed S / W Room lamp
Y BG
LW180 LW181 WR823 WR Y BG
Lever lock L / S Lever lock solenoid
LR906
LR906
R3 9 15 BG
OFF VW170 OR850 B760
Front window L / S (1) LR DOOR VY
YG BG ON
Horn S / W 6
F15 LgW175 LgW176 B722 VY480
R5
G851
20
BG Glow plug
(L) 14 G G
LgW175 R5 R107 F8 WR020
R2
L021 L021
LR907 LR907 B747 BrW BrW525 BrR524
H 7
(R)
LR908 R6 YR909 B749 GrR Wiper controller
H 3 10
LgW177 YR Washer
LY830 LY 18
R6 8
19 LR F14 BrR190 2
WV841
M
B742
Computer A W135 1
LR489 1 Wiper motor
CNC1-4 BG613 GrR
13 VW
GW228 7
V809 YR
PL056 PL056 12 VR M
CNC2-12 4 8
BO450 LR
CNC1-1 PW055 PW055 11
CNC2-4 13 GW
LY430 5
Throttle volume CNC1-25 GR
6
Y410 WL061
CNC2-7 CNC2-10
W060 BrR523
Auto / Manual CNC2-3
WR063 LgR531
S/W CNC3-12
F17 VR866 WR062
GW215 CNC3-11 PB082
L867 L868 YL820 BW064
CNC2-2
R13 CNC4-17
GrR337 DIAG S/W
LgR530
46 ECM PB082 PB083 BG691
L867 R13 WR917 52
CNC4-22
W133
R112
F25 VW170 Glow relay
R13 W132 BrR339
BrR916
B B759 CNC4-11 R2 10 MEMORY CLEAR
WR521
W131 BrY084 BG692
CNC4-12 LR336 32
W130 24
VR866 B758 CNC4-1
R12 BrR523 R1 Main relay
CNC1-8 RG125 RG125 WR330
LgR531 2 BG608
CNC1-7 YR332
21 R1
R12 Engine stop S / W WR331 5
GW215 LR915 B757 YR333
M RG126 LG340 40
47
107 L371
WR062
F22
BW064
WL061
BG694
W140 LG528
W060
BrW236 BrW236 BrW236 CN9-1 G372
CN9-2 B737 106 CKP sensor
VW817
CN9-3
CN9-12 DIAGNOSTIC PL080 108
BW689
F21 BG634 38
LgR532
Connector
VY480
GW225 GW226 GW227 R10 VW858 CN9-13 11 4 7 12 2
BG635 P042 W373
CN9-14 18 99
GW225 W840 PG045 BY069 L374
A CNC4-18 CN9-11 CN9-6 8 98 CMP sensor
P044 Y065 EST PG043
BL687
CN9-10 CN9-7 1 connector 37
F13 Free swing Travel alarm (B) B790 Magnetic clutch
100
GR250 GR257 VY806 YL066 4 PB082 Dust S / W
GL910 CN9-8 3 1
CNC4-14 R12
BG693
R10 YR067 BG690 BrR GW980 W981 B W307

GW226 CN9-9 6 5 87
Swing brake SOL To beacon PL080
R251 VG800 C/R 7 L317 Common rail
CNC4-6 82
connector Connection to controller B B720
L318
pressure sensor
P040 P040 P046 A F12 90
Travel 2nd speed SOL CNC2-6 C
R252 LG801 R151 LR205 R BrW556
CNC4-4 B R12 CN29-18 G327
101
DEUTSCH EST connector (A) B721
Boosted pressure PL081 PL080
CN28-6
94 GB363 U
R253 YG802 PG041 PG041 PG047
CNC4-7 CNC2-14 D E Filter check 93 GW364 EGR position sensor
V
Blower amp W557 GR365
P042 P042 CN29-21 92 W
Blower motor WG558
PG043 PG043
F11 R13 CN29-22
WR200 LR RL BrY551
M CN29-13
WR360
LG528 LG528 LB550 CN29-12 111 U
F9 CNC1-20
F10 WB361
LW260 LY807
CNC4-15
103 V M EGR valve motor
VR547 VW548 CN29-8 WL362
OPT 2nd speed R13 110 W
BrY855 VY463 VR195
CNC1-3 CN28-14 WB303
80
Knob R Evaporator sensor
Y313
GL861 GL861 B714 B L560
CN28-2
67 Oil pressure sensor
BY323
79
Knob L Fuel sensor Temperature sensor
GL412 BG660 Sb559 RG316 BY
GW862 B713 CNC1-15 CN28-1 84 Coolant temperature sensor
BG620
Computer S CN28-5 YG315 BY
Knob R Air cleaner sensor 83 Fuel temperature sensor
B724
Solar radiation sensor
YL863
CNC1-16 LW471 BG661 F6 WY563
CN28-7
P048 RB145 R115 RW304
CNC7-8 CNC6-1 95
WL564
Knob L PG049 CN28-8
CNC7-16 CNC6-2 91 L314 Boost
YG864 B723 GR541 pressure sensor
Filter indicator CNC6-12
Motor actuator CN29-2 GW324
YL472 BG663 109
GY464 CNC1-5 CNC6-13
CNC1-17 LgR533 (air mix) M
GR312 RL
CNC6-7 G555 74 Boost temperature sensor
CN29-17
One-touch IDL
Air conditioner RW368
YL475 BG610 105
CNC2-15 S/W
GW542 113 RW369 SCV (suction control valve)
CN29-3 panel
Reserve tank L / S LY540 CN29-1 RG366
89
GrW470 BG662 GL553 CN29-15
CNC2-8 RG367
BL549 97
CN29-11
Anti-theft protection setting knob
VG481 BG632
CNC2-16 Motor actuator LY
(mode) YL552 CN29-14 W350 Injector #1
121
B L352
YR543 119
CN29-4
M
W400 Pump horsepower proportional valve Y554
CNC1-11 CN29-16
YR940 Injector #2
CNC3-3
Y420
P1 sensor CNC1-21 BY941 BARO 118
P355
CNC3-6
YW544 (atmospheric pressure)
L421 CN29-5
P2 sensor CNC1-9 Pump flow proportional valve sensor
LR545
Motor actuator CN29-6 W300
Lg422 LR942 61 R351 Injector #3
N1 sensor CNC1-22 CNC3-2
(recirculate) M
116
YL310 Y353
BL943 71 120
Br423 CNC3-5 LG562
N2 sensor CNC1-10 CN28-4
G424 B701 B701 G320

Swing P sensor CNC1-23 CNC4-5 60
B702 LW546 Injector #4
CNC4-16
V425 CN29-7 G321 L311
Upper side P sensor CNC1-12
BG601 BG601 VY480 72
117
G354
CNC4-2 CN28-9
YG426 BG602 LgR532 Suction air temperature
Travel P sensor CNC1-24 CNC4-13 CN29-20 sensor
Over load Y904 B770
WG488 BG612 CN28-13 1
Arm P sensor CNC1-18
B771
GR428 3
HBCV sensor CNC1-26 B772
OL822 OL822 4
CNC4-19 CN28-11
BW440 CNC1-14 BG670
CN28-10 43
BG671
Oil temperature sensor 62
BW451 BrW411 BG672
CNC1-2 81
Front window L / S (2)
VG478 BG615
* Front window L / S (1) and (2) are the same switches.
1 NST-05-03-005E
1
Block Diagram
1. Computer A
Computer A
LR489
CNC1-4 BG613
GW228
V809
Monitor
PL056 PL056
BO450 CNC2-12 4
CNC1-1 PW055 PW055
CNC2-4 13
LY430
Throttle volume CNC1-25
Y410 WL061 WL061
CNC2-7 CNC2-10 12
W060 W060
Auto / Manual CNC2-3 7
WR063 EST
S/W CNC3-12 connector (B)
F17 VR866 WR062 WR062
GW215 CNC3-11 4
YL820 BW064 BW064 BG694
L867 L868 CNC2-2 11 2
R13 CNC4-17
L867 R13 WR917 Engine stop S / W F4

LG528 RG126 RG125 R103 R101
R13 CNC1-20
BrR916 B759
B W133
CNC4-22
W132
CNC4-11
W131
CNC4-12 F5 BR
W130 W130 LR104
CNC4-1
F21 Safety relay

GW225
A CNC4-18
Travel alarm BrR523 BrR523
CNC1-8 R
F13 Free swing
GR250 GR257 VY806
CNC4-14
KEY S / W
Swing brake SOL
R251 VG800
CNC4-6
Alternator
Br016
L
Travel 2nd speed SOL LgR531 G015
R252 LG801 CNC1-7 R
CNC4-4
Boosted pressure
R253 YG802
CNC4-7
Power save ECM
P040 P042
CNC2-6 18
F9 LW260 LY807
CNC4-15 PG041 PG043
CNC2-14 37
OPT 2nd speed
BrY855 VY463
CNC1-3
Knob R
GL861 GL861 B714 B
Knob L
GW862 B713 Fuel sensor
CNC1-15 GL412 BG660
Knob R
YL863 B724 Air cleaner sensor
CNC1-16 LW471 BG661
Knob L
YG864 B723
GY464 Filter indicator
CNC1-17 YL472 BG663
CNC1-5
One-touch IDL
YL475 BG610
CNC2-15
Reserve tank L / S
CNC2-8 GrW470 BG662
Anti-theft protection setting knob

VG481 BG632
CNC2-16
W400 Pump horsepower proportional valve

CNC1-11
YR940
CNC3-3
Y420
P1 sensor CNC1-21 BY941
CNC3-6
L421
P2 sensor CNC1-9 Pump flow proportional valve
Lg422 LR942
N1 sensor CNC1-22 CNC3-2
BL943
Br423 CNC3-5
N2 sensor CNC1-10
G424 B701 B701

Swing P sensor CNC1-23 CNC4-5
B702
CNC4-16
V425
Upper side P sensor CNC1-12
BG601 BG601
CNC4-2
YG426 BG602
Travel P sensor CNC1-24 CNC4-13
Over load
WG488 BG612
CNC1-18
GR428
HBCV sensor CNC1-26
BW440 CNC1-14 Air conditioner S / W panel

Oil temperature sensor OL822 OL822
BW451 BrW411 CNC4-19 CN28-11
CNC1-2
2 NST-05-03-005E
2
2. ECM
KEY S/W ECM

LgR530 LR336 24 L371
M ST 107
Glow relay G372 CKP sensor
106
BrR339 BW689
R2 10 108
R11
GrR009 GrR010 GrR337 99 W373
46
L374 CMP sensor
98
BL687
100
Main relay
YR332 87 W307
R1 21
YR333 L317 Common rail
40 82
L318
pressure sensor
90
F4 R1
RG125 WR330 G327
2 101
WR331 5
94 GB363 U
Engine stop S / W 93 GW364 EGR position sensor
V
RG126 LG340 92 GR365
47 W
111 WR360 U
DIAGNOSTIC Connector 103 WB361 V M EGR valve motor
CN51 WL362
110 W
BG691 DIAG S/W PB083 PB082 WB303

52 80
Y313
BG692 MEMORY CLEAR BrY084 79
BY323
32
RG316 BY
84 Coolant temperature sensor
83 YG315 BY
Fuel temperature sensor
RW304
95
91 L314 Boost
Computer A pressure sensor
GW324
109
GR312 RL
P040 P042 74 Boost temperature sensor
CNC2-6 18
PG041 PG043 RW368
CNC2-14 37 105
113 RW369 SCV (suction control valve)
89 RG366
97 RG367
121 W350 Injector #1

L352
119
Injector #2
BARO 118
P355
(atmospheric pressure)
sensor
W300
61
116
R351 Injector #3
YL310
71 Y353
120
G320
60
Injector #4
Suction air temperature G354
sensor 117
G321 L311
72
B770
1
B771
3
B772
4
BG670
43
BG671
62
BG672
81
NST-05-03-005E 3
3
3. Monitor Display
Wiper controller
Washer
F14 BrR190 2
WV841
M
B742
1
Wiper motor
GrR
13 VW
YR 7
12 VR M
8
LR 11
GW
5
GR
6
Monitor Display
Breaker / crusher switch
19 WIPER INT OUT1
GW Crusher
18 WIPER CNT OUT2 IN3 CRUSH S / W 17 BG
LW
IN2 BREAKER S / W 16
3 WASHER OUT3 Breaker
OPT 2nd speed S / W
Y BG
Computer A IN4 OPT 2ND SPEED 15
PW055 Front window L / S

CNC2-4 13 MON TXD UART YG BG
IN1 FRONT WINDOW 6
PL056 VG
CNC2-12 4 MON RXD UART
F5 W130 W135
1 BATT BG
GND 20
F7 R155 Alternator
2 IGN
BrW525
HOUR 7 L
CLOCK
G
8 14 ILUMI
Cab light 70 W
Cab light 70 W
R4
GR903
F26 GrR185 WR824
R4 Boom light 70 W
F16 Y900 B740
LW180 WR823
R3 9 OUT4
House light 70 W
R3 L901 B741
Y900
F15 LgW175 LY830

R6 8 HORN VOL OUT5
Horn S / W
G851 G B722
R5
(L)
R5 LR907 B747
H
(R)
R6 YR909 B749
H
4 NST-05-03-005E
4
4. Air Conditioner
Dust S / W Magnetic clutch

R12
BrR GW980 W981 B
B720
F12
LR205 R BrW556 BrW556
R12 CN29-18
B721
CN28-6
Filter check
Blower amp W557 CN29-21
Blower motor WG558
F11 R13 CN29-22
WR200 LR RL BrY551
M CN29-13
LB550 CN29-12
F10
VR547 VW548
R13 CN29-8
VR195
CN28-14
Evaporator sensor
L560
CN28-2
Temperature sensor
Sb559
CN28-1
BG620
CN28-5
Solar radiation sensor
WY563
CN28-7
WL564
CN28-8
GR541 GR541
Motor actuator CN29-2
(air mix) M
G555 G555
CN29-17
GW542 GW542
CN29-3
LY540 LY540 CN29-1
GL553 GL553 CN29-15
BL549 BL549
CN29-11
Motor actuator LY
Air conditioner
S/W
(mode) YL552 YL552 CN29-14 panel
B
YR543 YR543
CN29-4
M Front window
Y554 Y554 L/S
CN29-16
BG615
CN28-10
YW544 YW544
CN29-5
LR545 LR545
Motor actuator CN29-6
(recirculate) M
LG562 LG562 CN28-4
LW546 LW546
CN29-7
KEY S / W
LgR530 LgR532
B M CN29-20
Computer A
OL822
CNC4-19 CN28-11
R3 Y900 Y904
CN28-13
Room lamp
OFF
R9 DOOR VY480
LR906 CN28-9
ON
NST-05-03-005E 5
5
5. Lever Lock
Lever lock L / S Lever lock solenoid

F25 VW170 OR850 B760
KEY S / W
B M ST BG609 B600
R11
F3 RW120 R11 Safety relay
GrR010
S
BrR523 B750 B700

R E
Computer A
BrR523
CN1-8
Alternator
Br016
L
G015
R
6. Horn
Horn S / W
F15 LgW175 LgW176 G851 G B722
R5
Horn
Horn (L)
LgW175 R5 LR907 LR907 B747
H
LR908
Horn (R)
R6 YR909 B749
H
Monitor S / W
LgW177 LY830
R6 CN5-8
6 NST-05-03-005E
6
7. Working Light
Cab light 70 W
R4 Cab light 70 W
F26 GrR185 GR903
GrR185
GrR186 R4 WR824
S/W
F16
LW180 LW181 WR823
R3 CN5-9
R3
House light 70 W
LW180 Y900 L901 B741
Boom light 70 W
Y900 B740
8. Option
F9 LW260 LW260 LY807 LY807
VY463
OPT(2SP)
LW261 BrY855 LG856 GL858
(LB856)
OPT1 LEV R-R

LW262 GL861 GL861 B714
OPT1 LEV R-L

LW263 GW862 GW862 B713
OPT2 LEV L-R

LW264 YL863 YL863 B724
YL466
OPT2 LEV L-L
LW265 YG864 YG864 B723
YG467
GY464
NST-05-03-005E 7
7
9. Others
F19 Cigar lighter

YR210 B
YR212 B712 B711
YR211 YR211 To KAB. SEAT
Fuel pump
F23
PW230 B753 B700
M
PW231 B754
DC / DC converter
F20 OR220
CN22-6
F7 R150 R157
CN22-2
12 V output RY280
CN45 CN22-3
12 V output WR281
CN46 CN22-1
WR282
B705 B700
CN22-5
Accessory socket 12V
BW706
CN47 CN22-4
8 NST-05-03-005E
8
10.Electrical Symbol List
Symbol Name Symbol Name
Fuse Variable solenoid valve
Diode Resistor
LED Variable resistor
Toggle switch "a" contact Variable resistor
Push switch "a" contact Alarm

A
Limit switch "a" contact Buzzer

B
Limit switch "b" contact Horn

H
R Relay coil M Motor
R
Relay contact "a" contact Solar radiation sensor
R Relay contact "b" contact Speaker
Solenoid valve Lamp
NST-05-03-005E 9
9
10 NST-05-03-005E
Electrical Connector Wiring Diagram SH130

Wire Harness
1. Main FrameHarness
1 NST-05-04-010E
1
2. Cab Main Harness
2 NST-05-04-010E
2
3. Cab Sub Harness
3 NST-05-04-010E
3
4. In-CabHarness
4 NST-05-04-010E
4
5. Engine Harness
5 NST-05-04-010E
5
6. Console Right Harness
7. Console Left Harness
6 NST-05-04-010E
6
Electrical Parts and Wiring Assembly Diagram SH130

Main Frame Part name Code Q'ty
Wire harness; Frame (Main) 1 1
Pressure sensor (725.2 psi) G1/4 2 3
Horn; Electric (High) 3 1
Horn; Electric (Low) 4 1
Ground wire; Floor 5 1
Alarm; Travel 6 1
H A C E
A
F D
D L
C
G B N
G
Q
M
N P
F Q K
O I
H
O
I J K
1 NST-05-05-010F
1
Cab
DESCRIPTION SYM QTY
WIRE HARNESS 1 1
CAP 2 9
WIRE HARNESS 3 1
WIRE HARNESS 4 1
RELAY; SPL. 5 13
ANTENNA CODE 6 1
WIRE HARNESS 7 1
WIRE HARNESS 8 1
WIRE HARNESS 9 1
STARTER SWITCH 10 1
EARTH WIRE 11 1
SWITCH SPL. 12 1
SWITCH SPL. 13 1
WIRE HARNESS 14 1
SWITCH SPL. 15 1
WIRE HARNESS 16 1
WIRE HARNESS 17 1
WIRE HARNESS 18 1
RADIO SET 19 1
2 NST-05-05-010F
2
Explanation of Functions and Operations SH120

Explanation of Electrical Functions
No. Item Control Contents
The engine speed, work mode, and boosted pressure state
1 Throttle Control
are switched by the throttle volume.
2 Idling Control With auto/one-touch switchover function
Engine Speed 3 Idling Start Runs the engine at low idle speed when it starts up.
1
Control
In order to prevent the engine from stalling, during operation,
4 Idle Up
raises the low idle speed to the auto idle speed.
If the coolant temperature is low, warm-up operation is exe-
5 Auto warm up
cuted automatically when the engine starts
Engine Start/Stop
1 Judgment based on engine speed from ECM
Judgment
When key ON → OFF, 4 s delay; when engine running → OFF,
Engine Start/ 2 Power-cut Delay
2 7 s delay
Stop Control
Engine Emergency When the emergency stop switch is pressed, the ECM recog-
3
Stop nizes this and stops the engine.
4 Neutral Start Control Engine start load (cell not turning) when lever locked
Linked with the throttle, the SP/H/A mode is switched over and
1 Work Mode Control
the pump horsepower is controlled.
Pump horsepower The pump horsepower milli-amp is raised when there is a high
2
3 Pump Control boost control load or sharp load.
The pump horsepower milli-amp is reduced by the transient
Pump Horsepower Cut
3 load control, engine stall prevention control, and PID control
Control
conditions.
When the upper and swing are not operated, the swing brake
1 Swing Brake
is operated automatically and during travelling too
Swing free swing
2 Swing option for North America
(OPT)
There is a swing lock function (for servicing) with monitor oper-
4 Swing 3 Swing lock
ations.
When a swing starts, the flow is reduced with the front side
4 Swing Relief Cut
proportional valve and the excess oil is eliminated.
The front side flow is controlled to suppress the speed rise due
5 Swing Speed Limit
to increased pump flow.
Travel Speed Switcho-
1 Travel speed low-speed/high-speed switchover
5 Travel ver
2 Travel Alarm Buzzer sounded (for 10 s) during travel
1 Lever Lock Operation is not possible unless the gate lever is raised.
Solenoid Sticking Pre-
2 When key ON, solenoid switched ON/OFF for 0.25 s.
6 Valve Control vention
Pressure Boost Con- The computer automatically raises the pressure from 4975 PSI
3
trol (34.3 MPa) to 5337 PSI (36.8 MPa) when necessary.
Output port control method change, liftcrane and option screen
1 Monitor Function
Monitor Con- added to display screens, etc.
7
trol Bar graph display of coolant temperature, oil temperature, and
2 Monitor Bar Graph
fuel level on monitor
1 NST-05-06-005E
1
No. Item Control Contents
1 Horn Switching between 1 or 2 horns with horn volume select switch
Right housing and boom light illumination (option setting for 2
2 Working Light
lights at top of cab)
Wiper with rise-up used (intermittent, continuous, washer)
3 Wiper and Washer
8 Accessories Same one used as for Model 3
The room lamp lights up when the door is opened and lights
4 Room Lamp up for exactly 30 s from when the door is opened with the key
OFF.
5 Radio Mute Mute switch setting on the knob
1 Anti-theft Anti-theft set with password input to monitor
When the key is ON, no output to travel switchover, boost,
2 Battery Save Function power save, bucket lock, option switchover and free swing
9 Others solenoid valve.
Alternator Power Gen-
3 Alternator L terminal voltage judged with 10 V comparator
eration Detection
4 Overload Alarm Only mounted on machines for Europe
1 Option Line Control Switchover crusher ⇔ breaker with just rocker switch in cab
There are 5 flow settings each for the breaker and crusher, for
2 Option Line Control
a total of 10 settings.
3 DC-DC converter Convert 24 V into 12 V.
10 Options Feed Pump Automatic Feed pump automatic stop Full tank detected by fuel level
4
Stop sensor and the pump stopped automatically
Return Filter Clogging Alarm issued when return filter clogged (only for breaker spec-
5
Detected ifications)
Beacon Control (rotat-
6 Standard for Europe, Japan liftcrane specifications
ing light)
NST-05-06-005E 2
2
Engine Speed Control
1. Throttle Control
(1)Throttle display
[1] Configuration
1 Monitor 3 Engine
2 Computer A 4 Throttle volume
[2] Summary
The throttle volume voltage signal is first input to computer A. Computer A converts the volt-
age signal to a target speed and sends it to the ECM with CAN communication.
At the same time, computer A sends the throttle display data to the monitor.
(2)Throttle volume position detection
[1] Configuration
1 Throttle volume
2 Computer A
3 Potentio-meter
3 NST-05-06-005E
3
[2] Structure
The detent and notches provide a click feel. (15 notches; Notch 1 is the "SP mode" position.)
[3] Characteristic
NST-05-06-005E 4
4
[4] Potentio-meter characteristic
[5] Throttle volume degree of opening calculation

The throttle volume degree of opening (%) that can be checked on the CHK screen is calcu-
lated with the standard below.
100 % ...… When the detent is in the 1+position
0 % .......… When the detent is in the 15-position
Therefore, even if the detent is in the 1 position (SP), this does not necessarily mean that the
degree of opening is 100 %.
In the same way, even if the detent is in the 15 position, the degree of opening is not neces-
sarily 0 %.
5 NST-05-06-005E
5
[6] Table
For the angle, voltage, and degree of opening for each detent position, see the following
table.
Angle Voltage Degree of opening
Detent
[deg] [V] [%]
1+ 131.2 4.86 100.0
1 128.7 4.77 98.0
1- 126.2 4.67 96.1
2+ 109.6 4.06 83.0
2 107.1 3.97 81.1
2- 104.6 3.87 79.1
3+ 95.2 3.53 71.7
3 92.7 3.43 69.8
3- 90.2 3.34 67.8
4+ 88.0 3.26 66.1
4 85.5 3.17 64.1
4- 83.0 3.07 62.2
5+ 80.8 2.99 60.4
5 78.3 2.90 58.5
5- 75.8 2.81 56.5
6+ 73.6 2.73 54.8
6 71.1 2.63 52.8
6- 68.6 2.54 50.9
7+ 66.4 2.46 49.1
7 63.9 2.37 47.2
7- 61.4 2.27 45.2
8+ 59.2 2.19 43.5
8 56.7 2.10 41.5
8- 54.2 2.01 39.6
9+ 52.0 1.93 37.8
9 49.5 1.83 35.9
9- 47.0 1.74 33.9
10+ 44.8 1.66 32.2
10 42.3 1.57 30.2
10- 39.8 1.47 28.3
11+ 37.6 1.39 26.5
11 35.1 1.30 24.6
11- 32.6 1.21 22.6
12+ 30.4 1.13 20.9
12 27.9 1.03 18.9
12- 25.4 0.94 17.0
13+ 23.2 0.86 15.2
13 20.7 0.77 13.3
13- 18.2 0.67 11.3
14+ 16.0 0.59 9.6
14 13.5 0.50 7.6
14- 11.0 0.41 5.7
15+ 8.8 0.33 3.9
15 6.3 0.23 2.0
15- 3.8 0.14 0.0
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6
2. Idling Control (auto/one-touch)
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 1st option pressure switch 11 Pressure sensor (travel)
4 Coolant temperature sensor 8 2nd option pressure switch
<Operation explanation>
[1] Auto/one-touch switchover function
The operator can switch between one-touch and auto by pressing the auto idle switch on the
monitor in the figure below.
When auto idle is ON, the LED at the side of the switch lights up.
1 Auto idle switch

2 LED
[2] Auto idle control

1) When auto idle is set, if the lever is left continuously unoperated for 5 s, the engine speed auto-
matically becomes the auto idle speed (1200 min-1 {1200 rpm}).
* This 5 s setting for auto idle operation is the default setting value. This setting can be
changed to from 1 - 30 s with service support operations.
2) When the lever is operated, the engine speed is automatically returned to the engine speed set
for the throttle volume.
3) Even with auto idle set, it is possible to move to auto idle or return from auto idle by pressing
the knob switch (one-touch idle switch) on the right operation lever.
7 NST-05-06-005E
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[3] One-touch idle control
When auto idle is not set, regardless of lever operation, it is possible to move to auto idle or
return from auto idle by pressing the knob switch (one-touch idle switch) on the right operation
lever.
The idling speed for one-touch idle control is 1050 min-1 {1050 rpm}.
[4] Idling speed
1) Auto idling speed .................. 1200 min-1 {1200 rpm}
2) One-touch idling speed ......... 1050 min-1 {1050 rpm}
3) Low idling speed ................... 1050 min-1 {1050 rpm}
The speeds above are the default values. They can be set to from 1000 - 1600 min-1{1000 - 1600
rpm} with service support operation. (See monitor operation procedure.) However, the settings
are based on the following conditions.
Low idle speed = One-touch idle speed ≦ Auto-idle speed
(The one-touch idle speed and auto-idle speed settings can be changed.)
3. Idling Start
[1] When the engine starts, the engine speed becomes the low idle speed regardless of the throttle
position.
[2] When the low idle speed is changed, the engine speed is controlled at this new speed.
[3] During an idling start, the idling icon is displayed at the top left of the monitor.
No message is displayed.
1 Idling icon
[4] An idling start is ended in the following cases and control becomes normal.
1) When the one-touch idle switch is pressed
2) When the throttle volume is operated
3) When the operation lever is operated (upper, travel, swing pressure sensor ON)
[5] Back-up operation
1) Sensor trouble
If trouble occurs in a sensor (upper, travel, swing), the idling start is ended.
2) Throttle volume trouble
Even if the throttle volume is operated, the idling start is not ended. Also, even if the idling start
is ended with some other method, the throttle cannot be adjusted.
3) One-touch idle switch trouble
Even if the switch is pressed, the idling start is not ended.
NST-05-06-005E 8
8
4. Idle Up
A function that when the engine speed is less than the auto idling speed, causes lever operation to
automatically raise the engine speed to the auto idling speed (idle speed engine stall prevention
function).
<Operation condition>
[1] Control only when the engine speed is lower than the auto idling speed
[2] The idle up speed is the same as the auto idling speed. (Factory setting 1200 min-1 {1200 rpm})
[3] This control does not operate when the idling speed is higher than the auto idling speed. Also,
when auto idling is operated, normally the auto idling function operates.
[4] Even with one-touch idling operating, this control operates to raise the idling speed.
[5] Lever operation judgement is performed when the engine load ratio threshold is exceeded.
[6] If trouble occurs in any of the above pressure sensors, idle up control is not executed.
5. Auto warm up
If the coolant temperature is low when the engine starts up, warm-up operation is executed, auto-
matically raising the engine speed in steps.
[1] Auto warm up is used if the coolant temperature is lower than 122F° (50C) ° when the engine starts.
[2] If the coolant temperature is 122F° (50C)° or higher, auto warm up is not used and an "idling start"
is executed.
[3] Operation
The engine speed is raised in steps from the low idle speed until 2000 min-1 {2000 rpm} as below.
When the low idle speed is changed, the engine speed starts from the newly set speed.
The warm-up time is the same, 14 minutes.
When the coolant temperature reaches 122F° (50 C) ° , the engine speed falls immediately to low
idle. (Idling start)
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[4] Monitor display
During auto warm up, the "auto warm up icon" is displayed at the top left of the monitor.
1 Auto warm up icon
[5] In the cases below, auto warm up is ended and operation shifts to "idling start".
1) When the coolant temperature reaches 122F° (50C) °
2) When the one-touch idle switch is pressed
3) When the entire auto warm up process ends (after 14 minutes)
[6] In the cases below, auto warm up is ended and operation shifts to the engine speed for the throt-
tle position.
1) When the lever is operated (as detected by a pressure sensor)
2) When the throttle volume is operated
[7] Back-up operation
1) Sensor trouble
If trouble occurs in a sensor (upper, travel, swing, arm in, coolant temperature sensor), auto
warm up is not operated. Also, even trouble occurs in a sensor partway through a warm up, the
warm up is ended and operation shifts to normal control.
2) One-touch idle switch trouble
Even if the switch is pressed, auto warm up is not ended.
3) Throttle volume trouble
Even if the throttle volume is operated, the auto warm up is not ended.
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10
Engine Start/Stop Control
[1] Configuration
1 Computer A
2 Cam sensor
3 Crank sensor
[2] Summary
Engine start and stop is judged based on the engine speed sent from the ECM with CAN com-
munication.
[3] Judgment value
Start 500 min-1 {500 rpm}, stop 200 min-1 {200 rpm}
☆）Concerning hysteresis; for Model 3, judged with no hysteresis 500 min-1 {500 rpm}
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2. Power-cut Delay
[1] Configuration (fuses etc. omitted)
1 Computer A 5 Load A
2 Key switch 6 Power supply
3 Battery relay 7 Key switch signal
4 Battery 8 Battery relay hold
[2] Summary
After the key is switched OFF, after the battery relay is held for a certain period, the power supply
is cut off.
[3] Purpose
1) This secures time after the key is switched OFF for data to be written in the EEPROM in the
ECM and computer A.
2) This waits until the engine completely stops to avoid load dumping.
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12
[4] Operation
1) When the key is ON, the battery relay is held by the battery relay hold output (OUT1) from the
ECM and the key switch.
2) After the key is switched OFF, the battery relay is only held by the ECM.
3) After it detects the key going OFF through the key switch signal input (IN1), the ECM starts the
count down.
4) After a certain time has passed, the ECM stops output to the battery relay and the battery relay
goes OFF.
At the same time, the power supply to electrical parts, including the ECM and computer A is
cut. (Except the backup power supply)
5) The time from the key being switched OFF until the power supply goes OFF (the delay time)
depends on whether or not the engine was started.
* After the key is switched ON, if the key is switched OFF without the engine being started =
about 4 s
* If the key is switched OFF after the engine was started = about 7 s
[5] Differences from Model 3
With Model 3, the main unit side computer (called computer A in Model 5) held the battery relay.
With Model 5, the ECM bears this responsibility. (Engine manufacturer requirement)
3. Engine Emergency Stop
Function for stopping the engine in an emergency
When the emergency stop switch on top of the left console is pressed, the engine is stopped regard-
less of the key switch position.
1 Monitor display
2 Computer A
3 Engine
4 Emergency stop switch
[1] Circuit
1) When the emergency stop switch is pressed, a 24 V signal enters the ECM input port.
2) When the 1) signal enters, the ECM controls the injector, suction control valve, and EGR valve
to stop the engine.
3) The emergency stop switch signal enters computer A too and computer A sends the engine
stop command to the ECM with CAN communication.
4) At the same time, computer A sends the emergency stop display and buzzer instructions to the
monitor with serial communication.
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[2] Display, alarm
1) When the emergency stop switch is switched ON, the "ENGINE STOP" message is displayed
on the monitor.
2) Even if there is another message, the "ENGINE STOP" message is displayed with priority for 5
s after the switch is switched ON.
3) At the same time as 1), the buzzer in the monitor buzzes intermittently at 1 Hz.
4) If any kind of trouble is detected during the 1 Hz intermittent buzzing of 3), after the 5 s continu-
ous buzzing, which is the trouble alarm, the buzzing returns to the 1 Hz intermittent buzzing.
5) Even if the buzzing continues after the switch ON/OFF message display (for 5 s), the message
display is not extended.
6) The above message display and buzzer operate whether the engine is running or stopped.
[3] An emergency stop takes priority over any other control and stops the engine.
* The engine stops even during lifting magnet suction, during elevator cab rising, and fan
reverse operation (large machine only).
[4] When an emergency stop is made, it is not recorded in the trouble log.
[5] The engine can be cranked with the emergency stop switch ON, but the engine will not start.
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14
4. Neutral Start
[1] Purpose and summary
The engine will not start with the gate lever lifted. (It will not crank.)
This prevents accidental operation if the operation lever is accidentally bumped into when the
engine is started.
[2] Configuration
1 Key switch 5 Starter cut relay

2 Gate lock limit switch 6 Lever lock solenoid
3 Starter motor 7 Battery relay
4 Safety relay
[3] Operation
When the gate lever is raised (and the limit switch comes ON), the starter cut relay is excited, the
excitation to the safety relay is cut off, and the engine does not crank. At this time, nothing in par-
ticular is displayed on the monitor.
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15
Pump Control
1. Work Mode Control
<Purpose>
Work mode control enables the operator to select the work mode to match the work contents, for
example emphasizing speed, emphasizing fuel economy, etc.
At the same time, the engine speed is adjusted. (throttle adjustment)
1 Monitor
2 Computer A
3 Engine
4 Throttle volume
Pump horsepower control proportional
5
valve
6 Boost solenoid
<Operation>
[1] Manual switchover (main mode)
The operator can select 1 of the following work modes by turning the throttle volume.
For the correspondence between the throttle volume detents and the work modes, see the
attached table.
Mode Aim Display Monitor buzzer
The buzzer buzzes twice

(1) SP mode Speed emphasis
when this is selected.
Balances speed and The buzzer buzzes once

(2) H mode
fuel economy when this is selected.
Fuel economy
(3) A mode No buzzing
emphasis
[2] Automatic switchover (submode)

Each of the three main modes that can be selected manually has 2 submodes (high and low).
These submodes are switched automatically based on the sensor input values.
* For the high and milli-amps,refer to the explanation of the2. Pump Horsepower Boost Con-
trol in next page.
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16
2. Pump Horsepower Boost Control
<Purpose>
To prevent drop in the engine speed when the lever is operated sharply, when there is high load,
when travelling, etc.
Control milli-amp
Volume position (detent position) 1 2 3 4-8 9 - 15
Work mode SP H A
2000 1850 1700 1699 -1500 1499 -1050

Engine speed (min-1 {rmp})
{2000} {1850} {1700} {1699 -1500} {1499 -1050}
Model 5 Milli-amp for pump Max High 600 531 531 213 50
horsepower control
Max Low 571 491 491 213 50
proportional valve
(mA) Min 213 213 21 213 50
Boosted pressure Automatic Automatic Normal
<Operation>
[1] Reduces the amount of speed drop under high load (SP and H mode)
Operation conditions ....... For high load
When the P1 + P2 voltage becomes high voltage, the milli-amp to the pump horsepower con-
trol proportional valve Imax is changed low ⇒ high to increase the pump flow.
[2] Reduces the amount of speed drop under high load when digging with the arm in (SP and H
mode)
When the arm-in operation is detected by the arm-in pilot pressure sensor, high load is
detected faster than for other operations.
[3] Rise speed rise for sharp lever operation
Operation conditions ....... For sharp lever operation
When sharp lever operation is detected by the N1 or N2 negative control pressure sensor, the
milli-amp to the pump horsepower control proportional valve Imax is changed low ⇒ high to
increase the pump flow.
[4] For travel operation
For travel operation, the pump milli-amp is fixed to 600 mA.
However, if the engine speed is 1500 min-1 {1500 rpm} or less, the pump milli-amp is fixed to
50 mA. (Prevention of engine stalling is given priority)
17 NST-05-06-005E
17
3. Pump Horsepower Cut Control
<Purpose>
The pump milli-amp is controlled in order to prevent black smoke under the overload and engine
speed drop and in order to improve energy saving.
The control methods are the following 3.
[1] Overload reduction control
[2] Engine stalling prevention control
[3] PID control
1 Computer A
2 Pump
3 Engine
Pump horsepower control proportional
6
valve
(1)Overload reduction control

When the engine is overloaded, the milli-amp to the pump horsepower proportional valve first
drops to 50 mA.
After that, the milli-amp is gradually raised while watching the difference between the actual
engine speed and the target engine speed.
Overload reduction control is executed in all work modes.
• The engine is judged to be overloaded when the following conditions are met.
1) Sharp lever operation
When there is sharp lever operation, this is judged from the upper pressure sensor state.
2) Operation for high loads and sharp loads
Judged from the P1 or P2 pump pressure sensor and from the pump main pressure boost
state
(2)Engine stalling prevention control
When the target engine speed is 1300 min-1 {1300 rpm} or less, the milli-amp is 50 mA.
(3)PID control
When the engine actual speed falls 30 min-1 {30 rpm} or more below the target engine speed, the
milli-amp is gradually lowered to I Min.
When the difference of the actual engine speed from the target engine speed falls below 30 min-1
{30 rpm} the milli-amp rises to the I Max high for the each mode.
Backup control
If trouble occurs in a pressure sensor (P1, P2, upper), the overload restriction control is not car-
ried out.
If trouble occurs in the pump horsepower control proportional valve, the output from the computer
A stops.
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18
Swing
1. Swing Brake
[1] Configuration
1 Horn volume select switch 8 Swing brake solenoid

2 Computer A 9 Accumulator
3 Engine 10 Swing motor
4 Working light switch 11 Swing brake
5 Auto idle switch 12 Free swing solenoid
6 Upper pressure sensor 13 Free swing switch (momentary)
7 Swing pressure sensor
[2] Braking through upper operation

When the upper pressure sensor is ON, the brake goes OFF. 1 s after the upper pressure sensor
goes OFF, the brake comes ON.
[3] Braking control through swing operation
When the swing pressure sensor is ON, the swing brake goes OFF (swing brake solenoid =
OFF). 5 s after the swing pressure sensor goes OFF, the swing brake comes ON (swing brake
solenoid = ON).
[4] Swing lock with key OFF
When the key is OFF (during power-cut delay), the swing brake comes ON unconditionally.
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2. Swing Free Swing (option for North America)

[1] Free swing switchover
When the free swing switch is pressed, the free swing mode is switched ON ⇔ OFF. When the
(momentary) key is OFF, always start with free swing OFF. (Previous data reset)
[2] Free swing control
When free swing is ON, the free swing solenoid is ON and the swing brake solenoid is OFF.
[3] Mode display
When free swing is ON, the icon in the figure below is displayed on the monitor.
[4] Battery save
While the engine is stopped with the key ON, if free swing is switched ON, the icon is displayed,
but the free swing solenoid does not come ON. It does come ON after the engine starts.
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20
3. Swing Lock (for maintenance)
<Purpose>
This is used for measuring the swing relief pressure and other maintenance tasks.
[1] Swing lock switching
In order to prevent accidental operation under certain special circumstances, sometimes the
swing brake need to be left ON all the time. (Swing lock) At this time, the swing lock can be
switched ON/OFF by holding down the "horn volume select switch", the "working light switch",
and the "auto idle switch" at the same time for 3 s.
Additionally, turn the key to OFF with the swing lock ON, and have the swing lock ON when the
key is turned to ON again. (The previous data is held.)
[2] Swing lock control
When the swing lock is ON, even if the upper or the swing is operated, the swing brake keep
working. Be particularly careful about swing operation because the swing brake plate is dragged.
(The swing pilot pressure is not shut off. This is no more than a simple swing lock.)
[3] Competition with free swing (for North America)
If the swing lock is used, even if free swing is ON, the swing brake solenoid comes ON and the
free swing solenoid goes OFF. (Swing lock priority)
[4] Mode display
When swing lock is ON, the icon in the figure below is displayed on the monitor.
[5] Time chart (free swing {for North America} and swing lock)
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21
[6] Trouble mode
If trouble occurs in an input (upper/swing pressure sensor), communication (CAN), or output
(swing brake solenoid/free swing solenoid {for North America}), the system goes into trouble
mode. In trouble mode, the swing brake solenoid is OFF and the free swing solenoid is OFF.
Even if the trouble is recovered from, this does not recover the system from trouble mode.
4. Swing Relief Cut
<Purpose>
When swing single operation is running, the pump flow is reduced, and the excess oil ejected from
the swing motor relief valve is eliminated.
1 Computer A 8 Option 15 Travel (right)

2 Throttle volume 9 Boom (2) 16 Straight travel
3 Travel pressure sensor 10 Swing 17 P1 pressure sensor
4 1st option pressure switch 11 Travel (left) 18 P2 pressure sensor
5 N1 pressure sensor 12 Arm (2) 19 Regulator
6 N2 pressure sensor 13 Bucket 20 P1 flow control proportional valve
7 Arm (1) 14 Boom (1)
NST-05-06-005E 22
22
[1] Operation conditions for swing relief cut control
The swing relief cut control provides relief when the pressure is boosted for the start of the
swing due to sharp swing operation and the drained off excess oil is held to the lowest amount
possible. The purpose is to provide an energy saving effect.
Control is executed when all the conditions below are satisfied.
1) Sharp swing operation .......... When the swing lever is operated, this is judged from the swing
pilot pressure sensor pressure rise.
2) Within 1 s after start of swing
3) Travel non-operation .............. Travel pressure sensor OFF
4) No attachments other than boom down are operating
................. That no attachment is operating is judged from the N2 negative
control pressure and P1 pressure sensor.
5) Option line non-operation ...... Option pressure sensor OFF
[2] For the swing relief cut operation, after the milli-amp to the P1 flow control proportional valve is
increased and the P1 flow is reduced, while checking the P1 pump discharge pressure, the
system gradually reduces the output milli-amp to the P1 flow control valve and raises the P1
pump flow to the constant swing speed.
• Swing relief cut control flow
Judged as swing single operation + sharp operation ⇒ Swing relief cut operation ⇒ Increased
milli-amp to P1 flow control proportional valve ⇒ P1 pump flow reduced ⇒ Milli-amp gradually
decreased while watching swing pressure fall status ⇒ P1 pump flow increased
<Caution>
P1 flow control proportional valve: milli-amp (high) ⇒ P1 pump flow (low); milli-amp (low) ⇒ P1
pump flow (high)
[3] Swing relief cut end conditions
1) When swing operation is stopped
2) Travel ON
3) Boom up, arm out/in, bucket open/close
4) Boom-down sharp operation
5) Boom-down pressure boost
23 NST-05-06-005E
23
Travel
1. Travel Speed Switchover
The travel motor tilting angle is changed by switching the travel speed between low speed and high
speed with the switch.
However, in high-speed mode, if the drive force becomes high due to the functioning of the travel
motor itself, the tilting angle is automatically switched to low speed.
After that, when the drive force becomes low, the slope automatically returns to high speed.
1 Computer A
2 Engine
3 Travel high-speed select switch
4 Travel motor
5 Travel high-speed solenoid
6 Key switch
[1] Operation
1) When the key is ON, the speed becomes low speed. The previous travel mode is reset.
(If the service support operation is changed, it is possible to hold the previous data.)
2) Each time the travel high-speed switch is pressed, the speed is switched between low speed
and high speed. During high speed, the LED at the top left of the switch lights up.
3) While the engine is stopped with the key ON, if the travel high-speed switch is pressed, the
solenoid does not operate. The LED lights up.
(To prevent the battery being run down)
4) In high-speed mode, the tilting angle is automatically switched between low speed and high
speed by the travel motor drive force.
However, the electrical control remains at high speed, the high-speed LED remains lit, and the
solenoid remains ON.
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24
[2] Trouble mode
If an abnormality occurs in communication (serial/CAN) or computer A solenoid output, the
speed is fixed to low speed. (The travel high-speed solenoid comes OFF.)
2. Travel Alarm
[1] Configuration
1 Computer A Travel alarm mode select switch

3
2 Travel pressure sensor (alternator)
[2] Travel alarm (automatic stop)

When the travel pressure sensor comes ON due to travel operation, the travel alarm starts 1 Hz
intermittent buzzing. This buzzing automatically stops after 10 s.
[3] Travel alarm (continuous buzzing)
When the travel alarm mode select switch is switched ON, the buzzer buzzes continuously during
travel. (Function for North America only)
[4] Signals when key is ON
After the key is switched ON, the travel alarm sounds for 0.4 s as a signal.
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[5] Time chart
[6] Trouble mode

If trouble occurs in the travel pressure sensor, the machine goes into trouble mode and the travel
alarm is always OFF.
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Valve Control
1. Lever Lock
1 Gate lock limit switch 3 Lever lock solenoid

2 Starter cut relay 4 Battery relay
When the battery relay is excited by the key being switched ON, the power enters the lever lock limit
switch. When the gate lever is raised, the lever lock switch (limit switch) comes ON and the lever
lock solenoid is operated. (For details on neutral start control, see Neutral Start in Explanation of
Functions and Operations.)
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2. Solenoid Sticking Prevention
[1] Target solenoid
• Travel high-speed switchover solenoid
• Boost solenoid
• Option switchover solenoid
• Free swing solenoid
* Because the swing brake, and electromagnetic proportional solenoid go ON and OFF frequently
in regular work, they are not subject to control.
[2] Operation
When key ON, switched ON/OFF for 0.25 s.
After that, control is normal control. Control ends before the engine starts, so the machine does
not operate accidentally.
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3. Pressure Boost Control
[1] Configuration
1 Computer A 6 2nd option line pressure switch 11 P2 pressure sensor

2 Engine 7 Control valve 12 Pump 1
3 Upper pressure sensor 8 Main relief valve 13 Pump 2
4 Travel pressure sensor 9 Boost solenoid 14 Regulator
5 Option line pressure switch 10 P1 pressure sensor
[2] During upper operation (upper pressure sensor = ON), the next time the high-load conditions are
met, the boost solenoid valve on the 5 stack solenoid valve comes ON, and the main relief valve
pressure rises from 4970 PSI (34.3 MPa) to 5340 PSI (36.8 MPa).
<Conditions>
When the engine load ratio rises and the P1 or P2 pump pressure is boosted.
[3] Auto pressure boost (ended by time restriction)
When the work mode is SP or H, the boost continues a maximum of 8 s, then is automatically
ended (boost solenoid = OFF). When the work mode is AUTO, this time restriction is eliminated
and the pressure boost is always available.
[4] Auto pressure boost (ended by operation stop)
Even before the time limit for auto pressure boost, if the upper pressure sensor goes OFF, the
boost is ended.
[5] Boost prohibition
During travel (travel pressure sensor = ON) or the breaker is in use (option line pressure switch =
ON and
breaker mode), the boost is not used. (Actuator protection)
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[6] Auto pressure boost setting
Auto pressure boost can be switched ON/OFF and boost for breaker operation enabled/disabled
with service support operation.
[7] During boosting, the monitor displays an icon.
[8] Time chart (when work mode = SP or H)
[9] Trouble mode

If trouble occurs in an input (upper pressure sensor/travel pressure sensor), output (boost sole-
noid) or communication (CAN), the system goes into trouble mode. In trouble mode, the boost
solenoid is fixed to OFF.
* Even if trouble occurs in UART communication, the system does not go into trouble mode.
* Trouble in the (2nd) option line pressure switch cannot be detected.
[10] Recovery from trouble mode
Even if the trouble is recovered from, trouble mode continues.
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Monitor Control
1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge)
(1)Coolant temperature gauge
[1] Configuration
1 Coolant temperature gauge 3 Computer A

2 Monitor 4 Coolant temperature sensor
[2] Operation summary

The ECM reads the coolant temperature from the coolant temperature sensor installed on
the engine and send to computer A through CAN communication. After computer A receives
the coolant temperature, it judges the gauge level, and sends the display data to the monitor
with UART communication.
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[3] Gauge coolant temperature
The gauge level is judged based on the figure below.
[4] Preventing flickering

When the temperature moves up or down near the gauge level fluctuation threshold (for
example 123.8F° (51C), ° the gauge goes on and off repeatedly causing flickering. In order to
prevent that, the gauge level is judged using the temperature (judgment coolant tempera-
ture) after the following processing.
• Judgment coolant temperature = Average of the coolant temperatures obtained the past 32
times
• Coolant temperature obtained period = 1 s
• Bar graph update period = 32 s (updates when the 32nd coolant temperature obtained)
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[5] Trouble mode
If trouble occurs in the coolant temperature sensor or CAN bus, the bar graph itself is not
displayed.
1) If there is a short, the bar graph display is immediately ended.
2) For a disconnection, the display goes off 3 minutes after the engine starts.
If trouble occurs in UART communication (computer A → monitor), the display is fixed at the
last state sent.
When the trouble is recovered from, the display returns to normal.
For a disconnection, when the key is switched OFF more than 3 minutes after the engine
starts, then ON again, the display is recovered.
☆） Coolant temperature obtained during trouble

If a meaningless coolant temperature were obtained and the processing in [4] carried out,
display upon recovery would be strange. In order to prevent this, the coolant temperature
is not obtained during a coolant temperature sensor or CAN bus trouble.
[6] Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer
buzzes.
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(2)Oil temperature gauge
[1] Configuration
1 Oil temperature gauge 4 Hydraulic oil tank

2 Monitor 5 Oil temperature sensor
3 Computer A

Computer A reads the oil temperature from the oil temperature sensor installed in the
hydraulic oil tank outlet suction pipe and judges the gauge level. The gauge level is sent to
the monitor with UART communication.
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[3] Gauge and oil temperature
The gauge level is judged based on the figure below.

When the temperature moves up or down near the gauge level fluctuation threshold (for
example 77F° (25C), ° the gauge goes on and off repeatedly causing flickering. In order to pre-
vent that, the gauge level is judged using the temperature (judgment oil temperature) after
the following processing.
• Judgment oil temperature = Average of the oil temperatures obtained the past 32 times
• Oil temperature acquisition period = 1 s
• Bar graph update period = 32 s (updates when the 32nd oil temperature obtained)
[5] Trouble mode
If trouble occurs in the oil temperature sensor, the bar graph itself is not displayed. (Only for
trouble due to short)
If trouble occurs in UART communication (send: computer A → monitor), the display is fixed
at the last state sent.
☆）Oil temperature obtained during trouble

If a meaningless oil temperature were obtained and the processing in [4] carried out, dis-
play upon recovery would be strange. In order to prevent this, the oil temperature is not
obtained during an oil temperature sensor trouble.
[6] Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer
buzzes.
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(3)Fuel gauge
[1] Configuration
1 Monitor 3 Fuel tank

2 Computer A 4 Fuel sensor
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Computer A reads the fuel level from the fuel sensor installed in the fuel tank and judges the
gauge level.
The gauge level is sent to the monitor with UART communication.
[3] Relationship between gauge level and lever angle
R: Lever angle percentage [%]
Gauge level and fuel level gal. (L)
Model 1 2 3 4 5 6 7 8
（R ≦ 0％）（R ＜ 22％）（R ＜ 38％）（R ＜ 52％）（R ＜ 67％）（R ＜ 82％）（R ＜ 100％）（R ≧ 100％）
≦ 5.8 ＜ 15.8 ＜ 25.6 ＜ 35.1 ＜ 45.5 ＜ 55.5 ＜ 65.5 ≧ 68.7

Model 5
( ≦ 21.9) ( ＜ 59.9) ( ＜ 96.8) ( ＜ 132.7) ( ＜ 172.3) ( ＜ 210.1) ( ＜ 247.8) ( ≧ 260.0)
[4] Message display

When the gauge level reaches 1, "LOW FUEL" is displayed on the monitor and the buzzer
buzzes. (See "Message Display List".)
When the fuel surface in the tank shakes and the fuel sensor lever angle moves up or down
near the gauge level fluctuation threshold (for example 7 %), the gauge goes on and off
repeatedly causing flickering.
In order to prevent that, the gauge level is judged using the lever angle (judgment lever
angle) after the following processing.
• Lever angle acquisition period = 1 s
• Bar graph update period = 5 s
• The judgment value when the bar graph is updated = average lever angle over the past 20
seconds
[6] Trouble mode
If trouble occurs in the fuel sensor, the bar graph itself is not displayed.
If trouble occurs in UART communication, the display is fixed at the last state sent.
(Send: Computer A → Monitor)
[7] Lever angle obtained during trouble
If lever angle were obtained and the processing in [5] carried out, display upon recovery
would not be normal.
In order to prevent this, the lever angle is not obtained during a fuel sensor trouble.
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Accessories
1. Horn
Basic operation
[1] When the horn switch is pressed, the horn is driven via a relay.
[2] When the volume select switch is switched ON, the LED indicator lights up and only the horn (L)
sounds. (Horn volume down)
The volume select switch state is retained even when the key is switched OFF. (The previous
data is held.)
[3] Communication with computer A
When this switch is pressed, the signal is first sent to the computer A and processed.
Then, the drive command is sent to the monitor and the monitor drives the horn (R) relay.
[4] Trouble mode
If there is an error in UART communication, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in [2] on its own without receiving com-
mands from the computer A.
However, the previous data is not held. (The monitor always starts up with normal volume.)
When the error is recovered from, trouble mode ends too and the monitor returns to normal
mode.
1 Monitor panel 6 Horn (L) relay

2 Horn volume select switch (with LED indicator) 7 Horn (R) relay
3 Horn switch 8 Horn (R)
4 Computer A 9 Horn (L)
5 Key switch
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2. Working light
Basic operation
[1] When turning the key to ON, always start with the working light OFF. (Previous data reset)
[2] Each time the working light switch is pressed, the working light is switched between ON and OFF.
(Momentary)
When this light is ON, the LED indicator lights up.
[3] Communication with computer A
When the working light switch is pressed, the signal is first sent to the computer A and pro-
cessed.
Then, the light command is sent to the monitor and the monitor drives the relay.
[4] Trouble mode
If there is an abnormality occurs in UART communication, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in [2] on its own rather than commands
from the computer A.
When the communication error is recovered from, trouble mode is exited and the monitor returns
to normal mode.
1 Monitor panel 6 Working light relay (cab)

2 Working light switch (with LED indicator) 7 Working light (boom)
3 Computer A 8 Working light (tool etc.)
4 Key switch 9 Working light (cab top)
5 Working light relay (upper)
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3. Wiper and Washer
[1] Configuration
1 Monitor panel 4 Monitor 7 Key switch

2 Washer switch 5 Front window limit SW 8 Wiper motor
3 Wiper switch (with LED indicator) 6 Computer A 9 Washer motor
[2] Wiper basic operation

When the wiper switch is pressed, it switches to the next state in the order: intermittent operation
→ continuous operation → OFF → intermittent. In intermittent operation, the I LED is lit and in
continuous operation, the II LED lights up. (When the wipers are OFF, both are OFF.) When turn-
ing the key ON, always start from OFF. (Previous data reset)
[3] Washer basic operation

While the washer is pressed, the washer operates.
[4] Wipers linked with washer
While the washer switch is pressed, after 0.5 s, the washer starts to
operate linked with the wipers.
When the washer switch is released, the washer stops, and after 2
wipes, the wipers stop too.
1) Auto rise up 1 Wiper switch
Even during wiper operation, if the key is turned OFF, the wipers are automatically stopped and
retracted.
2) Overload prevention
If the blades are locked, the monitor output is stopped.
[5] Front window open detection
If the front window is opened while the wipers or washer are operating, it is stopped.
The operations of [2] and [3] are not carried out while the front window is open.
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[6] Wiper controller duty
The wiper controller is responsible for [2] - [4]. [5] is provided by the monitor/controller detecting
the front window being opened and the output to the wiper controller being switched OFF.
[7] Computer A duty
Computer A receives switch signals from the monitor through UART communication (wiper
switch, washer switch, front window limit switch).
This signal is processed by computer A and the 3 ports that control the wiper controller (WIPER
(INT), WIPER (CNT) and WASHER) are controlled as in the following time chart.
[8] Time chart
1) During washer operation, wiper operations are handled automatically by the wiper controller
even if there is no output to WIPER (INT) or WIPER (CNT).
2) Wiper stop by front window open detection
3) Washer-linked wiper stop by front window open detection
[9] Trouble mode
If there is an error in UART communication, the monitor cannot receive drive commands from
computer A. At this time, the monitor goes into trouble mode and executes the same control as
for on its own as in [8].
When the UART communication error is recovered from, the monitor recovers from trouble mode
and follows the drive commands from computer A.
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4. Room Lamp
[1] Configuration
1 Key switch 4 Room lamp

2 Clock unit 5 Door limit switch
3 Room lamp relay
• The clock unit is not connected with computer A or B and controls the room lamp relay on its
own.
• For the connection destination, see "Air Conditioner".
• The clock unit is connected to the backup power supply and continues to operate even if the key
is switched OFF.
[2] Door link
When the room lamp switch is set to the DOOR position, the lamp lights when the door is open
and goes out when the door is closed.
[3] Auto lamp off
In [2], in order to prevent the battery from being run down, the room lamp goes out 30 s after the
door is opened. However, this function only works when the key switch is OFF. If it is ACC or ON,
auto lamp off does not work. (Because even if the room lamp relay is OFF, power is supplied from
ACC.)
The only purpose of this auto lamp off function is to prevent the battery from being run down if the
door is left open with the key OFF.
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[4] Time chart
The time chart shows how the function in [3] works. The room lamp switch is set to DOOR.
0）Door linked room lamp

1）Even after the door is closed, the room lamp relay is ON for 30 s.
2）30 s is counted from the last time the door was closed.
3）After 30 s, the lamp goes off automatically.
4）Auto lamp off does not work if the key switch is ON or ACC.
5）When the key is switched OFF, the lamp goes out. (After power-cut delay)
[5] Trouble mode
Since the clock unit does not have a trouble detection function for either input (IN1) or output
(OUT1), it does not go into trouble mode.
[6] Time chart
This shows the operation when the room lamp switch is ON.
1) If the key is OFF, the lamp goes out automatically after 30 s.

2) Auto lamp off does not work if the key switch is ON or ACC.
3) Power-cut delay
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5. Radio Mute
[1] Configuration
1 Mute switch (knob) 4 Speaker (L) relay 7 Speaker (R)

2 Clock unit 5 Speaker (R) relay
3 Radio 6 Speaker (L)
[2] Summary and purpose

The radio volume can be switched ON/OFF with one-touch
by switching the speaker (L, R) signal lines on and off with a relay.
[3] Operation
Each time the mute switch on the knob is pressed, the radio volume is switched between ON ⇔
OFF. (Momentary)
When the key is switched ON, the radio always starts with mute off (normal radio volume).
(Previous data reset)
[4] Battery save
In order to prevent the battery from being run down, when the key is at ACC (accessory), the
radio is always set to mute off (normal radio volume).
[5] Time chart
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Others
1. Anti-theft
Anti-theft control
If the anti-theft password does not match (anti-theft is not ended), the machine operation is con-
trolled.
1 Computer A 4 P2 pressure sensor 7 Swing brake solenoid

2 Engine 5 Travel pressure sensor 8 Travel alarm
3 P1 pressure sensor 6 Upper pressure sensor
[1] If the engine is started without shutting off the anti-theft device, the machine is controlled.
1) The engine speed is fixed at low idle.
2) The swing brake cannot be released. (Solenoid operation is not possible.)
3) The travel alarm buzzes continuously.
[2] In the state in [1], if any of the following operations is executed, the engine is forced to stop.
1) Upper or travel operation (Detected by the corresponding sensor)
2) The P1 or P2 pressure rises to 725.2 PSI (5 MPa) or higher.
3) The engine load ratio is 50 % or higher for 2 s cumulative.
4) The upper, travel, P1, or P2 pressure sensor is removed.
[3] Even in the state in [1], the anti-theft control can be ended by inputting the correct password.
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2. Battery Save Function
[1] Summary and purpose
In order to prevent the battery from being run down when the key is ON and the engine is
stopped, solenoid and proportional valve output is suppressed.
[2] Operation
See the table below.
Control targets Operation when the engine is stopped with the key ON.
Travel high-speed Fixed to OFF (low speed) whether the travel speed select switch ON or OFF.
switchover solenoid However, the LED at the side of the switch is linked with the switch.
Fixed to OFF (free swing OFF) whether the free swing switch ON or OFF.
Free swing solenoid
However, the free swing icon on the monitor is linked with the switch.
Fixed to OFF (crusher side) whether the breaker/crusher mode switch ON or
Option return line
OFF
switchover solenoid
However, the attachment icon on the monitor is linked with the switch.
Fixed to OFF (no boost) regardless of the work mode (throttle volume position).
Boost solenoid
However, the status icon on the monitor is linked with the throttle.
0 mA, so the standby milli-amp for detecting disconnections of 50 mA does not
Pump horsepower
flow.
proportional valve
Disconnections are only detected after the engine has started.
Pump flow proportional
Same as above
valve
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3. Alternator Power Generation Detection
[1] Configuration (fuses etc. omitted)
1 Computer A 3 Battery relay

2 Key switch 4 Alternator
[2] Separated from battery voltage

When the battery relay is closed, by looking not at the B terminal, where the battery voltage is
applied, but rather to the independent L terminal, defects in the alternator alone are detected.
(The battery voltage is monitored by the ECM. (IN2))
[3] Operation
Alternator L terminal output voltage judged with 10 V comparator
ON when L terminal voltage ≧ 10 V
OFF when L terminal voltage < 10 V * The threshold value of 10 V has a tolerance of±1 V.
[4] Power generation defect judgment
If the 10 V comparator input is OFF even though the engine is running, it is judged that there is a
power generation defect. For details on the judgment conditions, see the "Main Unit Diagnostic
Trouble Code List".
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4. Overload Alarm (Option for Europe)
[1] Configuration
1 Overload alarm switch (alternate) 4 Boom cylinder bottom pressure sensor

2 Monitor panel 5 Boom
3 Computer A 6 Boom cylinder
[2] This function is only mounted on machines for Europe

[3] Alarm judgment
When the overload alarm switch is ON, the overload alarm is switched ON/OFF according to the
following conditions.
ON: (Boom cylinder bottom pressure ≧ set pressure) for continuously for 1 s
OFF: (Boom cylinder bottom pressure ≦ set pressure -290.1 PSI (-2 MPa) for continuously for 1 s
*For the set pressure for each model, see "Overload set pressure".
*The set pressure can be changed with CFG.
[4] Operation when alarm judgment ON
The "OVERLOAD" message is displayed on the monitor and the buzzer buzzes intermittently.
This message is handled as an "alert". For details, see "Message Display List".
[5] Ending the alarm
To end an alarm that has been issued, either switch the overload alarm switch OFF or operate
the attachment in such a way that the judgment in [2] goes OFF.
Be aware that there is no buzzer stop switch like the one in Model 3.
[6] Trouble mode
If trouble occurs in the boom cylinder bottom pressure sensor, this function goes into trouble
mode and the alarm judgment is fixed to OFF.
Even if the trouble is recovered from, trouble mode continues until the key is switched OFF.
[7] Trouble judgment
The boom cylinder bottom pressure sensor trouble judgment is made after the overload alarm
switch has come ON once.
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[8] Time chart
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Options
[1] Configuration
[Multi purpose circuit with 2nd option line]
1 Monitor panel 7 4th pump 13 1st option pedal

2 Breaker mode switch 8 Control valve 14 1st option pressure switch
3 Option select switch 9 3-direction valve 15 1st option switch (L)
4 Crusher mode switch 10 Shut-off valve 16 1st option switch (R)
5 2 pumps flow switch 11 Solenoid valve for 2 pumps flow
6 2nd option control valve 12 Option switchover solenoid valve
Option select switch switchover (breaker mode ⇔ crusher mode)

<Operation>
When the option select switch is set to the breaker mode switch side, the option switchover sole-
noid valve is operated and the shut-off valve is switched to the 3-direction valve. When the switch
is switched to crusher mode, the option switchover solenoid valve goes OFF.
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1 2nd option pedal

2 2nd option switch (L)
3 2nd option switch (R)
2 pumps flow select switch (1 pump ⇔ 2 pumps)

<Operation>
When the 2 pumps flow switch is switched ON, the solenoid valve for 2 pumps flow switches to 2
pumps flow.
Difference between pedal type and knob switch type

For the pedal type, solenoid valve for 2 pumps flow hydraulic pressure source is the secondary
pressure via the option 1 pedal shuttle, but for the knob switch type, the solenoid valve for 2
pumps flow hydraulic pressure source comes directly from the gear pump.
Therefore, when the 2 pumps flow switch is switched ON, operation becomes always 2 pumps
flow.
In order to prevent this, whereas for the pedal type the ground treatment for the 2 pumps flow
switch is to ground directly,
with the knob switch type, it is set so that the switch is not grounded unless one or the other of
the option switches is ON.
* Be careful. With Model 5, the shuttle valve is built into the option 1 pedal remote control valve.
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Mode select switch
When the breaker mode switch/crusher mode switch is pressed, the option line mode changes as
follows.
* The factory setting is that only breaker 1 mode and crusher 1 mode can be selected.
* With settings on the service screen, the number of modes can be increased to 5 each for the
breaker and for the crusher, for a total of 10.
[2] For [1], the following icons are displayed according to the mode.
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[1] Configuration
[Multi purpose circuit with 2nd option line (pedal type)]
1 Computer A 9 Bucket 17 2nd option pedal

2 N2 pressure sensor 10 Boom (1) 18 2nd option pressure switch
3 Arm (1) 11 Travel (right) 19 Boost solenoid
4 Option 12 Straight travel 20 P1 pump
5 Boom (2) 13 Swing pressure sensor 21 P2 pump
6 Swing 14 Travel pressure sensor 22 P1 flow control proportional valve
7 Travel (left) 15 Option pedal
8 Arm (2) 16 Option pressure switch
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[2] Option line operation control
The table below shows the control for operation of the single option and compound operation.
Option line mode Breaker Crusher 2nd option
1st option pressure switch 1st option pressure switch 2nd option pressure switch
Operation … ON (IN3 is ground) … ON (IN3 is ground) … ON (IN4 is ground)
Single Compound Single Compound Single Compound
Boost cut Yes Yes No
Flow restriction Yes Yes No No function (4th pump)
Engine speed/pump
According to the command for the work mode selected with the throttle
horsepower milli-amp
• The flow is not cut for compound crusher operation. (To secure speed for compound operation)
• Since the breaker often works while the machine is jacked up with the boom (compound opera-
tion), the flow is cut even for compound work. (The same as the engine reduction for the current
breaker)
• The pressure boost is cut when Option 1 and Option 2 are operated at the same time. (Boost cut
priority)
• The engine speed and pump horsepower milli-amp are according to the work mode currently
selected with the throttle.
(cannot be forced to change to another mode only for breaker/crusher.)
[3] Option 1 single operation judgment conditions
When all the conditions below are satisfied, it is judged that this is single operation.
<Conditions>
1st option pressure switch … ON Swing pressure sensor … OFF
Travel pressure sensor … OFF N2 pressure sensor ≧ 348.0 PSI (2.4 MPa)
[4] Flow cut

The maximum flow for option line operation is restricted to the flow for the option line mode
selected with "Option line selection and 2 pumps flow".
Also, be careful about the fact that since the flow set for the option line is the flow for SP mode,
when used in H/A mode, the flow is slightly less than the display.
When neither the braker or crusher mode is selected (normal mode), the minimum flow amount
(50 L/min {13.2 gpm}) is produced when the pedal is pressed. (For prevention of damage to
attachments)
[5] Trouble mode
If a trouble occurs in input (swing pressure sensor, travel pressure sensor, N2 pressure sensor)
or output (boost solenoid, flow proportional valve),
the machine goes into trouble mode and
• Output command to boost solenoid = fixed to OFF
• Output command to flow proportional valve = fixed to OFF
Mode continues until the key is switched OFF.
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3. Feed Pump Automatic Stop
[1] Configuration
1 Computer A 4 Fuel tank 7 Feed stop relay

2 Feed switch 5 Oil feed start relay 8 Full tank detection buzzer
3 Fuel sensor 6 Oil feed pump made by Jabsco
Feed pump main unit accessory (original) switch.

This must be fixed ON beforehand in order to use this function.
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[2] Operating method
1) With the engine stopped and the key ON, if the feed switch is flipped down to the Auto side, the
fuel feed starts.
2) When the tank is full, the fuel feed stops automatically and the buzzer buzzes to announce that.
3) Returning the feed switch to the center stops the buzzer.
4) To feed more fuel
Press the feed switch manual side. The fuel is fed while the switch is pressed.
[3] Computer A control targets
Input = Fuel sensor (0 - 100 %)
Output = Feed stop relay
[4] System state (when relay OFF)
When the feed switch is set to the Auto side, the start relay comes ON and the pump operates.
[5] System state (when relay ON)
When the feed switch is set to the Auto side, the start relay goes OFF, and the pump does not
operate. Also, the buzzer buzzes.
[6] Feed stop relay control (while engine stopped and key ON)
When (fuel level ＜ 94 % continuously for 3 s), OFF (auto feed enabled)
When (fuel level ≧ 94 % continuously for 3 s), ON (auto feed disabled)
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[7] Time chart
1) Fuel feed is not possible unless the key is switched ON.

2) When the operator forgets and leaves the switch switched to the Auto side, the pump operates
during the power-cut delay. (When fuel level under 98 %)
3) Power-cut delay
[8] Trouble mode
If trouble occurs in an input (fuel sensor), output (feed stop relay) or communication (CAN), the
system goes into trouble mode and the feed stop relay is fixed to OFF. Be careful. In trouble
mode, even if the feed switch is set to Auto, the fuel feed is not stopped.
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4. Return Filter Clogging Detected
[1] Configuration
1 Computer A
2 Return filter clog pressure switch
4 Return filter
[2] Return filter clog pressure switch specifications
[3] Detection cancellation when breaker used

When the breaker is used, the return oil pressure pulse is intense, so clog detection is not
attempted.
[4] Detection cancellation when oil temperature low
When the oil temperature is less than 86F° (30C),
° its viscosity rises and filter pressure damage
increases, so clog detection is not attempted.
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[5] Solution for machines with no breaker setting
Machines with no breaker setting in accordance with [3].
(= Machines with no return filter clog pressure switch) Even with these machines, filter clogs
would be detected. In order to prevent this, a special connector is set that is always shorted.
1 Computer A
[6] Disconnection detection

When the key is ON, if IN1 was OFF before the engine was started, the situation is judged to be
a disconnection abnormality.
5. Beacon (Option for Europe)
[1] Configuration
1 Beacon switch (alternate)

2 Computer A
3 Beacon
[2] Destination
This function is for Europe.
[3] Operation
The beacon is driven via the beacon relay linked with the beacon switch.
This function is not mediated by the computer A.
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Service Support
Service Support
Screen Operations
1. Screen Shift
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[1] Operation for shifting to
support screen
1) If both the travel high-speed switch and the horn volume select switch on the switch
panel are held down for 3 s, the display switches to the service support screen.
2) If both the travel high-speed switch and the horn volume select switch on the switch
panel are held down again for 1 s , the display returns to the normal screen.
[2] Service support screen switching operation
1 Mode 3 Page
2 Section
1) Mode select switch: Switching with travel high-speed switch

2) Section switch: Switching with horn volume select switch
3) Page switching: Going forward with light switch and backward with washer switch
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Screen Display List
1. CHK (status display) Screen List
In CHK mode, in addition to the machine status (milli-amp, oil pressures, temperatures, etc.), it is
possible to check sensor and switch input/output states, as well as the angle, load ratio and work
radius, etc. at the applied machine (liftcrane specifications machine, lifting magnet machine).
1 Section
2 Page
For the CHK mode section types and their contents, see the separate sheet.
* From the CHK mode screen, if the washer switch and the light switch are held down for 3
s, the display shifts to the model selection screen.
MAIN
[1] Engine and pump
Eng : Engine speed
Actual milli-amp for horsepower control propor-
Power : tional valve
Actual milli-amp for flow control proportional
Flow :
valve
P1 : Pump １ Discharge pressure
P2 : Pump 2 Discharge pressure
N1 : Pump 1 Negative control pressure
[2] Temperature and pressure

Coolnt : Radiator coolant temperature
HydOil : Hydraulic oil temperature
FuelT : Fuel temperature
Baro : Atmospheric pressure
EngOil : Engine oil pressure
BstT : Boost temperature
Air : Suction air temperature
[3] Load and boost

Eng : Engine speed
Load : Load ratio
Power :
tional valve
BstP : Boost pressure
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[4] Load and milli-amp for horsepower control proportional valve
Eng : Engine speed
Load : Load ratio
Power :
tional valve
[5] Target and actual milli-amp for horsepower control proportional valve
Eng : Engine speed
Load : Load ratio
Power :
tional valve
-4- : *
tEng : Target engine speed
ThVol : Throttle volume degree of opening
tPower : Target milli-amp for horsepower control propor-
tional valve
[6] Target and actual milli-amp for flow control proportional valve
Eng : Engine speed
Power :
tional valve
Flow : Actual milli-amp for flow control proportional
valve
Swg : Swing pilot pressure
Target milli-amp for flow control proportional
tFlow :
valve
[7] Target and actual milli-amp for hydraulic fan proportional valve
Eng : Engine speed
Actual milli-amp for hydraulic fan proportional
Fan : valve
HydOil : Hydraulic oil temperature

FuelT : Fuel temperature
Target milli-amp for hydraulic fan proportional
tFan :
valve
[8] Pilot pressure

Cyl (B) : Boom bottom pressure
Upr : Upper pilot pressure
Swg : Swing pilot pressure
Trv : Travel pilot pressure
AmCls : Arm-in pilot pressure
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[9] Input/output and pressure for hydraulic circuit
Hydraulic circuit input/output state ( ○ =OFF, ● =ON)
1 Pressure sensor; Arm in 5 Solenoid; Free swing/beacon 9 Relay; Travel alarm

2 Pressure sensor; Travel 6 Solenoid; Travel high-speed switchover 10 Solenoid; Fan reverse (large machine only)
3 Pressure sensor; Swing 7 Solenoid; Boost 11 Solenoid; Option line switchover
4 Pressure sensor; Upper 8 Solenoid; Swing brake 12 Solenoid; Power save
[10] Input/output for electrical circuit

Eng : Engine speed
Batt : Battery voltage
FuelLv : Fuel level
Electric circuit input/output state ( ○ =OFF, ● =ON)
1 Switch; Anti-theft 6 Glow signal

2 Battery charge 7 Engine stop due to trouble
3 Switch; Key 8 Low idle restriction due to trouble
A/C coolant temperature sending mode Restriction on milli-amp for horsepower control
4 9
(1: Low/2: Medium/3: High) proportional valve due to trouble
5 Relay; Feed pump automatic stop
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MNT
[1] Computer S information
* The longitude and latitude are displayed when the continuous GPS position
measurement time is 5 min. or longer.
* UTC is global standard time. Japan is +9 hours from UTC.
Example) If the time is May 28, 2006, 03:14:32 UTC, the time in Japan is May
28, 2006, 12:14:32.
If the time is May 27, 2006, 20:14:32 UTC, the time in Japan is May
28, 2006, 05:14:32.
* Displayed after the completion of GPS position measurement.

* For 3D position measurement, the altitude can be measured.
* GCC is a land station. 130 is the GCC for Japan. (122 is South Korea.)
GPS continuous position measurement time

1
(For example, 5 min. 30 s of continuous position measurement)
2 Computer S part number bottom 4-digit display (Example, KHR14401)
3 Latitude Inside the ○ , 0=North latitude, 1=South latitude

(Example, 35 degrees 47.83 min. north latitude)
4 Longitude Inside the ○ , 0=Longitude east 1=Longitude west

(Example, 140 degrees 41.32 min. longitude east)
GPS position measurement status
0=GPS not yet operating, Default setting send status
0=Waiting for default settings send
1=GPS measuring, 1=Waiting due to sending currently being prohibited
5 2=2D measurement status, 7
3=3D measurement status, 2=Resending default settings
3=Default settings send complete, sending stopped
8=Faulty GPS module, 4=Default settings send complete, sending permitted
9=Faulty GPS antenna
Satellite communications status
0=No Satellite data acquired,
6 8 BLANK
1=Satellite data acquired,
9=Satellite communications abnormal
10 Altitude (Example:170.6 ft)
UTC
9 (Example: May 28, 2006, 03:14:32) 11 Send GCC number
The time in Japan is May 28, 2006, 12:14:32.
12 Data acquisition GCC number
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Event send setting

The default state is fuel volume warning, anti-theft operation warning event send inhibited.
These can be changed to enabled with signals from the web server. When this signal is received, No. 4 becomes the display below.
Anti-theft operation warning Anti-theft operation warning

Fuel volume warning
(without position information) (with position information)
0028 Inhibited Inhibited Inhibited
0156 Enabled Inhibited Inhibited
0220 Enabled Enabled Inhibited
0188 Enabled Inhibited Enabled
0092 Inhibited Enabled Inhibited
0060 Inhibited Inhibited Enabled
1 Engine start enable setting 0=Inhibited, 1=Enabled

2 Send destination count
* The send destination is the server, so it is fixed at 1.
Time until next sending
3 (Example: 3 hours 24 min. more until the next sending)
4 Send wait message count (Example: 2)
Q1200 status
0= Waiting,
5 1=Sending,
4=Receiving,
5=Receiving complete
Send distribution setting
6 0248=STD,
0252=Liftcrane specifications
7 Event send setting 0028=Default setting
Send inhibition setting
8 0=Sending default settings
128=Default settings send complete
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H/W-A
[1] Digital input/output
Input/output state ( ○ =OFF, ● =ON)
1 Solenoid; Power save 9 Relay; Feed pump 17 Switch; Pressure (Option)

2 Solenoid; Boost 10 Switch; Clog (Air cleaner) 18 Switch; Fan reverse
3 Solenoid; Travel high-speed switchover 11 Switch; Level (Coolant) 19 Switch; Clog (Return filter)
4 Solenoid; Swing brake 12 Switch; Anti-theft 20 Alternator
5 Buzzer; Travel alarm 13 Switch; One-touch idle 21 Switch; Engine emergency stop
6 Solenoid; Option line switchover 14 Switch; Travel alarm/overload 22 Switch; Key
7 Solenoid; Free swing 15 Switch; Free swing
8 Solenoid; Fan reverse 16 Switch; Pressure (2nd option)
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[2] Digital output/output monitor
1 Solenoid; Power save 4 Solenoid; Swing brake 7 Solenoid; Free swing

2 Solenoid; Boost 5 Buzzer; Travel alarm 8 Solenoid; Fan reverse
3 Solenoid; Travel high-speed switchover 6 Solenoid; Option line switchover 9 Relay; Feed pump
[3] Potentio-meter voltage

Pot1 : Sensor pressure P1
Pot2 : Sensor pressure P2
Pot3 : Sensor pressure N1
Pot4 : Sensor pressure N2
Pot5 : Sensor pressure Swing
Pot6 : Sensor pressure Upper
Pot7 : Sensor pressure Travel
[4] Potentio-meter and sensor voltage (resistance)

Pot8 : Sensor pressure Arm in
Pot9 : Sensor throttle
Pot10 : Sensor pressure Overload
Sn1 : Sensor temperature Hydraulic oil
Sn2 : Sensor level Fuel
Sn1 : Sensor temperature Hydraulic oil
Sn2 : Sensor level Fuel
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[5] PWM data
PWM# : PWM channel number
actcur :
tional valve
tgtcur : Target milli-amp for horsepower control propor-
tional valve
duty : Duty
freq : Frequency
volt : Voltage
Overcurrent detection status
ovc : (+: Overcurrent/-: Normal)
[6] PWM data

actcur : Actual milli-amp for hydraulic fan proportional

valve
tgtcur : valve
duty : Duty
freq : Frequency
volt : Voltage
ovc :
(+: Overcurrent/-: Normal)
[7] PWM data

Actual milli-amp for flow control proportional
actcur : valve
Target milli-amp for flow control proportional
tgtcur :
valve
duty : Duty
freq : Frequency
volt : Voltage
[8] Frequency and communication

FreqIn : Frequency input
CAN : CAN reception state
UART : UART reception state
RS232 : RS232C communication state
-5- : *
-6- : *
-7- : *
Input/output state ( ● =receiving)
1 Computer S reception state

2 Computer B reception state
3 ECM reception state
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H/W-B
[1] Computer B digital input/output
1 Solenoid; Lever lock 4 Switch; Crane mode 7 Switch; Lifting magnet mode
2 Rotating light and bucket lock 5 Switch; Crane (Display switching) 8 Switch; Interference (Shut-off release)
3 Buzzer; Crane 6 Switch; Interference (Temporary end)
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[2] Digital output/output monitor
1 Solenoid; Lever lock

2 Rotating light and bucket lock
3 Buzzer; Crane
[3] Potentio-meter voltage

Pot1 : Sensor; Angle (Boom)
Pot2 : Sensor; Angle (Arm)
Pot3 : Sensor; Angle (Offset)
Pot4 : Sensor; Pressure (Bottom)
Pot5 : Sensor; Pressure (Rod)
Pot6 : *
Pot7 : *
[4] Potentio-meter and sensor voltage (resistance)

Pot8 : *
Pot9 : *
Pot10 : *
Sn1 : *
Sn2 : *
Sn1 : *
Sn2 : *
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[5] PWM data
actcur : Actual milli-amp for boom proportional valve
tgtcur : Target milli-amp for boom proportional valve
duty : Duty
freq : Frequency
volt : Voltage
Overcurrent detection status (+: Overcurrent/-:
ovc :
Normal)
[6] PWM data

actcur : Actual milli-amp for offset proportional valve
tgtcur : Target milli-amp for offset proportional valve
duty : Duty
freq : Frequency
volt : Voltage
[7] PWM data

actcur : Actual milli-amp for arm proportional valve
tgtcur : Target milli-amp for arm proportional valve
duty : Duty
freq : Frequency
volt : Voltage
ovc :
(+: Overcurrent/-: Normal)
[8] Frequency and communication

FreqIn : Frequency input
CAN : CAN reception state
UART : UART communication state
RS232 : RS232C communication state
-5- : *
-6- : *
-7- : *
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H/W-M
[1] Monitor
1 Working light 7 Switch; Travel high-speed select 13 Switch; Washer

2 Motor washer 8 Switch; Auto idle select 14 Switch; Reserve
3 Wiper CNT 9 Switch; Horn volume select 15 Switch; 2 pumps flow
4 Wiper INT 10 Switch; Breaker select 16 Switch; Crusher select
5 Relay horn volume switchover 11 Switch; Limit front window
6 Switch; Working light 12 Switch; Wiper
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2. DIAG (trouble diagnosis) Screen
[1] In diagnosis mode, you can check from the contents for the trouble currently occurring to a log of
trouble that has occurred in the past.
1 Status occurrence count 4 Diagnostic trouble code

2 Initial occurrence time 5 Cursor movement
3 Final occurrence time
• In "DTC-1" through "DTC-4", the data is displayed in order from the most recently occurring diag-
nostic trouble code.
• The cursor is moved with the wiper switch and auto idle switch . (The cursor moves
between "DTC-1" and "DTC-4".)
* There is no "section" in diagnosis mode.
• The information for the diagnostic trouble code for the location under the cursor is displayed in
the order "ST/OC", "1st", "Last".
• The ○ mark displayed at the left most of "ST/OC" shows whether or not the trouble is currently
occurring.
The black circle ● means the trouble is currently occurring.
The clear circle ○ means the trouble is not occurring now, but has occurred in the past.
• "1st" indicates the time at which this trouble occurred the first time and "last" indicates the time at
which this trouble occurred the last time.
[2] For details on the "Diagnostic trouble codes" that can be read in diagnosis mode and their con-
tents, see the Main Unit Diagnostic Trouble Code List below.
(1)Screen
(4)
(1)
(2)
(3)
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[1] Displays the status at the cursor and the occurrence count.
[Status]
Displays whether the diagnostic trouble code under the cursor is current or from the past.
For ● , the trouble is current or continuing.
For ○ , the status is normal or recovered.
(The trouble is not occurring now, but has occurred in the past.)
[Occurrence count]
The number of times that diagnostic trouble code under the cursor has occurred
[2] Displays the time at which the trouble under the cursor first occurred
Occurred first at 10 hours
[3] Displays the time at which the trouble under the cursor last occurred
Occurred last at 901 hours
[4] Diagnostic trouble code
The troubles are sorted with the last one to occur at the top of the list.
The diagnostic trouble code under the cursor is displayed in (1) - (3).
Maximum display count

4 codes per page x 16 pages = 64 diagnostic trouble codes are displayed. From the 65th
code onward, the oldest code is erased. However, even though these codes are not dis-
played, the data is retained.
(2)Operation
[1] Cursor up/down
Up operation............. wiper switch
Down operation ........ auto idle switch
[2] Page forward/back
Forward operation .... light switch
Back operation ......... washer switch
(3)Reset
If the washer switch and the light switch are held down for 10 s, the trouble log is reset.
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3. HR (usage log) Screen List
In HR mode, operation times for mechanical parts, electrical parts, etc., operation counts for
switches and solenoids, as well as pressure distributions, etc. can be displayed.
1 Section
2 Page
(1)MAIN
[1] Main unit operation time
KeyOn : Computer A power supply ON time
EngOn : Alternator power generation time
Work : Machine operation time (upper ON or travel ON)
Upr : Upper operation time
Swg : Swing operation time
Trv : Travel operation time
TrSolo : Travel single operation time
[2] Electrical parts operation time

WpInt : Wiper (intermittent) Operation time
WpCnt : Wiper (continuous) Operation time
Wsh : Washer Operation time
WLight : Working light ON time
HornLo : Horn volume low time
DrOpn : *
WinOpn : Front window open time
[3] Idle time

1 : Auto idle time
2 : One-touch idle time
3 : Boosted pressure time
4 : Low-speed travel time
5 : High-speed travel time
6 : *
7 : *
[4] Pressure switch operation count

1 : Upper pressure sensor ON count x 1000
2 : Swing pressure sensor ON count x 1000
3 : Travel pressure sensor ON count x 1000
4 : Arm-in pressure switch ON count x 1000
5 : 1st option pressure switch ON count x 1000
6 : 2nd option pressure switch ON count x 1000
7 : *
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[5] Operation switch operation count
1 : Key ON count x 10
2 : Engine start count x 10
3 : Front window open count x 10
4 : *
5 : Boost solenoid ON count x 1000
6 : Swing brake solenoid ON count x 1000
7 : Power save solenoid ON count x 1000
[6] Work mode

1 : Mode usage time SP-hi
2 : Mode usage time SP-lo
3 : Mode usage time H-hi
4 : Mode usage time H-lo
5 : Mode usage time A1-hi
6 : Mode usage time A1-lo
7 : Mode usage time, other than above
[7] Breaker usage time

1 : Breaker 1 operation time
6 : Breaker 1-5 operation time
7 : *
[8] Crusher usage time

1 : Crusher 1 operation time
6 : Crusher 1-5 operation time
7 : *
[9] P1 pressure (P) distribution

1 : P < 1450 PSI Time
2 : 1450 PSI ≦ P < 2900 PSI Time
3 : 2900 PSI ≦ P < 2625 PSI Time
4 : 2625 PSI ≦ P < 4350 PSI Time
5 : 4350 PSI ≦ P < 5075 PSI Time
6 : 5075 PSI ≦ P < 5075 PSI Time
7 : 5075 PSI ≦ P Time
[10] P2 pressure (P) distribution

1 : P < 1450 PSI Time
2 : 1450 PSI ≦ P < 2900 PSI Time
3 : 2900 PSI ≦ P < 2625 PSI Time
4 : 2625 PSI ≦ P < 4350 PSI Time
5 : 4350 PSI ≦ P < 5075 PSI Time
6 : 5075 PSI ≦ P < 5075 PSI Time
7 : 5075 PSI ≦ P Time
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[11] N1 pressure (P) distribution
1 : P < 1450 PSI Time
2 : 1450 PSI ≦ P < 2900 PSI Time
3 : 2900 PSI ≦ P < 2625 PSI Time
4 : 2625 PSI ≦ P < 4350 PSI Time
5 : 4350 PSI ≦ P < 5075 PSI Time
6 : 5075 PSI ≦ P < 5075 PSI Time
7 : 5075 PSI ≦ P Time
[12] N2 pressure (P) distribution

1 : P < 145.0 PSI Time
2 : 145.0 PSI ≦ P < 217.5 PSI Time
3 : 217.5 PSI ≦ P < 290.0 PSI Time
4 : 290.0 PSI ≦ P < 362.5 PSI Time
5 : 362.5 PSI ≦ P < 362.5 PSI Time
6 : 362.5 PSI ≦ P < 435.0 PSI Time
7 : 435.0 PSI ≦ P Time
[13] P1 + P2 pressure (P) distribution

1 : P < 2625 PSI Time
2 : 2625 PSI ≦ P < 5075 PSI Time
3 : 5075 PSI ≦ P < 5800 PSI Time
4 : 5800 PSI ≦ P < 7250 PSI Time
5 : 7250 PSI ≦ P < 8700 PSI Time
6 : 8700 PSI ≦ P < 10510 PSI Time
7 : 10510 PSI ≦ P Time
[14] Oil temperature (T) distribution

1 : T < 113F° Time (bar graph 1st and 2nd gradation)
2 : 113F° ≦ T < 140F° Time (bar graph 3rd gradation)
3 : 140F° ≦ T < 176F° Time (bar graph 4th gradation)
6 : 203F° = T < 208F° Time (bar graph 7th gradation)
7 : 208F° ≦ T Time (bar graph 8th gradation)
(2)ENG
[1] Oil temperature/coolant temperature/pressure maximum values
(Measured 10 min. after engine started)
Coolnt : Radiator coolant maximum temperature
HydOil : Hydraulic oil maximum temperature
FuelT : Fuel maximum temperature
Air : Suction air maximum temperature
BstT : Boost maximum temperature
BstP : Boost maximum pressure
EngOil : Engine oil minimum pressure
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[2] Engine actual speed (S) distribution
1 : S < 1025 rpm Time
2 : 1025 rpm ≦ S < 1225 rpm Time
3 : 1225 rpm ≦ S < 1425 rpm Time
4 : 1425 rpm ≦ S < 1625 rpm Time
5 : 1625 rpm ≦ S < 1825 rpm Time
6 : 1825 rpm ≦ S < 2025 rpm Time
7 : 2025 rpm ≦ S Time
[3] Coolant temperature (T) distribution

1 : T < 171 °F Time (bar graph 1st and 2nd gradation)
2 : 171F° ≦ T < 180F° Time (bar graph 3rd gradation)
7 : 221F° ≦ T Time (bar graph 8th gradation)
[4] Fuel temperature (T) distribution

1 : T < 104F° Time
2 : 104F° ≦ T < 122F° Time
3 : 122F° ≦ T < 140F° Time
4 : 140F° ≦ T < 158F° Time
5 : 158F° ≦ T < 176F° Time
6 : 176F° ≦ T < 194F° Time
7 : 194F° ≦ T Time
[5] Suction air temperature (T) distribution

1 : T < -4F° Time
2 : 4F° ≦ T < 32F° Time
3 : 32F° ≦ T < 59F° Time
4 : 59F° ≦ T < 86F° Time
5 : 86F° ≦ T < 113F° Time
6 : 113F° ≦ T < 140F° Time
7 : 140F° ≦ T Time
[6] Boost temperature (T) distribution

1 : T < 122F° Time
2 : 122F° ≦ T < 176F° Time
3 : 176F° ≦ T < 230F° Time
4 : 230F° ≦ T < 284F° Time
5 : 284F° ≦ T < 338F° Time
6 : 338F° ≦ T < 392F° Time
7 : 392F° ≦ T Time
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[7] Atmospheric pressure (P) distribution
1 : P < 17.72 in•Hg Time
2 : 17.72 in•Hg ≦ P < 20.38 in•Hg Time
3 : 20.38 in•Hg ≦ P < 23.03 in•Hg Time
4 : 23.03 in•Hg ≦ P < 25.69 in•Hg Time
5 : 25.69 in•Hg ≦ P < 28.35 in•Hg Time
6 : 28.35 in•Hg ≦ P < 31.01 in•Hg Time
7 : 31.01 in•Hg ≦ P Time
[8] Engine oil pressure (P) distribution

1 : P < 0 PSI Time
2 : 0 PSI ≦ P < 22 PSI Time
3 : 22 PSI = P < 44 PSI Time
4 : 44 PSI = P < 65 PSI Time
5 : 65 PSI ≦ P < 87 PSI Time
6 : 87 PSI ≦ P < 106 PSI Time
7 : 106 PSI ≦ P Time
[9] Boost pressure (P) distribution

1 : P < 22 PSI Time
2 : 22 PSI ≦ P < 26 PSI Time
3 : 26 PSI ≦ P < 30 PSI Time
4 : 30 PSI ≦ P < 35 PSI Time
5 : 35 PSI ≦ P < 39 PSI Time
6 : 39 PSI ≦ P < 44 PSI Time
7 : 44 PSI ≦ P Time
[10] Load ratio (R) distribution

1 : R ＜ 30 ％ Time
2 : 30 ％ ≦ R ＜ 40 ％ Time
3 : 40 ％ ≦ R ＜ 50 ％ Time
4 : 50 ％ ≦ R ＜ 60 ％ Time
5 : 60 ％ ≦ R ＜ 70 ％ Time
6 : 70 ％ ≦ R ＜ 80 ％ Time
7 : 80 ％ ≦ R Time
[11] Load ratio (R) distribution for SP mode

1 : R ＜ 30 ％ Time
2 : 30 ％ ≦ R ＜ 40 ％ Time
3 : 40 ％ ≦ R ＜ 50 ％ Time
4 : 50 ％ ≦ R ＜ 60 ％ Time
5 : 60 ％ ≦ R ＜ 70 ％ Time
6 : 70 ％ ≦ R ＜ 80 ％ Time
7 : 80 ％ ≦ R Time
[12] Load ratio (R) distribution for H mode

1 : R ＜ 30 ％ Time
2 : 30 ％ ≦ R ＜ 40 ％ Time
3 : 40 ％ ≦ R ＜ 50 ％ Time
4 : 50 ％ ≦ R ＜ 60 ％ Time
5 : 60 ％ ≦ R ＜ 70 ％ Time
6 : 70 ％ ≦ R ＜ 80 ％ Time
7 : 80 ％ ≦ R Time
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4. CFG (setting change) Screen
• Hold down the auto idle switch for 1 s. The cursor is displayed and the value starts to flash.
• The flashing value can be changed with the washer switch /working light switch .
• When the travel high-speed switch is pressed, value is finalized and the change is reflected in
the actual machine.
• When the horn volume select switch is pressed, the change is cancelled.
(1)Operation
[1] View mode (screen switching operation)

1) Switching to edit mode
Hold down the auto idle switch for 1s.
The mode switches to edit mode and the
cursor is displayed.
2) Page forward/back
Forward operation.. light switch
Back operation....... washer switch
[2] Edit mode (setting change operation)

1) Cursor up/down
Up operation .......... wiper switch
Down operation ..... auto idle switch
2) Numeric value increase/decrease
Increase value ....... light switch
Decrease value...... washer switch
3) Enter
Enters the set contents.
4) Cancel
Cancels the set contents.
When 3) or 4) is executed, this exits edit
mode and shifts the mode to view mode.
(The cursor disappears.)
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[3] Reset
If the washer switch and the light switch are held down for 10 s, the setting contents
are reset and all settings return to their default values.
(2)Screen
[1] MAIN 1
Item name Explanation Setting range Default value

Min speed - auto idling
LowIdl Low idling speed 1000
speed
AtIdl1 Auto idling shift time 1 - 30 5
AtIdl2 Auto idling speed Low idling speed - 1500 1200
PrUp1 Auto pressure boost yes/no ＋ : YES, － : NO ＋
PrUp2 Auto pressure boost for option line usage yes/no ＋ : YES, － : NO －
PwrAj Transient load minimum milli-amp 50 - 400 300
-7- High altitude correction milli-amp 0 - 250 0
* PwrAj is the previous high altitude mode.
[2] MAIN 2

TrSpd Travel speed previous data held yes/no ＋ : YES, － : NO －
TrAlm1 Travel alarm buzzing yes/no ＋ : YES, － : NO ＋
TrAlm2 Travel alarm automatic stop time 1 - 30 10
CoolDn
EPF EPF (Engine Protection Feature) yes/no ＋ : YES, － : NO ＋
Unit Display unit ＋ : YES, － : NO 0
-7-
* Display units … MPa={MPa, ℃ }, PSI={psi, °F｝, kgf/cm2={kgf/cm2, ℃ }
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[3] MAIN 3

Spd1
Spd2
OvLd Pressure at which alarm starts
MntMsg "SERVICE DUE" display yes/no ＋ : YES, － : NO ＋
Cycle "SERVICE DUE" display range 0 - 5000 500
Remain Time until next "SERVICE DUE" display 0 - 5000 500
-7- New harness yes/no ＋ : YES, － : NO ＋
* OvLd is an option for Europe.
* -7- is battery charge and engine emergency stop port substitution
[4] A.INTF 1

Front Front surface stop area compensation value
Right Right surface stop compensation value
BkLen Bucket toe distance
BkWd Bucket width
-5- N/A
-6- N/A
-7- N/A
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5. CAL (troubleshooting support) Screen
(1)Operation
[1] View mode (screen switching operation)

1) Switching to edit mode
Hold down the auto idle switch for 1s.
The mode switches to edit mode and the
cursor is displayed.
2) Page forward/back
Forward operation . light switch
Back operation....... washer switch
[2] Edit mode (setting change operation)

1) Cursor up/down
Up operation .......... wiper switch
Down operation ..... auto idle switch
2) Numeric value increase/decrease
Increase value ....... light switch
Decrease value...... washer switch
3) Enter
Enters the set contents.
4) Cancel
Use the travel high-speed select switch
or the horn volume select switch
to cancel. Exits edit mode and shifts to
view mode. (The cursor disappears.)
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(2)Screen
[1] Engine pump override 1

tEng Target engine speed 500 - max speed Low idle
Target milli-amp for horsepower control propor-
tPower 50 - 740 50
tional valve
tFlow Target milli-amp for flow control proportional valve 50 - 740 50
P1 P1 pressure - -
P2 P2 pressure - -
N1 N1 pressure - -
N2 N2 pressure - -
[2] Engine pump override 2

tEng Target engine speed 500 - max speed Low idle
Target milli-amp for horsepower control propor-
tPower 50 - 740 50
tional valve
tFlow Target milli-amp for flow control proportional valve 50 - 740 50
P1+P2 P1+P2 pressure - -
Eng Actual engine speed - -
Power - -
tional valve
Flow Actual milli-amp for flow control proportional valve - -
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[3] Hydraulic pressure drive fan override

Eng Actual engine speed - -
Coolnt Coolant temperature - -
tFan - -
valve
HydOil Oil temperature - -
FuelT Fuel temperature - -
BstT Boost temperature - -
Actual milli-amp for hydraulic fan proportional
Fan - -
valve
[4] Crane initial adjustment

Cyl (B) Boom cylinder bottom pressure -
Cyl (R) Boom cylinder rod pressure -
-3- * -
Maximum
STEP Adjustment step number 0 - Maximum value
value
Bm A Angle sensor voltage value -
Am A Angle sensor voltage value -
Of A Angle sensor voltage value -
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[5] Interference prevention initial adjustment

Cyl (B) Boom cylinder bottom pressure -
Cyl (R) Boom cylinder rod pressure -
-3- * -
STEP Adjustment step number 0 - Maximum value 5
Bm A Angle sensor voltage value -
Am A Angle sensor voltage value -
Of A Angle sensor voltage value -
6. Check the Monitor Switch (self-diagnosis function)

[1] After the key is switched ON, the "SUMITOMO" logo screen is displayed on the monitor.
At this time, the display can be switched to the monitor switch check screen by pressing the one-
touch idle switch 5 times.
The switch contents are as follows.

SW1 Front window limit switch
SW2 Breaker mode switch
SW3 Crusher mode switch
SW4 2 pumps flow mode switch
SW5 Not used
WIPER SW Wiper switch
WASHER SW Washer switch
W. LAMP SW Working light switch
T. MODE SW Travel high-speed select switch
A. IDLE SW Auto idle switch
HORN VOL. SW Horn volume select switch
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[2] Configuration
1 Switch panel 4 Breaker mode switch

2 2 pumps flow switch 5 Crusher mode switch
3 Front window limit switch 6 Monitor
[3] Differences from CHK screen [CHK|H/W-M|1]

Monitor main unit input/output can also be checked on the CHK screen. However, for the CHK
screen,
1) after the switch input is sent to computer A with communication,
2) the switch input is processed by computer A and
3) the results are sent to the monitor as screen data
and displayed. On the monitor switch check screen, the switch input recognized by the monitor
itself is displayed directly on the screen (without involving communication or computer A), so it is
possible to diagnose purely the switches themselves.
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7. Option Flow Setting
[1] When 3 s have passed, the logo screen shifts to the user screen.
With the user screen being displayed, if either the "breaker" or "crusher" rocker switch on the
right panel is held down for 3 s, the "option flow setting screen" is displayed on the monitor.
[2] Flow setting

1) Press the breaker or crusher mode switch to select the mode to set the flow for.
1 Flow increase 3 Crusher mode (1 - 5) switchover

2 Flow decrease 4 Breaker mode (1 - 5) switchover
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2) The flow setting for the selected mode is selected by pressing the wiper switch or auto idle
select switch .
The flow setting can be set to 10 levels from level 1 - level 10.
Caution
The set flow is the flow value when SP mode is selected.
Be careful. If run with the engine speed reduced, the actual flow is not the flow displayed.
Unit 130
1 pump flow (flow level 1) gpm 34
2 pumps flow (flow level 1) gpm 68
[3] There is no need to do anything to finalize the setting. End by leaving this screen or switching
OFF the key.
The factory settings for each mode are as follows.
There are no 4 or 5 settings for the breaker or crusher. Just a hyphen is displayed for these set-
tings.
Mode Flow display

Breaker circuit 1/Crusher 1 Level 3 flow
Breaker circuit 4/Crusher 4 ---- (Not used)
Breaker circuit 5/Crusher 5
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8. Anti-theft Setting
[1] Anti-theft Setting and Password Registration
1) Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear
cover, the anti-theft function is enabled. The factory setting is for these knob terminals to be dis-
connected.
2) Setting the password

When the knob terminals are connected, then the key switched ON, the following screen is dis-
played.
Enter any 4-digit number made up of the numbers 1 - 9.
(If all 4 digits are not input, “ERROR” is displayed.)
Input by using the monitor switches as follows.
1. When the Enter button is pressed, the password is stored into memory and display
returns to the normal screen.
1 Enter 3 Numeric value increase/decrease

2 Cursor movement
3) Changing the password

If the password has been forgotten or it is desired to change the password, if the knob terminal
in [1]-1) is disconnected and the key switched ON, the password is cleared. To re-input the
password, repeat the procedure in [1].
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[2] Anti-theft function operation
1) Enabling the anti-theft function
1. If the key is switched twice in a row ON → OFF → ON → OFF with the engine stopped, the
anti-theft function is switched ON.
(All the key switching operations must be done within 2 s.)
2. When the anti-theft comes ON, the monitor buzzes and the “key” icon is displayed.
(Once the anti-theft is switched ON, this icon is displayed while the power is OFF.)
3. The next time the key is switched ON, the anti-theft operates and the password input screen
is displayed.
Input the password made up of 4 digits 0 - 9.
Input by using the monitor switches below.
If an incorrect number is input, “ERROR” is displayed and the buzzer buzzes.
The key must be switched OFF, then ON again before the password can be re-input.
1 Enter 3 Numeric value increase/decrease

2 Cursor movement
2) Disabling the anti-theft function

1. If the engine is stopped by switching OFF the key, the anti-theft function does not operate.
2. To disable the anti-theft function, disconnect the anti-theft knob terminals VG (purple/green)
and BG (black/green). The registered password is canceled.
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9. Model Setting
[1] If the model selection has not been completed, immediately after the key is switched ON, the
“Model select screen” is displayed.
1 Cursor 3 Computer B; Part number

2 Computer A; Part number 4 Error display section
1) For the "CONT.A:" item, the part number for computer A is automatically displayed.
2) In the same way, if computer B is connected (for the liftcrane specifications or interference pre-
vention specifications), the part number for computer B is automatically displayed for the
"CONT.B:" item.
3) Items that must be input are displayed with '?'.
a) MACHINE ： Model (130X2, 160X2, 210X2, 240X2, 290X2)
b) TERRITORY ： Destination (0: Domestic, general export, 1:LBX, 2:CASE NA, 3:CASE EU, 4: IHI）
c) LANGUAGE ： Language （0: Japanese, 1: English, 2: Thai, 3: Chinese, 4: German, 5: French,
6: Italian, 7: Spanish, 8: Portuguese, 9: Dutch, 10: Danish,
11: Norwegian, 12: Swedish, 13: Finnish, 14: Turkish, 15: Arabic,
16: Malay, 17: Indonesian, 18: Icon)
d) SPEC ： Main unit specifications (Input 0)
e) ATT.No. ： Attachment specifications (input 0)
4) Input operating method
Input by using the monitor switches as follows.
* When the model select screen is displayed on the monitor, the normal monitor switch func-
tions do not work.
1 Enter button
2 Numeric value change
3 Cursor movement
When the throttle volume position or all the input is complete, press ‘ ’ (Enter button). (The
throttle volume must always be at the "H" mode position.)
If the input is inappropriate (*), “CONT. A.ERR” is displayed.
* When there is still an item left with "?" displayed or the combination of model, destination,
specification, and the like is inappropriate
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5) On the model setting screen, the ECM part number is automatically checked.
If the input model and the ECM part number do not correspond, “ECM ERR” is displayed.
6) Even after the model selection is complete, it is possible to change just the LANGUAGE setting
without one of the half resets or all resets listed below.
7) Half reset
On the model select screen, if the washer switch and the light switch are held down for
3 s, data in the table below is erased.
8) All reset
On the model select screen, if the washer switch and the light switch are held down for
10 s, data in the table below is erased.
Difference between all reset and half reset
Reset.......................................... ○
Not reset .......................................................................×
Reset when model information has changed. ....... △
Half reset All reset
Model information (*1) ○ ○
Control data (*2) ○ ○
Computer A memory information Usage log (*3) × ○
Trouble log (*4) × ○
Engine information (*5) × ○
Computer S memory information Transmission information (*6) × ○
*1 Contents displayed on model selection screen
*2 Contents displayed on CFG screen
*3 Contents displayed on HR screen
*4 Contents displayed on DIAG screen
*5 Contents displayed on engine service screen
*6 When transmission information is reset, transmission with the G@NAV server is restarted from
the initial send.
In this case, transmission with the G@NAV server cannot be done until a send permission signal
is sent from the control center.
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10.Engine Screen Information
[1] Purpose
It has been made possible to copy the engine information (Q adjustment, QR code, engine serial
number) stored in the ECM to the new ECM when the ECM and injector are replaced.
[2] How to go to this screen
See the service support screen operations.
[3] Engine start restriction
When this screen is displayed, the engine cannot be started.
[4] Screen
The engine information held in computer A can be checked as follows.
1) Pages 1 - 4: Injector cylinder 1- 4 QR code (Pages 5 and 6 are not used and cannot be input.)
1 Page
2 24-digit QR code
3 Error code
Indicates the display mode.
4 Currently displays the information in
computer A.
2) Page 7: Q resistance data
1 3-digit Q resistance data
3) Page 8: Engine serial number
1 6-digit engine serial number
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4) ECM part number
1 ECM part number
[5] Operating method

See the Engine Maintenance Standards.
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Screen Display Details
1. Message Display List
Display Message Display ON timing Display OFF timing
type
LOW OIL PRESS. Warning When the "Engine oil pressure abnormally low" trouble occurs None Does not go off while the key is ON.
When the "ECM mismatch" trouble occurs
CHECK ENGINE Warning None Does not go off while the key is ON.
Also, when a diagnostic trouble code is sent from the ECM
When any of the troubles below occur
“Sensor; Pressure (P1)”, “Sensor; Pressure (P2)”, “Sensor; Pres-
sure (N1)”,“Sensor; Pressure (N2)”, “Sensor; Pressure (Over-
load)”, “Sensor; Pressure (Bottom)”, “Sensor; Pressure (Rod)”,
“Sensor; Pressure (Upper)”, “Sensor; Pressure (Swing), “Sensor;
Pressure (Travel)”
“Sensor; Fuel level”, “Sensor; Oil temperature”
"Pressure switch; Return filter clog"
"Solenoid; Swing brake", "Solenoid; Travel high-speed"
ELEC.
PROBLEM (*1) Warning "Relay; Feed pump automatic stop", "Solenoid; Option return cir- None Does not go off while the key is ON.
cuit", "Solenoid; Free swing"
"Air conditioner signal output"
"Rotating light and solenoid; Bucket lock"
"Proportional valve; Horsepower pump", "Proportional valve; Flow
pump"
"Communication monitor", "Communication ECM", "Communica-
tion computer B", "Communication computer S",
"CAN bus"
When any of the troubles below occur When all the troubles below are recovered
OVER HEAT Warning ”Abnormally high coolant temperature 1”, “Abnormally high oil tem- from “Abnormally high coolant tempera-
perature” ture 1” “Abnormally high oil temperature”
LOW COOLANT Warning When the “Coolant level low” trouble occurs None Does not go off while the key is ON.
ALTERNATOR Warning When the “Abnormally low alternator voltage” trouble occurs None Does not go off while the key is ON.
CHECK HYD.OIL Warning When the “Return filter clogged” trouble occurs None Does not go off while the key is ON.
FILTER
AIR FILTER Warning When the “Air cleaner clogged” trouble occurs None Does not go off while the key is ON.
BOOST Warning When the “Abnormally high boost temperature 1” trouble occurs When the “Abnormally high boost temper-
TEMP.HIGH ature 1” trouble is recovered from
When the “Fuel level low” trouble is recov-
LOW FUEL Warning When the “Fuel level drop” trouble occurs
ered from
SWITCH TO When the conditions on the left are no lon-
1-PUMP Alert When the breaker mode is ON and 2 pumps flow is ON ger met
ENGINE STOP Alert When the engine emergency stop switch is ON When the conditions on the left are no lon-
ger met
When the boom cylinder bottom pressure exceeds the set pres- When the conditions on the left are no lon-
OVER LOAD Alert
sure ger met
When the conditions on the left are no lon-
IDLING Icon During one-touch idling or auto idling ger met
Icon During auto pressure boost When the conditions on the left are no lon-
POWER UP ger met
ENG. PRE HEAT Icon When power ON to glow plug
ger met
AUTO WARM UP Icon During auto warm up ger met
INITIAL SET- When the crane interference prevention initial adjustment has not When the conditions on the left are no lon-
TINGS INCOM- Status
PLETE been completed ger met
SERVICE DUE Status When the key is ON and the hour meter has reached the regulation After 1 min. after the key was switched ON
time
(*1) Even if one of the following troubles occurs, “ELEC. PROBLEM” is not issued.
"Travel alarm buzzer", "Monitor thermistor", "Air conditioner coolant signal output"
Message type
[1] Status................. Message only
[2] Alert ................... The intermittent alarm continues to sound at 1-second intervals.
[3] Warning ............. The continuous alarm sounds for just 5 s.
[4] Icon .................... Icon only
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Trouble Display
1. Diagnostic Trouble Code Display
[1] Purpose and summary
When a trouble occurs, the diagnostic trouble code (DTC) is displayed on the user screen.
This enables the operator to verbally communicate the trouble to the service engineer.
[2] Screen
Displayed with the ! mark next to the work mode followed by a 4-digit number.
If there is no trouble, nothing at all is displayed.
ELEC. PROBLEM
[3] Trouble display

The “ELEC. PROBLEM” or “CHECK ENGINE” message is displayed.
When trouble occurs, the corresponding diagnostic trouble code is displayed. If the message
makes clear the trouble location, the location is not displayed elsewhere.
For details, see the “Main Unit Diagnostic Trouble Code List”. All the diagnostic trouble codes
sent from the ECM are subject to display.
[4] Displayed trouble status
Only current and ongoing troubles are displayed. Troubles that have been recovered from are not
displayed.
[5] Multiple trouble display
When multiple troubles occur, they are displayed in turn at 5-second intervals.
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2. Main Unit Diagnostic Trouble Code List
(1)Electrical troubles (input) [7000-7199]
Diagnostic Occurrence
Trouble Recovery judgment
Trouble mode trouble code Judgment timing Prerequisites judgment
location
DTC Display Conditions Conditions
Ground short/
Sensor; Immediately after Voltage ≦ 0.25 V
disconnection 7000 ○ None 0.25 V < Voltage < 4.75 V
Pressure (P1) key switched ON
Power supply short Voltage ≧ 4.75 V
Ground short/
Pressure (P2) key switched ON
Ground short/
Pressure (N1) key switched ON
Ground short/
Pressure (N2) key switched ON
Sensor; Ground short/
Immediately after EU selected as Voltage ≦ 0.25 V
Pressure disconnection 7004 ○ 0.25 V < Voltage < 4.75 V
key switched ON destination
(Overload) Power supply short Voltage ≧ 4.75 V
Immediately after Liftcrane Voltage ≦ 0.25 V
key switched ON selected
(Bottom) Power supply short Voltage ≧ 4.75 V
Immediately after Liftcrane Voltage ≦ 0.25 V
key switched ON selected
(Rod) Power supply short Voltage ≧ 4.75 V
Immediately after Voltage ≦ 0.25 V
Pressure disconnection 7020 ○ None 0.25 V < Voltage < 4.75 V
key switched ON
(Upper) Power supply short Voltage ≧ 4.75 V
key switched ON
(Swing) Power supply short Voltage ≧ 4.75 V
key switched ON
(Travel) Power supply short Voltage ≧ 4.75 V
Sensor; Disconnection Immediately after Resistance ≧ 100 ?
Fuel level
7040 ○ key switched ON
None 2 ? < Resistance < 100 ?
Short Resistance ≦ 2 ?
Resistance ≧
3 min. after
Disconnection 67200?
Sensor; Oil engine start 111? < Resistance < 67200?
7041 ○ None (Voltage ≧ 4.93 V )
temperature (0.5 V < Voltage < 4.93 V)
Immediately after Resistance ≦ 111?
Short
key switched ON (Voltage ≦ 0.5 V )
Monitor; Disconnection
Immediately after Trouble bit received No trouble bit received from
Thermistor 7045 × None
Short key switched ON from monitor monitor
(*1)
Pressure From
switch; immediately after Pressure switch =
Return
Disconnection 7063 ○ key switched ON
None
OFF
Pressure switch = ON
filter clog until engine starts
(*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed.
For items for which × is displayed, the "ELEC. PROBLEM" message is not displayed. Also, there
is no DTC display on the user screen.
However, the DTC is recorded on the service (DIAG) screen.
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(2)Electrical troubles (output) [7200-7399]
Diagnostic Occurrence
Trouble Recovery judgment
Trouble mode trouble code Judgment timing Prerequisites judgment
location
Solenoid; Disconnection Immediately after Output ≠ Output
Swing brake
None Output = Output monitor
Short monitor
Solenoid; Disconnection
Immediately after Output ≠ Output
Travel 7201 ○ key switched ON
Short monitor
high-speed
Boost
Short monitor
Travel alarm Disconnection Immediately after Output ≠ Output
7203 × None Output = Output monitor
buzzer (*1) Short key switched ON monitor
Feed pump Disconnection
automatic stop 7205 ○ key switched ON
Short monitor
relay
Solenoid; Disconnection
Option return 7206 ○ key switched ON
Short monitor
circuit
Free swing
Short monitor
Fan reverse
Short monitor
Air Disconnection
conditioner
coolant Immediately after Output ≠ Output
7209 × None Output = Output monitor
temperature Short key switched ON monitor
signal output
(*1)
Rotating light Disconnection
relay and 7211 ○ key switched ON
Short monitor
bucket lock
Proportional Disconnection After engine start Milli-amp ≦ 30 mA
valve;
Horsepower
7240 ○ Immediately after None 30 mA < Milli-amp < 3 A
Short Milli-amp ≧ 3 A
pump key switched ON
Proportional Disconnection After engine start Milli-amp ≦ 30 mA

valve; 7241 ○ Immediately after None 30 mA < Milli-amp < 3 A
Flow pump Short Milli-amp ≧ 3 A
key switched ON
(*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed.
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(3)Mechanical troubles [7400-7599]
Diagnostic Occurrence Recovery judgment
Trouble trouble code judgment
location Trouble mode Judgment timing Prerequisites
Abnormally high Coolant temperature Coolant temperature Coolant temperature

temperature 1
7400 ○ ≧ 221F° (105C)
° < 221F° (105C)
°
sensor = Normal
Coolant 1 min. after CAN communication
temperature engine start = Normal
Abnormally high 7402 Coolant temperature Coolant temperature
temperature 2 ○ ECM 5 V power supply
≧ 230F° (110C)
° < 221F° (105C)
°
voltage = Normal
Abnormally high Coolant temperature Coolant temperature
temperature 3
7403 ○ ≧ 248F° (120C)
° < 248F° (120C)
°
Oil Abnormally high 1 min. after Oil temperature sensor Oil temperature Oil temperature
temperature temperature 7404 ○ engine start = Normal ≧ 208.4F° (98C)
° < 208.4F° (98C)
°
Boost temperature sensor
= Normal,
Abnormally high 7405 CAN communication Boost temperature Boost temperature
temperature 1 ○ = Normal, ≧ 176F° (80C)
° ≦ 158F°
Boost 1 min. after
temperature engine start ECM 5 V power supply
voltage = Normal
Abnormally high Boost temperature Boost temperature
temperature 2 7406 ○ ≧ 194F° (90C)
° < 194F° (90C)
°
Alternator Abnormally low 10 s after Generated voltage ≦ Generated voltage >
voltage voltage
7420 ○ engine start
None
10 V 10 V
Immediately after
Coolant level Drop 7421 ○ key switched ON
None Level switch = ON Level switch = OFF
Oil pressure sensor

= Normal,
Engine oil Abnormally low 30 s after CAN communication Pressure ≦ 5.8 PSI Pressure > 5.8 PSI
pressure pressure
7422 ○ engine start = Normal, (40 kPa) (40 kPa)
ECM 5 V power supply
voltage = Normal
10 s after
Air cleaner Clog 7423 ○ engine start None Vacuum switch = ON Vacuum switch = OFF
10 s after Return filter pressure

Return filter Clog 7424 ○ engine start switch = Normal Pressure switch = OFF Pressure switch = ON
(4)Faulty communication [7600-7799]

Diagnostic Occurrence judgment Recovery judgment
Trouble Trouble mode trouble code Judgment timing Prerequisites
location
Immediately after Bus off or error When the occurrence
CAN bus Faulty bus 7600 ○ key switched ON None passive conditions are not met
Faulty reception Packets not coming When the occurrence

Communica- from monitor conditions are not met
Immediately after
tion 7601 ○ key switched ON None Reception from
monitor Faulty transmis- monitor Defective When the occurrence
sion packet received conditions are not met
Communica- Immediately after Messages not coming When the occurrence

tion Time out 7602 ○ key switched ON None from ECM conditions are not met
ECM
Communica- Immediately after Messages not coming When the occurrence
tion Time out 7603 ○ key switched ON None from computer S conditions are not met
computer S
Communica- Immediately after Liftcrane or interference Messages not coming When the occurrence
tion Time out 7604 ○ key switched ON prevention selected from computer B conditions are not met
computer B
10 s after engine Model ≠ ECM
ECM Mismatch 7605 ○ start Model selection completed
calibration No.
None No recovery
Previously stored Previously stored

Immediately after
EEPROM Faulty data 7606 × key switched ON None checksum ≠ Current checksum = Current
calculated checksum calculated checksum
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3. Diagnostic Trouble Code (monitor display)
Diagnostic Patterns for
Trouble contents Main symptoms when trouble occurs Diagnostic trouble code display conditions Back-up function Conceivable causelm recovery from
trouble code trouble
The ratio for the fuel flow command signal to
the SCV is 33 % or less. Fuel system clogged, line (hose) blocked
Differential pressure send amount is 2800 Charge fuel pump defect (discharge defect)
Multi-injection stop Wiring defect (short) between ECM and common rail pressure sensor
No pump pressure send (2nd stage) 1093
Engine vibration, idle instability, drop of output power, rev- mm3/s or longer Target common rail pressure upper limit 11603 PSI Injector defect 1
up defect, black smoke, engine stalling When any of the above occurs and the condi- (80 MPa) Supply pump defect
tion below At 1200 rpm or higher, actual rail Common rail pressure sensor defect (common rail)
pressure is 4351 PSI (30.0 mpA) or more Pressure limiter defect (common rail)
below the target rail pressure for 5 s or longer
Wiring defect (disconnection, short, high resistance) between ECM and
Faulty boost temperature sensor 1112 Nothing in particular The boost temperature sensor voltage is 0.1 No backup boost temperature sensor *2
(abnormally low voltage) V or lower for 4 s or longer. Boost temperature sensor defect
ECM internal defect
Faulty boost temperature sensor 1113 Nothing in particular The boost temperature sensor voltage is 4.95 No backup boost temperature sensor *2
(abnormally high voltage) V or higher for 4 s or longer. Boost temperature sensor defect
ECM internal defect
Wiring defect (short) between ECM and engine coolant sensor
Drop of output power
Overheat 1173 If the coolant temperature exceeds 226.4F° during over- The coolant temperature is higher than 248F° No backup Engine cooling system trouble (radiator clog or the like) 2
for 5 s or longer. Engine coolant level too low
heating, the fuel flow is restricted. Engine coolant sensor defect
Injector monitor inputs for all common 1 sys- No. 1, 4 injector harness defect (disconnection, short)
Faulty injection nozzle common 1 Engine vibration, idling instability, drop of output power Common 1 stop (No. 1, 4 cylinder stop)
drive system 1261 Possibility of rev-up defect, engine stalling tem EGR stop Injector defect 1
No signal for 3 s or longer ECM defect
Injector monitor inputs for all common 2 sys- No. 2, 3 injector harness defect (disconnection, short)
Faulty injection nozzle common 2 1262 Engine vibration, idling instability, drop of output power tem Common 2 stop (No. 2, 3 cylinder stop) Injector defect 1
drive system Possibility of rev-up defect, engine stalling EGR stop
No signal for 3 s or longer ECM internal defect
No fault during engine rotation, but when it is stopped No correct CMP sensor pulse in crank gap No change when error occurs (shift to crank sensor) CMP sensor
CMP sensor out of phase 1345 1
once, it cannot be restarted. position However, engine cannot be restarted. Camshaft gear installation defect
Flywheel installation defect
Main relay input power supply voltage 1 V or main relay
Faulty main relay 1625 Engine starting difficulty, power supply not cut off lower for 2 s or longer No backup Wiring defect (disconnection, short, high resistance) with fusible link main 2
Even when the main relay coil OFF command relay
is issued, the relay does not cut off within 5 s Main relay defect
ECM internal defect
Analog sensor system default processing (sensors
operating with default values, because conversion not
possible)
Faulty A/D conversion 1630 Drop of output power, black smoke Analog/digital conversion not possible ECM internal defect 2
Multi-injection stop
Target common rail pressure upper limit 11603 PSI
(80 MPa)
Faulty 5 V power supply 2 voltage Power supply circuit wiring defect (short) between ECM and atmospheric
Black smoke at high altitudes, insufficient output at low Key switch power supply voltage 5.5 V or EGR control stop
(atmospheric pressure sensor power 1632 altitudes higher or 4.5 V or lower for 0.5 s or longer Default value setting 80 kPa (equivalent to 250) pressure sensor 2
supply) ECM internal defect
Power supply circuit wiring defect (short) between ECM and oil pressure
Faulty 5 V power supply 3 voltage 1633 Poor starting and black smoke at low temperatures Key switch power supply voltage 5.5 V or Control using default values sensor 2
(engine oil pressure sensor) higher or 4.5 V or lower for 0.5 s or longer
ECM internal defect
Faulty 5 V power supply 4 voltage Key switch power supply voltage 5.5 V or Power supply circuit wiring defect (short) between ECM and boost pres-
1634 Black smoke Control using default values sure sensor 2
(boost pressure sensor) higher or 4.5 V or lower for 0.5 s or longer ECM internal defect
Faulty 5 V power supply 5 voltage Power supply circuit wiring defect (short) between ECM and common rail
Possibility of poor engine rev-up, drop of output power, Key switch power supply voltage 5.5 V or
(common rail pressure sensor, EGR 1635 back smoke, engine stalling higher or 4.5 V or lower for 0.5 s or longer Control using default values pressure sensor 2
position sensor) ECM internal defect
Engine speed that computer A sends with computer A
Faulty CAN bus 2104 Engine speed down to 1500 rpm. Engine speed down to 1500 rpm. 2
CAN stops for 1 s or longer. ECM internal defect
Computer A internal defect
Control from actual machine side stops working because Engine speed that computer A sends with computer A
Faulty CAN time-out 2106 CAN communication become impossible. The engine Engine speed down to 1500 rpm. 2
speed drops to 1500 rpm. CAN stops for 2 s or longer. ECM internal defect
Computer A internal defect
Fuel system clogged (element), line (hose), etc. blocked
Wiring defect (short) between ECM and common rail pressure sensor
No pump pressure send (fuel leak) 0087 Possibility of engine vibration, idle instability, drop of out- Actual rail pressure of 2176 PSI (15.0 MPa) or Target common rail pressure upper limit 11603 PSI Injector defect 1
put power, black smoke, excess output lower for 3 s or longer Common rail pressure sensor defect
(80 MPa) Supply pump defect
Pressure limiter defect
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Service Support
Patterns for
Diagnostic
Trouble contents trouble code Main symptoms when trouble occurs Diagnostic trouble code display conditions Back-up function Conceivable causelm recovery from
trouble
1st stage
Rail pressure exceeds 26832 PSI (185 MPa)
for 5 s or longer, common rail pressure sensor Fuel system line (hose), etc. blocked
voltage is 3.9 V or higher Multi-injection stop
Faulty common rail pressure 0088 Engine vibration, idle instability, drop of output power, rev- 2nd stage Target common rail pressure upper limit 11603 PSI Air in fuel system (check hose connection.) 1
(1st stage, 2nd stage) up defect Common rail pressure sensor defect
1st stage established, rail pressure exceeds (80 MPa) Supply pump defect
27557 PSI (190 MPa) for 5 s or longer, com-
mon rail pressure sensor voltage is 4 V or
higher
Faulty common rail pressure Engine vibration, idle instability, drop of output power, rev- Actual rail pressure 5802 PSI (40.0 MPa) or Multi-injection stop Common rail pressure sensor defect
0089 more above the target rail pressure for 5 s or Target common rail pressure upper limit 11603 PSI Supply pump defect 1
(pump sending too much pressure) up defect longer (80 MPa) ECM, SCV, common rail pressure sensor connector connection defect
When the SCV drive milli-amp exceeds the
SCV defect
SCV drive system disconnection, rated milli-amp for 2 s or longer Multi-injection stop Wiring defect (disconnection, short, high resistance) between ECM and
0090 Black smoke and excess output When the difference between the target and Target common rail pressure upper limit 11603 PSI 2
+B short, ground short actual milli-amp exceeds the rated milli-amp (80 MPa) SCV
ECM internal defect
for 2 s or longer
EGR control stop Wiring defect (disconnection, short, high resistance) between ECM and
Faulty atmospheric pressure sensor Black smoke at high altitudes, insufficient output at low The atmospheric pressure sensor voltage is atmospheric pressure sensor
(abnormally low voltage) 0107 altitudes 0.5 V or lower for 5 s or longer. Default value setting 11.6 PSI (80 kPa) (equivalent to Atmospheric pressure sensor defect 2
2673.4 yd (8020.1 ft)
ECM internal defect
EGR control stop Wiring defect (disconnection, short, high resistance) between ECM and
Faulty atmospheric pressure sensor Black smoke at high altitudes, insufficient output at low The atmospheric pressure sensor voltage is atmospheric pressure sensor
(abnormally high voltage) 0108 altitudes 3.8 V or higher for 4 s or longer. Default value setting 11.6 PSI (80 kPa) (equivalent to Atmospheric pressure sensor defect 2
2673.4 yd (8020.1 ft)
ECM internal defect
Faulty suction air temperature sensor Possibility of white smoke when starting at low tempera- The suction air temperature sensor voltage is EGR control stop Wiring defect (short) between ECM and suction air temperature sensor
0112 Default value setting Suction air temperature sensor defect *2
(abnormally low voltage) tures 0.1 V or lower for 4 s or longer. Starting: 14F° (10°
C) Running: 77F° (25C)
° ECM internal defect
EGR control stop
Faulty suction air temperature sensor 0113 Possibility of white smoke when starting at low tempera- The suction air temperature sensor voltage is Default value setting suction air temperature sensor *2
(abnormally high voltage) tures 4.95 V or higher for 4 s or longer. Suction air temperature sensor defect
Starting: 14F° (10°
C) Running: 77F° (25C)
Faulty engine coolant temperature EGR control stop Wiring defect (short) between ECM and engine coolant sensor
Poor starting at low temperatures, black smoke, drop of The coolant temperature sensor voltage is 0.1
sensor 0117 output power V or lower for 4 s or longer. Default value setting Engine coolant sensor defect *2
(abnormally low voltage) Starting: -4F° (-15C)
° Running: 176F° (176C)
Faulty engine coolant temperature Increase in noise, white smoke at low temperatures, rough The coolant temperature sensor voltage is EGR control stop, default value setting engine coolant sensor
sensor 0118 *2
(abnormally high voltage) idling 4.85 V or higher for 4 s or longer. Starting: -4F° (-15C)
° Running: 176F° (176C)
° Engine coolant sensor defect
ECM internal defect
Wiring defect (short) between ECM and fuel temperature sensor
Faulty fuel temperature sensor 0182 Nothing in particular The fuel temperature sensor voltage is 0.1 V Default value setting Fuel temperature sensor (supply pump) defect *2
(abnormally low voltage) or lower for 4 s or longer. Starting: -4F° (-15C)
° Running: 158F° (70C)
°
ECM internal defect
Faulty fuel temperature sensor The fuel temperature sensor voltage is 4.85 V Default value setting fuel temperature sensor
(abnormally high voltage) 0183 Nothing in particular or lower for 4 s or longer. Starting: -4F° (-15C)
° Running: 158F° (70C)
° Fuel temperature sensor (supply pump) defect *2
ECM internal defect
Faulty common rail pressure sensor The common rail pressure sensor voltage is common rail
(abnormally low voltage) 0192 Engine rev-up defect, hunting 0.7 V or lower. Default value setting 11603 psi Common rail pressure sensor defect (common rail) 2
ECM internal defect
Faulty common rail pressure sensor The common rail pressure sensor voltage is common rail
0193 Possibility of drop of output power and engine stalling Default value setting 11603 psi 2
(abnormally high voltage) 4.5 V or higher. Common rail pressure sensor defect (common rail)
ECM internal defect
No. 1 injector intermediate connector
No. 1 cylinder injector drive circuit disconnec-
Injection nozzle #1 drive system High engine vibration, idle instability, drop of output power, tion/short detected No. 1 cylinder injection stop No. 1 injector terminal looseness
0201 Wiring defect (disconnection, high resistance) between No. 1 injector inter- 1
disconnection rev-up defect No. 1 cylinder injector monitor input EGR control stop mediate connector and No. 1 injector terminal
No signal for 2.4 s or longer
No. 1 injector defect
ECM internal defect
ECM internal defect
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Service Support
Patterns for
Diagnostic
trouble
ECM internal defect
ECM internal defect
Faulty engine main unit (common rail, supply pump, injector)
The engine speed is It is necessary to check whether or not there is another diagnostic trouble
Injection quantity restriction
Overrun 0219 Drop of output power the set speed of 2000 rpm or higher for 1 s or When the speed drops, the restriction ends. code. 2
longer. Mechanical engine trouble (turbo damaged, engine oil mixed in)
ECM internal defect
Faulty boost pressure sensor 0237 Nothing in particular The boost pressure sensor voltage is 0.1 V or Default value setting 22 PSI (MPa) boost pressure sensor 2
(abnormally low voltage) lower for 3 s or longer. Boost pressure sensor defect
ECM internal defect
Faulty boost pressure sensor 0238 Black smoke The boost pressure sensor voltage is 4.9 V or Default value setting 22 PSI (MPa) boost pressure sensor 2
(abnormally high voltage) higher for 3 s or longer. Boost pressure sensor defect
ECM internal defect
Possibility of drop of output power, white smoke, engine Wiring defect (disconnection, short, high resistance) between ECM and
Faulty crank position (CKP) sensor 0335 vibration There is a CMP signal, but not a CKP signal. When the CMP sensor is normal, cam standard con- CKP sensor 1
(no signal) Possibility of engine stalling (when the CMP sensor is nor- trol CKP sensor defect
mal, restarting is possible.) ECM internal defect
Possibility of drop of output power, white smoke, engine Wiring defect (short) between ECM and CKP sensor
Faulty crank position (CKP) sensor 0336 vibration CKP signal pulses do not match When the CMP sensor is normal, cam standard con- CKP sensor defect 1
(faulty signal) Possibility of engine stalling (when the CMP sensor is nor- trol Flywheel ring gear tooth missing
mal, restarting is possible.) ECM internal defect
While engine turning: When the CKP sensor is nor- CMP sensor
Faulty cam position (CMP) sensor No fault during engine rotation, but when it is stopped mal, crank standard CMP sensor defect
(no signal) 0340 once, it cannot be restarted. There is a CKP signal, but not a CMP signal. After engine stop: Restart is impossible due to inability Faulty cam gear 1
to discriminate cylinders Supply pump defect
ECM internal defect
Wiring defect (short) between ECM and CMP sensor
While engine turning: When the CKP sensor is nor- CMP sensor defect
Faulty cam position (CMP) sensor No fault during engine rotation, but when it is stopped When excess cam pulses detected or insuffi- mal, crank standard
(faulty signal) 0341 once, it cannot be restarted. cient cam pulses detected After engine stop: Restart is impossible due to inability Faulty camshaft gear 1
Supply pump defect
to discriminate cylinders ECM internal defect
Wiring defect (disconnection, short, high resistance) between fuse and
The glow relay drive instruction signal and glow relay
Faulty glow relay 0380 Low-temperature starting defect glow relay monitor signal (line 339 in electrical No backup glow relay 1
circuit diagram) are different.
Glow relay defect
ECM internal defect
Faulty EGR position sensor 0487 Nothing in particular Signal inputs from EGR position sensor U, V, EGR valve all-close command EGR position sensor 2
and W all ON or all OFF for 3 s or longer EGR valve (position sensor) defect
ECM internal defect
When the difference between the target valve
Faulty EGR valve control 0488 Nothing in particular lift and the actual position is larger than 20 % EGR valve all-close command EGR motor 2
EGR valve defect
for 10 s or longer ECM internal defect
Wiring defect (short) between ECM and oil pressure sensor
Faulty oil pressure sensor The oil pressure sensor voltage is 0.1 V or
(abnormally low voltage) 0522 Nothing in particular lower for 4 s or longer. No backup Oil pressure sensor defect 2
ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and oil
Faulty oil pressure sensor The oil pressure sensor voltage is 4.85 V or pressure sensor
0523 Nothing in particular No backup 2
(abnormally high voltage) higher for 4 s or longer. Oil pressure sensor defect
ECM internal defect
Faulty ROM Faulty ROM detected
(ECM internal component part) 0601 Engine stop Reflash failure No backup (engine stop) ECM internal defect 2
Faulty EEPROM
0603 Nothing in particular Faulty EEPROM detected No backup ECM internal defect 2
(ECM internal component part)
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Service Support
Patterns for
Diagnostic
trouble
The CPU monitoring IC detects faulty main
CPUs for 328.1 fts after the key is switched
Faulty CPU 0606 Drop of output power, starting not possible ON. Injection quantity restriction ECM internal defect 2
(ECM internal component part) The RUN-SUB pulse (signal between CPU
and SUB-CPU) was unchanging for 65.7 fts or The SUB-CPU stopped the CPU.
longer.
The RUN-SUB pulse (signal between CPU
Abnormality with IC monitoring CPU 0606 Drop of output power and SUB-CPU) was unchanging for 65.7 fts or Injection quantity restriction ECM internal defect 2
longer.
ECM terminal, ECM ground terminal defect (disconnection, high resis-
Engine vibration, idling instability, drop of output power When the ECU charge circuit bank 1 voltage Common 1 stop (No. 1, 4 cylinder stop)
Faulty charge circuit 1 0611 Possibility of rev-up defect, engine stalling is low for 1.5 s or longer EGR stop tance) 2
ECM internal defect
ECM terminal, ECM ground terminal defect (disconnection, high resis-
Faulty charge circuit 2 0612 Engine vibration, idling instability, drop of output power When the ECU charge circuit bank 2 voltage Common 2 stop (No. 2, 3 cylinder stop) tance) 2
Possibility of rev-up defect, engine stalling is low for 1.5 s or longer EGR stop
ECM internal defect
Fuel system line (hose), etc. blocked
Air in fuel system (check hose connection.)
When the pressure limiter is open or when the Pressure limiter defect
Pressure limiter open 1095 Drop of output power, hunting common rail pressure exceeds 29008 psi for 1 Injection quantity restriction Common rail pressure sensor defect 1
s or longer Wiring defect (short) between ECM and common rail pressure sensor
Supply pump defect
ECM internal defect
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Service Support
Note:Patterns for recovery from trouble
Trouble recovery can be roughly divided into 2 types.
Sometimes, one more cycle is required after the cycle below for the diagnostic trouble code dis-
played on the monitor screen by the actual machine to go out.
Pattern 1:
In the cycle in which the diagnostic trouble code was detected, even if the machine recovers to
normal (including intermittent problems), the diagnostic trouble code does not disappear from
the monitor screen and backup mode does not recover to normal mode. After the key is
switched OFF, when the engine is restarted, the trouble judgment is made and if it is judged
that the status is normal,
• generally, the trouble judgment ends immediately and if it is judged that the status is normal,
the diagnostic trouble code disappears and operation recovers to normal.
• For a temperature sensor or the like in the section marked *, trouble judgment takes 3 - 10
min. and if it is judged that the status is normal, the diagnostic trouble code disappears and
operation recovers to normal.
Time chart
Name
1 Diagnostic trouble code detection
2 Repair and inspection
3 Recovery to normal
Pattern 2:
If the machine recovers to normal (including intermittent problems) in the cycle in which the
diagnostic trouble code was detected, the diagnostic trouble code disappears from the moni-
tor screen and backup mode recovers to normal mode.
Time chart
Name
1 Diagnostic trouble code detection
2 Recovery to normal
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Service Support
4. Sensor Trouble Operation Table
• The table below shows the operations when there is trouble with a sensor (current, recovered from, ongoing).
• ‘*’ indicates that it is not related to (not affected by) that trouble.
Input Coolant temperature

Upper pressure sensor Swing pressure sensor Travel pressure sensor P1 pressure sensor P2 pressure sensor N1 pressure sensor N2 pressure sensor Oil temperature sensor Fuel sensor
Output and function sensor
Trouble continuation 0 PSI 0 PSI 0 PSI 0 PSI 0 PSI 0 PSI 0 PSI -40F° (-40C)
° 417.2F° (214C)
° 0%
Backup value
Recovery Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value
Backup value control Backup value control Backup value control
Auto idle (*1) (*1) (*1) * * * * * * *
Idling start Backup value control Backup value control Backup value control * * * * * * *
(*2) (*2) (*2)
Engine target speed
Auto warm up * * * * * * *
(*3) (*3) (*3)
Idle up (*4) (*4) (*4) * * * * * * *
Engine Anti-theft Fixed to ON (*21) * Fixed to ON (*21) Fixed to ON (*21) Fixed to ON (*21) * * * * *
Stop command
Static horsepower control * * * * * * * * * *
Dynamic horsepower con- Backup value control * * Backup value control Backup value control * * * * *
trol (*5) (*5) (*5)
Milli-amp for pump
horsepower control Backup value control
Travel horsepower boost * * * * * * * * *
proportional valve (*6)
Arm-in boost horsepower * * * * * * * * * *
Engine stall prevention * * * * * * * * * *
Pump flow proportional Relief cut Fixed to 50 mA (*7) Fixed to 50 mA (*7) Fixed to 50 mA (*7) Fixed to 50 mA (*7) Fixed to 50 mA (*7) Fixed to 50 mA (*7) Fixed to 50 mA (*7) * * *
valve Speed limit Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) * * *
Auto pressure boost * Fixed to OFF (*11) * * * * *
(*9) (*10) (*10)
Boost solenoid
Always boosted * * Fixed to OFF (*11) * * * * * * *
Boost cut * * Fixed to OFF (*11) * * * * * * *
Auto brake Fixed to OFF (*12) Fixed to OFF (*12) * * * * * * * *
Swing brake solenoid Swing lock Fixed to ON (*13) Fixed to ON (*13) * * * * * * * *
Anti-theft Fixed to ON (*14) Fixed to ON (*14) * * * * * * * *
Travel alarm * * Backup value control * * * * * * *

(*15)
Travel alarm Key ON alarm * * * * * * * * * *
Anti-theft * * * * * * * * * *
Coolant temperature Coolant temperature dis-
gauge play * * * * * * * * Not displayed (*16) *
Oil temperature gauge Oil temperature display * * * * * * * Not displayed (*17) * *

Fuel gauge Fuel level display * * * * * * * * * Not displayed (*18)
Backup value control
Air conditioner Cold blast prevention * * * * * * * * *
(*19)
- Symptom -
(*1) Idle cannot be ended. Idles even during work. (*8) No swing speed limit. (Excessive swing speed) (*15) Travel alarm stops. (Key ON alarm sounds)
(*2) Idle cannot be ended. (*9) Auto pressure boost stops. (Constant pressure boost for A mode is executed.) (*16) Coolant temperature gauge is not displayed. (Goes out)
(*3) Auto warm up cannot be ended. (*10) Auto pressure boost is not carried out for a pump load on only one side. (*17) Oil temperature gauge is not displayed. (Goes out)
(*4) Idle speed cannot be raised. (*11) Boost is always OFF. (*18) Fuel gauge is not displayed. (Goes out)
(*5) Dynamic horsepower control (for transient loads) is not possible. (*12) Swing brake is always OFF. (*19) Air flow max.
(*6) No horsepower boost even for travel. (*13) During a swing lock, held ON even if there is trouble. (*20) The engine cannot be started if the password has not been input.
(*7) No swing relief cut. (deterioration in fuel economy) (*14) During swinging with anti-theft prevention, held ON even if there is trouble.
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Service Support
5. EPF (Engine Protection Feature)
This feature controls the engine speed or stopping when the coolant temperature rises, the boost
temperature rises, or the oil pressure drops.
- Trouble state -
Recovered = State in which trouble recovered from during the key ON cycle
Ongoing = State in which the key was switched OFF, then ON again with the previous trouble under-
way (or continuing)
- Speed restriction control -
0: None
1: Backup speed
2: Low idle
3: Stop (restart possible, low idle)
4: Stop (restart not possible)
Speed restriction Explanation

control
Trouble 0: None ?
underway
Coolant
temperature
over 221F° Recovered 0: None ?
Ongoing 0: None ?
Trouble
underway 2: Low idle The engine goes to low idle at a coolant temperature of 230F° (110C)
° or higher.
Coolant When the coolant temperature falls to 221F° (105C)

° or less, the system recovers and controls
temperature Recovered 0: None returns to normal.
over 230F°
When the key is switched ON again and the engine starts, for the time (1 min.) until judgment
Ongoing 2: Low idle starts, the engine speed is restricted to low idle. After that, the status moves to trouble under-
way or recovered based on the judgment results.
The engine stops at a coolant temperature of 248F° (120C) ° or higher. The engine cannot be
Trouble 4: Stop
underway (restart possible) restarted until the key is turned to ON again or the coolant temperature falls to 248F° (120C)
° or
less.
Coolant When the coolant temperature falls to 248F° (120C)

° or less, the restriction due to the coolant
temperature Recovered 0: None temperature being over 248F° (120C)
° goes to 0. (Normal control) However, if the restriction
over 248F° due to the coolant temperature being over 230F° (110C)° is not 0, that restriction is applied.
Trouble
2: Low idle The engine goes to low idle at a boost temperature of 176F° (80C)
° or higher.
underway
Boost When the boost temperature falls to 158F° (70C)
° or less, the system recovers and controls
Recovered 0: None
temperature returns to normal.
over 176F°
Trouble 4: Stop Engine stop. The engine cannot be restarted until either the key is switched ON again or the
underway (restart possible) boost temperature recovers to the normal level.
Boost When the boost temperature falls to 194F° (90C)

° or below, the restriction due to the boost tem-
Recovered 0: None perature being over 194F° (90C)
° goes to 0. (Normal control) However, if the restriction due to
temperature the boost temperature being over 176F° (80C)° is not 0, that restriction is applied.
over 194F°
Engine stop. The engine cannot be restarted until the key is switched ON again. Recovery
Trouble 4: Stop
underway (restart possible) cannot be judged until the engine is restarted, so the system does not move from trouble
underway to be recovered.
Engine
oil pressure Recovered 0: None The engine oil pressure recovers to 5.8 psi or higher and control returns to normal.
drop
When the key is switched ON again and the engine starts, for the time (30 s) until judgment
way or recovered based on the judgment.
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Service Support
50 NST-05-07-007LX
Engine Summary SH120
Engine Summary
Engine Summary
Main Data Table (changes from model 3)
130X2 130LX
Engine model name - Isuzu 4JJ1 Isuzu 4BG1
4-cycle, water cooled, overhead 4-cycle, water cooled, overhead
Model - camshaft, vertical in-line, direct valve, vertical in-line, direct
injection type injection type
Dry weight lbs 723 805
Displacement cu•in 183 264
Number of cylinders - bore X
in 4 - 3.76 x 4.13 4 - 4.13 x 4.92
stroke
Compression ratio - 17.5 18.0
Rated output HP/rpm 95/2000 100/2000
Maximum torque lbf•ft/rpm 265/1600 270/1600
No-load maximum speed rpm 2000 2200
No-load minimum speed
rpm 1050 1000
(idling)
Rated fuel consumption ratio g/kW・hr 227.6 max. 258.0 max.
HP3 model common rail from ADS model inline-type pump
Fuel unit -
Denso Corp. from Bosch Corp.
Control device - ECM made by Transtron Inc. ECU made by Bosch Corp.
Cooling fan in 8N suction ?21.7 plastic 8N suction ?21.3 plastic
Bell mouth-type fan guide - Yes No
Fan belt - Drive by one V-rib belt Drive by two B-model V belts
50 A-24 V, made by Nikko 50 A -24 V, made by Mitsubishi
Alternator -
Electric Industry Co., Ltd. Electric Corp.
4.0 kW-24 V, made by Nikko 4.5 kW-24 V, made by Nikko
Starter -
Electric Industry Co., Ltd. Electric Industry Co., Ltd.
Turbo - RHF55 model made by IHI RHG6 model made by IHI
Preheat unit - QOS-II QOS-II
Inter cooler - Yes No
Fuel cooler - Yes No
Charge fuel pump - Yes No
4 µ main unit remote type with 20 µ with water separator
Fuel filter -
water separator function function with engine
10 µ main unit remote type with
Fuel prefilter - -
water separator function
Oil filter - Remote type With engine
Oil pan capacity gal 2.9 - 3.9 2.9 - 3.5
Oil pan drain cock - Yes No
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Engine Summary
Overall Appearance Diagram
1 Engine oil fill port 6 Bell mouth-type fan guide

2 Alternator 7 Starter motor
3 Turbo 8 Supply pump (SCV)
4 EGR valve 9 Common rail
5 EGR cooler
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Engine Summary
Sensor and Auxiliary Equipment Layout (left)
1 Engine coolant temperature sensor 6 Starter motor

2 Boost temperature sensor 7 Oil pressure sensor
3 Common rail pressure sensor 8 Suction control valve
4 ERG valve 9 Fuel temperature sensor
5 Boost pressure sensor
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Engine Summary
Sensor and Auxiliary Equipment Layout (rear)
1 Cam position sensor

2 Crank position sensor
Engine System Diagram
1 Air cleaner 7 Turbine side 13 Muffler

2 Fuel cooler 8 Engine 14 Fuel main filter
3 Inter cooler 9 Injector 15 Fuel tank
4 Radiator 10 Common rail 16 Fuel prefilter
5 Turbo 11 Supply pump 17 Charge fuel pump
6 Compressor side 12 EGR cooler
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Engine Summary
Fuel System Diagram
1 Charge fuel pump 5 Pressure limiter 9 Fuel tank

2 Fuel main filter 6 Fuel prefilter 10 CMP sensor
3 Common rail pressure sensor 7 Supply pump 11 CKP sensor
4 Common rail 8 Fuel cooler 12 Injector
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Engine Summary
Detailed Parts Diagrams
1. ECM (engine control module)
3 roles of the ECM

[1] The ECM constantly monitors information sent from the various sensors and controls the power
train systems.
[2] The ECM executes system function diagnosis, detects problems in system operation, issues
trouble alarms to warn the operator and stores the diagnostic trouble code into memory.
The diagnostic trouble code identifies the area in which the problem occurred and supports
repair work by the service engineer.
[3] The ECM puts out 5 V and other voltages to supply power to the various sensors and switches.
The ECM controls output circuits by controlling ground or power supply circuits via one device or
another.
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Engine Summary
2. Supply Pump/SCV (suction control valve)
1 Fuel temperature sensor

2 SCV (suction control valve)
3 Feed pump
Supply pump
The supply pump uses the force of the engine rotation to raise the fuel pressure and send fuel to the
common rail. The SCV, fuel temperature sensor, and feed pump are installed on the supply pump.
SCV (suction control valve)
The SCV is installed on the supply pump and controls the sending of fuel to the common rail (dis-
charge volume). The ECM controls the electrified time to the SCV and controls the fuel discharge
volume.
3. Common Rail
1 Common rail
[1] Common rail

The common rail receives the fuel from the supply pump, holds the common rail (fuel) pressure,
and distributes the fuel to each cylinder. The common rail pressure sensor and pressure limiter
are installed on the common rail.
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Engine Summary
4. Common Rail Pressure Sensor/Pressure Limiter
1 Common rail pressure sensor

2 Pressure limiter
[1] Common rail pressure sensor

This sensor sends the pressure inside the common rail to the ECM as a voltage signal. From the
signal sent, the ECM calculates the actual common rail pressure (fuel pressure) and uses this for
fuel injection control.
[2] Pressure limiter
If the pressure in the common rail becomes abnormally high, the pressure limiter relieves the
pressure by returning excess fuel to the tank.
5. Injector
The injectors are installed on the cylinder head sections. They are controlled from the ECM and
inject fuel. The injector drive voltage is boosted (to 118 V) inside the ECM and applied to the injec-
tors. By controlling the injector electrified time, the ECM controls the fuel injection, injection timing,
etc.
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Engine Summary
6. Engine Coolant Temperature Sensor
The engine coolant temperature sensor is installed on the engine block. The resistance of its therm-
istor varies with the temperature.
The resistance is low when the engine coolant temperature is high and high when the coolant tem-
perature is low. From the ECM voltage variation, the ECM calculates the engine coolant temperature
and uses this for fuel injection control etc.
7. Engine Oil Pressure Sensor
The engine oil pressure sensor is installed near the cylinder block starter motor. It detects the
engine oil pressure, converts this pressure into an electrical signal, and sends that signal to the
ECM.
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Engine Summary
8. Cam Position Sensor (CMP sensor)
This sensor sends a signal to the ECM when the engine camshaft cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses
this information to control the fuel injection and to calculate the engine speed.
Also, it provides a back-up function in case of trouble in the CKP sensor. There is no change in
behavior while the engine is running even if there is trouble in the CMP sensor system. However, it
will be difficult to restart the engine after it has been stopped.
9. Crank Position Sensor (CKP sensor)
This sensor sends a signal to the ECM when the projection section of the engine flywheel passes
this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses
this information to control the fuel injection and to calculate the engine speed.
In case of trouble in the CKP sensor, the CMP sensor provides a back-up function.
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Engine Summary
10.Atmospheric Pressure Sensor
The atmospheric pressure sensor is installed in the cab. The ECM converts the atmospheric pres-
sure into an electric signal and calculates the atmospheric pressure from this voltage signal and cor-
rects the fuel injection quantity according to the atmospheric pressure.
11.Suction Air Temperature Sensor
The suction air temperature sensor is installed midway through the suction air duct. It detects the
suction air temperature in order to optimize the fuel injection quantity.
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Engine Summary
12.Boost Pressure Sensor
The boost pressure sensor uses a pressure hose between the boost pressure sensor and intake
pipe to detect the boost (suction air pressure), converts this pressure into an electrical signal, and
sends that signal to the ECM.
13.Boost Temperature Sensor
The boost temperature sensor is installed on the upstream side of the EGR valve of the intake man-
ifold.
This sensor is the thermistor type. The internal resistance of the sensor changes with the tempera-
ture.
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Engine Summary
14.Charge Fuel Pump
Converting the fuel filter and pre-filter to remote operation increased the distance from the fuel tank
to the feed pump.
Therefore, this new pump was added to assist in drawing the fuel from the tank and to make it easy
to bleed out air during maintenance.
This pump always operates when the key switch is ON.
15.EGR Cooler
1 Coolant in let
2 Coolant path (outside of exhaust gas path)
3 Exhaust gas path
The EGR Cooler (cooling system installed in the path) uses the engine coolant to cool exhaust gas
at high temperature about 1292F° (700C)
° down to about 392F° (200C),° to drop the combustion tem-
perature, and to reduce NOx.
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Engine Summary
16.EGR Valve
The operation of the EGR valve (lift amount) is controlled by signals from the ECM.
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Engine Summary
Engine Control Summary
Electronic control fuel injection system (common rail type)
This is a system in which the engine speed, engine load, and other information (signals from many
sensors) are acquired from the engine control module (ECM) and based on that information, the ECM
sends electrical signals to the supply pump, injectors, etc. to appropriately control the fuel injection
quantity and timing for each cylinder.
Injection quantity control
To provide the optimum injection quantity, the ECM controls the injectors based mainly on the engine
speed and the instructed speed from computer A and controls the fuel injection quantity.
Injection pressure control
The injection pressure is controlled by controlling the fuel pressure in the common rail. The appropriate
pressure in the common rail is calculated from the engine speed and fuel injection quantity and by con-
trolling the supply pump, the appropriate quantity of fuel is discharged and the pressure sent to the
common rail is controlled.
Injection timing control
Instead of a timer function, the injectors are controlled primarily by calculating the appropriate fuel
injection timing from the engine speed, injection quantity, etc.
Injection ratio control
In order to improve the combustion in the cylinder, at first only a small amount of fuel is injected (pre-
injection), the fuel is ignited, then once the fuel has ignited, a second injection (main injection) is car-
ried out. This injection timing and quantity control is effected by controlling the injectors.
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Engine Summary
NST-06-01-005LX 16
Explanation of Engine Terms SH120

Name Function
Receives the high-pressure fuel sent under pressure from the supply
1 Common rail pump, holds the fuel pressure, and distributes the fuel to each injec-
tor.
Pressure limiter Operates to allow pressure within the common rail to escape if the
2
(common rail component part) pressure in the common rail becomes abnormally high.
Common rail pressure sensor Detects the pressure inside the common rail, converts it to a voltage,
3
(common rail component part) and sends that voltage to the ECM.
4 Injector Controlled by the ECM and injects the fuel.
Raise the fuel pressure and send it under pressure to the common rail
5 Supply pump
by using the force of the engine rotation.
Controls the fuel pressure (discharge volume) sent to the common
SCV (suction control valve) rail.
6
(supply pump component part) The ECM controls the electrified time to the SCV to increase or
decrease the volume of fuel discharged.
Fuel temperature sensor Detects the fuel temperature and sends it to the ECM.
7
(supply pump component part) Used for supply pump control etc.
Recirculates part of the exhaust gas in the intake manifold and mixes
8 EGR the EGR gas with the suction air to reduce the combustion tempera-
ture and reduce NOx.
The EGR valve operation (open and close) timing and the lift amount
EGR valve
9 are controlled by signals from the ECM. (The valve lift amount is
(EGR position sensor)
detected by the EGR position sensor)
10 EGR cooler Cools the high-temperature EGR gas by using the engine coolant.
ECM Constantly monitors the information from each sensor and controls
11
(engine control module) the engine system.
Determines the glow time according to the engine coolant tempera-
QOS ture, operates the glow relay, and makes starting at low temperatures
12
(quick on start system) easy and also reduces white smoke and noise immediately after the
engine starts.
This sensor sends a signal to the ECM when the projection section of
the engine flywheel passes this sensor.
CKP sensor
13 The ECM uses this sensor input in the calculation of engine speed.
(crank position sensor)
In case of trouble in the CKP sensor, the CMP sensor provides a
back-up function.
Detects the engine oil pressure and sends it to the ECM.
Used for oil pressure drop alarms etc.
Detects the engine coolant temperature and sends it to the ECM.
15 Engine coolant temperature sensor
Used for fuel injection control, QOS control, etc.
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Name Function
This sensor sends a signal to the ECM when the engine camshaft
cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, deter-
mines the crank angle, and uses this information to control the fuel
CMP sensor injection and to calculate the engine speed.
16
(cam position sensor) Also, it provides a back-up function in case of trouble in the CKP sen-
sor.
There is no change in behavior while the engine is running even if
there is trouble in the CMP sensor system. However, it will be difficult
to restart the engine after it has been stopped.
Detects the atmospheric pressure and sends it to the ECM. The injec-
tion quantity is corrected according to the atmospheric pressure.
Detects the suction air temperature and sends it to the ECM. Opti-
18 Suction air temperature sensor
mizes the fuel injection quantity.
Detects the boost (suction air pressure) inside the intake pipe and
19 Boost pressure sensor sends it to the ECM. Used to control fuel injection with the boost pres-
sure.
Detects the boost temperature and sends it to the ECM. Used for fuel
20 Boost temperature sensor
injection control etc.
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Explanation of Engine Terms SH120

Name Function
Receives the high-pressure fuel sent under pressure from the supply
1 Common rail pump, holds the fuel pressure, and distributes the fuel to each injec-
tor.
Pressure limiter Operates to allow pressure within the common rail to escape if the
2
(common rail component part) pressure in the common rail becomes abnormally high.
Common rail pressure sensor Detects the pressure inside the common rail, converts it to a voltage,
3
(common rail component part) and sends that voltage to the ECM.
4 Injector Controlled by the ECM and injects the fuel.
Raise the fuel pressure and send it under pressure to the common rail
5 Supply pump
by using the force of the engine rotation.
Controls the fuel pressure (discharge volume) sent to the common
SCV (suction control valve) rail.
6
(supply pump component part) The ECM controls the electrified time to the SCV to increase or
decrease the volume of fuel discharged.
Fuel temperature sensor Detects the fuel temperature and sends it to the ECM.
7
(supply pump component part) Used for supply pump control etc.
Recirculates part of the exhaust gas in the intake manifold and mixes
8 EGR the EGR gas with the suction air to reduce the combustion tempera-
ture and reduce NOx.
The EGR valve operation (open and close) timing and the lift amount
EGR valve
9 are controlled by signals from the ECM. (The valve lift amount is
(EGR position sensor)
detected by the EGR position sensor)
10 EGR cooler Cools the high-temperature EGR gas by using the engine coolant.
ECM Constantly monitors the information from each sensor and controls
11
(engine control module) the engine system.
Determines the glow time according to the engine coolant tempera-
QOS ture, operates the glow relay, and makes starting at low temperatures
12
(quick on start system) easy and also reduces white smoke and noise immediately after the
engine starts.
This sensor sends a signal to the ECM when the projection section of
the engine flywheel passes this sensor.
CKP sensor
13 The ECM uses this sensor input in the calculation of engine speed.
(crank position sensor)
In case of trouble in the CKP sensor, the CMP sensor provides a
back-up function.
Detects the engine oil pressure and sends it to the ECM.
Used for oil pressure drop alarms etc.
Detects the engine coolant temperature and sends it to the ECM.
15 Engine coolant temperature sensor
Used for fuel injection control, QOS control, etc.
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Name Function
This sensor sends a signal to the ECM when the engine camshaft
cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, deter-
mines the crank angle, and uses this information to control the fuel
CMP sensor injection and to calculate the engine speed.
16
(cam position sensor) Also, it provides a back-up function in case of trouble in the CKP sen-
sor.
There is no change in behavior while the engine is running even if
there is trouble in the CMP sensor system. However, it will be difficult
to restart the engine after it has been stopped.
Detects the atmospheric pressure and sends it to the ECM. The injec-
tion quantity is corrected according to the atmospheric pressure.
Detects the suction air temperature and sends it to the ECM. Opti-
18 Suction air temperature sensor
mizes the fuel injection quantity.
Detects the boost (suction air pressure) inside the intake pipe and
19 Boost pressure sensor sends it to the ECM. Used to control fuel injection with the boost pres-
sure.
Detects the boost temperature and sends it to the ECM. Used for fuel
20 Boost temperature sensor
injection control etc.
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Explanation of Engine Structure SH130

Technology for Exhaust Gases
1. Common Rail System
1 High pressure pump

2 Common rail
3 Injector
4 Fuel tank
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2. Multi Stage Fuel Injection (multiple injection)
Injection start
With conventional models, there is the no-injection state, but with common rail models, pre-injection
is started and ignition starts.
Ignition
Conventional models start injection at this point in time, but common rail models have already
ignited with pre-injection and now start the 2nd injection (main injection).
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2
Common rail models

Conventional type injection
(main injection)
Combustion
Common rail models divide the high-pressure fuel injection over many times to make it possible to
create a uniform, complete combustion state in the combustion chamber and also to reduce the
engine noise and vibration.
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3. Inter Cooler
1 Inter cooler
2 Radiator
3 Engine
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4. EGR (Exhaust Gas Recirculation)
1 EGR cooler 6 Suction air temperature sensor

2 EGR valve 7 Engine speed
3 EGR position sensor 8 Engine coolant temperature
4 Boost temperature sensor 9 Engine load
EGR (exhaust gas recirculation)

EGR system is an abbreviation for "exhaust gas recirculation" system. The EGR system recirculates
part of the exhaust gas in the intake manifold and mixes inactive gases with the suction air to reduce
the combustion temperature and suppress the generation of nitrogen oxides (NOx). The EGR quan-
tity is controlled by the operation (opening and closing) of the EGR valve, which is installed between
the exhaust manifold and the intake manifold.
The ERG quantity is determined from the engine speed and engine load ratio (fuel injection quan-
tity) and the EGR amount is controlled. A cooling system (EGR cooler) is installed in the EGR gas
path to cool the high-temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with
new air intake to make the combustion temperature lower than with normal EGR, which contributes
to the reduction of NOx. (Cooled EGR)
Furthermore, a lead valve is used in the EGR system to suppress EGR gas back flow and allow the
EGR gas to only flow in one direction.
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Engine load etc.
No EGR control during idling
Engine speed
The ECM operates the motor according to such engine states as the speed and load and controls
the EGR valve lift amount.
The valve lift amount is detected by the EGR position sensor. The sections shown in darker color in
the diagram have larger valve lift amount. The darkest color indicates a lift amount near 100 %.
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Explanation of Engine Operation SH130

Engine Overall
1. Comparison of 4BG1T and 4JJ1
1 2 valves OHV 5 Roller rocker

2 Cam flat tappet 6 4 valves combustion improvement high output
3 Overhead cam 7 High-rigidity crankcase
4 High-rigidity cylinder head 8 High-rigidity cylinder block
1 Bearing cap structure

2 Ladder frame structure
With the ladder frame structure, the crank shaft bearing is supported as one piece by the frame.
(Increased engine rigidity and reduced noise)
1 NST-06-04-008LX
1
Fuel Unit
1. Common Rail System Summary
The common rail system pressurizes the fuel to high pressure and injects the fuel mist widely into
the cylinder to increase the surface of contact with the air and improve the combustion state.
NST-06-04-008LX 2
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Relationship between ECM and sensor actuators
1 Throttle volume (computer A) 5 Injector

2 Crankshaft position sensor 6 Common rail pressure sensor
3 Camshaft position sensor 7 Supply pump
4 Other sensors 8 EGR valve
2. Change Points for Injection Method (governor, common rail)

Inline type Common rail system
System
Injection quantity
Pump (governor) ECM, injector
adjustment
Injection timing
Pump (timer) ECM, injector
adjustment
Pressure boost Pump Supply pump
Distribution method Pump Common rail
Injection pressure According to engine speed and injection
Supply pump (SCV)
adjustment quantity
1 Pipe 5 Nozzle
2 Timer 6 Common rail
3 Supply pump 7 Injector
4 Governor
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3. Explanation of Injector Operation
(1)When there is no signal from the ECM (state before injection)
The outer valve in the injector is pushed down by the force of the spring A and seals the fuel into
the control chamber.
The hydraulic piston and spring B are pushed down by the fuel in the control chamber and the
nozzle is in the closed state.
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Spring A
6 Inner valve
7 Control chamber
8 Spring B
9 Nozzle
(2)When there is a signal from the ECM

When the signal from the ECM passes power through the injector solenoid, the outer valve com-
presses spring A and moves up.
The outer valve opening allows the fuel in the control chamber to return to the tank via the return
line.
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Solenoid
6 Spring A
7 Inner valve
8 Control chamber
9 Nozzle
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(3)Injection start state
Fuel in the control chamber flowing into the return line creates a pressure difference between the
control chamber side and the hydraulic piston and nozzle, which causes the nozzle to open and
fuel to be injected.
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Inner valve
6 Control chamber
7 Spring B
8 Nozzle
9 Outer valve
(4)When the signal from the ECM is cut off

Because the power to the injector solenoid is cut off, the outer valve is pushed back down by the
force of the spring A and the outer valve closes the return line path.
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Solenoid
6 Spring A
7 Inner valve
8 Valve close
9 Nozzle
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5
(5)Injection stop state (injection end)
Because the fuel is sealed into the return line, the control chamber is filled with fuel again.
The hydraulic piston and the spring B are compressed down by the filled fuel and the nozzle is
closed.
This ends the injection.
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Inner valve
6 Control chamber
7 Spring B
8 Nozzle
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4. Explanation of Supply Pump Operation
The drive shaft is driven by the force of engine rotation.
The feed pump is turned by the power of the drive shaft and draws up fuel from the fuel tank.
The fuel pressurized by the feed pump has feed pressure pulse stabilized by the adjusting valve.
Part of this fuel remains at the suction control valve to lubricate the plunger and cam and is returned
to the fuel tank via the over flow.
The signal from the ECM is input to the suction control valve and the opening stroke varies accord-
ing to the quantity of power passed through.
The quantity of fuel corresponding to the stroke is sent to the suction valve under pressure and is
compressed to high pressure at the plunger.
The fuel raised to high pressure at the plunger is sent under pressure from the delivery valve to the
common rail.
The fuel temporarily built up in the common rail is distributed to the injectors for each cylinder.
1 Fuel tank 8 Return spring 15 Injector

2 Fuel filter 9 Plunger 16 Drive shaft
3 Suction 10 Suction valve 17 Suction pressure
4 Fuel inlet 11 Delivery valve 18 Feed pressure
5 Feed pump 12 Over flow 19 High pressure
6 Adjusting valve 13 Return 20 Return pressure
7 Suction control valve 14 Common rail
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5. Supply Pump Disassembly Diagram
1 Suction valve 5 Suction control valve

2 Plunger 6 Feed pump
3 Cam ring 7 Fuel temperature sensor
4 Delivery valve
1 Delivery valve 6 Plunger

2 Fuel temperature sensor 7 Adjusting valve
3 Feed pump 8 Cam ring
4 SCV (suction control valve) 9 Eccentric cam
5 Pump housing 10 Camshaft
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6. Pressure Limiter
When the pressure within the common rail reaches 29000 PSI (200 MPa), for the sake of safety, the
pressure limiter opens and returns fuel to the tank.
When the pressure drops to 4350 PSI (30 MPa), the valve closes to return operation to normal.
7. Cautions for Maintenance

(1)Cautions concerning fuel used
With common rail engines, the supply pump and injector are lubricated by the fuel running
through them.
Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of non-speci-
fied fuel is strictly prohibited.
Please be aware that troubles resulting from the use of non-specified fuel are "not covered by the
warranty".
Specified fuel
JIS No. 2 diesel, JIS No. 3 diesel, special No. 3 diesel
The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel
path are made with extremely high precision.
Therefore, they are extremely sensitive to foreign matter. Foreign matter in the fuel path can dam-
age it, so use great care to keep out foreign matter.
[1] Clean and care for the fuel line and its surroundings before starting maintenance.
[2] Those working on the fuel line must have hands clean of dirt and dust. Wearing gloves while
working is strictly prohibited.
[3] After removing fuel hoses and fuel pipes, always seal the hoses and pipes by covering the
open sections with plastic bags or the like.
[4] When replacing parts, do not open the packing for the new parts until it is time to install
them.
[5] Do not reuse any gaskets or O-rings. Replace them with new ones.
9 NST-06-04-008LX
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• Do not reuse fuel system high pressure lines or injector pipes. If they are removed, replace
them with new parts.
• Do not replace a pressure limiter, fuel temperature sensor alone. If there is any problem,
replace the common rail assembly and all the fuel pipes.
The SCV pump alone cannot be replaced because the fuel temperature sensor is installed on the
pump main unit. Always replace the supply pump assembly.
1 Injector pipe
2 Common rail pressure sensor
3 Fuel temperature sensor
4 Pressure limiter
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Judging individual cylinders as OK or not by starting up the engine and loosening the injection
pipes is strictly prohibited when there is engine trouble. (Never do this. The high-pressure fuel
sprays out dangerously.)
1 Loosening when engine starts strictly prohibited
Be careful. High voltage of 118 V or higher is applied to the injectors. Disconnect the battery
cable ground before replacing injectors.
1 Injector
2 Injector harness
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Explanation of Engine Control
1. Fuel Injection Quantity Correction
The ECM calculates the basic injection quantity from the throttle volume boost sensor, CKP sensor,
CMP sensor, and other signals.
According to the common rail pressure, engine coolant temperature, and other conditions at this
time, the ECM controls the SCV and controls the injector electrified time to attain optimum injection
timing and correct the injection quantity.
2. Starting Q Correction
The engine starting Q correction is terminated at the idling speed +? min-1 (+? depends on the cool-
ant temperature.).
Also, below the system recognition engine speed (30 min-1) {30 rpm}, the ECM cannot recognize
engine rotation, so starting Q correction and engine starting become impossible.
3. Preheat Control (QOS quick on start)

The ECM determines the glow time (pre-glow, glow, and after-glow) according to the engine coolant
temperature and makes the glow relay operate.
The QOS system makes starting at low temperatures easier and reduces white smoke and noise
immediately after starting.
When the key is switched ON, the ECM detects the coolant temperature with the signal from the
engine coolant sensor and varies the glow time to always obtain the optimum starting conditions.
Also, the after-glow function makes it possible to stabilize the idling rotation immediately after start-
ing.
Also, if there is trouble in the engine coolant temperature sensor system, control assumes a fixed
coolant temperature of -4F° (-20C)° for engine starting and 176F° (80C)° for running.
Also, EGR control stops. (Thermostat valve opening temperature 203F° (95C)) °
4. Atmospheric Pressure Correction (high altitude correction)

The ECM calculates the current altitude from the atmospheric pressure sensor signals.
The ECM controls the SCV and controls the injector electrified time to attain optimum fuel flow
according to the altitude and other conditions at the time.
Also, if there is sensor trouble, control assumes a fixed atmospheric pressure of 12 PSI (80 kPa)
(equivalent to an altitude of 2000 m) and stops EGR control too.
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5. Control for Overheating
When the engine overheats, in order to protect the engine, if the engine coolant temperature
exceeds 212F° (100C), ° fuel flow restriction is started.
If the temperature rises further, the fuel flow is further restricted.
If engine coolant temperature rises to 248F° (120C), ° the engine is stopped.
The protection function is started 1 min. after the engine starts. (In order to detect a stable coolant
temperature)
Judgment
Setting Engine control Recovery condition
time
212F° - -
(100C)
°
ECM: Reduced fuel injection quantity
8th on coolant Computer A: Normal
221F° temperature
(105C)
° gradation 7th or lower on coolant
temperature gradation
230F° ECM: Reduced fuel injection quantity
5s
(110C)
° Computer A: Idling
248F° 5s ECM: Reduced fuel injection quantity Key switched ON after engine
(120C)
° Computer A: Engine stopped stopped
* The protection function does not work if any of the error codes below occurs.
0117 (Coolant temperature sensor abnormally low voltage)
0118 (Coolant temperature sensor abnormally high voltage)
2104 (Faulty CAN bus)
2106 (Faulty CAN time-out)
0090 (CAN communication error)
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6. Control for Boost Temperature Rise
If the boost temperature exceeds 176F° (80C),
° fuel flow restriction is started.
If temperature rises to 194F° (90C),
° the engine is stopped.
The protection function is started 1 minute after the engine starts. (In order to detect a stable boost
temperature)
Setting Judgment time Engine control Recovery condition
176F° 5s ECM: Normal State of 158F° (70C)
° or less
(80C)
° Computer A: Idling control continues for 30 s
194F° ECM: Normal Key switched ON after engine
5s
(90C)
° Computer A: Engine stop control stopped
1112 (Boost temperature sensor abnormally low voltage)
1113 (Boost temperature sensor abnormally high voltage)
7. Control for Engine Oil Pressure Drop

If the engine oil pressure drops, the engine is stopped to prevent engine damage.
The protection function is started 30 s after the engine starts. (In order to detect a stable engine oil
pressure)
Setting Judgment time Engine control Recovery condition
6 PSI ECM: Normal Key switched ON after engine
5s
(40KpA) Computer A: Engine stop control stopped
0522 (Oil pressure sensor abnormally low voltage)
0523 (Oil pressure sensor abnormally high voltage)
1633 (Faulty 5 V power supply 3 voltage/sensor power supply)
8. Start Control (coolant temperature monitoring)

[1] Purpose
When the coolant temperature is 32F° (0C)° or lower, the ECM controls the fuel amount depending
on the coolant temperature, for stable engine starting.
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9. Long Cranking Control
[1] Purpose
For the purpose of reducing black smoke when starting the engine and as backup in case ade-
quate starting Q (fuel injection) is not obtained, for example due to injector wear, after the stipu-
lated time after the start of cranking, the starting Q is raised the stipulated amount to improve
startability.
ST-Q Standard starting Q

UP-Q Starting Q after increase
NL-Q Q for no load
10.Starting Control for Reduced Number of Cylinders

When the fact that there is a stopped injector is detected with trouble diagnosis (when an error code
is detected), for the purpose of emergency escape, the fuel injection quantity is corrected to secure
engine startability.
[1] The injection quantity for the troubled injector is allocated to the normal injectors. (The total injec-
tion quantity is made the same.)
* The injector correction factors are as follows.
Number of effective cylinders 4 3 2 1 0
Correction factor 1.0 1.33 2.0 1.0 1.0
Caution:
No control if there is trouble in injectors for 3 or more cylinders.
No control if an injector has a mechanical trouble.
11.Normal Stop (key switch OFF operation)

[1] The key switch is set OFF.
[2] When the ECM recognizes that the key is OFF, [3] - [5] are carried out at the same time.
[3] Injector injection quantity calculation stop
[4] Suction control valve (SCV) full close instruction
[5] EGR valve full close instruction, EGR valve initial correction
[6] When the operations in [3] - [5] end, the trouble log etc. are written to the EEPROM in the ECM.
[7] The main relay is switched OFF and the power feed to the ECM is switched OFF.
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15
12.Engine Start/Stop Judgment
Engine start and stop is judged based on the engine speed sent from the ECM with CAN communi-
cation.
Judgment value Start: 500 min-1 {500 rpm}
Stop: 200 min-1 {200 rpm}
Configuration diagram
1 Computer A
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Engine Maintenance Standards SH120

Engine Information Screen
1. Purpose
It has been made possible to copy the engine information (Q resistance, QR code, engine serial
number) stored in the ECM to the new ECM when the ECM and injector are replaced.
2. How to Go to This Screen
See the service support operation procedure.
3. Engine Start Restriction
When this screen is displayed, the engine cannot be started.
4. Screen
The engine information held in computer A can be checked as follows.
The information inside the ECM is checked by changing the display mode with the method shown in
"Replacing computer A at the Same Time".
[1] Pages 1 to 4: Injector cylinder 1to 4 QR code (Pages 5 and 6 are not used and cannot be input.)
1 Page
2 QR code 24 digits
Indicates the display mode.
3
Currently displays the information in computer A
4 Error code
[2] Page 7: Q resistance
1 Q resistance data 3 digits
[3] Page 8: Engine serial number
1 Engine serial number 6 digits
1 NST-06-06-003E
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Monitor Operation Method
1. View Mode
2. Edit Mode
* Can only be shifted to during QR code display.
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Engine Information (Q resistance, QR code, engine serial number) Copying Method
If the ECM is replaced with a new one for any reason, the engine information is copied with the proce-
dure below.
[1] Arrange for a service ECM.
Engine information can only be copied to a service ECM.
[2] Connect the service ECM and check the following.
1) The old ECM information must still be in computer A.
2) The ECM must match the model.
3) There must be no faulty EEPROM on computer A or the ECM.
[3] Go to the engine information screen, then hold down for 3 s. The buzzer buzzes and the
copy starts.
* The display may be any page (1 to 8) and either display mode (computer A or ECM).
During copying, the display is as below.During writing, the error code 99 is displayed.
Wait about 10 s.
When the copy ends normally, the error code 00 is displayed.
When the copy ends abnormally, error code displayed.
Example: Starting copying from the Q resistance screen
[4] When the copy ends normally, check that the information has been rewritten by switching the key
switch OFF → ON once.
3 NST-06-06-003E
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Rewriting Injector QR Codes
When an injector is replaced, input and write the QR codes with the following procedure.
[1] Arrange for the replacement injector.
Input the part below from the character array written on the injector.
Input the QR codes one at a time.

Engine information screen Pages 1 to 4 correspond to the injectors with those numbers.
(See the figure below.)
[2] Hold down for 1 s to shift to edit mode.
NST-06-06-003E 4
4
[3] Cursor is displayed.
[4] Move the cursor with to raise and lower the value with
and input the QR codes written on the injector.
[5] When the QR code input is complete, press .

The buzzer buzzes once and the writing starts.
The error code 99 (writing) is displayed. When the copy ends normally, the error code 00 is dis-
played.
When the copy ends abnormally, an error code is displayed. (To cancel input, press .)
[6] Switch the key switch OFF and then ON again, and check that the QR codes have been written.
5 NST-06-06-003E
5
When Replacing Computer A at the Same Time
If the ECM and computer A have trouble at the same time and the engine information inside the ECM
cannot be used, restore the engine information with the procedure below.
[1] Rather than a service ECM, arrange for an ECM with the engine information already written into
it and use that as the replacement.
* An ECM with the engine information already written into it means one into which the Q resis-
tance data has been written with EMPS.
[2] Input the injector QR codes one at a time. (with the procedure in the preceding item)
Engine Information Acquisition Timing

After factory assembly, engine information is acquired only once the first time the key is switched ON.
Redoing Engine Information Acquisition
Engine information acquisition can be redone by holding down and for 10 s in the
engine information screen.
Trouble Display
If the engine information cannot be displayed correctly due to an ECM time-out, CAN communication
trouble, or faulty EEPROM, the display is all Fs.
[1] Display for faulty ECM EEPROM, CAN communication trouble, or ECM time-out
NST-06-06-003E 6
6
Exhaust Gas Regulations SH200

Features of Materials Subject to Exhaust Gas Regulation
Exhaust Gas Regulation Values
1 RST-06-08-002E
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[Example of method for meeting exhaust gas 3rd regulations]

In order to simultaneously reduce both NOx and PM, which have a trade-off relationship, more
complex fuel injection is required. Therefore, fuel injection is now completely electronically
controlled.
Common rail engine (high pressure injection/multiple injection/injection ratio control)
In addition, depending on the engine size, it may be necessary to change from 2 to 4 valves, install
an inter cooler, and use EGR (exhaust gas recombustion).
* With the Model 5 SPACE5, all these systems are used.
RST-06-08-002E 2
2
Cautions for Fuel Used SH200

Engine Fuel and Maintenance of Fuel Filters
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 spec-
ified 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 genuine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and mainte-
nance of the fuel and the fuel elements.
1. 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
[6] With less content of carbon residue
(1)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)
No. 2-D
Based on SAE-J-313C
BS (British Standard)
Class A-1
Based on BS/2869-1970
If a standard applied to the fuel for the diesel engine is stipulated in your country, check the
standard for details.
(2)Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other require-
ments 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.
1 RST-06-09-004E
1
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 dis-
persive 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.
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property
resulting in acceleration of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the
fuel filter.
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.
Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets
the criteria 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 fol-
low 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 periodical interval below.
Engine oil Every 250 hour of use
Engine oil filter element Every 250 hour of use
[3] Inspect and exchange the EGR parts and fuel injector parts of engine by periodical interval
below.
EGR (*) parts Every 3000 hour of use
Fuel injector parts Every 3000 hour of use
* EGR : Exhaust Gas Recircultion
For the detail of inspection and replacement for the above engine parts, please contact
your nearest SUMITOMO outlet.
[4] In addition above if the value of HFRR or water content in the fuel you use is more then limi-
tation in above table of this manual, please also contact your nearest SUMITIMO outlet.
RST-06-09-004E 2
2
2. 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 filters 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 a periodic intervals.
Replacement criteria
Every 250 hour of use Every 500 hour of use
Pre-filter 
Main filter 
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.
Time to replace filters may be advanced according to properties of the fuel being supplied.
Running the engine with the fuel filter blocked may cause the engine to be stopped due to estab-
lishment of engine error code.
If much foreign objects are found in the fuel, carry out earlier inspection and regular replacement
of the filters.
If dust or water get mixed with the fuel, It may cause the engine trouble and an accident.
Therefore, take measures to prevent dust or water from being entered in the fuel tank when sup-
plying 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.
3 RST-06-09-004E
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RST-06-09-004E 4
Changes from Model 3 SH130

Change List
○ : Changed X: Deleted ● New
Change Part name Q'ty Comment
Controller eliminated by use of one-piece controller with
× Controller 1
control panel
Due to the controller change, the motor actuator was also
○ Motor control 3
changed (Step motor → DC motor + potentio-meter)
○ Cooler part evaporator 1 Changed due to change in expansion valve.
○ Case unit, front 1
The hole position was changed due to the motor actuator
○ Case unit, rear 1
change, so the case was also changed.
○ Case unit, bottom 1
○ Expansion valve 1 Expansion valve shape change
○ Thermo-sensor 1 Connector changed
○ Heater core 1 Fuel line bore increased (to ?17.3)
Blower controller
○ (blower amp)
1
○ Relay 2 Compressor clutch relay added

● Inside air intake port packing 1
○ Inside air filter 1 Changed from mesh to paper
○ Outside air filter 1 Thickness increased
1 NST-07-00-002E
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NST-07-00-002E 2
Layout Diagram SH120
Layout Diagram
Layout Diagram
Air Conditioner Overall Diagram
1. Frame
Part name Code Q'ty
Condenser 1 1
Cooler hose (liquid2) 2 1

Cooler hose (suction) 3 1
Rubber hose 16 X 2800 4 1
Rubber hose 16 X 2700 5 1

Compressor 6 1
Cooler hose (discharge) 7 1
Tension pulley (with cover) 8 1

Compressor bracket 9 1
Slide shaft 10 1
Cooler hose (liquid1) 11 1

Dryer receiver 12 1
V belt B55.5 (L = 1430) 13 1
Air conditioner unit 14 1

Engine 15 1
NST-07-01-003E 1
1
Layout Diagram
2 NST-07-01-003E
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Layout Diagram
2. Cab
Part name Code Q'ty

Face grille 1 1
Control panel 2 1
Duct; FACE-B 3 1
Duct; FACE-C 4 1
Duct; H and C box 5 1
Box; Hot and cool 6 1
Duct; VENT (Right) 7 1
Duct; VENT (Left) 8 1
Rear box 9 1
Suction duct (FRESH) 10 1
Air conditioner unit 11 1
Duct; FOOT 12 1
Duct; DEF-C 13 1
Duct; DEF-B 14 1
Face grille 15 6
Drain hose 16 2
Air filter 17 1
Box bracket (left) 18 1
Cushion seal 19 1
3 NST-07-01-003E
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Layout Diagram
Code Part name

1 Motor actuator (mode)
2 Compressor relay
3 Blower OFF relay
4 Motor actuator (refresh/recirculate switch)
5 Interior temperature sensor
6 Blower motor
7 Blower amp
8 Motor actuator (air mix)
9 Evaporator sensor
4 NST-07-01-003E
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Circuit Diagram AH120
Circuit Diagram
Circuit Diagram
Air Conditioner Circuit Diagram
1 NST-07-02-002E
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Circuit Diagram
2 NST-07-02-002E
Explanation of Functions SH130
Explanation of Functions
Explanation of Control
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the vehicle main key power supply
or operation panel ON/OFF switch, the set temperature and all the other setting states are stored in
memory, so the next time air conditioner operation starts, it goes into the same state as before it was
stopped.
When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal
EEPROM. However, if the main key power supply is cut off within 0.5 s of switch input, that switch input
is not stored into memory. Also, the data read out from EEPROM when the power is switched ON is
judged to see if it is within the valid range. If data outside the valid range was written into memory, for
example due to noise, then operation starts from the default setting values to avoid abnormal opera-
tion.
Fahrenheit temperature display
To switch, hold down both the temperature setting UP and DOWN switches for 5 s. The display toggles
between Celsius and Fahrenheit display each time the switches are both held down for 5 s.
The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "° F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power
supply is switched OFF, the display status is retained. Internal calculations are all done in Celsius. Only
the operation panel display is in Fahrenheit. Therefore, the display may differ slightly from the exact
Fahrenheit temperature.
The Fahrenheit display temperature and the Celsius temperature in relation to Fahrenheit temperature
during internal processing are shown below.
<Caution>
These specifications are written with Celsius as the standard. Therefore, refer to the table below to
convert Fahrenheit displays to Celsius display values.
Fahrenheit and Celsius correspondence
Interior recognition set
Fahrenheit display F]
[°
temperature (Celsius) [ ℃ ]
63 18.0
64 18.5
65 19.0
：：
77 25.0
：：
91 32.0
1 NST-07-03-002E
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1. Air Mix Motor Actuator Control
[1] Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the
current blow mode, various restrictions are applied, and the target degree of opening is calcu-
lated. Then drive is output to move the motor actuator position to the target degree of opening.
Below are the details.
[2] Restrictions on operation angle according to the blow mode
When the blow mode motor actuator is in the B/L, FOOT, or DEF position, it is prohibited for this
motor actuator degree of opening to be less than 20°
[3] Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position. How-
ever, if the target degree of opening is less than 0° , the actuator is treated as having reached the
target degree of opening when it reaches 0° , then it moves to the specified position.
(A stop in the fully-open direction is used as the standard.)
[4] Operation start/stop judgment
1) The operating motor actuator stops when the current position comes within the target position.
2) The stopped motor actuator operates when the current position goes beyond the target posi-
tion.
[5] Motor actuator operation priority order
The operation priority for this motor actuator is No. 1. This means that if the target degree of
opening for this motor actuator changes and operation becomes necessary, even if some other
motor actuator is operating, that other motor operation is paused, and this motor actuator oper-
ates.
2. Blow Mode Motor Actuator Control

The blow mode is switched by rotating the diffuser switching damper with the motor actuator.
There are 2 types of control: auto and manual.
[2] Auto control
When the AUTO blow mode signal is recognized, the blow mode changes to auto control. During
auto control, the diffuser is switched according to the target blow temperature Auto control contin-
ues until operation of the blow mode select switch is recognized.
NST-07-03-002E 2
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[3] Manual control
1) When operation of the blow mode select switch is recognized, the motor actuators are driven to
attain the output shaft angle below and the display is switched too. Each time operation of the
switch is recognized, the display switches MODE1 → MODE2 → MODE3 → MODE4 →
MODE1 → ... However, if this switch is pressed during auto control, auto control is ended and
the diffuser is fixed at its current position.
2) MODE5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode
becomes the one that was in effect just before operation of the DEF select switch was recog-
nized.
Blow mode and display and motor actuator angle
Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5
Blow mode motor actuator
90° 65.5° 46.5° 26.6° 0°
degree of opening
Panel display
[4] Mode unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening a, it returns to the specified position.
However, if a is less than 0°
, the actuator is treated as having reached the target degree of opening
a when it reaches 0°, then it moves to the specified position.
(A stop in the VENT or FACE direction is used as the standard.)
[5] Operation start/stop judgment
1) The operating motor actuator stops when the current position comes within the target position.
2) The stopped motor actuator operates when the current position goes beyond the target posi-
tion.
[6] Blow mode control priority order
The priority order for auto control and manual control is as follows.
Control priority order
Priority order Control
1 Manual control
2 Auto control
3. Refresh/Recirculate Switch Motor Actuator Control

[1] Recirculate mode
In refresh mode, when it is recognized that the refresh/recirculate select switch on the operation
panel has been closed, the system goes into recirculate mode. At this time, the display switches
to recirculate and the refresh/recirculate switch motor actuator operates to the recirculate angle.
[2] Refresh mode
In recirculate mode, when it is recognized that the refresh/recirculate select switch on the opera-
tion panel has been closed, the system goes into refresh mode. At this time, the display switches
to refresh and the refresh/recirculate switch motor actuator operates to the refresh angle.
3 NST-07-03-002E
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[3] Operation stop judgment
When one of the limiters is detected, operation stops.
Refresh/recirculate mode and refresh/recirculate display and motor actuator angle
Refresh/recirculate mode Recirculate Refresh
Refresh/recirculate motor actuator degree of opening 0° 90°
Panel display
4. Blower Amp Control

The air flow is controlled by outputting to the blower amp connected in series with the blower
motor. The air flow is switched by varying the analog voltage output by changing the PWM output
duty ratio and increasing or decreasing the blower motor speed.
There are 2 types of air flow control: auto air flow control and manual air flow control. Also, in auto
air flow control, the air flow is restricted by the cold blast prevention control etc.
Auto air flow control has no levels and manual control has 4 levels.
[2] Manual air flow control
Each time it is recognized that the air flow UP switch has been closed,
Lo → M1 → M2 → Hi
the air flow is fixed to the next higher level of air flow. When Hi is already displayed, the air flow is
not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed,
Hi → M2 → M1 → Lo
the air flow is fixed to the next lower level of air flow. When Lo is already displayed, the air flow is
not changed.
The same is true when air flow control is switched from auto to manual. For example, when
AUTO M1 is displayed, if it is recognized that the air flow DOWN switch has been closed, the dis-
play becomes Lo and AUTO is no longer displayed.
Also, the change speed for air flow output switchover is the same as discussed for auto below.
Relationship between air flow and PWM output
Air flow Display Target % (about)
Hi (maximum air flow) 100 %
M2 75 %
M1 59 %
Lo (minimum air flow) 40 %
NST-07-03-002E 4
4
[3] Auto air flow control
When it is recognized that the AUTO switch has been closed, the air flow is controlled automati-
cally and AUTO is displayed.
1) The air flow during auto air flow control is set as shown in the graph below according to the tar-
get blowing temperature.
2) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is
recognized.
3) The auto air flow amount calculation results are continuous, not divided into levels.
4) When it is recognized that the AUTO switch has been closed, the display becomes as in the
table below according to the auto air flow amount calculation results.
5) The normal auto air flow output change is roughly 5 V/s.
6) Auto air flow control is restricted by the cold blast prevention control described in [4], which is
the next item.
Relationship between air flow and target blow temperature
Display refreshing and air flow output correspondence table

Current display Item Target % (about)
Lo display Output range changed to M1 When 53 % or higher
Output range changed to Lo When 46 % or lower
M1 display
Output range changed to M2 When 70 % or higher
Output range changed to M1 When 64 % or lower
M2 display
Output range changed to Hi When 92 % or higher
Hi display Output range changed to M2 When 83 % or lower
5 NST-07-03-002E
5
[4] Cold blast prevention control
The air flow is restricted according to the value of the coolant temperature data and other param-
eters sent from the vehicle side. The air flow restriction has 2 levels - air flow 0 and air flow Lo.
Whether or not to use the restriction is determined from the judgment results.
1) Conditions under which cold blast prevention control is used
1. Auto air flow
2. When set temperature - inside air sensor temperature ≧ 11
3. When the coolant temperature signal from vehicle is the less than 95F° (35C)
° signal or the 95
F° (35C)
° or higher but less than 113F° (45C)
° signal
Under the condition above, the inside air sensor temperature is the value immediately after the
vehicle main key power supply is switched ON and AUTO and Tset are according to the current
switch states. Therefore, when the AUTO switch is pressed after the air flow has been set man-
ually, if the coolant temperature is within the cold blast prevention range, the air flow is
restricted. In the same way, even if the set temperature is changed, if the conditions are met,
the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted
air flow.
2) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 86F° (30C) ° signal, the air flow
is set to 0. This continues until a coolant temperature signal of 86F° (30C)
° or higher is received.
Once a coolant temperature signal of 86F° (30C) ° or higher is received and these conditions are
no longer met, air flow 0 is ended.
3) Air flow Lo control
When the coolant temperature signal from vehicle is the 95F° (35C) ° or higher but less than 113F°
(45C)° signal, the air flow is set to Lo. This continues until a coolant temperature signal of 113F°
(45 C)
° or higher is received. Also, the same as for (2), this shift is irreversible. Once a coolant
temperature signal of 113F° (45C) ° or higher is received, control is normal.
Coolant temperature signal sent from the vehicle (1 cycle)
* Finalized by the same waveform for 3 cycles. However, for the first combustion after the
ignition switch is switched ON, judged with the latest 1 cycle.
* The default state for the coolant temperature signal when the ignition is switched ON is 113F°
(45C)° or higher.
NST-07-03-002E 6
6
[5] Air flow control priority order
The priority order for auto air flow control, manual air flow control, and cold blast prevention con-
trol is as follows.
Control priority order
Priority order Control
Blower air flow control when mode motor actuator angle
1
switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
5. Compressor Clutch Control

The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an
external relay. This control is executed by thermo operation, the condensation prevention func-
tion, and the fletching prevention function. Thermo operation has control mode 1 and control
mode 2. These modes are applied according to the blow mode and other conditions. However, for
blower air flow 0, the compressor clutch is switched OFF. The operation temperature does not
include the thermistor variation.
[2] Thermo operation (AC switch ON)
1) Control mode switchover
• When the blow mode is B/L and the target blow temperature is as in the figure below, control
mode 2 is used.
As the figure shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.
Relationship between control mode and target blow temperature for B/L
2) Control mode 1
• OFF temperature: 5 ± 33.8F° (1C) °
When this temperature or lower is detected, the compressor clutch is switched OFF.
(It is kept OFF until a temperature at or above the ON temperature is detected.)
• ON temperature: OFF temperature + 2 ± 32.9F° (0.5C) °
When this temperature or higher is detected, the compressor clutch is switched ON.
(It is kept ON until a temperature at or below the OFF temperature is detected.)
3) Control mode 2
• OFF temperature: 5 ± 33.8F° (1C)
°
• ON temperature: OFF temperature + 2 ± 32.9F° (0.5C)
°
7 NST-07-03-002E
7
[3] Condensation prevention function
1) Timer set temperature: 8 ± 35.6F° (2C)°
When this temperature or lower is detected, the timer is set and starts counting. (It is not reset
until a temperature at or above the timer cancel temperature is detected.)
2) Timer cancel temperature: Timer set temperature + 1 ± 33.8F° (1C)°
When this temperature or higher is detected, the timer is reset.
3) Count-up time: 10 ± 1 min.
When the timer count reaches this time, the compressor clutch is switched OFF. After this,
when the timer recovery temperature or higher is detected, the compressor clutch is switched
ON and timer setting is prohibited.
4) Timer recovery temperature: Timer set temperature + 2 ± 33.8F° (1C)
°
When this temperature or higher is detected, the compressor clutch is switched ON and timer
setting is permitted.
[4] Fletching prevention function
1) Operation conditions
After the end of initial operation, if 5 ± 1 min. continue with the air flow M2 or higher and the
compressor clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the vehicle main key power supply being switched OFF and this con-
trol starts again when this power supply is switched ON again.
Compressor clutch ON time: 1 ± 0.6 s
2) This control takes priority over all other control.
[5] AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and
AUTO is displayed.
1) Compressor clutch control is the same control as for the AC switch being switched ON.
2) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out.
Even when it is recognized that the AC switch has been switched ON again, AUTO is not dis-
played.
However, at this time, if the main key power supply is switched OFF, then ON again, since the AC
ON, air flow AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.
6. COOLMAX Control and HOTMAX Control

[1] When the set temperature is 64.4F° (18.0C)
° [COOLMAX] (or 18.E)
1) The air mix motor actuator is set to the 0° limiter position (fully closed).
2) For auto air flow control, the air flow is set to Hi.
3) For AUTO blow mode control, the blow mode is set to VENT.
[2] When the set temperature is 89.6F° (32.0C) ° [HOTMAX]
1) The air mix motor actuator is set to the 90° limiter position (fully open).
2) For auto air flow control, the air flow is set to M2.
3) For AUTO blow mode control, the blow mode is set to FOOT.
NST-07-03-002E 8
8
7. Trouble Detection and Control after Trouble Detected
If there is trouble in a motor actuator drive line or sensor controller input circuit, the trouble is
detected and control from after detection is performed as described below.
In any of these cases, once trouble has been detected, even when that location is returned to
normal, trouble control is not ended. Trouble control is only ended when the vehicle main key
power supply is switched OFF or when air conditioner operation is stopped with the ON/OFF
switch on the operation panel. However, motor actuator restriction is only ended by switching
OFF the main key power supply.
[2] Trouble in a motor actuator and its input/output circuits
1) Disconnection detection
Immediately after the main key power supply is switched ON, if a motor actuator potentio-meter
line is disconnected or shorted, the display in the table below for that motor actuator is carried
out and that motor actuator is not driven until the main key power supply is switched OFF, then
ON again.
Disconnection detection display
Trouble location Trouble display
HL.E is displayed on the set temperature display
Air mix motor actuator
LCD. See the figure below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate motor actuator Potentio-meter line not used
2) Motor lock detection

If the output shaft rotation angle for a motor actuator does not reach its target value within 15 s,
this is treated as lock detection, output to that motor is stopped, and trouble is displayed on the
controller according to the trouble location.
Motor lock detection display
Trouble location Operation panel trouble display
HL.E is displayed on the set temperature display
Air mix motor actuator
LCD. See the figure below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor
The refresh/recirculate mark flashes.
actuator
9 NST-07-03-002E
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[3] Trouble in a sensor or its input/output circuits (disconnection or short)
1) Disconnection or short in the inside air sensor or its input/output circuits
1. Operator compartment temperature control end
• All control related to the operator compartment temperature (target blow temperature) is stopped
and the air mix degree of opening is directly adjusted according to the temperature adjustment
switch input.
• Accompanying this, the operation panel set temperature display changes as in the figure
below.
* is a value from 0 - 9.Each time the DOWN switch is closed, this value decreases by 1;
each time the UP switch is closed, this value increases by 1.
For any blow mode other than FACE or VENT, the minimum value is set to 1.
Display and control for inside air sensor trouble
* value Motor actuator degree of opening ( )°
0 0°
1～8 * value x 10 °
9 90 °
2. Auto air flow control end

• The air flow is temporarily fixed at that in effect when the inside air temperature sensor trouble was
detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3. AUTO blow mode control end
• The blow mode is temporarily fixed at that in effect when the inside air temperature sensor trouble
was detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4. Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is
not displayed in the * section below the decimal point and the air mix damper degree of opening
display is given priority.
• HL.E is only displayed for air mix motor actuator trouble.
5. Thermo operation control mode fixed
• Switching of the control mode according to the blow mode and target blow temperature is stopped
and the control mode is fixed at control mode 1.
2) Disconnection or short in evaporator sensor or its input/output circuits
1. Compressor control is not executed and the compressor clutch is always OFF. However,
fletching prevention control is executed.
2. E is displayed in the first fraction position of the set temperature display LCD. See the figure
below.
(The temperature setting is in 33.8F° (1C) ° steps.)
However, E is not displayed for inside air sensor trouble.
NST-07-03-002E 10
10
3. The A/C mark flashes.
Disconnection or short in evaporator sensor or its input/output circuits
3) Disconnection or short in solar radiation sensor or its input/output circuits

1. The solar radiation compensation data is set to 0.
2. E is not displayed in the first fraction position of the set temperature display LCD as it is for
other sensors.
4) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.
8. Monitor Mode
Monitor mode is a mode for understanding trouble in the controller itself or in other control. The
system goes into monitor mode when there is the special switch input below on the operation
panel.
[2] Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON/OFF switch
closed path continues for 1 s while the refresh/recirculate select switch closed path is ongoing,
monitor mode is started.
[3] Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 s. An LCD with trouble does not
light up.
2) Sensor diagnosis
The detection value (AD value or ℃ ) for each sensor is displayed.
3) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
[4] Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 s. An LCD with trouble does not
light up.
2) Sensor diagnosis
The detection value ( ℃ ) for each sensor is displayed.
[5] Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal
recognition, etc.) is displayed in the 3 digits of the 7-segment display for the temperature setting.
The data displayed is selected with the blower UP/DOWN switches and AUTO switch. The blower
UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through
16 displays, 0 - F, and the corresponding data is displayed. (Table A on next page) Hexadecimal
data display and decimal data display can be selected with the AUTO switch. Only for the coolant
temperature signal recognition value, the value detected immediately before entry into monitor
mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3rd digit of the
7-segment display. For hexadecimal data, “H” is displayed there and for decimal data, numbers
(0 - 9) are displayed there.
11 NST-07-03-002E
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1) Hexadecimal display
AD values 00H - FFH are displayed. When the AD value corresponds to that in Table B on the
next page (or Table C for the solar radiation sensor), this indicates a disconnection or short. In
the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadeci-
mal display changes with it. If the display before entering monitor mode was , the
error judgment value is displayed. (In other words, the value detected before the trouble was
detected) In the same way, if the display before entering monitor mode was , the dis-
play becomes **.E and the error judgment value is displayed.
2) Decimal display
From -147.8F° (-99.9C)
° to 211.82F° (99.9C)
° is displayed with decimals. Also, the “-” minus display
displays the arrow mark for FOOT mode.
[6] Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until
monitor mode is ended, operations and settings of basic control through all the switches are not
possible.
[7] Ending monitor mode
In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 s while the
refresh/recirculate select switch closed path is ongoing, monitor mode is ended and the system
returns to the basic control state. The same also occurs if the vehicle main key power supply is
switched OFF.
Table A
Dedicated monitor
mode 7-segment Display contents
display
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
Coolant temperature signal status data
86F° (30C)° or
Lower than 86F° higher and lower 113F° (45C)
° or
C Abnormal
(30C)
° than 113F° higher
(45C)°
4 1 2 3
3 - 9 and B - F Data (sensor diagnosis etc.)
Table B
Sensor name Short Disconnection
Inside air sensor F6H 0CH
Evaporator sensor F6H 0CH
Table C
Sensor name 5 V short Ground short
Solar radiation sensor C7H 0CH
NST-07-03-002E 12
12
9. Door Switch Control
This control adds a restriction to air conditioner operation with the door switch or front window
switch. Its purpose is to prevent overheating of the vehicle main unit. Concretely, it suppresses
condenser heating and controls in a way restricted in order to obtain a feeling of comfort.
[2] Door switch/front window switch signal
The signal input into the controller is as follows for both the door and front window switches.
1) When door/front window open
When contact closed. In other words, the control controller input is at ground level.
2) When door/front window closed
When contact open. Pulled up to 5 VDC inside the control controller.
[3] Control restricted by door switch/front window switch
1) Starting restricted control
When either the door or front window is open continuously for 1 s or longer, it is recognized that
the switch is open. At the count of 60 s, the buzzer buzzes the same way as for switch input to
tell the operator that restricted control is starting and that control starts.
2) Restricted control
1. For both auto and manual blow mode control
Even if auto or manual blow mode is selected, unless the blow mode is FACE, the following
air flow restriction is executed. (If the blow mode is FACE, the air flow is not restricted.)
. If the target blow temperature ＜ 68F° (20C)
? ° , the air flow upper limit is set to M1.
. If the target blow temperature ≧ 77F° (25C),
? ° the air flow restriction in I is ended.
2. When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3. When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is
changed to FACE. After this, all the blow modes can be selected with manual operation.
3) Ending the restriction
When both the door and front window are closed continuously for 1 s or longer, it is recognized
that the switches are closed. After a count of 1 s, the buzzer buzzes the same way as for switch
input to tell the operator that restricted control has been ended.
When the restricted control is ended, the air flow restriction discussed in item 1 of number 2)
above and the change from VENT to FACE in item 3 of number 2) are ended and control
returns to normal. However, if the blow mode has been manually selected, even if the mode
was changed from VENT to FACE by the above restriction, it does not return to VENT when the
restricted control is ended.
10.Inside Air Filter Clogging Detection Control

This control recognizes the blower milli-amp with the dedicated shunt resistor voltage input,
judges from that value whether or not the AC unit inside air filter is clogged and if it judges that
that filter is clogged, it issues a warning to encourage the operator to replace the filter.
[2] Filter detection control
1) Starting detection control (detection timing)
2) Detection method
Cooling/heating is judged from the operation mode and in this way the air mix motor actuator
target position is determined. Also, the mode motor actuator target value is set to FOOT, the
blower air flow target value is set to M1, and output is made to attain the target values. When all
the target values are attained, the blower milli-amp from the shunt resistor voltage is recog-
nized, and the filter clog is judged by comparing this milli-amp with the default milli-amp.
13 NST-07-03-002E
13
(Cooling/heating judgment)
When the operation mode is FACE or VENT ：Cooling (COOLMAX)
When FOOT or DEF ：Heating (HOTMAX)
When B/L: Final inside air temperature If < 71.6F° (22C),
° heating
When B/L: Final inside air temperature ≧ 71.6F° (22C),
° cooling
(Detection milli-amp threshold)
Relative to the default milli-amp For cooling ：0.37 ± 0.02 A min.
For heating ：0.51 ± 0.03 A min.
If the value is below this three times in a row, it is judged that there is a clog.
(Default milli-amp)
Milli-amp found in the initialization operation described below.
3) Clog warning
(Buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 s.
(Display)
“FIL” is displayed on the 7-segment display for the set temperature for 10 s. Other marks go
out.
However, if there is any switch input, the “FIL” display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50 % of the clog detection threshold.
5) ON/OFF switching
This function is switched ON/OFF by pressing the [Refresh/Recirculate], [MODE], and [DEF]
switches at the same time. The factory setting for this function is OFF. This function does not
come ON until the init
ialization operation discussed below is executed.
(Buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(Display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state
after switching. Other marks go out.
6) Initialization operation
When the [Refresh/Recirculate] and [DEF] switches are pressed at the same time, the default
milli-amp is detected and all the data for filter detection is initialized. Before executing this oper-
ation, make sure that the air conditioner unit (with a new inside air filter installed), ducts, and
grilles (with all grilles fully open) are all installed in their normal states on the vehicle. If initial-
ization is carried out in any other state, there is a danger of the clog detection judgment control
making an incorrect judgment. Immediately after replacing the inside air filter with a new one,
execute the initialization operation.
(Buzzer)
When operation of the switch is recognized, the buzzer buzzes with the normal switch input
sound. When the detection ends, the buzzer buzzes for 3 s.
7) Detection processing avoidance
• When the refresh/recirculate damper is not at the recirculate position immediately before the
milli-amp is read.
• When the power supply voltage is not in the tolerance range for the voltage during the initial-
ization operation.
• Trouble in any of the motor actuators.
NST-07-03-002E 14
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Actuator Inspection SH200
Actuator Inspection
Actuator Inspection
Air Mix Motor Actuator Inspection
1 Control amp
2 Air mix motor actuator
3 Connector 1
4 Connector 9
1 RST-07-04-003E
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Actuator Inspection
Chart
RST-07-04-003E 2
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Actuator Inspection
Refresh/Recirculate Motor Actuator Inspection
1 Control amp
2 Refresh/recirculate motor actuator
3 Connector 1
4 Connector 2
5 Connector 11
3 RST-07-04-003E
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Actuator Inspection
Chart
RST-07-04-003E 4
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Actuator Inspection
Mode Motor Actuator Inspection
1 Control amp
2 Mode motor actuator
3 Connector 1
4 Connector 10
5 RST-07-04-003E
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Actuator Inspection
Chart
RST-07-04-003E 6
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Self-diagnosis Function With Panel Display SH200

Trouble Display and Self-check Procedure
Motor actuator and sensor troubles can be checked on the panel display.
1. Trouble Display Position
2. Explanation of Trouble Display

(1)Motor actuator trouble
[1] HL.E displayed on 3-digit 7-segment display
Check the air mix damper motor actuator for harness dis-
connection or disconnected connector.
[2] MODE flashes.
Check the blow mode damper motor actuator for harness

disconnection or disconnected connector.
[3] The R/F flashes.
Check the refresh/recirculate motor actuator for harness

disconnection or disconnected connector.
Caution
With the panel ON/OFF switch ON, the above display and flashing does not function even
if a harness disconnection or disconnected connector occurs.
After trouble occurs, when the panel ON/OFF switch is switched ON, the function is dis-
played.
After trouble occurs, the trouble display and flashing are not ended until the main switch
is switched OFF → ON.
1 RST-07-05-002E
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(2)Sensor trouble
[1] HL.* displayed on 3-digit 7-segment display
Check the inside air sensor and check its harness for
disconnection, short, or connector connection defect.
[2] **.E and the mark flashing display are displayed on the 3-digit 7-segment.
(** displays the set temperature value at that time still remaining.)
Check the evaporator sensor and its harness for
disconnection, short, or connector connection defect.
Caution
The display in [1] and [2] above is displayed on the 3-digit 7-segment display when trouble
occurs with the panel ON/OFF switch ON.
After the trouble section is repaired, end the trouble display by switching the panel ON/
OFF switch OFF → ON.
RST-07-05-002E 2
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3. Explanation of Monitor Mode
2. (2) When sensor trouble is displayed, the sensor status (disconnection, short) can be checked in
monitor mode.
(1)Monitor mode display position
(2)Monitor mode display operating method
1 Refresh/recirculate select switch

2 Blower switch UP/DOWN switch
3 ON/OFF switch
[1] Hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for
1 s or longer.
[2] Press the AUTO switch.
(All the segments light up for 1 s, then the system enters monitor mode.)
[3] Numbers 0 - 9 or letters A - F are displayed in the 2nd and 3rd digit of the 3-digit 7-segment
display.
"H" is displayed in the 1st-digit.
[4] The 0 - 2 display on the dedicated 7-segment display is carried out with the blower UP/
DOWN switches. The necessary sensor is selected from the table below.
[5] To end the monitor display, either hold down the refresh/recirculate select switch and the
ON/OFF switch at the same time for 1 s or longer or switch the vehicle main switch OFF.
Caution
1. During monitor mode, operations and settings of basic control through all the switches
are not possible until the air conditioner control operation is stopped and monitor
mode ended.
2. During monitor mode, even if a sensor is repaired, the trouble display is recorded in
memory, and until the ON/OFF switch is switched OFF, then ON again, the trouble dis-
play is not ended.
3 RST-07-05-002E
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(3)Display contents in monitor mode
See the dedicated monitor 7-segment display table and 3-digit 7-segment table.
[1] Display example 1
The dedicated monitor 7-segment display is 0 (indicates
the inside air sensor state).
From the 3-digit 7-segment table 3F → The sensor is
normal.
→ The inside air sensor is normal.

the evaporator sensor state).
From the 3-digit 7-segment table 00 → The sensor is
disconnected.
→ The evaporator sensor is disconnected.

the solar radiation sensor state).
From the 3-digit 7-segment table FF → The sensor is
shorted.
→ The solar radiation sensor is shorted.
3-digit 7-segment table
RST-07-05-002E 4
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5 RST-07-05-002E
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7 RST-07-05-002E
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9 RST-07-05-002E
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RST-07-05-002E 12
Part Function and OK/NG Judgment SH200
Part Function and OK/NG Judgment

Control Panel and Control Unit
The control panel and control unit are formed into one piece. The operation of its built-in microcom-
puter compares, operates on, and processes the sensor input signals and control panel switch input
signals, switches the output side actuators (refresh/recirculate switching, air mix) and comprehensively
controls the fan motor and compressor.
It is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the con-
trol specifications.)
Blower Amp
The blower amp receives the control signals from the control unit and changes the speed of the blower
motor.
Normal
Terminal number
Conductance
1 2 3
+ - Conductance (4.7 k± 5 %)
- + No conductance
Tester
Conductance
+ -
(diode parallel forward direction)
[1] Remove the blower amp connector.

[2] Check the conductance between the blower amp side
terminals.
* The installation position is on the left side of the air conditioner unit.
1 RST-07-06-002E
1
Relay
4-pole relays are used for the blower OFF relay and compres-
sor relay.
Blower OFF relay
This relay receives the signal from the control amp and
switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply
voltage is fed to the blower motor via the blower amp and the
blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp
compressor control;
Relay inspection contents
[1] Relay
[2] Coil resistor: 320 Ω
[3] Specification voltage: 20 - 30 V DC
[4] Be careful. The coil side of this relay must be installed with the poles facing correctly.
[5] Inspection: Inspect the conductance between 3 and 4 under the conditions below.
20 - 30 V applied between Terminals 1 and 2 : Conductance
No voltage applied between Terminals 1 and 2 : No conductance
Air Mix Actuator

The air mix actuator is installed at the center of the air condi-
tioner unit. It opens and closes the air mix damper via the link.
Built into the air mix actuator is the potentio-meter which var-
ies linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit
reads in the potentio-meter position in the actuator and determines whether the motor turns forward or
reverse.The contacts move linked with the motor. When the contacts move open or the target potentio-
meter position is reached, the control unit output signal goes OFF and the motor stops.
(See "Air Mix Motor Actuator Inspection".)
Refresh/Recirculate Actuator
The refresh/recirculate switch actuator is installed on the
blower intake unit. It opens and closes the refresh/recirculate
damper via the link.
Built into the refresh/recirculate switch actuator is the position
detection switch that changes linked with the actuator shaft.
When the refresh/recirculate damper position is determined by the refresh/recirculate switch on the
control panel, the control unit reads in the signal of the position detection switch in the actuator and
determines whether the motor turns forward or reverse.The contact moves linked with the motor and
when the contact reaches the position detection switch and separates, the motor stops.
(See "Refresh/Recirculate Motor Actuator Inspection".)
RST-07-06-002E 2
2
Blow Mode Actuator
The blow mode actuator is installed on the back surface of the
air conditioner unit. It opens and closes the blow damper via
the link.
Built into the blow mode actuator is the potentio-meter which
varies linked with the actuator shaft.
When the blow mode position is determined by the temperature control switch, the control unit reads in
the potentio-meter position in the actuator and determines whether the motor turns forward or
reverse.The contacts move linked with the motor. When the contacts move open or the target potentio-
meter position is reached, the control unit output signal goes OFF and the motor stops.
(See "Mode Motor Actuator Inspection".)
Evaporator Sensor
In order to prevent the evaporator freezing, the evaporator blow temperature is detected and the com-
pressor ON/OFF controlled.
• Evaporator sensor inspection method
(specifications value)
Disconnect the evaporator connector from the main har-
ness and measure the resistance between the sensor side
connector terminals using the tester.
When the sensor section detection
Resistance : 7.2 kΩ
temperature is 158F° (70C)
°
between
terminals When the sensor section detection
: 2.2 kΩ
temperature is 77F° (25C)
°
Dual Pressure Switch

The dual pressure switch is installed on the receiver dryer.
When there is pressure trouble in the coolant high-pressure
side line (abnormally high pressure or abnormally low pres-
sure), the dual pressure switch contacts open up to cut off the
compressor power and protect the cooling cycle.
• Simple inspection method for dual pressure switch
[1] With the cooling cycle stopped, disconnect the connec-
tor from the switch and check the conductance between
the switch side connector terminals using the tester.If
there is conductance, the switch is normal.(When the
outside air temperature is 32F° (0C)
° or higher)
[2] Connect the gauge manifold high-pressure side hose to
the high-pressure side charge port. With the cooling
cycle operating, the condenser front surface is covered
with the plate top and the high-pressure rises.If the
compressor stops around 455.3 PSI (3.14 MPa) , the
switch is normal.
[3] With the coolant removed, check the conductance
between the switch side connector terminals using the
tester.If there is no conductance, the switch is normal.
3 RST-07-06-002E
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Solar Radiation Sensor
This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photo-
diode, converts it into current and sends that to the control panel.
• Solar radiation sensor inspection method
Disconnect the solar radiation sensor connector from the
harness and measure the resistance between the sensor
side connector terminals using the tester's voltage mea-
surement mode.
The voltage must be different when light is striking the pho-
toreceiver section and when it is not.(The voltage is 0 V
when absolutely no light is striking the photoreceiver.)
Caution
Always measure with the tester in voltage measurement mode (V mode).
Measuring with the tester in resistance mode (?mode) would destroy the sensor.
RST-07-06-002E 4
4
New Machine Performance SH200

Performance Evaluation Check Sheet
= Confirmation, S = Measurement, A = Adjustment
Inspection Item Confirm Remarks Inspection Item Confirm Remarks
Fluid/Oil Level Inspection Engine inspection
1. Radiator fluid level 1. Engine speed
2. Engine oil level Idling rpm
3. Hydraulic oil level Maximum with no load rpm
Brake-in Operation Inspection 2. Conditions of engine rotation
1. Engine start/stop (1) When idling (As
2. Air bleeding (2) Without load required)
3. Individual operation 3. Engine exhaust hue

4. Oil leakage 4. Engine sound and vibration
Hydraulic Oil Contamination 5. Engine stop
Inspection
(1) Turning OFF the key switch
Electrical System Inspection
(2) Emergency stop switch
1. Machine type choice
Hydraulic Equipment Inspection
2. Monitor display
Pressure of each component
3. Throttle volume functions 1.
(refer to separate sheet)
4. One-touch/Auto idle function 2. Abnormal sounds of each part
5. Lever lock function Natural lowering level of each
3.
cylinder (refer to separate sheet)
6. Neutral start function
Operation speed of each cylinder
7. 2-speed travel function 4.
8. Horn volume select function
Swing speed (As
5.
9. Travel alarm function (refer to separate sheet) required)
10. Power shut-off delay function Swing brake performance
6.
11. Accessories operation
Condition and sound of swing
(1) Radio 7.
motions
(2) Air conditioner
Travel speed
8.
(3) Windshield wiperblades (refer to separate sheet)
(4) Horn 9. Turns
(5) Working light 10. Condition and sound of travelling
(6) Interior lights Operation Inspection
(7) Clock 1. Operation condition of each lever
(8) Hour meter Shoe Tension
(9) Backup lights Others
1. Oil leaks at each part
2. Oil leaks at rubber hoses or piping
Looseness or fall off of bolts and
3.
nuts
4. Cab inspection
5. Cylinder inspection
1 RST-08-01-004F
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Performance Evaluation Recording Sheet
Evaluation Date
Model of Machine: Model Number: Evaluated by
(mm/dd/yy)
Attachment
Hour Meter: Remarks
Arm m3 Bucket
Idling speed rpm
1 Engine speed
Maximum engine speed without load rpm
Relief Name Operation Measured pressure
Standard psi
Pressure check of each Main relief
component Boosting psi
2 (Evaluate as required) Swing relief Left/Right psi
Pilot relief - psi
For measurement and adjustment methods, refer to procedures for hydraulic oil pressure measurement and adjustment in
Service Manual.
Boom cylinder in
Drift for each cylinder Arm cylinder in

3
(10 minutes) Bucket cylinder (when open) in
Overall (10 minutes) in
1st Reading 2nd Reading 3rd Reading Total Average
Up
Boom
Down
Operation speed for each
4 Out
cylinder (s) Arm
In
Open
Bucket
Closed
Swing speed
5 Swing Left
(s/1 revolution)
Swing Right
Swing angle 180°, neutral brake flow angle 1st Reading 2nd Reading 3rd Reading Total Average
6
(degrees)
Travel speed
7 Forward
(s/6 m)
Reverse
Front low
Number of drive sprocket revolutions
8 Back low
(s/10 revolutions)
Front high
Back high
Horizontal in
9 Degree of turntable bearing shift
Vertical in
Amount of shoe tension ranging from the bottom side frame to
10 in
shoe surface
11 Travel devition spec. in
12 Travel motor drain flows gpm
13 Swing motor drain flows gpm
14 Backlash at bucket tiptoe in
RST-08-01-004F 2
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New Machine Performance Judgment Standards SH130

Reference Values (130)
SP Mode (with Sumitomo standard bucket)
Reference
Item Unit
value
Idling 1000±10
No load A mode 1700±10
1 Engine speed rpm
No load H mode 1850±10
No load SP mode 2000±10
Standard 4970±290
Main relief
Boosted pressure 5380±290
Up 5680±290
Boom relief
Down 4785±290
Open
Arm relief 5800±290
Close
Open 5800±290
2 Pressure in each section Bucket relief psi
Close 5945±290
Swing relief Left and right 4470±290
Travel relief Left and right, front and back 4970±290
4th pump relief 2990±72.5
Pilot pump 570±145
For crusher
Option relief
For breaker
Boom cylinder retraction 0.2 max.
Natural fall distance (position Arm cylinder extension 0.47 max.
3 change) for each cylinder with in
no load (in 10 min.) Bucket cylinder retraction 0.51 max.
Overall bucket tip falling 9.8 max.
Up (stroke 27.2 in) ±0.6
Boom (bucket open)
Down (stroke 27.2 in) ±0.6
Open ±0.6
4 Attachment speed Arm sec.
Close ±0.6
Open ±0.6
Bucket
Close ±0.6
5 Swing speed (one rotation) Left and right sec. ±0.6
6 Swing brake angle (180°) Left and right deg. Below
7 Swing motor leakage amount gpm
sec./19.7 ft ±2
High speed
Travel speed (19.7 ft travel mph ±0.4
8 Forwards and backwards
speed) sec./19.7 ft ±2
Low speed
mph ±0.2
1 NST-08-02-007F
1
SP Mode (with Sumitomo standard bucket)
Reference
Item Unit
value
Travel sprocket speed (10 High speed ±2

9 sec.
rotations) Low speed ±2
Travel turning amount High speed
10 (65.6 ft travel meandering Forwards and backwards in 40 max.
amount) Low speed
11 Shoe tension amount in 11 to 12

12 Travel motor leakage amount gpm
Swing ball race bearing Up and down Below

13 in
movement distance Left and right Below
14 Bucket tip movement amount Left and right in Below
Compression 16.5
15 Recoil spring dimensions in
Free 18.8
Travel high speed
Boosted pressure
Coil resistance of each
16 Coil resistance temperature 20℃ Swing brake ? 40
solenoid valve
Lever lock
Power save
SP mode 571±20
No load H mode 491±20
Milli-amp for hydraulic pump A mode 491±20
17 electromagnetic proportional mA
valve SP mode 600±20
2 reliefs H mode 531±20
A mode 531±20
NST-08-02-007F 2
2
Measurement Method and Posture SH200
Measurement Method and Main Unit Posture
Measurement Method and Posture

Engine Speed
Measurement method
[1] No load operation mode at high idle:
SP mode, H mode and A mode speed
[2] Operation mode at low idle: SP mode speed
Main unit posture: bucket on ground
Pressure in Each Section

Measurement method
[1] Engine high idle
[2] Oil temperature is 113 F° - 131 F° (45 C
° - 55 C).
°
[3] Travelling and swing is measured between the counter bal-
ance and motor.
[4] Measure the main relief pressure before adjusting the
overload pressure, and then measure the overload pres-
sure after the main pressure has been increased to a level
as high or higher than the overload pressure. Return the
main pressure to regulation pressure after measurement.
Main unit posture: operate each attachment in the travel pos-
ture.
Cylinder Falling Amount

Measurement method
[1] Have oil flow into each cylinder before measurement with the oil at 113 F° - 131 F° (45
C
° - 55 C).
°
(Record the oil temperature before and after measurement)
[2] Make the height of the boom foot pin and the bucket pin the same.
The arm cylinder is fully retracted, and the bucket cylinder is fully opened.
[3] Engine is stopped.
[4] After 10 min., measure the extension amount and retraction amount of the boom, arm, and
bucket cylinder rod.
[5] Along with measuring the movement amount of the cylinders after 10 min., measure the tip
displacement.
Main unit posture
Same height
1 RST-08-03-003E
1
Attachment Speed
Measurement method
° - 55 C).
°
[3] No load
Main unit posture
Boom cylinder
With the arm fully out and the bucket fully
opened, measure the operation time it takes the
boom cyclinder to go from fully upwards to the
ground and also from the ground to fully
upwards
[Note] When the boom is lowered, make sure
not to directly hit the concrete (place tires
on the ground).
Arm cylinder
With the arm cylinder fully out and the arm hori-
zontal to the ground, measure the operation time
it takes the arm cylinder to do a full stroke with
bucket cylinder fully out
Bucket cylinder
Measure the operation time for a full stroke at
the maximum radius.
RST-08-03-003E 2
2
Swing Speed
Measurement method
° - 55 C).
°
[3] No load
[4] The time required for the next rotation after one rotation
Main unit posture
Swing (180°) Brake Angle

Measurement method
° - 55 C).
°
[3] No load
[4] Swing 180°and measure the flow angle after neutral braking
Main unit posture: same as the above
Travel Speed
Measurement method
[1] Engine high idle and oil temperature is 113 F° - 131 F° (45 C
° - 55 C)
° with no load.
[2] Measure the required time to travel 19.7 ft (6 m) after a 4 - 5 m {13.1 - 16.4 ft} running start. If
the off travel distance is 3.3 ft (1 M) or more, however, use the off travel distance as a refer-
ence value to correct the off travel, then measure the travel speed again.
[3] Travelling should be done on concrete.
[4] Conduct both high-speed and low-speed travelling.
3 RST-08-03-003E
3
Off Travel Amount
Measurement method
[1] Engine high idle and oil temperature is 113 F° - 131 F° (45 C
° - 55 C)
° with no load.
[2] Measure the required time to travel 65.6 ft (20 m) after a 13.1 - 16.4 ft (4 - 5 m) running start.
[3] Shoe tension amount should be standard.
[4] Measure for both forward and backward traveling.
[5] Measure for both high-speed and low-speed traveling.
Main unit posture: same as with travel speed measurement.
Travel Sprocket Speed

Measurement method
° - 55 C).
°
[3] Raise a shoe, and after achieving a constant speed, mea-
sure the time required for the sprocket to rotate 10 times
both forwards and backwards.
[4] Measure for both high-speed and low-speed traveling.
Main unit posture: 90°swing, shoe raised.
Shoe Tension Amount
Measurement method
[1] Raise the shoe and, at the central position of the track, measure the gap between the under-
side of lower side frame and the topside of the shoe plate.
[2] Measure for both the left and right sides.
RST-08-03-003E 4
4
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount
Measurement method
A) Up and down direction measurement
[1] Measure the up and down movement amount at two locations in front of and behind the ball
race.
[2] Move the arm cylinder out and close the bucket cylinder, and move the bottom surface of the
bucket 11.8 in (30 cm) above the ground. Attach a dial gauge to the lowering section as shown
in the figure below and do zero point adjustment.
[3] Jack up the main unit and measure the amount of movement with the dial gauge.
* Jack up the main body until the swinging of the dial gauge becomes constant.
Main unit posture
B) Left and right direction measurement

[1] Measure the left to right movement amount at the front side of the ball race and the left to right
movement amount of the bucket tip.
[2] The arm cylinder and bucket cylinder are in the open position, apply 66.1 - 88.2 lb (294.2 -
392.3 N) of force to one side, and zero point adjustment is done for these conditions.
[3] 88.2 lb (294.2 - 392.3 N) of force is applied to the opposite side and the left to right movement
is measured.
Main unit posture
5 RST-08-03-003E
5
RST-08-03-003E 6
Pressure Measurement and Adjustment Procedures SH130

Procedures for Pressure Measurement from the Monitor Display
■ Monitor and switch panel
1 Liquid crystal monitor 4 Design panel

2 Switch panel 5 Installation bracket
3 Hour meter
1. Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display.
(The pilot pressure cannot be measured.)
2. Operating Method
[1] If both the travel mode select switch and the horn volume select switch on the switch panel are
held down for 3 s, the display switches to the service support screen.
[2] The respective pressures are displayed in the service support screen's "P1" (P1 pump main
pressure), "P2" (P2 pump main pressure), "N1" (N1 negative control pressure), and "N2" (N2
negative control pressure) columns.
* If both the travel mode select switch and the horn volume select switch on the switch panel are
held down again for 1 s , the display returns to the normal screen.
1 NST-09-01-005F
1
Procedures for Measuring Hydraulic Oil Temperature from the Monitor Display
1. Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
2. Operating Method
[1] If both the travel mode select switch and the horn volume select switch on the switch panel are
held down for 3 s, the display switches to the service support screen.
[2] With the travel mode select switch (mode select switch), set the mode to "CHK".
[3] With the horn volume select switch (section switch), set the section to the "MAIN" section.
[4] With the light switch (page +), switch to Page "2".
[5] The hydraulic oil temperature is displayed in the "Hydoil" column.
1 Section 5 Page (-)

2 Mode 6 Page (+)
3 Page 7 Mode select switch
4 Section switch
NST-09-01-005F 2
2
Procedures for Pressure Measurement by Installing Pressure Gauge
1. Preparations
Workers 2 Role (Worker 1: Work supervisor, pressure adjustment)
Role (Worker 2: Operator)
2. Items to Prepare
1 Vacuum pump power supply (for vacuum pump) 7 Extension cable

2 Pressure gauge (1450 PSI (10 MPa) x 1) 8 Hydraulic oil tank lid (vacuum pump)
3 Pressure gauge (8700 PSI (60 MPa) x 2) 9 Recording sheet
4 Hexagon wrench (8 mm, 6 mm) 10 Pen
5 Wrenches (17, 19, 24, 27 x 2, 32, 36 x 2) 11 Cleaning fluid
6 Rags 12 Ratchet
3 NST-09-01-005F
3
Pressure Measuring Ports
There are the following 3 ports for measuring the pressure.
• Main pressure: Pressure ports (P1, P2)
• Negative control pressure: Pressure ports (N1, N2)
• Pilot pressure: Pressure port (P3)
1 Pump 4 Pressure port: N1

2 Pressure port: P2 5 Pressure port: N2
3 Pressure port: P1 6 Pressure port: P3
NST-09-01-005F 4
4
Control Valve
1. Location of Relief Valves
Tools Pressure per
Set pressure
Position rotation of adjusting Measuring port
Lock nut Adjusting screw PSI (MPa)
screw PSI (MPa)
Main Hexagon diagonal Hexagon diagonal
a 4970 (34.3) 21.3 {3090} Monitor P1
(normal use) 27 mm 27 mm
①
Main Hexagon diagonal Hexagon diagonal
b 5260 (36.3) 28.4 {4120} Monitor P1
(boosted pressure) 32 mm 27 mm
② Boom up 5540 (38.2) 21.2 {3070} Monitor P2
③ Boom down 4680 (32.3) 21.2 {3070} Monitor P2
④ Arm in Hexagon diagonal 5540 (38.2) 21.2 {3070} Monitor P1

17 mm Hexagon diagonal
⑤ Arm out 5540 (38.2) 21.2 {3070} Monitor P1
6 mm
⑥ Bucket close 5540 (38.2) 21.2 {3070} Monitor P2
⑦ Bucket open 5540 (38.2) 21.2 {3070} Monitor P2

Hexagon diagonal
⑧ Pilot
24 mm
570 (3.92) 2.0 {290}
1 Boosted pressure lock nut

2 Boosted pressure adjusting screw
3 Standard pressure adjusting screw
4 Standard lock nut
5 NST-09-01-005F
5
Pressure Measurement Preparations
[1] Items to prepare
1) Pressure gauge For 1450 PSI (10 MPa)
(for pilot and negative control
pressure measurement)
For 8700 PSI (60 MPa)
(for main pressure measurement)
2) Tools Wrench (closed wrench) 17 mm
Hexagon wrench 6 mm
3) Others Rags
Cleaning fluid
[2] Monitor check

Use the service check to check the no-load
engine maximum speed and the SP mode
pump input milli-amp.
Engine MAX SP mode milli-amp
2000 min-1 {2000 rpm} 600 mA (operating)
[3] Main unit installation

Put the main unit on solid, level ground, put the
bucket cylinder at its open stroke end, the arm
cylinder at its out stroke end, lower the boom,
and touch the arm top to the ground.
[4] Ignition key

Switch OFF the ignition key, check that the
engine has stopped, then switch the ignition key
ON again. (Do not start the engine.)
1 Ignition key
NST-09-01-005F 6
6
[5] Oil temperature check
Use the service check to check the hydraulic oil
temperature.
113 F° - 131 F°
Oil temperature
(45 C
° - 55 C)
°
If the oil temperature is low, raise the oil temper-
ature according to the warm-up operation pro-
cedure in the operator's manual.
[6] Bleeding pressure from inside circuits

Push the gate lock lever forward, then turn the
upper operation lever about 10 times to bleed
out the pressure.
Move the travel lever back and forth about 5

times to bleed out the pressure.
[7] Bleeding pressure from inside the hydraulic oil

tank
Press the air breather button on top of the
hydraulic oil tank to release the pressure inside
the tank.
2 Lever
3 Upper operation lever
4 Gate lock lever
5 Travel lever
6 Air breather button
7 NST-09-01-005F
7
[8] Side door opening and closing
Open the side door. At this time, be sure to lock.
7 Lock
8 Side door
This completes the preparations.
NST-09-01-005F 8
8
1. Main Pressure Measurement
[1] Pressure gauge installation
Install pressure gauges at the pump pressure
measuring ports.
(Measuring ports: P1/P2)
(Port size: G3/8)
P1: Can be measured P2: Can be measured
Travel left Travel right
Option Bucket
Swing Boom
Arm
Use a hexagon wrench (8 mm) to remove the

cap.
Install adapters where the caps were removed.
Install pressure gauge on the adapter and fas-

ten.
1 Pump 3 Adapter
2 Cap 4 Pressure gauge
9 NST-09-01-005F
9
A. Attachment pressure measurement
Example: Arm-out pressure measurement
Measure with the following operations.
Engine speed 2000 min-1 {2000 rpm}
Work mode SP mode
Lever operation Arm-out relief
113 F° - 131 F°
Oil temperature
(45 C
° - 55 C)
°
1 pump: P1 port
Measuring port
2 pumps: P2 port
Boosted pressure:
5260 PSI (36.3 MPa)
Set pressure 5 Arm-out relief
Standard:
4970 PSI (34.3 MPa)
When the attachment operates, since the pressure boost operates automatically, the set boosted
pressure can be checked for about 8 s. After 8 s or more, the standard set pressure can be
checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.
Bucket Bucket
Lever operation Arm out Arm in Boom up Boom down
open close
Work mode SP mode
Oil temperature 45 - 55 ℃ {113 - 131°
F}
1 pump flow
P1 P1 P2 P2 P2 P2
measuring port
2 pumps flow
P2 P2 No No P1 P1
measuring port
5260 PSI 5260 PSI 5260 PSI 5260 PSI 5260 PSI 5260 PSI
Boosted pressure
(36.3 MPa) (36.3 MPa) (36.3 MPa) (36.3 MPa) (36.3 MPa) (36.3 MPa)
4970 PSI 4970 PSI 4970 PSI 4970 PSI 4970 PSI 4970 PSI
Standard pressure
(34.3 MPa) (34.3 MPa) (34.3 MPa) (34.3 MPa) (34.3 MPa) (34.3 MPa)
Boom-down pressure measurement

For pressure measurement with the boom
down, put the arm cylinder at its out stroke
end, open the bucket, put the bucket tip on
the ground, carry out the boom-down opera-
tion, and measure.
6 Boom-down relief
NST-09-01-005F 10
10
B. Travel pressure measurement
[1] Install the stopper on the crawler sprocket
section and lock the travel motor.
[2] Measure with the following operations.
Work mode SP mode
Lever operation Travel relief
113 F° - 131 F°
Oil temperature
(45 C
° - 55 C)
°
Left travel: P1 port
Measuring port
Right travel: P2 port
Set pressure 34.3 MPa {4970 psi}
7 Stopper
8 Sprocket
C. Swing pressure measurement

[1] Set the swing lock with the monitor.
Work mode SP mode
Lever operation Swing relief
Oil temperature 4970 PSI (34.3 MPa)
Measuring port P1 port
Set pressure 4046 PSI (27.9 MPa)
[3] After the end of pressure measurement,

release the swing lock with the monitor. 9 Horn volume select switch
10 Working light switch
11 Auto idle switch
Swing lock switching

In order to prevent accidental operation under certain special circumstances, sometimes the
swing brake need to be left ON all the time. (Swing lock) At this time, the swing lock can be
switched ON/OFF by holding down the "horn volume select switch", the "working light switch",
and the "auto idle switch" at the same time for 2 s. When turning the key to ON, always start
with the swing lock OFF. (Previous data reset)
11 NST-09-01-005F
11
D. Option line pressure measurement
[1] Close the option line stop valve.
[2] With the option operation select switch in the

cab, switch to the option line to measure.
(Breaker, shuttle)
Work mode SP mode
Pedal operation Option relief
113 F° - 131 F°
Oil temperature
(45 C
° - 55 C)
°
1 pump: P2 port
Measuring port 12 Stop valve
2 pumps: P1 port 13 Option operation select switch
Set pressure * 29.4 MPa {4260 psi}
* Adjust the set pressure to match the specifications of the attachment used.
Factory pressure settings

Breaker circuit: 5260 PSI (36.3 MPa)
Shuttle, multi purpose (crusher) circuit: 5260 PSI (36.3 MPa)
NST-09-01-005F 12
12
2. Pilot Pressure Measurement
Install a pressure gauge at the pump pressure
measuring port with a wrench.
(Measuring port: P3)
(Port size: G1/4)
Install the adapter.
Install the pressure gauge and measure the

pressure.
Work mode SP mode
113 F° - 131 F°
Oil temperature
(45 C
° - 55 C)
°
1 Wrench
2 Adapter
3 Pressure gauge
13 NST-09-01-005F
13
3. Negative Control Pressure Measurement
Remove the pump a1 or a2 pressure sensor.
(The pressure sensor location becomes the
measurement port.)
(Measuring port: N1/N2)
(Port size: G1/4)
Install the pressure gauge at the port from

which the a1 or a2 pressure sensor was
removed.
Measure the negative control pressure for each

operation.
Work mode SP mode
113 F° - 131 F°
Oil temperature
(45 C
° - 55 C)
°
P1 pump side: a1 port
Measuring port
P2 pump side: a2 port
1 Pressure sensor
2 Plug
3 Ratchet (17 mm)
4 Plug
5 Pressure gauge
NST-09-01-005F 14
14
Pressure Adjustment
1. Main Pressure Adjustment
■ Pressure measurement and adjustment preparation work
Pressure is adjusted with control valves.
The following preparations are required for adjusting with control valves.
[1] Engine hood opening and closing
Release the 2 engine hood lock levers.
Open the engine hood.

Always check that the lock is locked.
1 Engine hood
2 Lock lever
3 Lock
15 NST-09-01-005F
15
[2] Cover removal
Remove the 4 screws, then remove the cover.
4 Screw
5 Cover
NST-09-01-005F 16
16
(1)Main relief pressure adjustment
Engine speed 2000 PSI (2000 min-1)
Work mode SP mode
Lever operation Arm-in relief
Oil temperature 113 F° - 131 F° (45 C
° - 55 C)
°
Boosted pressure:
Measurement 5260 PSI (36.3 MPa)
pressure Standard:
4970 PSI (34.3 MPa)
Boosted pressure:
Pressure per 5800 PSI (40 MPa)/rotation
rotation of
adjusting screw Standard:
5800 PSI (40 MPa)/rotation
Before adjusting, remove the pilot hose for the
boosted pressure signal connected to the main
relief valve, then plug the hose side. The proce-
dures for boosted pressure and standard pres-
sure are different.
For boosted pressure
a) Loosen the standard lock nut (27 mm) and
tighten the adjusting screw (27 mm). Fasten with
a wrench (27 mm) so that the boosted pressure
adjusting screw does not turn.
b) After tightening until the adjusting screw stops
turning, tighten the lock nut.
c) Start the engine and run it at maximum rotation.
d) Move the arm lever to the in side, set the relief
state, and hold.
e) Loosen the boosted pressure lock nut (32 mm)
and adjust the set pressure with the adjusting
screw (27 mm).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first lower
below the set pressure, then adjust on the tight-
ening side.
f) After adjustment, fasten the adjusting screw with
a wrench (27 mm), then tighten the lock nut.
g) After locking, check the boosted pressure side
pressure. 6 Control valve
Repeat a) - f) until the set pressure is correctly 7 Main relief valve
adjusted. 8 Plug
For standard pressure 9 Wrench (19 mm)
10 Pilot hose for the boosted pressure signal
h) Loosen the standard lock nut (27 mm). 11 Boosted pressure lock nut Wrench size (32 mm)
i) Loosen the adjusting screw, lower below the set Boosted pressure adjusting screw Wrench size
12
pressure, then adjust on the tightening side. (27 mm)
j) After adjustment, tighten the lock nut while fas- 13 Standard lock nut Wrench size (27 mm)
tening the adjusting screw with a wrench. Standard pressure adjusting screw Wrench size
14 (27 mm)
k) After locking, check the pressure.
Repeat h), i), and j) until the set pressure is cor-
rectly adjusted.
l) Stop the engine.
17 NST-09-01-005F
17
(2)Overload relief pressure adjustment
Engine speed 2000 PSI (2000 min-1)

Work mode SP mode
Oil temperature 113 F° - 131 F° (45 C
° - 55 C)
°
Measuring port P1/P2 port
Boom down:
Measurement 4680 PSI (32.3 MPa)
pressure
Others: 5610 PSI (38.7 MPa)
Boom down:
Pressure per 4350 PSI (30 MPa)/rotation
rotation of
adjusting screw Others:
4350 PSI (30 MPa)/rotation
Since the overload relief pressure is set higher

than the main relief pressure, it is necessary to
provisionally set the main relief pressure higher
than the overload relief pressure. (Except for
boom down)
Main relief pressure provisional setting
• Using the main pressure adjustment procedure
for reference, temporarily set the boosted pres-
sure and standard pressure to at least 5610 PSI
(38.7 MPa).
* For boom down, since the overload set pressure
is lower than the main relief set pressure, there
is no need to temporarily set the main relief
pressure.
Pressure adjustment
Example: Arm-in overload relief lmadjustment
a) Loosen the lock nut and adjust by turning the
adjusting screw.
• When lower than the set pressure, tighten.
• When higher than the set pressure, first loosen
to a pressure lower than the set pressure, then
adjust on the tightening side.
b) After adjustment, lock the lock nut.
c) After adjusting the overload relief pressure,
adjust the boosted pressure and standard pres-
sure to their normal values referencing the main
pressure adjustment procedure.
* For the position of each overload relief, see the
"Control Valve Relief Locations".
15 Control valve
16 Overload relief
17 Boom up
18 Arm in
19 Wrench (17 mm)
20 Adjusting screw
21 Lock nut
22 Hexagon wrench 6 mm
NST-09-01-005F 18
18
(3)Swing relief pressure adjustment
Work mode SP mode
Oil temperature F (45 - 55 ℃ )
113 - 131°
Measurement pressure 4046 PSI (27.9 MPa)
[1] Using the swing pressure measurement pro-

cedure for reference, lock the swing, and
check the swing pressure.
23 Motor
24 Relief valve
[2] Check the currently set pressure.

[3] The number of shims for adjustment is deter-
mined by the difference between the current
pressure and the set pressure.
Set pressure - current
Number of shims pressure
5
[4] Remove the swing motor port relief assembly

from the motor main unit.
[5] When removing both sides at the same time,
mark the assemblies so that they can be re-
assembled on the correct sides.
[6] Fasten the port relief assembly with a vise
table, take off the cap, then remove the pis-
ton, liner, spacer, poppet, shim, and spring.
[7] Remove the poppet and spring and add (or
remove) one or more shims between the
spring and spacer. Find the number of shims
in [3] above.
[8] After adjusting the shims, install the poppet,
spring, spacer, shims, piston, and liner in the
sleeve.
[9] Fasten the sleeve on the vise table and
install the cap.
Cap tightening
115.6 lbf•ft (156.9 N•m)
torque
19 NST-09-01-005F
19
[10] Install the port relief assembly on the swing
motor main unit and check the pressure.
57.9 ft•lbs
Relief assembly tightening torque
(78.5 N•m)
4046 ± 58 PSI}
Set pressure
(27.9 ± 0.4 MPa)
[11] If the pressure is off from the set pressure,

re-execute from [1].
If the pressure is within the range of the set pres-

sure, the pressure adjustment is complete.
25 Sleeve
26 Spacer
27 Shim
28 Spring
29 Cap
30 Piston
31 Liner
32 Poppet
2. Pilot Pressure Adjustment

[1] Pressure measurement
a) Install the pressure gauge.
b) While holding the plug with a wrench (24 mm), adjust with a hexagon wrench (6 mm).
Lever operation Neutral
Measuring port P3
Set pressure 570 psi (3.9 MPa)
33 Wrench (24 mm)

35 Pressure gauge
NST-09-01-005F 20
20
Hydraulic Pump Flow Measurement Procedure SH130

Procedures for Flow Measurement from the Flow Meter Installation
1. Preparations
Workers 3 Role (Worker 1: Work supervisor, pressure adjustment)
Role (Worker 2: Operator)
Role (Worker 3: Flow, pressure measurement, recording)
2. Items to Prepare
1 Vacuum pump, power supply (for vacuum pump) 8 Adapter (flange type)
2 Flow meter 9 Hydraulic hose (for flow measurement)
3 Pressure gauge (8700 PSI {60 MPa} x 2) 10 Recording sheet
4 Hexagon wrench (8 mm, 6 mm) 11 Pen
5 Wrenches (17, 19, 24, 27 x 2 32, 36 x 2) 12 Cleaning fluid
6 Extension cable 13 Rags
7 Hydraulic oil tank lid (for vacuum pump)
1 NST-09-02-003E
1
Work Preparations
[1] Check that the main unit is in its work posture
(arm-vertical).
[2] Bleed out the pressure. (See the details on
Bleeding Pressure in the Pressure Measure-
ment and Adjustment Procedures.)
* Check the swing stop.
[3] Use a wrench (17 mm) to remove the feed port

cover.
[4] Use the bolts removed in [3] to install the hydra

ulic oil tank lid (for vacuum pump).
[5] Install the vacuum pump on the hydraulic oil

tank lid.
1 Feed port cover

2 Hydraulic oil tank lid (for vacuum pump)
3 Vacuum pump
NST-09-02-003E 2
2
[6] After setting the vacuum pump as in the figure
on the right, switch on the power.
(If the cable is too short, use an extension
cable.)
[7] Use a hexagon wrench (8 mm) to remove the

split flange and hydraulic hose.
(This section explains flow measurement at the
P2 pump.)
4 Vacuum pump
5 Split flange
6 Bolt
7 Hydraulic hose
8 Hexagon wrench
3 NST-09-02-003E
3
9 Elbow adapter 14 Hydraulic hose (OUT)

10 Adapter 15 Hydraulic hose
11 Hydraulic hose (IN) 16 Split flange
12 Flow meter 17 Adapter (flange type)
13 Orifice
[8] Use the split flange to install the adapter [14] Install the (prepared) hydraulic hose on the
(flange type) on the tip of the hydraulic hose flow meter OUT side, then fasten with the
removed in [7]. wrench.
* When connecting, always check the con-
[9] Install the adapter at the position from
nection positions.
which the hydraulic hose was removed.
* Always have the orifice fully open.
[10] When the parts are set as in the figure
[15] Install pressure gauges on P1 and P2.
above, remove the plug.
(See “Main Pressure Measurement”.)
[11] Use the wrench to connect the adapter
[16] Remove the vacuum pump and re-install
installed on the pump in [9].
the hydraulic oil tank the same way it was.
[12] If necessary, install an “elbow adapter” on
[17] Open the engine hood.
the (prepared) hydraulic hose connected to
(See “Main Pressure Adjustment”.)
the flow meter IN side.
[18] Remove the cover.
[13] Install the hydraulic hose on the flow meter
IN side, then fasten with the wrench. [19] Remove the pilot hose for the boosted pres-
sure signal, then plug the hose side.
(See “Main relief pressure adjustment”.)
This completes the preparation for flow measure-
ment.
NST-09-02-003E 4
4
Flow Measurement
[1] Measure the flow.
When measuring the flow, position the workers
as in the figure on the left.
(Worker 1: Work supervisor, pressure adjustment)
(Worker 2: Operator)
(Worker 3: Flow, pressure measurement, recording)
[2] At the signal from the work supervisor, the

operator starts the engine.
[3] Check the hydraulic oil temperature on the
monitor. (122F° {50 ℃ })
Check that the engine rotation and pump cur-
rent are normal.
[4] The operator signals the arm-out relief opera-
tion to worker 1.
[5] Worker 2 lowers the arm-out port relief.

(Min: 3480 PSI {24 MPa} P1 + P2)
[6] Start of flow measurement
[7] The arm-out relief operation is carried out.
[8] Data measured in units of 290 PSI (2.0 MPa)
(P1 + P2)
* The measurement is carried out from 3480 -
11020 PSI (24.0 - 76.0 MPa) and ends when
the maximum pressure is reached.
[9] Remove the flow meter.
* Because from 5800 PSI (40 MPa ) the pres-
sure exceeds the permitted value for the
flow meter pressure gauge maximum pres-
sure
[10] Reset the arm-in port relief valve to normal pressure.
(For details on this adjustment, see “Pressure
Adjustment”.)
[11] Remove the pressure gauges etc. and put
everything back to normal. This completes the 1 Worker 1
work. 2 Worker 2
3 Worker 3
4 Ignition key
5 Wrench 17 mm
5 NST-09-02-003E
5
NST-09-02-003E 6
Drain Volume Measurement Procedure SH130

Preparations
Measuring conditions
Mode SP mode
Oil temperature About 122F° (50 ℃ )
* Be careful. The drain volume varies greatly with the oil temperature.
Travel Motor Drain Volume Measurement

[1] Ground the bucket as in the figure on the right,
then make the shoe crawler on one side float.
[2] Remove the bolts, then remove the cover.
[3] Always lay a rag underneath before removing

the drain hose.
[4] Use a wrench to remove the drain hose.
(Always install a cap on the drain hose.)
1 Shoe crawler
2 Bucket
3 Cover
4 Bolt
5 Drain hose
6 Rags
1 NST-09-03-005E
1
[5] Install the extension hose for measurement on
the side of the motor from which the drain hose
was removed.
[6] Prepare a waste oil can and measuring con-

tainer and set them as in the figure on the right.
[7] Catch the stopper between the sprocket sec-

tion and the frame and lock the travel motor.
7 Extension hose for measurement

8 Waste oil can
9 Measuring container
10 Stopper
NST-09-03-005E 2
2
[8] In SP mode at medium speed, relieve the travel
operation and at the same time the motor starts,
move the extension hose to the measuring container.
(When the motor starts, start measurement
with a stop watch.)
[9] After 30 s, move the extension hose to the
waste oil can.
[10] Measure the volume of oil in the measuring
container as the drain volume for 30 s.
Forward Backward
1st 2nd 1st 2nd
speed speed speed speed
Right
Left
* Measure at least 3 times each for left, right,

forward, and backward. 11 Waste oil can
12 Measuring cup
13 Stop watch
3 NST-09-03-005E
3
Swing Motor Drain Volume Measurement
[1] Remove the drain hose and put a plug in the
hose side.
(Wrench size: 22 mm, clamp 19 mm (hose
side))
0+
[2] Install the extension hose for measuring the

drain volume on the side which the drain hose
was removed.

0+
[3] Prepare a waste oil can and measuring con-

tainer and set them as in the figure on the right.
For details on the method for locking the swing
motor, see "Swing Relief Pressure Adjustment".
[4] In SP mode, relieve the swing operation and at
the same time the motor starts, move the
extension hose to the measuring container.
(When the motor starts, start measurement
with a stop watch.)
[5] After 60 s, move the extension hose to the
waste oil can.
[6] Measure the volume of oil in the measuring
container as the drain volume for 60 s.
Measure at least 3 times each for left and right.
1 Drain hose
Right Left
2 Plug
3 Extension hose
4 Stop watch
5 Measuring cup
6 Waste oil can
NST-09-03-005E 4
4
Air Bleed Procedure SH130
Air Bleed Procedure
Air Bleed Procedure

Always bleed off any air in the hydraulic circuits after replacing the hydraulic oil, repairing or
Caution replacing hydraulic equipment, or removing hydraulic pipes.
* Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and
lead to damage.
Hydraulic Pump
[1] Loosen the air bleed plug and check that oil
oozes from the air bleed port.
[2] If oil does not ooze out, remove the air bleed
plug, and fill hydraulic oil from the air bleed port
into the pump case.
[3] Temporarily tighten the air bleed plug.
[4] Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air
bleed port section.
[5] Completely tighten the air bleed plug.
1 Air bleed plug

2 Pump
3 Hydraulic oil
1 NST-09-04-005E
1
Air Bleed Procedure
Travel Motor
[1] Remove the bolts, then remove the cover.
[2] Use a hexagon wrench (6 mm) to remove the air

bleed plug as in the figure on the right.
[3] Pour in about 500 cc of hydraulic oil from the air

bleed port.
[4] When inside the motor is filled with hydraulic oil,
tighten the air bleed plug.
[5] Start the engine and execute a slow travel oper-
ation.
[6] Repeatedly travelling forward and backward
bleeds off the air.
1 Cover
2 Bolt
3 Hexagon wrench
4 Air bleed plug
5 Hydraulic oil
NST-09-04-005E 2
2
Air Bleed Procedure
Swing Motor
[1] Run the engine at low idle, use a hexagon
wrench (8 mm) to remove the air bleed plug as
in the figure. Check that oil oozes from the air
bleed port section.
* Do not execute a swing operation.
0+
[2] If oil does not ooze out, stop the engine for now,
and fill hydraulic oil from the air bleed port into
the motor case.
[3] Temporarily tighten the air bleed plug.
[4] Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air
bleed port section.

[5] Completely tighten the air bleed plug.
[6] With the engine at low idle, slowly swing evenly
left and right at least 2 rotations.
Check
After the air bleeding is complete, stop the engine
0+
for at least 5 min. to allow any air bubbles in the
hydraulic oil tank to dissipate. 1 Air bleed plug
2 Hexagon wrench
3 Hydraulic oil
4 Air bleed port section
3 NST-09-04-005E
3
Air Bleed Procedure
HBCV (for Export, Europe)
The HBCV air bleeding work requires 2 workers: an operator and an air bleed worker.
Caution Decide the signals beforehand and work safely.
Set the main unit so that the arm HBCV is at the highest position. (See the figure below)
1. Boom Cylinder HBCV

[1] Start the engine and lower the boom without
jacking up the main unit.
[2] In the above state, loosen the hose mouthpiece
at the position in the figure.
[3] Foaming hydraulic oil comes out from the hose
mouthpiece section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece.
[4] Execute steps [2] and [3] for the opposite side
boom cylinder too.
[5] Check boom operations. If there is a delay in the
operation response, bleed the air again with the
same procedure.
1 Hose mouthpiece
2. Arm Cylinder HBCV

For arm-in operations, bleed the air from the arm
cylinder HBCV using the same procedure as for
boom cylinder HBCV air bleeding.
1 Hose mouthpiece
NST-09-04-005E 4
4
Procedures for Replacing Consumable Parts SH130

Air Conditioner Belt and Fan Belt Replacement
If the belt is loose, battery charging defects, engine overheating, and rapid belt wear occur.
1. Air Conditioner Belt Replacement
[1] Use a box wrench (19 mm) to remove the bolts,
then remove the bottom cover.
[2] The air conditioner belt is at the position in the fig-

ure on the right.
[3] Use a box wrench (14 mm) to remove the nut.
1 Cover
2 Nut
3 Air conditioner belt
4 Box wrench
1 NST-09-05-005E
1
[4] Use a wrench (14 mm) to loosen the tension bolt.
[5] Remove the air conditioner belt from the tension

pulley and replace it.
Tension adjustment
After replacing the air conditioner belt, it is neces-
sary to adjust the belt tension.
[1] Use a box wrench (14 mm) to tighten the tension
bolt.
[2] Adjust the belt so that when the center section of
the belt is pressed with a finger, it deflects about
0.4 in (1 cm). (See the figure.)
[3] Securely fasten the nut.
5 Tension bolt 8 Air conditioner belt

6 Wrench 9 Nut
7 Tension pulley
NST-09-05-005E 2
2
2. Fan Belt Replacement
[1] Remove the air conditioner belt.
(See "Air Conditioner Belt Replacement".)
[2] Use a wrench (14 mm) to remove the bolt.
[3] Use a wrench (14 mm) to remove the bolt.

[4] Remove the bracket.
[5] Remove the fan guard.
1 Bolt
2 Bolt
3 Bracket
4 Fan guard
3 NST-09-05-005E
3
[6] Use a box wrench (17 mm) to loosen the bolt,
then free the alternator adjuster plate.
[7] Use a box wrench (17 mm) to loosen the alterna-

tor tension bolt.
[8] Remove the fan belt from the alternator.
[9] While slowly turning the fan, pass the fan belt
over the five one at a time and remove it.
5 Box wrench
6 Alternator
7 Adjuster plate
8 Nut
9 Tension bolt
10 Alternator
11 Fan
12 Fan belt
NST-09-05-005E 4
4
Tension adjustment
After replacing the fan belt, it is necessary to adjust
the belt tension.
[1] Use a box wrench (17 mm) to tighten the alterna-
tor tension bolt.
[2] Adjust the fan belt so that when the center section
of the belt is pressed with a finger, it deflects
about 0.4 in (1 cm).
[3] Securely fasten the nut.
5 Box wrench
8 Nut
9 Tension bolt
12 Fan belt
5 NST-09-05-005E
5
Fuel Main Filter Replacement
1. Filter Replacement
When replacing the fuel filter, always bleed the air.
Main filter
[1] Close the fuel line stop valve.
[2] Use a wrench (10 mm) to loosen the air bleed

plug.
[3] Loosen the cap at the bottom and drain out
any remaining fuel.
* Put a waste oil can underneath.
1 Fuel line
2 Stop valve
3 Wrench
4 Air bleed plug
5 Cap
6 Waste oil can
NST-09-05-005E 6
6
[4] Remove the main filter cover with the special
filter wrench.
[5] Remove the element and replace it.
7 Special filter wrench

8 Filter cover
9 Element
10 O-ring
[6] Open the fuel line stop valve.
7 NST-09-05-005E
7
Pre-filter
[1] Close the fuel line stop valve.

plug.
[3] Loosen the cap at the bottom and drain out
any remaining fuel.
* Put a waste oil can underneath.
[4] Remove the pre-filter cover with the special fil-

ter wrench.
1 Fuel line
2 Stop valve
3 Cap
4 Waste oil can
6 Filter cover
NST-09-05-005E 8
8
[5] Remove the element and replace it.
7 O-ring
8 Element
[6] Open the fuel line stop valve.
9 NST-09-05-005E
9
2. Air Bleeding
If air gets into the fuel system, this can cause difficulty starting and poor engine condition. When the
fuel tank has been emptied, water drained from the fuel, the element replaced, or other such work
carried out, always bleed the air.
[1] Install the air bleed hose at the position in the fig-
ure.
plug.
[3] When the filter case priming pump is turned in the

direction of the arrow, the knob pops out.
[4] Press the knob a few times.

When fuel appears inside the filter case, gently
tighten the air bleed plug for now. Press the knob
a few times with the plug and knob as they are.
Finally, hold the knob pressed in and slightly
loosen the air bleed plug.
Fuel oozes out from the hose like bubbles.
[5] Repeat the operation in [4] until no more bubbles
appear.
[6] Tighten the air bleed plug, then turn the knob and
lock it.
1 Air bleed hose

2 Wrench
3 Air bleed plug
4 Knob
5 Hose
NST-09-05-005E 10
10
Engine Oil Filter and Engine Oil Replacement
If the engine oil is severely dirty or deteriorated, replace it quickly even if it is not yet time for
Caution periodic replacement.
1. Engine Oil Replacement

[2] Remove the engine oil cap.
[3] Put a waste oil can underneath the engine oil

drain port.
[4] Remove the bottom cover.
1 Engine oil cap

2 Waste oil can
3 Cover
4 Bolt
11 NST-09-05-005E
11
[5] Remove the drain plug.
[6] Install the drainer plug with hose and screw it

in.
The valve is pressed automatically and the oil
is drained.
[7] After draining the oil, securely install the drain
plug.
5 Drain plug
6 Drainer plug
NST-09-05-005E 12
12
2. Engine Oil Filter Replacement
[1] Remove the engine oil filter cover with the spe-
cial filter wrench.
[2] Replace the engine oil filter.
[3] When installing the engine oil filter, check that
the O-ring is not damaged, then install.
Also, if the O-ring is replaced, apply oil to it
before installing it.
[4] Fill engine oil from the feed port at the top.
[5] Check on the oil gauge that the oil volume is

correct.
[6] Start the engine and let it idle for a few min..
During this idling, check for oil leaking.
[7] Stop the engine, wait about 20 min., then
inspect the oil volume again.
If the oil volume is correct now, the oil change is
OK.
If the oil is low, fill more.

2 Engine oil filter
3 Engine oil
4 Oil gauge
13 NST-09-05-005E
13
Radiator Coolant Replacement
[2] Remove the radiator cap.
[3] Use a box wrench (19 mm) to remove the bolts,

then remove the bottom cover.
[4] Turn the drain cock to the left and drain the
coolant.
[5] Return the drain cock to its original position, fill
the radiator with hot water up to the radiator
port, then run the engine slightly faster than
idling.
Run for about 10 min. to raise the water tem-
perature to 176F° (80 ℃ ), then drain the water.
[6] Fill the radiator with coolant up to the radiator

port.
Run the engine for about 10 min., then ade-
quately bleed the air from the cooling system.
[7] Stop the engine and check the coolant level.
If the coolant level is low, fill in more.
1 Radiator cap
2 Cover
3 Drain cock
4 Coolant
NST-09-05-005E 14
14
Air Cleaner Cleaning and Replacement
[1] Open the door.
[2] Release the 3 locks, then remove the cover.
[3] Remove the air cleaner (outer).
1 Door
2 Lock
3 Cover
4 Air cleaner (outer)
15 NST-09-05-005E
15
[4] Use a compressed air gun to blow out from the
inside of the air cleaner and clean it.
[5] Remove the air cleaner (inner) and replace it.

This air cleaner cannot be cleaned. Always
replace it.
5 Air gun
6 Air cleaner (outer)
7 Air cleaner (inner)
NST-09-05-005E 16
16
Hydraulic Oil Filter Replacement
・ When replacing the hydraulic oil, be careful to keep dirt, water, sand, and all other foreign
matter out of the tank.
・ When replacing the hydraulic oil, always replace the filter and element with new ones.
Caution ・ When using with a hydraulic breaker mounted, the deterioration of the hydraulic oil is more
severe than for normal excavation work, so maintain the hydraulic oil frequently enough.
・ Manage the hydraulic oil (by checking samples for contamination and deterioration) every
1000 hour per engine running time.
Put the main unit into the posture for transport or

shipping.
1. Return Filter Replacement

[1] Press the rubber cap at the breather section on
the top of the hydraulic oil tank to bleed off the
pressure in the tank.
[2] Use a wrench (17 mm) to remove the bolts,
then remove the cover.
(There is an O-ring on the rear.)
[3] Take the spring, valve, and return filter out from
the tank.
[4] Replace the return filter.
[5] If the O-ring on the rear of the cover is worn or
damaged, replace it.
[6] The installation procedure is the reverse of the
removal procedure.
1 Bolt
2 Cover
3 Spring
4 Valve
5 Return filter
6 O-ring
17 NST-09-05-005E
17
2. Suction Filter Replacement
then remove the feed port cover.
(There is an O-ring on the rear.)
[3] Remove the suction strainer.

[4] Replace the suction strainer with a new one.
[5] If the O-ring is worn or damaged, replace it.

removal procedure.
* When installing the feed port cover, align it
with the position in the figure on the right,
then install it. Align
1 Bolt
2 Feed port cover
3 O-ring
4 Suction strainer
NST-09-05-005E 18
18
3. Air Breather Element Replacement
[2] Use a wrench (19 mm) to remove the hexagon
nut.
[3] Remove the cover.

[4] Replace the filter element with a new one.
removal procedure.
1 Rubber cap
2 Hexagon nut
3 Cover
4 Filter element
4. Pilot Oil Filter Replacement

[1] Use a filter wrench or the like to remove the
pilot oil filter cover.
[2] Replace the pilot oil filter.
[3] When installing the pilot oil filter, check that the
O-ring is not damaged, then install.
Also, if the O-ring is replaced, apply oil to it
before installing it.
1 Filter wrench
2 Pilot oil filter
19 NST-09-05-005E
19
5. Hydraulic Oil Replacement
[1] Rotate the main unit slightly before replacing
the hydraulic oil. (Enough to make the work
easy)

then remove the feed port cover.
[3] Insert the feed pump into the feed port.
1 Bolt
2 Feed port cover
3 Feed pump
NST-09-05-005E 20
20
[4] Prepare a waste oil receiver.
[5] Use a wrench (19 mm) to remove the bottom

cover.
[6] Use a box wrench (17 mm) to remove the drain

plug.
4 Waste oil can

5 Cover
6 Bolt
7 Box wrench
8 Drain plug
21 NST-09-05-005E
21
[7] Drain the oil into the waste oil can.
[8] After draining the oil, securely install the drain
plug.
Hydraulic oil filling

[1] Fill with the feed pump as in the figure on the
right.
[2] Check that the hydraulic oil comes to the correct
position on the level gauge.
9 Waste oil can

10 Feed pump
11 Level gauge
NST-09-05-005E 22
22
Others
1. Coolant Filling
Remove the reserve tank cap and pour in coolant.
1 Reserve tank
2 Coolant
2. Washer Fluid Filling

Remove the washer tank cap and pour in washer
fluid.
1 Washer tank
2 Washer fluid
23 NST-09-05-005E
23
NST-09-05-005E 24
Periodic Maintenance Procedures SH120

Maintenance Every 250 Hours
1. Battery Inspection and Replacement
Check the color from the battery cover inspec-
tion window.
Green : OK
Black : Charge (Charge the battery.)
White : Replace (Replace the battery.)
■ Battery replacement method

[1] Remove the 2 screws, then remove the bat-
tery cover.
[2] Remove the 2 cables connected to the bat-
tery terminals, then replace the battery with
a new one.
• Be careful not to mistake the and the ter-
minals.
1 Battery cover
2 Screw
3 Battery
4 Cables
1 NST-09-07-005E
1
Maintenance after First 250 Hours for New Machine/Every 1000 Hours from Then on
1. Swing Reduction Gear Oil Replacement
[1] Use a wrench (19 mm) to remove the bottom
cover.
[2] Prepare a waste oil can.
[3] Remove the feed plug.
1 Cover
2 Bolt
3 Waste oil can
4 Feed plug
NST-09-07-005E 2
2
[4] Use a wrench (27 mm) to remove the drain plug
and drain off the oil.
[5] After oil draining is complete, tighten the drain
plug.
5 Wrench
6 Drain plug
2. Gear Oil Filling

[1] Fill the stipulated amount of gear oil from the
feed port.
[2] When filling with oil, removing the level gauge
beforehand facilitates oil filling.
[3] After about 10 min., check the oil volume with
the level gauge.
[4] If the oil volume is correct, install the feed plug.
1 Gear oil
2 Level gauge
3 Stipulated volume of oil
3 NST-09-07-005E
3
Replace the Flange Packing at the Bottom of the Fuel Tank
[1] Whenever the fuel tank bottom cover is removed, for example for cleaning the fuel tank, replace
the packing.
[2] When installing the packing, apply liquid packing. (See the figure below)
• Replacement parts
Part name Part number
Joint seat packing KRH12180
Liquid packing 1194 KTC0075
1 Cover
2 Packing
NST-09-07-005E 4
4
Bolt Size and Torque Table SH160

Bolt and Nut Tightening
• Tighten alternating between left and right and top and bottom so that uniform tightening force is
applied.
• For bolts at critical locations, apply engine oil to the threads for a uniform tightening force without
catching on the thread peaks.
• For bolts and nuts at critical locations and at locations that cannot be inspected from the outside,
use wire, cotter pins, folded washers, or the like to securely prevent turning.
• If Locktite was used on a removed bolt (there is something white sticking to the bolt when it is
removed), clean the old Locktite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Locktite
to the thread section of the bolt.
Bolt and nut retightening [after 1st 50 hours for new machine] [every 250 hours]
Tighten and retighten bolts and nuts in each section according to the table. Also before and after
day-to-day work, inspect for loose or fallen out bolts and nuts. Retighten any that are loose and
replace any that have come out.
Inspect and retighten after the first 50 hours for a new machine and every 250 hours after that.
1 NST-09-08-005E
1
Retightening Torque Table
Tightening torque
Bolt nominal
Code Retightening location Wrench lbf•ft
diameter
(N•m)
Travel motor M16 24 mm 197 - 230

1
(267 - 312)
197 - 230
2 Drive sprocket M16 24 mm
(267 - 312)
197 - 230
3 Take-up roller M16 24 mm
(267 - 312)
197 - 230
4 Upper roller (carrier roller) M16 24 mm
(267 - 312)
197 - 230
5 Lower roller (track roller) M16 24 mm
(267 - 312)
275 - 330
6 Shoe bolt M16 30 mm
(373 - 451)
795 - 940
7 Counterweight M27 50 mm
(1078 - 1274)
206 - 230
8 Turntable bearing (lower frame) M16 24 mm
(280 - 312)
206 - 230
9 Turntable bearing (swing frame) M16 24 mm
(280 - 312)
206 - 230
10 Swing unit M16 24 mm
(280 - 312)
195 - 231
11 Engine (engine mount) M16 24 mm
(265 - 313)
47 - 55
12 Engine bracket M12 19 mm
(64 - 74)
47 - 55
13 Radiator M12 19 mm
(64 - 74)
47 - 54
14 M10 17 mm
(64 - 73)
Hydraulic pump
14 mm 164 - 182
15 M16
bar wrench (223 - 247)
171 - 203
16 Hydraulic oil tank M16 24 mm
(232 - 276)
171 - 203
17 Fuel tank M16 24 mm
(232 - 276)
197 - 230
18 Control valve M16 24 mm
(267 - 312)
65 - 79
19 M12 19 mm
(88 - 107)
Center joint
80 - 94
20 M12 19 mm
(109 - 127)
116
21 Cab M16 24 mm
(157)
15 - 21
22 Battery M10 17 mm
(20 - 29)
NST-09-08-005E 2
2
Caution
For items marked with ○ , always apply Locktite #262 or the equivalent and tighten with the speci-
fied torque.
lbf•ft (N•m) ÷ 9.8 gives the tightening torque in kgf•m.
The tightening for bolts and nuts not otherwise specified in the table above is as follows.
Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench [mm] 10 13 17 19 22 24 27 30
Hexagon bolt lbf•ft 5 14 29 43 72 115 145 216
Tightening torque
(N•m) (6.9) (19.6) (39.2) (58.8) (98.1) (157.0) (196.0) (294.0)
Hexagon Wrench mm 5 6 8 10 12 14 14 17
socket head lbf•ft 6 16 31 58 87 130 181 253
bolt Tightening torque
(N•m) (8.8) (21.6) (42.1) (78.4) (117.6) (176.4) (245.0) (343.0)
3 NST-09-08-005E
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NST-09-08-005E 4
4
5 NST-09-08-005E
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NST-09-08-005E 6
6
Main Unit Weight SH130
Main Unit Weight
Main Unit Weight

Divided Weight (standard specifications)
Weight (lb)
Sym
Component name 130X2
bol
A Operating weight 27110
Upper component
B 13140
(including counterweight and turntable bearing)
C Counterweight 5050
D Lower component (with grouser shoe) 9150
E Main unit weight 22290
F Attachments 4820
G Boom (including cylinders) 2690
H Arm (including cylinders and linkage) 1260
* The weights displayed are approximate weights.
1 NST-11-01-008LX
1
Main Unit Weight
Stand Alone Part Weight
Weight (lb)
1 Travel unit 320
2 Take-up roller 140
3 Upper roller 35
4 Lower roller 57
5 Swing unit 218
6 Turntable bearing 390
7 Engine 720
8 Radiator 174
9 Hydraulic pump 180
10 Fuel pump 185
11 Hydraulic oil tank 210
12 Control valve 350
13 Center joint 66
14 Boom 1580
Shoe Weight (per side)

Weight (lb)
1 500 mm grouser shoe 1565
Arm Weight
Weight (lb)
1 Standard arm 790
2 Short arm 700
3 Long arm 960
NST-11-01-008LX 2
2
Interchangeability SH130
Interchangeability
Interchangeability
Interchangeability
1. Main Part Interchangeability Table (130X2)
Interchang
Position Part name 130LX 130X2 Remarks
eability
A Travel motor KNA0767 ←×→ KNA10520 Drive force increased
Shoe (600 mm) KNA0809 ←○→ KNA10620
Contact surface with link
Lower roller KNA0693 ←○→ KNA10600
machining added
Lower- Upper roller KMA1275 ←○→ KMA1275
related
Take-up roller KMA1265 ←○→ KNA11040
Recoil spring KNA0692 ←×→ KNA10530 Specifications change
Drive sprocket KMA1256 ←×→ KNA0826 Tooth shape change
Center joint KNA0682 ←○→ KRA11190 The lock bar is different.
B Counterweight KNB0688 ←×→ KNB10810 Shape change
Turntable bearing KNB0782 ←×→ KNB10410 Strength increased
C Swing motor assembly KNC0087 ←×→ KNC10010 Specifications change
Swing motor LN00855 ←×→ －
Swing reduction gear LN00104 ←×→ －
H Exhaust gas 3rd regulation
Engine KNH0894 ←×→ KNH10510
engine
Radiator/oil cooler KNH0830 ←×→ KNH10450 Parallel type used
Air cleaner KRH1224 ←×→ KLH10150 Indicator position change
Muffler KNH0761 ←×→ KLH10140 Size increase
Fuel tank KNH0771 ←×→ KNH10480 Capacity increase
Upper-
J Hydraulic pump KNJ3021 ←×→ KNJ11850 Specifications change
related Control valve KNJ3053 ←×→ KNJ14640 Specifications change
Remote control valve
KRJ5804 ←×→ KHJ13270 Specifications change
(operating machine)
Remote control valve
(travel)
KNJ2557 ←○→ KRJ5803
Hydraulic oil tank KNJ3047 ←×→ KNJ14410 Shape change

N Cab KHN2867 ←×→ KHN16481 Structure change
Operator's seat KHN2112 ←×→ KHN11470 Specifications change
Console box KHN2344 ←×→ KHN12200 Design alteration
R Computer KHR2680 ←×→ KHR10024 Specifications change
Monitor display KHR3137 ←×→ KHR10051 Design alteration
Main unit only
Air conditioner unit KHR2756 ←○→ KHR13320
interchangeable
1 NST-11-02-008LX
1
Interchangeability
Interchang
Position Part name 130LX 130X2 Remarks
eability
V Boom (EMS) KNV1420 ←×→ KNV16450 Specifications change
The arm tip section has a
Arm (EMS) KNV1627 ←×→ KNV16530
steel bushing.
The bucket link section has a
Bucket link KNV1437 ←×→ KNV16970
steel bushing.
KNV1473 KNV1473
Attachment Arm link ←○→
KNV1474 KNV1474
-related
KNV1615 KNV14330
Boom cylinder ←×→ Specifications change
KNV1616 KNV14340
Arm cylinder KNV1617 ←×→ KNV14350 Specifications change
Bucket cylinder KNV1618 ←×→ KNV12540 Specifications change
Arm top and bucket pin only
Pin and bushing
interchangeable
The parts numbers are for reference. When arranging for parts, check with the parts
manual.
NST-11-02-008LX 2
2
Attachment Installation Methods SH130

Attachment Dimensions
Standard arm Bucket Arm link Bucket link

Position
A B C D E F G H I J1 J2 K1 K2 L1 L2 M1 M2 N O P Q R S T U1 U2
Dimensions
(2472.3) 23.27 12.99 14.32 7.53 7.65 20.96 ?6.14 ?4.72 ?2.56 ?2.56 10.04 10.00 15.00 15.55 10.04 10.04 ?2.56 13.98 20.08 18.90 10.00 36.22 10.00 ?2.56 ?2.76
in
97.34 (591) (330) (363.7) (191.3) (194.3) (532.5) (?156) (?120) (?65) (?65) (255) (254) (381) (395) (255) (255) (?65) (355) (510) (480) (254) (920) (254) (?65) (?70)
(mm)
Bucket pin Bucket cylinder

Position Bucket and arm connection section Bucket and bucket link connection section Maximum Cylinder top
Stroke
V W X Y V W X Y retracted length width
Dimensions
?2.56 0.87 16.02 0.67 ?2.56 0.87 14.69 0.67 63.74 43.62 3.58
in
(?65) (22) (407) (17) (?65) (22) (373) (17) (1619) (1108) (91)
(mm)
1 Arm boss
2 Maximum retracted length stroke
3 Bucket link
4 Bucket pin
1 NST-11-04-006E
1
2 NST-11-04-006E
Paint Colors SH200
Paint Colors
Paint Colors
Paint Colors
Color No. MUNSELL No.
1 Red F-222
2 Granite gray S-148
3 MS37 gray N-300 1.2Y 3.8 / 0.3
4 Black S-141 9.0YR 3.3 / 0.1
No. Paint location Color Color No. Paint part No.
• The upper of machine

(Except cabin, engine, muffler, exhaust pipe, house
1 door, engine hood, frame duct, front cover, tank cover, Granite gray S-148 KHP1444 (urethane)
electric parts, plastics)
• Rev.frame (front side)
2 • Attachment Red F-222 KHP1444 (urethane)
• Inside of house
3 MS37 Gray N-300 KHP1193 (one-coat)
• Rev.frame (expect front and lower side)
4 • Upper under cover MS37 Gray N-300 KHP1444 (urethane)
Granite gray S-148
5 • Outside of cabin - (Melamine)
Black S-141
6 • Inside of cabin Black S-141 - (Melamine)
7 • Frames of front window Granite gray S-148 - (Melamine)
8 • Floor, bracket trim MS37 Gray N-300 KHP1193 (one-coat)
• The lower of machine
9 • Rev.frame (lower side) Black S-141 KHP1189 (acryle)
• Include of turntable bearing
10 • Rev.frame (under engine&inside) MS37 Gray N-300 KHP1189 (acryle)
11 • Lower under cover MS37 Gray N-300 KHP1193 (one-coat)
Ceramic coating KHP1200
12 • Muffler and exhaust pipe Black
(K.K) (heat resist)
13 • House door, side cover Granite gray S-148 KHP1445 (baking)
14 • Engine hood Black S-141 KHP1445 (baking)
15 • Hand rail Black S-141 Powder coating
16 • Frame duct MS37 Gray N-300 KHP1445 (baking)
17 • Front cover, tank cover Black S-141 KHP1445 (baking)
1 NST-11-05-008LX
1
Paint Colors
NST-11-05-008LX 2
Unit Conversion Ratio SH200

× 
Weight unit SI unit
÷ 
Kgf 9.807 N
lbf 4.448 N
Kgfcm 0.0981 Nm
lbfft 1.356 Nm
lbfin 0.113 Nm
Kgf/cm2 0.0981 MPa
atm 0.1013 MPa
lbfin2 0.0069 MPa
mmHg 133.3 Pa
inHg 3386 Pa
Kgfm/s 0.00981 kW
lbfft/s 0.00136 kW
PS 0.7355 kW
HP 0.746 kW
Kgfm 9.807 J
Kcal 4186 J
Kgfs/cm2 98067 Pas
cP 0.001 Pas
P 0.1 Pas
cSt 1×10-6 m2/s
St 0.0001 m2/s
1 RST-11-06-001E
1
RST-11-06-001E 2
Contents SH130-5
Contents
Contents
Engine Section
Procedures for Replacing Consumable Parts ..................................................... 1
Engine Oil ................................................................................................................... 1
Removal and Installation of Engine Oil Filter Element................................................ 4
Fuel Filter.................................................................................................................... 5
Charge Fuel Pump Filter ............................................................................................ 9
Removal and Installation of Fan Belt ........................................................................ 11
Removal and Installation of Air Conditioner Belt ...................................................... 14
Assembly and Disassembly ................................................................................ 1

Removal and Installation of Engine Hood................................................................... 1
Removal and Installation of Engine Assembly............................................................ 3
Removal and Installation of Starter Motor ................................................................ 12
Removal and Installation of Alternator...................................................................... 14
Removal and Installation of Supply Pump ................................................................ 16
Removal and Installation of Installation of Common Rail ......................................... 21
Removal and Installation of Injector.......................................................................... 29
Removal and Installation of Muffler .......................................................................... 39
Removal and Installation of Turbo Charger .............................................................. 41
Removal and Installation of EGR Cooler and EGR Valve......................................... 45
Removal and Installation of Engine Sensors ............................................................ 47
Removal and Installation of Fuel Cooler................................................................... 48
Removal and Installation of Engine Inter Cooler ...................................................... 49
Air Conditioner Section

Assembly and Disassembly ................................................................................ 1
Removal and Installation of Compressor.................................................................... 1
Removal and Installation of Condenser...................................................................... 3
Removal and Installation of Receiver Dryer ............................................................... 5
Assembly and Disassembly of Unit ............................................................................ 7
Procedures for Gas Filling................................................................................... 1

Work Precautions ....................................................................................................... 1
Procedures for Filling.................................................................................................. 4
Maintenance Section
Procedure for Electrical Equipment Judgment .................................................... 1
Procedure for Electricity Measurement....................................................................... 1
Maintenance Standards ...................................................................................... 1

Check Sheet ............................................................................................................... 1
1 NSM-00-00-002E
1
Contents
Assembly and Disassembly Section
Track Shoe .......................................................................................................... 1
Removal and Installation of Shoe Assembly .............................................................. 1
Removal and Installation of Shoe Plate...................................................................... 6
Travel Unit ........................................................................................................... 1

Removal and Installation of Travel Motor.................................................................... 1
Assembly and Disassembly of Travel Motor ............................................................... 8
Take-up Roller ..................................................................................................... 1

Removal and Installation of Take-up Roller ................................................................ 1
Assembly and Disassembly of Take-up Roller............................................................ 3
Upper Roller ........................................................................................................ 1

Removal and Installation of Upper Roller ................................................................... 1
Assembly and Disassembly of Upper Roller............................................................... 3
Lower Roller ........................................................................................................ 1

Removal and Installation of Lower Roller ................................................................... 1
Assembly and Disassembly of Lower Roller............................................................... 4
Swing Unit ........................................................................................................... 1

Removal and Installation of Swing Unit ...................................................................... 1
Assembly and Disassembly of Swing Motor............................................................... 6
Center Joint ......................................................................................................... 1

Removal and Installation of Center Joint .................................................................... 1
Counterweight ..................................................................................................... 1
Removal and Installation of Counterweight ................................................................ 1
Hydraulic Pump ................................................................................................... 1

Removal and Installation of Hydraulic Pump .............................................................. 1
Procedures for Assembly and Disassembly of Pump Main Unit Section.................... 7
Pump Main Unit Section Maintenance Standards .................................................... 17
Explanation of Regulator Operation.......................................................................... 22
Procedures for Assembly and Disassembly of Regulator......................................... 28
Procedures for Assembly and Disassembly of PTO Unit.......................................... 39
PTO Unit Maintenance Standards ............................................................................ 45
NSM-00-00-002E 2
2
Contents
Remote Control Valve ......................................................................................... 1
Removal and Installation of Operation Remote Control Valve.................................... 1
Procedures for Assembly and Disassembly of Operation Remote Control Valve..... 10
Procedures for Assembly and Disassembly of Travel Remote Control Valve ........... 27
Control Valve ....................................................................................................... 1

Removal and Installation of Control Valve .................................................................. 1
Assembly and Disassembly Precautions.................................................................... 8
Inspection and Handling ............................................................................................. 9
Replacing the Main Plunger ..................................................................................... 11
Accessories .............................................................................................................. 12
External Shape Diagram .......................................................................................... 13
Cross-section Structure Diagram.............................................................................. 14
Assembly and Disassembly...................................................................................... 24
Radiator and Oil Cooler....................................................................................... 1

Removal and Installation of Radiator.......................................................................... 1
Removal and Installation of Oil Cooler ....................................................................... 9
Tank..................................................................................................................... 1
Removal and Installation of Hydraulic Oil Tank........................................................... 1
Removal and Installation of Fuel Tank........................................................................ 7
Attachments ........................................................................................................ 1
Removal and Installation of Bucket............................................................................. 1
Removal and Installation of Bucket Link ..................................................................... 3
Removal and Installation of Bucket Cylinder .............................................................. 6
Removal and Installation of Arm Cylinder................................................................. 10
Removal and Installation of Arm............................................................................... 15
Removal and Installation of Boom Cylinder.............................................................. 17
Removal and Installation of Boom ............................................................................ 22
Removal and Installation of Arm HBCV.................................................................... 27
Removal and Installation of Boom HBCV ................................................................. 29
Operation and Assembly/Disassembly of Hydraulic Cylinder ................................... 32
Lights................................................................................................................... 1
Removal and Installation of Boom Light ..................................................................... 1
Removal and Installation of Tool Box Light ................................................................. 2
3 NSM-00-00-002E
3
Contents
Procedures for Removal and Installation of Cab Inner and Outer Parts ............. 1
Removal and Installation of Cab Assembly ................................................................ 1
Removal and Installation of Operator's Seat .............................................................. 9
Removal and Installation of Wiper ............................................................................ 11
Removal and Installation of Wiper Controller ........................................................... 12
Removal and Installation of Wiper Motor.................................................................. 15
Removal of Wiper Motor ........................................................................................... 15
Removal and Installation of Monitor ......................................................................... 19
Removal and Installation of Cab Front Glass ........................................................... 20
Procedure for Window Lock Adjustment................................................................... 23
Hydraulic Equipment-related Parts...................................................................... 1

Accumulator................................................................................................................ 1
Suction Filter............................................................................................................... 2
Return Filter................................................................................................................ 4
Pilot Filter.................................................................................................................... 6
Other ................................................................................................................... 1
Removal and Installation of Side Door ....................................................................... 1
Draining Oil from Hydraulic Oil Tank........................................................................... 2
NSM-00-00-002E 4
4
Procedures for Replacing Consumable Parts SH120

Engine Oil
Warning ・ Keep away from fire.
Caution ・ Be sure to stop the engine before beginning work.
Items to prepare
• Wrench (19 mm)
• Special plug (drainer plug)
• Waste oil can
• Rag
• Cleaning fluid
1. Engine Oil Draining

[1] Use a wrench (19 mm) to remove the 4 bolts
(1), and then remove the under cover (2).
[2] Remove the drain cap (3).
1 NSM-06-10-002E
1
[3] Prepare a waste oil can (4).
[4] When the drainer plug (5) is screwed in, engine
oil will drain.
NSM-06-10-002E 2
2
2. Engine Oil Filling
[1] Remove the drainer plug used for draining oil.
[2] Attach the drain cock cap removed when oil was
drained.
[3] Fill at the feed port (3) with new engine oil (2).
Next, wait about 15 min. for the oil to completely
travel down to the oil pan, remove the oil level
gauge (1), and wipe the tip of the gauge off with
a rag before fully inserting the gauge again.
[4] Gently pull out the oil level gauge (1). If oil is
adhered to the area between the "upper limit"
and "lower limit", the amount of oil is appropri-
ate.
3. Inspection After Engine Oil and Element Replacement

Oil leak inspection
[1] Start the engine.
Slowly raise the rotation from idling rotation.
[2] Check the oil pan drain cock and each installation section of the oil filter for oil leaks.
Rechecking the oil volume
Stop the engine and wait 10 - 20 min. to recheck the engine oil volume. If the volume is low, fill up
with oil to the stipulated level.
The oil level will decrease due to engine oil entering the oil filter and oil path when the engine is
started.
Refill with oil if the oil level is low.
3 NSM-06-10-002E
3
Removal and Installation of Engine Oil Filter Element
Items to prepare
• Filter wrench
• Rag
• Cleaning fluid
1. Removal of Oil Filter Element

[1] Use a filter wrench (1) to remove the oil filter
element (2).
2. Installation of Oil Filter Element

Use the following procedure to install a new car-
tridge.
[1] Apply a thin layer of grease to the cartridge gas-
ket.
[2] After the cartridge is screwed in and the gasket
is touching the seal surface, use the filter
wrench to tighten cartridge 1 rotation.
NSM-06-10-002E 4
4
Fuel Filter
・ Always do air bleeding when the fuel tank has been emptied, water has been drained from
Caution fuel, the element has been replaced, or any other similar work has been done.
・ Be sure to stop the engine before beginning work.
Main filter
Items to prepare
• Wrench (10 mm)
• Filter wrench
• Waste oil can
• Rag
• Cleaning fluid
[1] Tighten the fuel line (1) stop valve (2).

[3] Use a wrench (10 mm) (5) to loosen the air
bleed plug (4).
[4] Loosen the cap (6) on the bottom side, and then
drain the remaining fuel.
* Place a waste oil can under the cap.
5 NSM-06-10-002E
5
[5] Use the filter wrench (7) to remove the cover
(8).
[6] Replace the element (9) and O-ring (10).

The O-ring cannot be reused. Always replace it
with a new one.
[7] After replacing the filter, use the filter wrench (7)
to attach the cover (8).
NSM-06-10-002E 6
6
bleed plug (4).
[9] When the filter case priming pump (11) is
turned in the direction of the arrow, the knob
pops out.
[10] Move the priming pump (11) in and out until the
fuel filter is filled with fuel (more than 10 times).
When fuel appears inside the filter case, lightly
tighten the air bleed plug (4). Press the knob a
few times with the plug tightened.
Finally, hold the knob pressed in and slightly
loosen the air bleed plug.
Fuel will ooze out from the hose (12) like bub-
bles.
[11] Repeat the operation in [10] until no more bub-
bles appear.
[12] Tighten the air bleed plug (4), and then turn the
knob and lock it.
Pre-filter
[1] Close the fuel line (1) stop valve (2).
7 NSM-06-10-002E
7
bleed plug (4).
[3] Loosen the cap (5) on the bottom side, and then
drain the remaining fuel.
* Place a waste oil can (6) under the cap.
[4] Remove the pre-filter cover (8) with the special

filter wrench (7).
[5] Remove the O-ring (9) and element (10) and

replace them.
[6] Open the fuel line (1) stop valve (2).
NSM-06-10-002E 8
8
Charge Fuel Pump Filter
Items to prepare
• Wrench (10 mm)
• Pliers
• Caps
• Rag
• Cleaning fluid
[1] Remove the connector (1).
[2] Use pliers or another tool to loosen the hose

bands (2), and then remove the hoses (3) and
(4).
• Use caps to cover the charge fuel pump filter
and hoses to prevent the entry of water, dust or
dirt.
9 NSM-06-10-002E
9
[3] Use a wrench (10 mm) to remove the 2 installa-
tion bolts (5), and then turn the filter cover (7) to
the left and remove the element (6).
NSM-06-10-002E 10
10
Removal and Installation of Fan Belt
Items to prepare
• Wrenches (14 mm, 17 mm)
• Rag
• Cleaning fluid
[1] Remove the air conditioner belt.

(See "Air Conditioner Belt Replacement".)
[2] Use a wrench (14 mm) to remove the bolt (1).
[3] Use a wrench (14 mm) to remove the bolts (2).

[4] Remove the bracket (3).
[5] Remove the fan guard (4).
11 NSM-06-10-002E
11
[6] Use a box wrench (17 mm) to loosen the lower
installation bolt (7) of the alternator (5).
• Use a closed wrench or a wrench (17 mm) to
loosen the lower installation bolt (7) while
holding the nut (16).
[7] Use a box wrench (17 mm) (8) to loosen the nut
(10), and keep the alternator (5) adjuster plate
(9) in a free state.
[8] Use a box wrench (17 mm) (8) to loosen the

tension bolt (11) of the alternator.
[9] Remove the fan belt from the alternator (5).
NSM-06-10-002E 12
12
[10] While slowly turning the fan (13), pass the fan
belt (14) over the 5 blades one at a time and
remove it.
Tension adjustment
After replacing the fan belt, it is necessary to adjust
the belt tension.
tension bolt (11) of the alternator.
[2] Adjust the fan belt (12) so that when the center
section of the belt is pressed with a finger, it
deflects about 1 cm.
[3] Securely fasten the nut (10).
[4] Use a box wrench (17 mm) (8) to fasten the
lower installation bolt (7).
• Use a closed wrench or a wrench (17 mm) to
tighten the lower installation bolt (7) while
holding the nut (6).
13 NSM-06-10-002E
13
Removal and Installation of Air Conditioner Belt
Items to prepare
• Wrench (19 mm)
• Box wrench (14 mm)
• Rag
• Cleaning fluid
[1] Use a box wrench (19 mm) to remove the bolts

(1), and then remove the lower section cover
(2).
[2] An air conditioner belt (5) is shown in the right

diagram.Use a box wrench (13 mm) to remove
the bolts (2), then remove the belt cover (3).
[3] Use a box wrench (14 mm) (6) to loosen the nut
(4).
NSM-06-10-002E 14
14
tension bolt (7).
[5] Remove the air conditioner belt (10) from the

tension pulley (9) and replace the belt.
Tension adjustment
After replacing the air conditioner belt, it is
necessary to adjust the belt tension.
[1] Use a box wrench (14 mm) to tighten the
tension bolt (7).
[2] Adjust the belt so that when the center section
of the belt is pressed with a finger, it deflects
about 1 cm. (See the diagram.)
[3] Securely fasten the nut (4).
[4] Install the belt cover (3) with the bolts (2).
15 NSM-06-10-002E
15
NOTES:
Assembly and Disassembly SH120
Assembly and Disassembly

Removal and Installation of Engine Hood
・ Do not perform this operation in strong wind.
Caution ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work.
・ Do not stand or pass under the suspended load.
Items to prepare
• Wrench (19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)
[1] Open the engine hood, and then remove the

Matsuba pin (1) and the flat washer (2).
[2] Pull out the lock arm (4) from the engine hood
(3).
1 NSM-06-11-002E
1
[3] After closing the engine hood, use a wrench (19
mm) to remove the 6 bolts (5) from the engine
hood.
[4] Wrap the nylon sling (6) around the engine

hood, and then use the crane to lift the engine
hood (7).
NSM-06-11-002E 2
2
Removal and Installation of Engine Assembly
・ Keep away from fire.
・ Be sure to release hydraulic pressure before beginning work.
Warning ・ The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splay-
ing out when loosening lines.
・ Do not use open flames and do not allow sparks near the battery.

Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
Items to prepare
• Wrenches (7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 14 mm, 17 mm, 36 mm)
• Shackle (with the required lifting capacity) x 2
• Wire ropes (with the required breaking load)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.
[1] Remove the counterweight.

(For details, see "Removal and Installation of
Counterweight".)
[2] Remove the pump.
Hydraulic Pump".)
[3] Use a wrench (14 mm) to remove the bolts (1)
and (2), and then remove the fan shroud (3).
3 NSM-06-11-002E
3
[4] Use a wrench (14 mm) to remove the bolts (4),
and then remove the fan guard (5).
[5] Use a wrench (7 mm) to loosen the hose band

(6) on the radiator, and then remove the upper
hose (7).

0(

(6) on the radiator, and then remove the lower
hose (8).
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt.

• Before removing the radiator hoses, completely
drain the coolant.
0(
[7] Use a wrench (12 mm) to loosen the line bolts

(9) in 2 locations, and then remove the 2 lines
(10) and (11) from the compressor.
• Always remove the low-pressure (suction side)
line (10) first.
• Attach caps or plugs to the compressor and line
to prevent any entry of water, dust or dirt.
NSM-06-11-002E 4
4
(12) on the inter cooler, and then remove the
hose (13).
• Use caps to cover the line and hose to prevent
the entry of water, dust or dirt.
[9] Remove the hose bands (14) in the 3 locations.
[10] Take the breather hose (15) that is on the out-

side and insert it inside.
5 NSM-06-11-002E
5
• Drain the engine oil before removing the engine
oil hose.
[12] Use a wrench (36 mm) to remove the 2 engine

oil remote hoses (17).
• Mark the engine and hoses so that the connec-
tors match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them
with a parts cleaner to prevent scratches and
prevent dirt from accumulating on the connec-
tors.
[13] Use a wrench (17 mm) to remove the bolt (18),

and then remove the battery cable (19) on the
negative side.
• When removing the terminal and harness,
secure them so that they do not interfere with
the frame.
Also, cover with a rubber cap to protect against
sparks.
NSM-06-11-002E 6
6
[14] Use a wrench (8 mm) to remove the 1 nut (20),
and then remove the control signal wire (21)
from the starter motor.
[15] Remove the jump-start protector (22), use a

wrench (14 mm) to remove the 1 nut (23), and
then disconnect the positive-side power (24) of
the starter motor.
[16] Remove the hose band (25), and then remove

the fuel hose (26).
• Attach caps or plugs to the engine and hose to
[17] Remove the hose band (27), and then remove

the fuel hose (28).
7 NSM-06-11-002E
7
(29), and then remove the box cover (30).
[19] Remove the connectors (31) in the box.

• Wrap the removed connectors in plastic after
tying them together.

(32), and then remove the heater hose (33).

(34), and then remove the heater hose (35).
NSM-06-11-002E 8
8
(36), and then remove the radiator hose (37).
any entry of water, dust or dirt.

(38), and then remove the air hose (39).

[25] Remove the connectors (42) from the alternator.
9 NSM-06-11-002E
9
[26] Use a wrench (10 mm) to remove the nut (43),
and then remove the wiring (44) from the alter-
nator.

and then remove the breather hose clamp (46).
[28] Install the 2 shackles (47), and then use the

wire rope (48) and crane to secure the engine.
NSM-06-11-002E 10
10
[29] Use a box wrench (24 mm) to remove the 4
bolts (49) from the mount.
[30] Use the wire rope (48) and crane to lift the
engine.
[31] Thoroughly check that the location is safe
before lowering the engine on wood planks, etc.
[32] To install the engine, perform the reverse of the removal procedure.
After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and per-
form filling for the air conditioner gas.
For details, see the individual explanations for each procedure.
[33] Run the engine at no-load idling and check for any water or oil leaks.
[34] Attach the hydraulic pump, covers, and counterweight.
For details, see the individual explanations for each procedure.
11 NSM-06-11-002E
11
Removal and Installation of Starter Motor
Warning ・ Do not use open flames and do not allow sparks near the battery.
Items to prepare
• Wrenches (8 mm, 14 mm, 17 mm)
• Rag
• Cleaning fluid

negative side.
the frame.
sparks.
[2] Use a wrench (8 mm) to remove the nut (3), and

then remove the control signal wire (4).
[3] Remove the jump-start protector (5), use a

wrench (14 mm) to remove the nut (6), and then
disconnect the positive-side power (7) of the
starter motor.
NSM-06-11-002E 12
12
and then remove the wiring on the ground side
(9).

and then remove the starter motor (11).
[6] To install, perform the reverse of the removal

procedure.
Mount nut tightening torque: 82.4 N•m
13 NSM-06-11-002E
13
Removal and Installation of Alternator
Warning ・ Do not use open flames and do not allow sparks near the battery.
Items to prepare
• Rag
• Cleaning fluid
[1] Remove the fan belt.

Fan Belt".)
negative side.
the frame.
sparks.

and then remove the wiring (5).
NSM-06-11-002E 14
14
and then remove the wiring (5).

and then remove the alternator (8).
[7] To install, perform the reverse of the removal

procedure.
Adjust the fan belt according to the tension
adjustment procedure.
15 NSM-06-11-002E
15
Removal and Installation of Supply Pump
Warning ・ Be sure to release hydraulic pressure before beginning work.
Each part of the fuel system is a high-precision part.

Caution Damage may result if foreign matter, etc. enters the fuel system, so use extreme caution when
handling these parts.
When high-pressure lines in the fuel system are removed, replace them with new lines.
Replace gaskets or O-rings with new ones.
Warning Fuel leaks may cause fires. Thoroughly wipe off fuel after work is completed, and carefully
check for any leaks after starting the engine.
Items to prepare
• Wrenches (8 mm, 10 mm, 12 mm, 14 mm, 17 mm, 19 mm, 22 mm)
• Hexagon wrench (4 mm)
• Gear puller
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Supply Pump

and then remove the hole cover (2).
[2] Turn the crankshaft in the correct rotation direc-

tion and align the reference mark of the 1st or
4th cylinder with the compression top dead cen-
ter position.
NSM-06-11-002E 16
16
[3] Use a wrench (8 mm) to loosen the hose bands
• Use caps and plugs to cover the hose and line

(6), and then remove the inlet pipe (7).
• Cover the line to prevent the entry of water, dust
or dirt.
• Clean the line by spraying with a parts cleaner
to prevent scratches and prevent dirt from accu-
mulating on the connectors.

on the clamps (8).
[7] Remove the connectors (9) and (10).
17 NSM-06-11-002E
17
bolt (11) on the clamp (12).

and then remove the oil gauge line (14).
• Use caps and plugs to cover the line to prevent
[10] Use a wrench (19 mm) to remove the sleeve

nuts (15), and then remove the injection pipe
(16).
[11] Remove the fuel hose (17).

NSM-06-11-002E 18
18
[12] Use a wrench (10 mm) to remove the bolt (19)
on the leak-off pipe (20).
[13] Use a wrench (12 mm) to remove the eye bolt
(18) on the leak-off pipe (20).
[14] Use a wrench (14 mm) to remove the eyebolts

(21) and (22) on the leak-off pipe (20).
[15] Remove the leak-off pipe (20).


[17] Use a wrench (22 mm) to remove the eyebolt
(25) on the fuel pipe (26).
19 NSM-06-11-002E
19
[18] Use a wrench (14 mm) to remove the nuts (27).
and (29).
[20] Remove the supply pump assembly (30).
• Use caps and plugs to prevent any entry of
water, dust or dirt.
• Clean the assembly by spraying it with a parts
cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
[21] Remove the nut securing the supply pump gear

(31) and use the gear puller (32) to remove the
gear from the supply pump assembly (30).
[22] Remove the 3 bolts (36), and then remove the

supply pump (33). Also remove the O-ring (34)
at the same time.
35 Bracket
NSM-06-11-002E 20
20
2. Installation of Supply Pump
[1] Install the O-ring (2) on the supply pump (1).
Install the pump on the bracket (3) and tighten
the 3 bolts (4) to the specified torque.
Tightening torque: 19 N•m
[2] Align the key of the supply pump shaft with the
gear (5), install the gear, and tighten the nut (6)
to the specified torque.
[3] A reference mark circle has been stamped onto

the end face surface of the gear.
Paint the upper part of the gear tooth just above
the stamped "0" mark white.
This paint is very important for checking the cor-
rect position.
21 NSM-06-11-002E
21
[4] Install the O-ring (7) on the supply pump
assembly (8).
Align the supply pump gear position with the ref-
erence mark (0 mark) on the gear end face sur-
face and the slit on the pump bracket side.
Install the supply pump assembly on the engine
so that the alignment position is correct.
Temporarily tighten the bolts (10) and (11) and
the nut (9).
[5] When looking from the plug hole, check that the
gear tooth with the reference mark (0 mark) and
white paint is at the center of the hole and in the
position shown in the diagram.
If alignment is not correct, adjust the gear posi-
tion again and install the pump on it.
Temporarily tighten bolts (10) and (11) and nut
(9) to the specified torque.
Tightening torque
Nut: 50 N•m
Bolt: 76 N•m
[6] Install the hole cover (13) in the plug hole.

Tighten the bolt (12) to the specified torque.
NSM-06-11-002E 22
22
[7] Connect the connectors (14) and (15).
Install the line (17) with the eyebolt (16).
[8] Install the leak-off pipe (18) with eyebolts (19),

(21) and (22) and bolt (20).
• Be careful not to allow entry of any water, dust
or dirt.
Always replace seals.
[9] Install the fuel hose (23).

or dirt.
23 NSM-06-11-002E
23
[10] Install the injection pipe (25). This injection pipe
cannot be reused, so always replace it with a
new one.
Tighten the sleeve nuts (24).
or dirt.
[11] Install the clamp (27) with the bolt (26).
[12] Install the oil gauge line (29) with the bolts (28).
or dirt.
[13] Install each wiring clamp (33) with a bolt (32)

and install the wiring connectors (30) and (31).
NSM-06-11-002E 24
24
[14] Install the inlet pipe (35) with the 3 bolts (34)
and tighten to the specified torque.
[15] Connect the connector (36).
[16] Install the air hose (38), and tighten the hose
bands (37).
or dirt.
25 NSM-06-11-002E
25
Removal and Installation of Supply Pump
Items to prepare
• Wrenches (10 mm, 12 mm, 14 mm, 17 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
See "Removal and Installation of Supply Pump" for procedures for removal and installation of the oil
level gauge pipe, intake hose, manifold, etc.

on the wiring clamp.
on the wiring clamp.
NSM-06-11-002E 26
26
[4] Use a wrench (14 mm) to remove the eyebolts
(4) and (5) on the leak-off pipe (6), and remove
the leak-off pipe.
[5] Use a wrench (10 mm) to remove the nuts (8)

on the line clamps (7).
[6] Use a wrench (17 mm) to remove each sleeve
nut (9) in the 4 locations.
• Replace the removed line in the same way as
the common rail.
[7] Use a wrench (12 mm) to remove bolts (11) and

(12) and nuts (10).
27 NSM-06-11-002E
27
[8] Remove the common rail (13).
[9] To install the common rail, perform the reverse

of the removal procedure.
High-pressure lines that have been removed
cannot be reused.
Always replace them with new ones.
NSM-06-11-002E 28
28
Removal and Installation of Injector
Warning Do not use open flames and do not allow sparks near the battery.
Warning Injector wirings are high voltage wirings, so make sure to remove the battery.
Caution ・ Be careful not to drop any removed parts inside the engine.
Items to prepare
• Wrenches (7 mm, 10 mm, 12 mm, 14 mm, 17 mm, 19 mm)
• Pliers
• Marking pen
• Torx wrench (T40)
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Injector
Removal and installation of the No. 1 injector is explained here as a representative example. Use
the same procedure for other cylinder injectors.
Be extremely careful when handling injectors. The nozzle tips are especially delicate. Hitting the
nozzles or wiping them with a rag may cause the hole to clog. Also, injector wiring use high voltage,
so make sure to remove the battery terminals before beginning work.
High-pressure lines, seals, and packing that have been removed cannot be reused, so always
replace them with new parts.
negative side.
the frame.
sparks.
29 NSM-06-11-002E
29
and then remove the oil gauge line (4).
[3] Use pliers to loosen the hose band, and then

remove the blow-by hose (5).
• Use caps and plugs to cover the hose and line
[4] Use a wrench (12 mm) to remove the bolt (6) on

the hose clamp (7).
NSM-06-11-002E 30
30
[5] Use a wrench (12 mm) to remove the 9 bolts (8)
on the cylinder head cover (10) and the 2 nuts
(9), and then remove the cylinder head cover.
31 NSM-06-11-002E
31
[7] Use a wrench (7 mm) to remove the 2 nuts (13)
at each of the 4 injector terminal locations.
[8] Use a wrench (14 mm) to loosen the 3 bolts
(12), and then remove the harness bracket (14).
• When removing the nuts, loosen them equally a
little bit a time to simultaneously remove them.
[9] Use wrenches (12 mm, 17 mm) to remove the 5

bolts (15) and (16) and the 5 gaskets (17) and
(18), and then remove the nozzle leak-off pipe
(19).
NSM-06-11-002E 32
32
on the line clamp (23).
[11] Use a wrench (17 mm) to remove the sleeve nut
(21) of the injector-side line.
[12] Use a wrench (19 mm) to remove the sleeve
nuts (22) of the common rail-side lines.
• Use caps and plugs to cover the lines to prevent
[13] Use a Torx wrench (T40) to remove the bolt (24)

on the injector clamp (26).
[14] Remove the injector (25).
[15] Use the injector remover (28) when it is difficult

to remove the injector (29).
Install the injector remover on the injector line
connection section. Also connect the sliding
hammer (27) and then remove the injector.
1) Sliding hammer
Isuzu Part No.: 5-8840-0019-0
2) Injector remover
Isuzu Part No.: 5-8840-2826
33 NSM-06-11-002E
33
2. Installation of Injector
[1] Record the "QR code" (2) that appears on the
top of the QR plate (1) of the replacement injec-
tor (3).
The "QR code" is different for each injector, so
match the cylinder to be installed with the injec-
tor and record the code.
[2] Always replace the gasket (5) and O-ring (7).

Apply Molybdenum to the threaded section of
the bolt (4) on the injector clamp (6) and seating
surface.
Install the injector (3) on the cylinder head. As
shown in the diagram, insert the injector by
pressing it in with the clamp. Temporarily tighten
the bolt on the injector clamp.
NSM-06-11-002E 34
34
[3] Apply a small amount of engine oil to the out-
side surface of the injector-side sleeve nut (10).
Install the line.
Carefully tighten each of the sleeve nuts (9) and
(10) until the line is touching the common rail
and injector.
Tighten the bolt (8) on the line clamp (11) to the
specified torque.
Fully tighten the bolt (4) on the injector clamp to

the specified torque.
Tighten the line sleeve nuts to the specified
torque.
[4] Install the nozzle leak-off pipe (16) with the bolts
(12) and (13).
Replace the gaskets (14) and (15).
Tighten each of the lines to the specified torque.
35 NSM-06-11-002E
35
[5] Secure the harness bracket (19) with the bolts
(17).
Secure the bolts in sequence from the inside to
the outside.
[6] Install the injector terminal nuts (18) on each
injector.
Tighten to the specified torque.
Be careful not to tighten the nuts too much.
Tightening all at once with a ratchet wrench,
etc. may cause damage to the terminal stud.
[7] Connect the injector harness connector (20).
NSM-06-11-002E 36
36
[8] Install the head gasket (24) on the cylinder head
cover (23) and tighten with each of the bolts
(21) and nuts (22).
Tighten in the order shown in the diagram.
Specified torque: 18 N•m
[9] Install the hose clamp (26) with the bolt (25).
[10] Install the blow-by hose (27).
37 NSM-06-11-002E
37
[11] Install the oil gauge line (29) with the bolts (28).
or dirt.
[12] Install the negative-side battery cable (31) ter-

minal.
Be careful of shorts with the terminal and har-
ness.
30 Bolt
[13] When replacing an injector (3) with a new one,

make sure to enter the QR code of the replaced
injector into the ECM.
[14] See the Service Text for this procedure.
NSM-06-11-002E 38
38
Removal and Installation of Muffler
・ The muffler is extremely hot just after stopping the engine. Wait for it to sufficiently cool
Warning before beginning work.
Items to prepare
• Caps
• Rag
• Cleaning fluid
1. Removal of Muffler
(1), and then remove the covers (2) and (3).
[2] Use a wrench (14 mm) to loosen the nut (5) to

remove the 2 bolts (4), remove the seal clamp
from the exhaust pipe, and then remove the line.
• Use caps to cover the line to prevent any entry
of water, dust or dirt.
[3] Use a wrench (14 mm) to remove the 2 nuts (6).
39 NSM-06-11-002E
39
[4] Remove the U-bolts (7), and then remove the
muffler (8).
2. Installation of Muffler
Perform the reverse of the removal procedure.
After installation, check for any leaks or vibration.
NSM-06-11-002E 40
40
Removal and Installation of Turbo Charger
The turbo charger is extremely hot just after stopping the engine.
Warning Wait for them to sufficiently cool before beginning work.
Items to prepare
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Turbo Charger

The engine oil line and coolant line wil be removed, so either drain the engine oil and coolant
beforehand or use stoppers on the ends of the lines to prevent leaking.
[1] Remove the muffler.
Muffler".)
(1), and then remove the intake hose (2).
• Use caps to cover the turbo charger and hose to

(3), and then remove the hose (4).
• Use caps to cover the turbo charger and hose to
41 NSM-06-11-002E
41
(5), and then remove the oil feed pipe (6).
• Use caps and plugs to cover the turbo charger
and oil feed pipe to prevent any entry of water,
dust or dirt.
• When removing the oil feed pipe, take care not
to damage or lose the packing.

(7), and then remove the water return pipe (8).
and water return pipe to prevent any entry of

(9), and then remove the water feed pipe (10).
and water feed pipe to prevent any entry of

(11), and then remove the oil return pipe (12).
and oil return pipe to prevent any entry of water,
dust or dirt.
NSM-06-11-002E 42
42
[8] Use a wrench (14 mm) to remove the 4 nuts
(13), and then remove the turbo charger (14).
[9] Use a wrench (13 mm) to remove the 8 nuts

(15), and then remove the line (16) from the
turbo charger.
43 NSM-06-11-002E
43
2. Installation of Turbo Charger
To install, perform the reverse of the removal procedure. During installation, replace each gasket
and the packing with new ones.
Make sure to check the engine oil and coolant levels and resupply as necessary.
Each of the installation tightening torque values are indicated below.
Check carefully for exhaust leaks, water leaks, and oil leaks.
1 Turbo charger assembly 35 N•m

2 Exhaust adapter 35 N•m
3 Oil return pipe 10 N•m
4 Oil feed pipe 22.5 N•m
5 Exhaust manifold 52 N•m
6 Water feed pipe 22.5 N•m
7 Water return pipe 22.5 N•m
NSM-06-11-002E 44
44
Removal and Installation of EGR Cooler and EGR Valve
The EGR cooler and EGR valve are extremely hot just after stopping the engine.
Warning Wait for them to sufficiently cool before beginning work.

Caution ・ Be sure to drain coolant before beginning work.
Items to prepare
• Pliers
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of EGR Cooler and EGR Valve

securing the turbocharger water feed pipe
bracket to the EGR cooler.
[2] Use pliers to loosen the hose bands (2) and (3),
and then remove the hoses (4) and (5).
• Use caps and plugs to cover the line hoses to
[3] Use a wrench (13 mm) to remove the manifold

(6) and EGR cooler (7) installation bolts (8).
45 NSM-06-11-002E
45
[4] Use a wrench (12 mm) to remove the nut (9)
and another wrench (14 mm) to remove the bolt
(10), and remove the EGR cooler.
2. Installation of EGR Cooler and EGR Valve

To install, perform the reverse of the removal procedure. During installation, replace gaskets with
new ones.
Check that there is sufficient coolant and resupply as necessary. Each of the installation tightening
torque values are indicated below.
Check carefully for exhaust leaks and water leaks.
NSM-06-11-002E 46
46
Removal and Installation of Engine Sensors
Sensor name Bolt or nut Tool size Remarks
1 Engine coolant temperature sensor Lock nut x1 Wrench (19 mm)
Bolt x2 Wrench (10 mm)
Clip x1 Pliers
Lock nut x1 Wrench (22 mm)
3 Overheat switch
Wiring fastener nut Wrench (7 mm)
4 Common rail pressure sensor Lock nut x1 Wrench (27 mm)
5 EGR valve DC motor Installation screw x4 Phillips screwdriver
6 Boost temperature sensor Lock nut Wrench (19 mm) Tightening torque: 82.4 N•m
7 Starter motor Installation nut x2 Wrench (17 mm)
8 Engine hydraulic pressure sensor Lock nut x1 Wrench (27 mm)
9 Suction control valve Installation bolt x2 Hexagon wrench (5 mm)
10 Fuel temperature sensor Lock nut x1 Wrench (19 mm)
11 Cam position sensor Installation bolt x1 Wrench (10 mm)
12 Crank position sensor Installation bolt x1 Wrench (10 mm)
47 NSM-06-11-002E
47
Removal and Installation of Fuel Cooler
Caution ・ As the fuel hose will be removed, strictly prohibit open flames.
Items to prepare
• Wrench (12 mm)
• Screwdriver
• Pliers
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Drip pan
1. Removal of Fuel Cooler

[1] Mark the fuel cooler (5) and hoses (1) and (2)
so that the connectors match at the time of
assembly.
• Use pliers to loosen the hose bands (3) and (4),
and then remove the hoses.
• Fuel will spill out, so place a drip pan directly
below the area.
• Attach caps or plugs to the fuel cooler and
hoses to prevent any entry of water, dust or dirt.

(6), and then remove the fuel cooler (5).
2. Installation of Fuel Cooler

• After connecting the hoses, carefully check for any fuel leaks.
NSM-06-11-002E 48
48
Removal and Installation of Engine Inter Cooler
Caution ・ As the fuel hose will be removed, strictly prohibit open flames.
Items to prepare
• Flathead screwdriver
• Wire cutters
• Caps
• Rag
• Cleaning fluid
1. Removal of Inter Cooler

[1] Remove the fuel cooler.
Fuel Cooler".)
[2] Use a wrench (13 mm) to loosen the 3 bolts (1),
and then remove the cover (2).
[3] Use a wrench (8 mm) or flathead screwdriver to

loosen the 2 hose bands (3) and remove the
hose (4).
[4] Use a wrench (8 mm) or flathead screwdriver to

loosen the 2 hose bands (3) and remove the
hose (5).
49 NSM-06-11-002E
49
[5] Use a wrench (12 mm) to loosen the bolt (6)
and remove.
[6] Attach a wire to the top section of the inter

cooler using a shackle, and lift the inter cooler to
remove it.
2. Installation of Inter Cooler

Check for any air leaks.
NSM-06-11-002E 50
50
Assembly and Disassembly SH120

Removal and Installation of Compressor
・ The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splay-
Warning ing out when loosening lines.

Caution ・ When removing and installing the compressor, check the compressor oil quantity.
Items to prepare
• Wrench (12 mm)
• Rag
• Cleaning fluid
1. Removal of Compressor
[1] Remove the counterweight.
Counterweight" (page 1).)
[3] Use a box wrench (12 mm) to loosen the bolts

(2) on the lines in the 2 locations, and then
remove the 2 lines (3) and (4).
• Always remove the low-pressure line (3) first.
• Attach caps or plugs to the compressor and line

(5), and then remove the compressor (6).
1 NSM-07-07-002E
1
2. Installation of Compressor
[1] The installation procedure is the reverse of the removal procedure.
Compressor installation bolt tightening torque: 19.6 - 29.4 N•m
[2] Check the compressor oil quantity.
The compressor contains 135 cc of oil.
The oil quantity being low will cause seizing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if needed.
Measure the oil quantity of the removed compressor. Only this oil quantity is necessary, so sub-
tract this quantity from 135 cc to determine the amount by which the oil quantity of the new com-
pressor should be reduced.
Example)
If the remaining oil quantity of the removed compressor is 30 cc:
Remove 135 cc - 30 cc = 105 cc from the new compressor to be installed.
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
[3] Perform air conditioner gas charging.
For details, see "Procedures for Gas Filling".
NSM-07-07-002E 2
2
Removal and Installation of Condenser
Caution ・ When removing and installing the condenser, resupply and check the compressor oil quantity.
Items to prepare
• Wire cutters
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Condenser
[1] Cut the wire band (1) with wire cutters, use a
wrench (17 mm) to press the condenser side
line (2), and then use a wrench (19 mm) to
loosen and remove the sleeve nut (3) of the low-
pressure line.
• Always remove the low-pressure line first.
• Attach caps or plugs to the condenser and line
[2] Use a wrench (22 mm) to press the condenser

side line (4), and then use a wrench (22 mm) to
loosen and remove the sleeve nut (5) of the
high-pressure line.
• The outer diameter of the high-pressure line
sleeve nut and low-pressure line sleeve nut are
different.The sleeve nut with the larger diameter
is for the high-pressure side.
• Attach caps or plugs to the condenser and line
3 NSM-07-07-002E
3
(6), and then remove the condenser (7).
2. Installation of Condenser
[1] To install, perform the reverse of the removal procedure.
• Condenser installation bolt Tightening torque: 17.7 - 21.6 N•m
• High-pressure line sleeve nut Tightening torque: 20 - 25 N•m
• Low-pressure line sleeve nut Tightening torque: 12 - 15 N•m
[2] Make sure to resupply and check the compressor oil quantity.
Resupply quantity: 40 cc
NSM-07-07-002E 4
4
Removal and Installation of Receiver Dryer
Caution ・ When replacing the receiver dryer, resupply and check the compressor oil quantity.
Items to prepare
• Wrench (10 mm)
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Receiver Dryer


tion bolts (2) and washers (3) for the lines (4).
• Attach caps or plugs to the receiver dryer and
lines to prevent any entry of water, dust or dirt.
• Clean the receiver dryer and lines by spraying
them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the
connectors.
5 NSM-07-07-002E
5
(5), and then remove the receiver dryer (6).
2. Installation of Receiver Dryer

[1] To install, perform the reverse of the removal procedure.
Receiver dryer installation bolt tightening torque: 6.9 N•m
[2] Check the compressor oil quantity.
Resupply quantity: 20 cc
NSM-07-07-002E 6
6
Assembly and Disassembly of Unit
Caution ・ When replacing the evaporator, resupply and check the compressor oil quantity.
1. Removal of Blower Unit

[1] Remove the connectors and har-
nesses (1) to (7) connected and
installed on the refresh/recirculate
motor actuator, blower motor, blower
controller, inside air sensor, and
blower case.
1 Evaporator sensor connector

2 Blower controller connector
3 Blower motor connector
4 Harness
5 Filter clog sensor
6 Refresh/recirculate motor actuator connector
7 Inside air sensor connector
[2] Remove the inside air filter (8) from

the intake duct (12), and remove the
3 T4 x 14 (T1) Phillips screws (16)
to remove the intake duct.
• Be careful as the inside air sensor
(15) is installed.
[3] Remove the filter clog sensor (11)
along with the nylon clip (17) from
the intake case (13).
[4] Remove the 4 T5 x 14 (T1) Phillips
screws (14) and remove the intake
case (13).
[5] Remove the 3 T5 x 14 (T1) Phillips
screws (18) and separate the blower
case (10) and air conditioner unit
(9).
7 NSM-07-07-002E
7
2. Replacement of Blower Motor
[1] Remove the coolant hose (4) connecting the
blower motor (5) and the blower case (6).
[2] Remove the 3 N5 x 16 (W) Phillips screws (3)
installed at the bottom of the blower unit case
and remove the blower motor (5).
removal procedure.
Do not remove the fan from the

Caution blower motor.
3. Replacement of Blower Controller

[1] Remove the 2 T4 x 14 (T1) Phillips screws (2)
installed at the bottom of the blower case and
remove the blower controller (1).
[2] The installation procedure for the new blower
controller (1) is the reverse of the removal pro-
cedure.
Never disassemble the blower con-

Caution troller.
4. Removal of Heater Core

[1] Drain the coolant.
[2] Remove the 1 N5 x 16 (T2) Phillips screw (2),
and remove the pipe clamp (3) fixing the heater
core (4) to the unit (1) to remove the heater core
from the unit.
removal procedure.
NSM-07-07-002E 8
8
5. Removal of Air Conditioner Unit Case Front, Rear and Bottom
[1] Remove the mode motor actuator (4) and evap-
orator sensor connector.
[2] Remove the mode rod (1) from the rod holder
(2) installed on the mode motor actuator (4)
lever MAL 1 (3).
[3] Remove the 3 N4 x 30 (T1) Phillips screws (6)
and remove the mode motor actuator (4)
installed on the bottom (5) and rear (7) of the
unit case.
[4] Remove the 11 N5 x 16 (T2) Phillips screws (8)

and remove the bottom (5) and front (10) of the
unit case.
While being careful not to let the evaporator
sensor (9) cord get caught by the case, pull the
front of the unit case upwards to remove it.
At this time, perform work with the

Caution heater core removed from the unit
case.
9 NSM-07-07-002E
9
6. Replacement of Evaporator and Expansion Valve
[1] Remove the evaporator assembly from the case
with the case heat insulating material and
expansion valve (3) attached to the evaporator.
[2] After removing the case heat insulating material
from the top and bottom of the evaporator
assembly, remove the evaporator sensor (1) as
one piece with the sensor holder.
[3] Use a hexagon wrench (4 mm) to remove the 2
M5 x 40 hexagon socket head bolts (2), and
remove the expansion valve (3) from the evapo-
rator (6).
[4] Install both O-ring (4) (NF O-ring 5/8) and (5)
(NF O-ring 1/2) on the new evaporator (6).
(Tightening torque 6.9 N•m)
Be careful of the O-rings getting

Caution caught, etc. when installing the
expansion valve.
7. Installation of Evaporator Sensor

[1] Make sure to install the evaporator sensor (1) in
the original position of the evaporator (2), as in
the diagram.
Be careful that the sensor cord does

Caution not get squeezed in the case when
the case is assembled.
NSM-07-07-002E 10
10
8. Replacement of Motor Actuator
[1] Replacement of mode motor actuator
Remove the connector connected to the motor
actuator (4).
Remove the mode rod (1) connecting the motor
actuator and mode cam from the rod holder (2).
Remove the 3 N4 x 30 (T1) Phillips screws (6)
that are used to install the motor actuator,
remove the motor actuator from the bottom of
the unit case (5) with the rod holder and lever
MAL 1 (3) attached, remove the rod holder and
lever MAL 1 from the motor actuator, and then
install the new motor actuator. The installation
procedure is the reverse of the removal proce-
dure.
[2] Replacement of air mix motor actuator
actuator (10).
Remove the AM rod (8) connecting the motor
actuator and lever AM (7) from the rod holder
(9).
that are used to install the motor actuator,
remove the motor actuator from the front of the
unit case (13) with the rod holder and lever MAL
1 (11) attached, remove the rod holder and lever
MAL 1 from the motor actuator, and then install
the new motor actuator. The installation proce-
dure is the reverse of the removal procedure.
[3] Replacement of refresh/recirculate motor actua-
tor
actuator (15).
that are used to install the motor actuator and
remove the motor actuator from the intake case
R (17) with the lever MAL 2 (14) attached.
Remove the lever MAL 2 from the motor actua-
tor and attach the new motor actuator. The
installation procedure is the reverse of the
removal procedure.
11 NSM-07-07-002E
11
NOTES:
Procedures for Gas Filling SH120
Procedures for Gas Filling

Work Precautions
・ Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a
experienced and qualified worker with the procedure performs this operation.
・ Always wear protective eyewear.
Warning ・ Gas entering the eyes may cause blindness.
・ Refrigerant in the liquid state is very cold (about -26 ℃ ), so be very careful during handling.
・ Refrigerant coming in contact with skin may cause frostbite.
Always use R134a refrigerant.
• Storage
Keep service cans (hereinafter, cans) with refrigerant in them at 40 ℃ or below.
The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises
there is the danger of internal pressure rising sharply and an explosion occurring.
Never store in direct sunlight, in a closed vehicle, or near open flames.
Be careful not to drop cans or have them collide with other objects.
• Filling operation
When cans are heated in order to fill them with refrigerant, make sure that the service can valve and
gauge manifold low-pressure valve are open and heat with water at 40 ℃ or below.
Direct heating or heating to 40 ℃ or higher may cause explosions, so use caution.
If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure
valve.
This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a
can or charging hose explosion.
Be careful not to allow the entry of dust or dirt into the air conditioner circuit.
Air, moisture and dirt are very bad for the cooling cycle.
Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter.
Be careful not to overfill with gas.
1 NSM-07-08-002E
1
Work Procedures
1. Air Conditioner Refrigerant Filling is Divided into the "Vacuum Operation" and "Gas Filling
Operation".
[1] The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during
operation such as freezing in the small hole of the expansion valve causing the circuit to clog and
rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation con-
sists of eliminating moisture inside the circuit through boiling and evaporation.
[2] The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life
of the parts which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and
this will cause reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor
will be poor and this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the oper-
ation using an incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrig-
erant filling.
2. Operation Chart
NSM-07-08-002E 2
2
3. Tools
No. Part name Q'ty Shape Application
1 Gauge manifold 1
Red: high-pressure side

2 Charging hose 3 Blue: low-pressure side
Yellow: vacuum pump side
3 Quick joint 1
4 Quick joint 1 Low-pressure side
5 T joint 1 For service can valve
6 Service can valve 2 For service can
7 Vacuum pump adapter 1 For vacuum pump
3 NSM-07-08-002E
3
Procedures for Filling
・ Because gauge manifold specifications such as hose color are different depending on the
Caution manufacturer, please read the Operator's Manual for the gauge manifold to be used for
details.
1. Charging Hose Connection Positions
1 High-pressure side (DIS) service valve

2 Low-pressure side (SUC) service valve
3 Air conditioner compressor
4 Condenser
5 Receiver dryer
6 Air conditioner unit
NSM-07-08-002E 4
4
2. Gauge Manifold Connection
[1] Close the high-pressure valve (HI) (8) and low-pressure valve (LO) (7) of the gauge manifold (9).
[2] Connect the charging hoses (red and blue) to the service valve.
Red hose (1):Gauge manifold high-pressure side (HI) → compressor high-pressure side (DIS)
service valve (10)
Blue hose (2):Gauge manifold low-pressure side (LO) → compressor low-pressure side (SUC)
service valve (11)
Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to
make sure they are secure and in the correct position.
[3] Connect the charging hose (yellow) (3) to the vacuum pump (4).
5 Low-pressure gauge
6 High-pressure gauge
5 NSM-07-08-002E
5
3. Vacuuming
[1] Open the high-pressure valve (HI) (3) and low-
pressure valve (LO) (2) of the gauge manifold
(1).
[2] Turn the vacuum pump (4) switch on and vac-
uum for at least 30 min.
[3] After the prescribed vacuuming time has
elapsed (degree of vacuuming achieved: -750
mmHg or less), close the gauge manifold (1)
high-pressure valve (3) and low-pressure valve
(2).
[4] Next, turn the vacuum pump (4) switch off.
[5] Perform a check of air-tightness.
Let the gauge manifold (1) sit for at least 5 min.
with the high-pressure valve (3) and low-pres-
sure valve (2) closed, and check that the gauge
indicator does not go back to 0.
If the gauge indicator starts to swing back to 0,
this indicates there is a leak. Tighten the line
connections, perform vacuuming again, and
check to see if there is still a leak.
4. Gas Filling Operation, High-pressure Side

First, start the filling operation from the high-pressure side.
[1] After repeating vacuuming, switch the charging
hose (yellow) (3) of the gauge manifold (1) from
the vacuum pump to the service can (6).
[2] Air purging
Open the valve for the service can (7). (How-
ever, keep the gauge manifold high-pressure
and low-pressure valves closed.) Next, press
the air purge valve (2) of the side service port
on the gauge manifold low-pressure side with a
screwdriver to discharge the air inside the
charging hose using the refrigerant pressure.
(Complete after the swooshing sound stops.)
[3] Open the high-pressure valve (4) of the gauge
manifold (1), and fill with coolant.
(Fill with refrigerant gas up to a gauge pressure
of 0.098 MPa.)
After filling, close the gauge manifold high-pres-
sure valve and valve for the service can (7).
Never operate the compressor. (This is very
dangerous, as the refrigerant will flow in the
opposite direction and may cause a service can
or hose explosion.)
[4] Gas leak check
Check for gas leaks in the cycle using the gas
leak tester.
If there are leaks, eliminate them through tight-
ening.
Always use the tester for R134a.
NSM-07-08-002E 6
6
5. Gas Filling Operation, Low-pressure Side
・ Never open the gauge manifold high-pressure valve.
Caution ・ Never tip over the service can. This may cause damage to the compressor.
After finishing the high-pressure side filling operation, perform the operation for the low-pressure
side.
[1] Check that the high-pressure valve (4) and low-
pressure valve (5) of the gauge manifold (1) and
the valve for the service can (2) are closed.
[2] Start the engine, increase speed to 1500 ± 100
min-1, and completely open the cab door and
window.
[3] Turn the air conditioner switch on, move the fan
switch to the maximum position, and move the
temperature adjustment switch to the maximum
cooling position.
[4] During filling, set the degree of discharge for the
compressor at 1.37 - 1.57 MPa.
[5] Open the low-pressure valve (5) of the gauge
manifold (1) and valve for the service can (2),
and fill with refrigerant until the air bubbles in
the receiver sight glass (9) are gone. (Total gas
filling amount: 950 ± 50 g)
・ Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air bub-
When the amount is bles are visible. The glass then becomes
correct transparent and turns to a pale, milky-
white color.
When overfilling After the AC is turned ON, no air bubbles

occurred at all are visible.
When filling was After the AC is turned ON, air bubbles

insufficient are seen continuously.
7 NSM-07-08-002E
7
[6] After refrigerant filling is complete, close the low-pressure valve (5) of the gauge manifold (1) and
the valve for the service can (2), and stop the engine.
• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging
effect on the compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insuf-
ficient cooling and there is the danger of pressure in the circuit becoming abnormally high. Be
sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (4).
• Never invert the service can (6).
(Gas is suctioned in liquid form, so this may cause damage to the compressor valve.)
[7] After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (8) from the low-pressure side (SUC)
service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98
MPa or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure
side charge hose (red) (7) from the high-pressure side (DIS) service valve.
NSM-07-08-002E 8
8
Procedure for Electrical Equipment Judgment SH200-5
Procedure for Electrical Equipment Judgment

Procedure for Electricity Measurement
Items to prepare
• Service connectors
• Tester
[1] Use service connector (female) (1) and service

connector (male) (2) for voltage measurement.
[2] Remove the connector (3) in which voltage is

to be measured.
1 Service connector (female)

2 Service connector (male)
3 Connector
1 RSM-09-13-001E
1
[3] Connect the service connector (female) (1) to
the removed connector, and attach the tester
(4) to measure voltage.
[4] Also attach the service connector (male) (2) to

the removed connector on the opposite side
and measure voltage with the tester (4).
1 Service connector (female)

2 Service connector (male)
4 Tester
RSM-09-13-001E 2
2
Maintenance Standards SH200
Maintenance Standards
Check Sheet
1. Drive Sprocket
* See the gauge list for measurement gauges.
Measured Standard Usage

Part name Code dimensions value limit Judgment Solution
(mm) (mm) (mm)
a 59 53 Acceptable/Unacceptable
b φ φ584.48 φ578.5 Acceptable/Unacceptable
Cladding by
Drive sprocket c φ φ652 φ646 Acceptable/Unacceptable welding or
replacement
d φ φ635.48 - Acceptable/Unacceptable
p 171.45 - Acceptable/Unacceptable
1 NSM-09-14-002E
1
2. Take-up Roller

(mm) (mm) (mm)
b 17.5 - Acceptable/Unacceptable
Cladding by
Take-up roller a φ φ510 φ506 Acceptable/Unacceptable welding or
replacement
c 68 64 Acceptable/Unacceptable
Shaft d φ φ55 φ54.5 Acceptable/Unacceptable Replacement
d φ φ55 φ55.8 Acceptable/Unacceptable
Bushing Replacement
e 55 54.6 Acceptable/Unacceptable
Hub f 19.9 20.4 Acceptable/Unacceptable Replacement
NSM-09-14-002E 2
2
3. Upper Roller

(mm) (mm) (mm)
a φ φ120 φ112 Acceptable/Unacceptable
Cladding by
Carrier roller b 10 - Acceptable/Unacceptable welding or
replacement
c 68 62 Acceptable/Unacceptable
Shaft d φ φ40 φ39.5 Acceptable/Unacceptable Replacement
d φ φ40 φ40.8 Acceptable/Unacceptable
Bushing Replacement
e 63 62.6 Acceptable/Unacceptable
Thrust plate f 5.5 5 Acceptable/Unacceptable Replacement
Cover g 22.5 22 Acceptable/Unacceptable Replacement
3 NSM-09-14-002E
3
4. Lower Roller

(mm) (mm) (mm)
a φ φ130 φ122 Acceptable/Unacceptable
Cladding by
Track roller b 15 - Acceptable/Unacceptable welding or
replacement
d 142 148 Acceptable/Unacceptable
Shaft e φ φ50 φ49.5 Acceptable/Unacceptable Replacement
e φ φ50 φ50.8 Acceptable/Unacceptable
Bushing Replacement
f 53 52.6 Acceptable/Unacceptable
Collar g 24.3 23.8 Acceptable/Unacceptable Replacement
NSM-09-14-002E 4
4
5. Track Shoe (grouser shoe)

(mm) (mm) (mm)
Shoe plate a 28 18 Acceptable/Unacceptable Replacement
b 89 84 Acceptable/Unacceptable
Cladding by
Link c 17 15 Acceptable/Unacceptable welding or
replacement
d 10.7 9 Acceptable/Unacceptable
e φ φ50.6 φ49.5 Acceptable/Unacceptable
Master bushing Replacement
f φ φ34.1 φ35.5 Acceptable/Unacceptable
Master pin g φ φ33.25 φ32.5 Acceptable/Unacceptable Replacement
Link pitch h 171.45 175 Acceptable/Unacceptable Replacement
e' φ φ50.6 φ49.5 Acceptable/Unacceptable
Track bushing Replacement
f' φ φ34.1 φ35.5 Acceptable/Unacceptable
Track pin g' φ φ33.5 φ32.5 Acceptable/Unacceptable Replacement
5 NSM-09-14-002E
5
6. Attachment (backhoe)
[1] Boom and swing frame installation section

(mm) (mm) (mm)
Swing frame a 569.5 577.5 Acceptable/Unacceptable -
Boom b 566 564 Acceptable/Unacceptable Replacement
Adjust with
Clearance c 0.5 - 3.0 Acceptable/Unacceptable Adjust with shims
shims
Pin d φ φ75 φ74 Acceptable/Unacceptable Replacement
Bushing (boom) e φ φ75 φ76.5 Acceptable/Unacceptable Replacement
NSM-09-14-002E 6
6
[2] Boom cylinder and swing frame installation section

(mm) (mm) (mm)
Swing frame a 83.5 89.5 Acceptable/Unacceptable -
Boom cylinder
b 82.5 80.5 Acceptable/Unacceptable Replacement
(foot section)
Adjust with
shims
Bushing (boom
e φ φ70 φ71.5 Acceptable/Unacceptable Replacement
cylinder)
7 NSM-09-14-002E
7
[3] Boom and boom cylinder installation section

(mm) (mm) (mm)
Boom cylinder
a 92 90 Acceptable/Unacceptable -
(top section)
Boom b 437 433 Acceptable/Unacceptable Replacement
Adjust with
shims
Bushing (boom
cylinder)
NSM-09-14-002E 8
8
[4] Boom and arm cylinder installation section

(mm) (mm) (mm)
Boom a 99 105 Acceptable/Unacceptable -
Boom cylinder
b 98 96 Acceptable/Unacceptable Replacement
(foot section)
Adjust with
shims
Bushing
(arm cylinder)
9 NSM-09-14-002E
9
[5] Boom and arm installation section

(mm) (mm) (mm)
Boom a 259 262 Acceptable/Unacceptable -
Arm b 256.5 254.5 Acceptable/Unacceptable Replacement
Adjust with
shims
Bushing (arm) e φ φ75 φ76.5 Acceptable/Unacceptable Replacement
Boom f φ φ75 φ76.5 Acceptable/Unacceptable Replacement
Boom g 60 58 Acceptable/Unacceptable Replacement
NSM-09-14-002E 10
10
[6] Arm and arm cylinder installation section

(mm) (mm) (mm)
Arm a 96.5 102.5 Acceptable/Unacceptable -
Arm cylinder (top
b 95.5 93.5 Acceptable/Unacceptable Replacement
section)
Adjust with
shims
Bushing
(arm cylinder)
11 NSM-09-14-002E
11
[7] Arm and bucket cylinder installation section

(mm) (mm) (mm)
Arm a 88 94 Acceptable/Unacceptable -
Bucket cylinder
b 87 85 Acceptable/Unacceptable Replacement
(foot section)
Adjust with
shims
Bushing
(bucket cylinder)
NSM-09-14-002E 12
12
[8] Arm and arm link installation section

(mm) (mm) (mm)
Arm link a 32 30 Acceptable/Unacceptable -
Arm b 254 252 Acceptable/Unacceptable Replacement
Adjust with
shims
Bushing (arm) e φ φ65 φ66.5 Acceptable/Unacceptable Replacement
13 NSM-09-14-002E
13
[9] Bucket and bucket link installation section

(mm) (mm) (mm)
Bucket a 255 251 Acceptable/Unacceptable -
Bucket link b 254 252 Acceptable/Unacceptable Replacement
Adjust with
shims
Bushing
(bucket link)
NSM-09-14-002E 14
14
[10] Bucket link and bucket cylinder installation section

(mm) (mm) (mm)
Arm link a 32 30 Acceptable/Unacceptable -
Bucket link b 254 252 Acceptable/Unacceptable Replacement
Adjust with
shims
Bucket link d φ 92 94 Acceptable/Unacceptable Replacement
Bucket cylinder
(top section)
e φ 91 89 Acceptable/Unacceptable Replacement
Adjust with
Clearance f -0.5 - 2.0 Acceptable/Unacceptable Adjust with shims
shims
Pin g φ70 φ69 Acceptable/Unacceptable Replacement
Bushing
h φ70 φ71.5 Acceptable/Unacceptable Replacement
(bucket link)
Bushing
i φ70 φ71.5 Acceptable/Unacceptable Replacement
(bucket cylinder)
15 NSM-09-14-002E
15
[11] Bucket and arm installation section

(mm) (mm) (mm)
Bucket a 255 261 Acceptable/Unacceptable -
Arm b 254 252 Acceptable/Unacceptable Replacement
Adjust with
shims
Bushing (bucket) d 16 8 Acceptable/Unacceptable Replacement
Pin e φ65 φ64 Acceptable/Unacceptable Replacement
Bushing (arm) f φ65 φ66.5 Acceptable/Unacceptable Replacement
Bushing (bucket) g φ65 φ66.5 Acceptable/Unacceptable Replacement
NSM-09-14-002E 16
16
7. Blade
[1] Blade and blade cylinder mounting section

(mm) (mm) (mm)
Blade a 71 77 Acceptable / Unacceptable Replacement
Blade cylinder b 70 68 Acceptable / Unacceptable Replacement
c Adjust with
Clearance 0.5 - 3.0 Acceptable / Unacceptable Adjust with shims
(a - b) shims
Pin d φ φ50 49 Acceptable / Unacceptable Replacement
Bushing
e φ φ50 51.5 Acceptable / Unacceptable Replacement
(blade cylinder)
17 NSM-09-14-002E
17
[2] Lower frame and blade cylinder mounting section

(mm) (mm) (mm)
Lower frame a 74 80 Acceptable / Unacceptable Replacement
Blade cylinder b 70 68 Acceptable / Unacceptable Replacement
c Adjust with
(a - b) shims
Pin d φ φ50 φ49 Acceptable / Unacceptable Replacement
Bushing
e φ φ50 φ51.5 Acceptable / Unacceptable Replacement
(blade cylinder)
NSM-09-14-002E 18
18
[3] Lower frame and blade mounting section

(mm) (mm) (mm)
Lower frame a 74 80 Acceptable / Unacceptable Replacement
Blade b 70 68 Acceptable / Unacceptable Replacement
c Adjust with
(a - b) shims
Pin d φ φ60 φ59 Acceptable / Unacceptable Replacement
Bushing (blade) e φ φ60 φ61.5 Acceptable / Unacceptable Replacement
19 NSM-09-14-002E
19
Inspection Gauge
1. For Drive Sprocket
2. For Take-up Roller
NSM-09-14-002E 20
20
3. For Upper Roller
4. For Lower Roller
21 NSM-09-14-002E
21
NOTES:
Track Shoe SH200-5
Track Shoe
Track Shoe
Removal and Installation of Shoe Assembly
・ When loosening the grease cylinder check valve, loosen it a little bit at a time.
・ The pressure inside the cylinder is very high, so there is the danger of grease being expelled
and the plug flying off. The check valve adjustment procedure should not be done in front of
Warning
the check valve.
・ Do not get under the main unit when it is jacked up.
Make sure to place the main unit on crossties to prevent falling.
Caution ・ Make sure to stop the engine for loosening shoes and when removing master pins.
Items to prepare
• Hammer
• Striking rod
• Crowbar
• Rag
• Lifting equipment (with the required breaking load)
• Crane (with the required lifting capacity)
1. Removal of Shoe Assembly
[1] Rotate the shoe and align it so that the master
pin (1) is next to the idler.
[2] Use a box wrench (19 mm) to loosen the check

valve (2) to slowly release grease, and then
loosen the shoe tension.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease
output and shoe loosening.
Use a rag to catch grease that trickles out of
the check valve.
If the check valve is loosened too much at this
time, it may fly off. Be careful not to work in
front of the check valve.
1 Master pin
2 Check valve
1 RSM-13-01-001E
1
Track Shoe
[3] Use a wrench (17 mm) to remove the check
valve stopper (4).
• If the check valve is removed, it is easier to
loosen the track shoe tension.
[4] Straighten out the S-pin (5) attached to the

master pin by striking one side of it with a ham-
mer, and use a crowbar, etc. to remove it.
[5] Use a hammer (6) and striking rod (7) to push

the master pin (1) out.
1 Master pin
3 Bolt
4 Stopper
5 S-pin
6 Hammer
7 Striking rod
RSM-13-01-001E 2
2
Track Shoe
[6] Remove the track shoe (8).
At this time, place a wood plank (9) under the
bottom track shoe so that it does not fall.
[7] Start the engine, raise the lower side frame of

the track shoe removal side about 20 cm,
slowly set the travel lever to backwards, and
move the track shoe to remove it from the
lower frame.
8 Track shoe
9 Wood plank
3 RSM-13-01-001E
3
Track Shoe
2. Installation of Shoe Assembly
[1] Raise the lower side frame about 20 cm.
Lift the track shoe (1) and align it with the
sprocket (2).
Pay attention to the backwards and forward
direction of the track shoe.
[2] Slowly set the travel lever to forward and feed

the track shoe to the take-up roller side as
shown in the diagram.
In the middle of this procedure when the track
shoe passes the upper roller, use a crowbar,
etc. to lift the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.
[3] Wrap the edge of the track shoe (4) onto the
take-up roller (3).
Place a wood plank (5) on the ground and lift
the bottom-side link to align the position where
the master pin is inserted.
1 Track shoe
2 Sprocket
3 Take-up roller
4 Track shoe
5 Wood plank
RSM-13-01-001E 4
4
Track Shoe
[4] Insert the master pin (7).
Insert the S-pin (6) and bend it so that it cannot
slip out.
[5] Tighten the check valve (8).

While monitoring the track shoe tension, inject
grease into the grease cylinder.
[6] To adjust the track shoe tension, raise the

lower side frame as shown in the diagram.
Adjust the tension so that the distance indi-
cated with A between the frame bottom (9) of
the center area of lower side frame and the
lowest hanging part of the top of the shoe plate
(10) is 280 - 300 mm.
5 Wood plank
6 S-pin
7 Master pin
8 Check valve
9 Frame lower section
10 Topside of shoe plate
5 RSM-13-01-001E
5
Track Shoe
Removal and Installation of Shoe Plate
Items to prepare
• Grease
• Rag
• Cleaning fluid

shoe bolts (1), and then remove the shoe plate
(2).
1 Shoe bolt
2 Shoe plate
RSM-13-01-001E 6
6
Travel Unit SH120
Travel Unit
Travel Unit
Removal and Installation of Travel Motor
・ When loosening the check valve, loosen it a little at a time and stop when any grease
Warning appears. (The pressure inside the cylinder is very high, so there is the danger of grease
being expelled and the plug flying off if the check valve is loosened too much.)
・ Before removing the shoes, be sure to bleed off any air in the hydraulic circuits.
Items to prepare
• Box wrenches (19 mm, 24 mm)
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Loctite #262
• Rag
• Cleaning fluid
1. Removal of Travel Motor

[1] Allow the bucket (1) to touch the ground so as to
elevate the side with the shoe (2) to be removed
as in the diagram.
[2] Slowly rotate the shoe so that the shoe joint

section (3) is aligned as in the diagram.
[3] Place wood planks (4) under the shoe and
return the bucket to its original position.
[4] Perform air bleeding for the hydraulic line.
For details, see Air Bleed Procedure.
1 NSM-13-02-002E
1
Travel Unit
[5] Use a box wrench (19 mm) to rotate the grease
cylinder check valve (5) and loosen the shoe
tension.
• Grease will flow out, so have rags ready. If the
check valve is loosened too much at this time, it
may fly off. Be careful not to work in front of the
check valve.
[6] Pull out the S-pin (6) from the rear of the joint
section.
[7] Place a striking jig (9) against the master pin (7)
and hit it with a hammer (8) to push the master
pin out.
[8] Open the shoe (2) to the rear.
NSM-13-02-002E 2
2
Travel Unit
(10), and then remove the cover (11).
[10] Use wrenches (27 mm for drain hose, 36 mm for

high-pressure hose) to remove the drain hose
(13) and 3 high-pressure hoses (12).
• Be sure to use plugs on the removed drain and
high-pressure hoses.
[11] Use a wrench (17 mm) to remove the pilot hose

(15) and elbow joint (14) as in the diagram.
3 NSM-13-02-002E
3
Travel Unit
[12] Attach the wire rope (17) to the travel motor (16)
as in the diagram.
Adjust the wire rope so that it is located at the
center of mass and lift it with the crane so that it
is slightly tensed.
[13] Use a box wrench (24 mm) to remove all 20

bolts (18).
[14] Remove the travel motor (16).
NSM-13-02-002E 4
4
Travel Unit
2. Installation of Travel Motor
[1] Attach the travel motor (1) to the lower frame as
in the diagram.
Be careful of the installation angles.
[2] Apply Loctite #262 to the installation bolt (2)

threaded sections and temporarily tighten them.
Tighten top and bottom alternately to the speci-
fied torque so that an even tightening force acts
on opposing corners as shown in the diagram
below.
[3] Use a wrench (17 mm) to remove the elbow

joint (3) and pilot hose (4) shown in the diagram.
5 NSM-13-02-002E
5
Travel Unit
[4] Use wrenches (27 mm for drain hose, 36 mm for
high-pressure hose) to install the drain hose (6)
and high-pressure hoses (5).

(7), and then install the cover (8).
[6] Wrap the shoe (9).
NSM-13-02-002E 6
6
Travel Unit
[7] Insert the master pin (11).
Insert the S-pin (10) and bend it so that it can-
not slip out.

[9] To adjust the track shoe tension, raise the lower

side frame as shown in the diagram.
Place a wood plank (13) under the lower frame
to prevent falling.
Adjust the tension so that the distance indicated
with A between the frame bottom (14) of the
center area of the lower side frame and the low-
est hanging part of the top of the shoe plate (15)
is 240 - 260 mm.
7 NSM-13-02-002E
7
Travel Unit
Assembly and Disassembly of Travel Motor
1. Maintenance Procedures
(1) Tools
1) Standard tools
No. Name Type and dimensions Q'ty
2.5 (for M5), 3 (for M6), 4 (for NPTF1/16), 5 (for PF1/8),
1 Hexagon wrench 1 each
6 (for PF1/4), 8 (for M10, PF3/8), 10 (for M12, PF1/2)
Socket wrench
2 Oval-shaped 1
(rachet handle) (JIS B 4641)
Dial type: 50 N range, Dial type: 100 N range, Dial type:
3 Torque wrench (JIS B 4650) 1 each
300 N range, Dial type: 560 N range
4 Adapter for torque wrench 1 each
5 Hexagon socket Diameter dimensions: 24 mm, 41 mm 1 each
6 Extension bar (JIS B 4637) 150 mm 1
7 Hammer Various types 1 each
8 Plastic hammer L = 400 mm range 1
9 Screwdriver (JIS B 4609) 50 mm range, 150 mm range 1 each
For shafts
10 Pliers for snap rings 1 each
For holes
11 Pliers (JIS B 4623) 200 mm 1
Lifting load of 2940 N or higher 1 set
Eyebolt (for M16) (2)
12 Lifting equipment Eyebolt (for M12) (3)
Eyebolt (for PF1/2) (2)
Wire with hook (1)
13 Container General-use pan W450 x D300 x H120 mm 2
14 Leather gloves 1 pair
2) Bolts
No. Name Type and dimensions Q'ty
1 Long hexagon socket head bolt M12 x P1.5 x 40 mm range 2
3) Equipment and materials
Applicable part
Name Type and standards Q'ty
(usage or part no.)
Product assembly
General work platform 1 set
and disassembly
Cleaning the prod-
Cleaning tank Rough cleaning and finish cleaning 1 set
uct and each part
24: Press capability of 9800 N or higher
24, 104, 149 Press work platform 104: Press capability of 1960 N or higher 1 se
149: Press capability of 1960 N or higher
Temperature raising capability of 100 ºC or higher
149 Heating tank 1 set
Volume 500 x 500 x 500 or higher
Drying of each part
after disassembly Compressed air Pressure 0.29 - 0.49 MPa
and cleaning
NSM-13-02-002E 8
8
Travel Unit
4) Special tools
Name: work platform for travel motor
• Work platform for easy and safe performance
of travel motor disassembly and reassembly.
Name: holder fitting (I)

• Part for inserting the spring (114), washer
(110) and snap ring (145) into the cylinder
block (104).
• Part for removing the spring (114) from the
cylinder block (104).
Name: holder fitting (II)

• Part for removing the ball bearing (149) from
the shaft (102).
Name: oil seal press-fit jig

• Part for press fitting the oil seal (132) in the
oil seal installation hole of the spindle (2).
9 NSM-13-02-002E
9
Travel Unit
Name: lock washer insertion jig
• Jig for inserting the lock washers (22) into
the spindle (2) groove.
Name: primary bearing press-fit jig

• Part for press fitting the angular ball bearings
(24) in the hub (1).
Name: steel rod (I)

• Part for removing the angular ball bearings
(24) from the hub.
Name: long eyebolt

• Part for lifting the travel motor, spindle (2),
and hub (1).
Application "A"
Hub (1) M16
Hub (1) M10
Spindle (2) M16
Travel motor M16
NSM-13-02-002E 10
10
Travel Unit
Name: scoop
• Used when removing the timing plate (109)
from the rear flange (301).
Name: floating seal installation jig (I)

• Part for installing the floating seals (29) in the
hub (1).
Name: floating seal installation jig (II)

hub (1) and spindle (2).
Name: floating seal installation jig (III)

spindle (2).
11 NSM-13-02-002E
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Travel Unit
(2) Tightening Torque
Hexagon bolt
Applicable part Bolt and nut used Tightening
width Q'ty
(structure diagram) torque ( N•m)
Name Nominal size (mm)
30, 357 Plug PF1/2 10 4 98.1 ± 19.6
35 Hexagon socket head bolt M10 (P1.5) 8 12 66.7 ± 3.92
Sleeve
203 PF1/2 24 (socket) 2 98.1 ± 19.6
(relief valve attachment)
205 Plug PF1/4 6 2 29.4 ± 4.90
324 Plug M36 (P1.5) 41 (socket) 2 441 ± 39.2
343 Hexagon socket head bolt M12 (P1.75) 10 10 102 ± 15.7
352 Plug PF1/8 5 3 12.3 ± 2.45
354 Hexagon socket head plug NPTF 1/16 4 5 9.81 ± 1.96
380 Plug PF3/8 8 2 58.8 ± 9.81
396 Hexagon socket head plug PT1/4 6 2 29.4 ± 4.90
398 Hexagon socket head plug PT1/8 5 6 12.3 ± 2.45
(3) Weight table

Applicable part
Name Weight (kg)
(structure diagram)
Travel motor assembly About 145
1 Hub About 46
2 Spindle About 27
3, etc. Carrier 1 assembly part About 12
7, etc. Carrier 2 assembly part About 24
Rear flange assembly
301, etc. About 13
part
NSM-13-02-002E 12
12
Travel Unit
2. Disassembly
(1) Preparations
Perform the preparations below before disassembly.
[1] Work platform preparation
• Prepare the work platform for the travel motor.
• So that assembly and disassembly of the built-in parts of the travel motor can be performed,
prepare a stable work platform with sufficient space to place parts so that parts will not fall or
move during work.
• Place a covering of rubber or plastic on the work platform.
[2] Tool and materials preparation
• Prepare the tools and materials indicated in "1.(1)".
(2) General work precautions
The built-in parts that are disassembled have gear oil and hydraulic oil adhered to them
and are slippery.
Caution Use sufficient caution when handling as parts can fall and cause injury or the parts them-
selves may be damaged.
Flammable materials such as white kerosene are used for cleaning parts.
Caution Use sufficient caution in handling, as flammable materials can ignite easily and cause a
fire or burns.
[1] Before disassembly, thoroughly judge inspection items and the nature of abnormalities that
have occurred, and then perform disassembly according to the procedures.
[2] Each part has been manufactured with a high degree of precision, so be careful to not let
parts bump each other or fall when handling them.
[3] If parts are struck or pried off with excessive force during work because they are tight, this
may cause burrs, damage, which may then cause faulty attachment or reductions in perfor-
mance. Perform work carefully and thoroughly.
[4] Rust may form on parts due to moisture or debris if they are left disassembled or if work is
abandoned in the middle of disassembly. If work must be halted, be careful about preventing
rust from forming and dust settling on parts.
[5] During disassembly, place reference marks on the matching surfaces of each part.
[6] To prevent damage to or loss of parts during disassembly, keep removed parts in order while
performing work.
[7] As a rule, seals are replaced once they have been disassembled even if there is no damage
seen on them.
Prepare replacement seals before disassembly.
[8] A representative model is shown in the photos and diagrams listed. Partial differences with
the parts the customer is using have no effect on disassembly procedures.
13 NSM-13-02-002E
13
Travel Unit
(3) Disassembly procedure
[1] Cleaning of travel motor
1) Attach eyebolts into the M16 threaded holes of the spindle (2), and lift the travel motor with
a crane and move it to the cleaning tank.
Note:
So that the 2 eyebolts are in opposing positions, tighten them into the spindle installa-
tion M16 threaded holes.
2) Clean each travel motor part with a vehicle washing brush.
Note:
Dirt enters the gap (floating seal installation section) between the hub (1) and spindle
(2), so clean this area especially thoroughly.
[2] Installation of travel motor
1) Install the travel motor on the work platform.
Note:
While aligning the travel motor with the threaded holes on the spindle (2) and on the
work platform, gently insert the travel motor into the installation holes on the work plat-
form.
2) Install the travel motor on the work platform so that the 2 hexagon socket head bolts are in
opposing positions.
Thoroughly tighten the hexagon socket head bolts. If they are not thoroughly tightened,
Caution the travel motor can fall and cause injury when it is inverted.
[3] Lubricating oil draining
1) Turn the travel motor sideways. (Make the drain port face down.)
2) Loosen the feed port plugs (30), bleed out pressure inside the reduction gear, and lightly
close the plugs again.
Note:
Lubricating oil may spray out if the inside of the reduction gear is pressurized when the
drain port plug is loosened.
3) Place a container in front of the drain port, slowly loosen the drain port plug to remove it,
and drain the lubricating oil.
Note:
Select a container that can hold 2.1 L - the amount of lubricating oil within the reduction
gear.
4) If the lubricating oil drains poorly, slowly loosen and remove the feed port plug.
5) Remove the O-rings (31) from the removed plugs.
Note:
Do not reuse the removed O-rings (31). This can cause oil leaks.
NSM-13-02-002E 14
14
Travel Unit
[4] Removal of cover
1) Invert the travel motor. (reduction gear
side faces up)
2) Loosen and remove the hexagon socket
head bolts (35).
3) The matching surfaces of the cover (14)
and hub (1) are coated with sealant, so
place a metal pin against the projected
part of the cover and strike it sideways
and upwards to remove the cover.
The cover may fly upwards and fall

when it is struck sideways and
Caution upwards. Be careful that the cover
does not fall on feet or other parts of
the body.
4) Install eyebolts into the PF1/2 ports and
lift the cover (14) from the hub and move
it.
[5] Removal of thrust plate

1) Remove the thrust plate (13).
[6] Removal of 1st stage gears

1) Hold the sun gear 1 (4) and remove it.
Note:
The sun gear 1 may be slippery due to
lubricating oil, so be careful not to drop
it.
15 NSM-13-02-002E
15
Travel Unit
2) Install bolts onto the 3 carrier 1 (3) lifting
M12 taps, and lift and move the carrier 1
assembly with a crane.
Note:
When lifting the carrier 1 assembly,
slowly lift with the center axis of the
hub (1) and carrier 1 assembly straight
so that the internal teeth of the hub are
not scratched by the end surface of
the planetary gears 1 (5).
[7] Removal of coupling

1) Remove the coupling (15) from the shaft
(102).
[8] Removal of 2nd stage gears

1) Install eyebolts into the 3 lifting M12 tap
locations of carrier 2 (7), and lift and
move the carrier 2 assembly with a crane.
Note:
When lifting the carrier 2 assembly,
slowly lift with the center axis of the
hub (1) and carrier 2 assembly straight
so that the internal teeth of the hub are
not scratched by the end surface of
the planetary gears 2 (9).
2) Hold the sun gear 2 (8) and remove it.
Note:
The sun gear 2 may be slippery due to
lubricating oil, so be careful not to drop
it.
[9] Removal of lock washer
1) Use the φ14 hole on the hub (1) and
secure the inversion platform.
NSM-13-02-002E 16
16
Travel Unit
2) Place an object like a flathead screw-
driver in the gap between 2 lock washers
(22) and tap on it sideways and down-
wards with a hammer to remove the lock
washers.
[10] Removal of hub

1) Remove the hexagon socket head bolt
securing the hub and inversion platform.
2) Install eyebolts (M10) into the hub and lift
the hub with a crane.
Hold the hub parallel with the spindle

axis and slowly lift it little by little. Lift-
ing sideways requires a gre
k and can result in injuries due to
Warning workers being struck by lifting equip-
ment. When lifting does not proceed
easily, rather than lifting with greater
force, use a press and confirm safety
while lifting.
[11] Removal of floating seal
1) Place hands on the inner diameter side of
the floating seals (29) and force it
upwards to remove it.
Note:
The edge of the floating seal can
cause cuts on hands. Wearing gloves
for removal is recommended. Also, if
dirt, etc. has gotten inside and
adhered to the surface, use an object
like a flathead screwdriver and use
leverage to remove the dirt.
17 NSM-13-02-002E
17
Travel Unit
[12] Removal of angular ball bearing
1) Place a pin punch against the outer race
end surface of the angular ball bearing
(24) and strike the circumference equally
in intervals at 3 or 4 locations to remove it
little by little.
Note:
The track surface of the angular ball
bearing will become scratched if the
inner race is struck and this will make
the ball bearing unusable, so do not
perform removal other than when the
angular ball bearing is to be replaced.
The ball bearing will fall from the hub if
the outer race bonding section of the
angular ball bearing is detached from
the hub (1), so place a container under
the work platform and place a rubber
mat on it so that parts are not
scratched.
[13] Removal of rear flange
1) Invert the travel motor. (motor faces up)
Note:
The next operation is to make the
plugs easy to remove when the inside
of the rear flange is disassembled. At
this time, loosen the plugs to a degree
so that they can be removed by hand.
When the inside of the rear flange is
not disassembled, do not loosen the
plugs.
2) Loosen the 2 plugs (324).
Note:
This operation is to make the plugs
easy to remove when the inside of the
rear flange is disassembled. When the
inside of the rear flange is not disas-
sembled, do not loosen the plugs.
5) Loosen the plug (357).
NSM-13-02-002E 18
18
Travel Unit
6) Loosen the 2 relief valve assemblies (201
- 213).
7) Remove the 2 relief valve assemblies

(201 - 213).
Note:
Do not reuse the removed O-rings
(207), (209), (212) or backup rings
(208), (210).
8) Loosen the 10 hexagon socket head bolts

(343) and remove them from the rear
flange (301).
9) Remove the rear flange (301) from the
spindle (2).
Note:
Hold the rear flange with both hands
and gently lift it directly upwards to
remove it. If the rear flange is pried off
with excessive force or struck in order
to remove it, the timing plate (109) can
fall and this can cause damage.
10)Remove the 2 parallel pins (34) from the
spindle (2).
19 NSM-13-02-002E
19
Travel Unit
11)Remove the O-ring (32) and the 2 O-rings
(33) from the spindle (2).
Note:
Do not reuse the removed O-rings (32)
and (33).
[14] Disassembly of parts mounted on rear

flange
1) Place the rear flange (301) on the work
platform so that the surface matching with
the spindle (2) faces up.
timing plate (109).
Note:
Stiffness may occur during removal
due to adherence of oil on the surface
that matches with the rear flange
(301). By insert a scoop into the cast-
ing grooves of the rear flange (301)
side matching surface, the timing plate
(109) can be removed by lightly lifting
it. Do not use sharp tools such as a
screwdriver for insertion into the
matching surface, as these can cause
scratches that can result in oil leaks.
3) Remove the ball bearing (150) from the
rear flange (301).
NSM-13-02-002E 20
20
Travel Unit
4) Remove the parallel pins (341) from the
rear flange (301).
[15] Disassembly of brake valve parts within the

rear flange
1) Remove the 2 plugs (324) from the rear
flange (301).
2) Remove the 2 washers (325) and 2
springs (328) from the rear flange (301).
3) Remove the spool (323) from the rear

flange (301).
Note:
Hold the end of the spool (323) and
pull it out because it will slip out and
fall if the plug port on one side of the
rear flange (301) is titled downwards.
4) Remove the O-rings (336) from the plugs

(324).
Note:
(336).
21 NSM-13-02-002E
21
Travel Unit
[16] Disassembly of 2nd-speed switchover spool
1) Remove the plug (357) from the rear
flange (301).
2) Remove the plug (357) from the O-ring
(359).
Note:
Do not reuse the removed O-ring
(359).
3) Remove the spool (363) and spring (366)

from the rear flange (301).
[17] Disassembly of piston

flange (301).
(380).
Note:
(383).

piston (381).
NSM-13-02-002E 22
22
Travel Unit
[18] Disassembly of check ball section
flange (301).
(352).
Note:
(358).
3) Remove the steel balls (353) from the

rear flange (301).
Note:
If the steel ball is difficult to remove,
use a magnet to remove it.
[19] Disassembly of parking brake section
If compressed air is suddenly

injected, the piston (112) can fly from
Caution the spindle (2) and cause injury, so
place a protective cover over the pis-
ton (112).
1) Inject compressed air into the path hole
for the spindle (2) parking brake, and
remove the piston (112) from the spindle
(2).
2) Remove the O-rings (135) and (139) from

the piston (112).
Note:
(135) and (139).
23 NSM-13-02-002E
23
Travel Unit
[20] Disassembly of hydraulic motor parts
Note:
Oil will spill out when the travel motor is
turned sideways, so place a container
under the travel motor.
1) Tilt the travel motor 90°.
2) Drain the oil inside the travel motor.
3) Remove the 4 partner plates (116) and 3
friction plates (115).
4) Hold the cylinder block (104) with one

hand and rotate it alternately 2 - 3 times
to detach the shoes (106) attached to the
swash plate (103).
Note:
If the cylinder block is removed as is,
the parts attached to the cylinder block
(pistons (105), shoes) will become
detached from the cylinder block and
fall inside the spindle (2) because the
shoe is attached to the swash plate.
5) Remove the cylinder block (104) from the

shaft (102).
6) Remove the piston assemblies (pistons
(105), shoes (106)) from the cylinder
block (104).
Note:
When removing the piston assembly,
hold the retainer plate (107) with both
hands and remove the pistons (105)
and shoes (106) together.
The pistons (105) and shoes (106) are
pressed and held together at the
spherical hole sections of the pistons.
Pistons (105) and shoes (106) cannot
be separated without damaging the
shoes (106). When replacement is
necessary, replace them as 1 set.
(referred to as piston assembly below)
NSM-13-02-002E 24
24
Travel Unit
7) Remove the piston assemblies (105) and
(106) from the retainer plate (107).
(9 sets)
8) Remove the thrust ball (108) from the cyl-

inder block (104).
9) Remove the 3 rollers (151) from the cylin-

der block (104).
[21] Removal of spring inside cylinder block

1) Place the cylinder block (104) on the
press work platform.
Note:
Only remove the spring (114) when
replacing it. Align the axis centers of
the holder fitting (I) and washer (110)
during spring removal to prevent dam-
age to the cylinder block (104) due to
contact.
Place a vinyl sheet over the cylinder
block so that the surface of the cylin-
der block does not get scratched.
25 NSM-13-02-002E
25
Travel Unit
2) Place the holder fitting (I) (B) on the
washer (110) and remove the snap ring
(145) from the snap ring groove of the
cylinder block (104) using the snap ring
pliers while pressing down on the holder
fitting (I) with the press (A).
If the press is suddenly loosened, the

Caution spring (114) can fly out and cause
injury. Loosen the press slowly.
3) Remove the snap ring (145), washer

(110), spring (114) and washer (110)
inside the cylinder block (104).
[22] Removal of swash plate

1) Remove the swash plate (103) from the
shaft (102).
Note:
Be careful when removing the swash
plate, as pivots (167) are sometimes
attached to it.
2) Remove the shaft (102) from the spindle

(2). At this time, the ball bearing (149)
attached to the shaft is also removed.
Note:
The shaft (102) can easily be removed
if the shaft end on the reduction gear
side is first struck lightly with a plastic
hammer. Be careful as the shaft can
fly out if it is struck forcefully.
3) Remove the 2 pivots (167) and 2 parallel
pins (171) from the spindle (2).
NSM-13-02-002E 26
26
Travel Unit
4) Remove the 2nd-speed switchover piston
assembly and spring (185) from the spin-
dle (2).
Piston (161)
Piston assembly
Shoe (162)
[23] Removal of ball bearing

Note:
Only remove the ball bearing when
replacing it.
1) Place the holder fitting (II) (C) on the
press work platform and insert the shaft
(102) within the holder fitting.
2) Press down on the shaft end section with
the press (A) to remove the ball bearing
(149) from the shaft (102).
Note:
Do not reuse the ball bearing.
[24] Removal of parts mounted on spindle
1) Remove the shim (23) from the spindle
(2).
2) Remove the floating seals (29) from the

spindle (2).
27 NSM-13-02-002E
27
Travel Unit
3) Remove the oil seal (132) from the spin-
dle (2).
Note:
Do not reuse the removed floating
seals (29) and oil seal.
[25] Rough cleaning of all parts

1) Divide the 4 parts: hub (1), spindle (2),
cover (14) and rear flange (301) from
other parts (referred to as built-in parts
below).
2) Place the hub (1), spindle (2), cover (14),
and rear flange (301) into the cleaning
tank and clean them.
Note:
Each part has dirt adhered to the
external surface, so thoroughly clean
parts and remove dirt. White kerosene
is flammable. Be very careful about
fires or burns and injuries due to fire.
Note:
Scratching can easily occur if parts
cleaning is begun just after parts are
immersed in white kerosene, so let
parts sit in white kerosene until debris
and grease sufficiently loosen off and
float to the surface.
3) Clean all parts by placing them in a rough
cleaning container filled with white kero-
sene.
NSM-13-02-002E 28
28
Travel Unit
[26] Finish cleaning
1) Clean all parts by placing them in a finish
cleaning container filled with white kero-
sene, and clean them thoroughly, includ-
ing the interior, while slowly rotating
them.
2) Use a rag to thoroughly remove white
kerosene adhered to parts.
Note:
Spray the inside surfaces of the hub
(1) and spindle (2) with compressed
air in a location free of dust and mois-
ture to dry them.
Coat each part with hydraulic oil after
drying.
Let the inside surfaces of the rear
flange (301), hydraulic motor parts,
and gears dry naturally in a location
free of dust and moisture. Coat each
part with hydraulic oil after drying.
29 NSM-13-02-002E
29
Travel Unit
3. Maintenance Standards
Perform maintenance according to these standards when the travel motor is disassembled and
inspected. Also, be very cautious about preventing scratching of moving and sliding sections.
(1) Seals
Replace all seals (O-rings, oil seals and floating seals) once they have been disassembled even
if there is no damage seen on them.
(2) Maintenance standards for worn parts
[1] Replace all parts that have significant external damage.
[2] Replace parts if the following corresponding abnormal conditions (symptoms) are present.
Reference Permissible
Part value limit value
Part name Symptom
number (standard (judgment
dimensions) value)
・ Significant external damage.
(1) Hub ・ Pitching on ring gear tooth surfaces. _ _
・ Abnormal wear due to seizing.
・ Significant external damage.
(2) Spindle _ _
・ Abnormal wear due to seizing.
(3) and
Carrier assembly ・ Abnormal wear due to seizing. _ _
(7) etc.
(4) Sun gear 1
・ Pitching on tooth surfaces.
(8) Sun gear 2
Planetary gear 1 ・ Flaking symptoms appearing on rolling surface of
_ _
(5)
(9) Planetary gear 2 bearing.
・ Indentations present.
(24) Ball bearing ・ Flaking symptoms appearing. _ _
・ Uneven wear.
・ Scratches on sections that slide against spools
(301) Rear flange _ _
(323), (363) and piston (381).
・ Surface in contact with oil seal (132) worn.
(102) Shaft _ _
・ Spline worn.
(103) Swash plate ・ Seizing symptoms present. _ _
・ Spline section worn.

・ Significant wear on bore inner surface.
(104) Cylinder block _ _
・ Scratches or uneven wear on surface that slides
against timing plate (109).
Piston assembly ・ Gap in axis direction of pistons (105) and shoes

Gap 0.05 Gap 0.15
(105) Piston (106).
(mm) (mm)
(106) Shoe ・ Abnormal wear and uneven wear on shoes (106).
・ Uneven wear on sections that slide against shoes
(106).
(107) Retainer plate _ _
・ Scratches or wear on surface that slides against
thrust ball (108).
・ Uneven wear on spherical section that slides
(108) Thrust ball _ _
against the retainer plate (107).
NSM-13-02-002E 30
30
Travel Unit
Reference Permissible
Part value limit value
Part name Symptom
number (standard (judgment
dimensions) value)
・ Seizing symptoms and uneven wear on sliding sur-
(109) Timing plate _ _
faces.
・ Uneven wear on both end surfaces. Braking Braking

(115) Friction plate torque 206 torque 206
・ Specified torque not produced.
(116) Partner plate ( N•m) or ( N•m) or
・ Seizing symptoms present. higher higher
(112) Piston ・ Scratches on outer circumference. _ _
・ Indentations present.
(149)
Ball bearing ・ Flaking symptoms appearing. _ _
(150)
・ Wear is present.
2-speed piston
assembly ・ Abnormal wear on outer circumference.
_ _
(161) Piston ・ Abnormal wear and uneven wear on shoe.
(162) Shoe
(323) ・ Uneven wear on outer circumference.
Spool _ _
(363) ・ Scratches on outer circumference.
(381) Piston ・ Scratches on outer circumference. _ _
31 NSM-13-02-002E
31
Travel Unit
4. Assembly
As a rule, assembly is the reverse of the disassembly procedure.
(1) Preparations
As with disassembly in section 2., prepare a work platform, tools and materials.
[1] Observe the same general work precautions as with disassembly in section 2.
[2] When performing assembly, remove metal fragments and foreign matter from all parts, and
check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to
remove them.
[3] Replace O-rings, oil seals, and floating seals with new parts.
[4] Remove adhesive remaining in the threaded holes (12 locations) of the hub (1) by removing
it from the M10 (P1.5) taps.
After this, clean and degrease the threaded holes, and use air blowing to remove the clean-
ing fluid.
Replace hexagon socket head bolts (35) with new parts.
[5] When installing O-rings, oil seals and floating seals, be careful not to damage them. (Apply a
thin layer of grease to ensure smooth installation.)
[6] Make sure to coat hydraulic motor section and valve section moving and sliding parts with
hydraulic oil (NAS-9 or higher) before attachment.
[7] Do not wear cloth gloves for assembly. (to prevent pieces of thread from causing operation
defects)
[8] Tighten bolts and plugs to the indicated torque in the tightening torque table on page 12 -
1.(2).
[9] When assembly is complete, place plugs in all of the ports to prevent entry of debris.
[10] A representative model is shown in the photos and diagrams listed. Partial differences with
the parts the customer is using have no effect on assembly procedures.
(3) Assembly procedures
Note:
It is necessary to perform angular ball bearing precompression adjustment when replacing
parts and then performing reassembly, so confirm whether the following parts have been
replaced before performing assembly.
Replacement parts in which angular ball bearing precompression adjustment is necessary
Hub (1), spindle (2), angular ball bearings (24)
Note:
When the parts above are replaced and then reassembly is performed, make sure that each
has had adjustment performed before performing reassembly. Use sufficient caution, as
including a part that has not been adjusted in reassembly will cause travel motor operation
defects and induce early damage.
NSM-13-02-002E 32
32
Travel Unit
[1] Assembly of hub section
1) Place the hub (1) on the press work plat-
form (B).
2) Insert the angular ball bearings (24) in
the hub, place the primary bearing press-
fit jig (C) in the angular ball bearing outer
race, and press down with the press (A)
to press-fit the jig into the hub.
3) Turn the hub upside down.
4) Press fit the angular ball bearings (24)
into the hub in the same way as 2) above.
Note:
Be careful to install the angular ball
bearings (24) in the correct direction.
5) Coat the O-rings of the floating seals (29)
with grease and install the floating seals
in the floating seal groove of the hub (1).
Note:
When coating the O-rings of the float-
ing seal with grease, remove the O-
rings from the floating seals to lightly
coat the entire circumference of the O-
rings.
Note:
For assembly of floating seals (29),
place the floating seal installation jig (I)
(D), floating seals (29), floating seal
installation jig (II) (E) in that order, and
press in until the floating seal installa-
tion jig (II) presses against the floating
seal installation jig (I). Remove the
floating seal installation jig and check
that the hub end surface and floating
seal surface are within 1 mm and par-
allel.
[2] Assembly of spindle section
1) Coat the O-rings of the floating seals (29)
with grease and install the floating seals
in the floating seal groove of the spindle
(2).
Note:
For assembly of floating seals (29),
place the floating seal installation jig
(III) (F), floating seals, floating seal
installation jig (II) (E) in that order, and
press in until the floating seal installa-
tion jig (II) presses against the floating
seal installation jig (III). Remove the
installation jig and check that the spin-
dle groove end surface and floating
seal surface are within 1 mm and par-
allel.
33 NSM-13-02-002E
33
Travel Unit
2) Install the 2 eyebolts in the spindle (2) so
that they are in opposing positions.
3) Install the spindle (2) on the work plat-
form so that the hexagon socket head
bolts are in opposing positions.
Thoroughly tighten the hexagon socket

head bolts. If they are not thoroughly
Caution tightened, the travel motor can fall and
cause injury when it is inverted.
[3] Precompression adjustment of angular ball

bearing
Note:
When the hub (1), angular ball bearings
(24) or spindle (2) are replaced, perform
precompression adjustment. If precom-
pression is not appropriate, the angular
ball bearing can become damaged in a
short period of time.
1) Temporarily install the lock washers (22)
on the spindle (2) and measure the
dimensions of X.
2) Measure installation width Y of the angu-
lar ball bearing.
Note:
Rotate the hub (1) and angular ball
bearing a number of times and mea-
sure the dimensions after rising sub-
sides.
3) Subtract dimension Y from X, and select
a shim (23) from the table below so that
the gap is + 0.13 to + 0.17 mm.
Code T (mm) Code T (mm)

A 0.9 G 1.5
B 1.0 H 1.6
C 1.1 I 1.7
D 1.2 J 1.8
E 1.3 K 1.9
F 1.4 L 2.0
NSM-13-02-002E 34
34
Travel Unit
4) Install the shim (23) on the spindle (2).
[4] Installation of hub

1) Install the angular ball bearings (24) on
the hub (1).
2) Make it so that the center axis of the hub
(1) and spindle (2) is straight, slowly
lower the hub, and insert the angular ball
bearings installed in the hub into the spin-
dle.
3) Use the φ14 hole of the hub and tighten

the long hexagon socket head bolts to the
work platform to secure the hub.
4) Place a metal rod against the inner race
of the reduction valve side angular ball
bearings (24) and lightly strike it with a
hammer to eliminate rising of the inner
race.
5) Align the lock washers (22) with the spin-

dle (2) groove.
35 NSM-13-02-002E
35
Travel Unit
6) Press the lock washers (22) into the jig
with the spindle.
Note:
Thoroughly press the lock washer into
the back of the groove so that it does
not interfere with lock washer when
carrier 2 (7) is installed.
7) Remove the long hexagon socket head
bolts connecting the hub (1) and work
platform.
8) Rotate the hub (1) 2 - 3 times.
Note:
Rotating the hub (1) makes the sliding
surfaces of the floating seals (29) fit
against the hub and prevents pseudo-
leaks.
9) Rotate the work platform and make the
motor side face upwards.
[5] Assembly of motor parts within the spindle
1) Press fit the oil seal (132) into the spindle
(2) using the press-fit jig (G) and hammer.
Note:
When installing the oil seal, coat the
oil seal lip section with lithium grease.
Be careful to install the oil seal (132) in
the correct direction.
2) Install the 2 parallel pins (171) into the
spindle (2) pin holes.
3) Coat the spherical surfaces of the 2 piv-
ots (167) with lithium grease to fit them
on the parallel pins (171) attached to the
spindle (2).
4) Coat the spring (185) with grease and
attach it in the piston assembly parts (pis-
ton (161) and shoe (162)).
5) Coat the sliding sections of the piston
assembly parts with hydraulic oil and
install into the piston hole of the spindle
(2).
6) Fit the 2 parallel pins (34) in the pin holes
of the spindle (2) rear flange matching
surface.
NSM-13-02-002E 36
36
Travel Unit
[6] Installation of shaft
Burns can occur, so use leather

Caution gloves when performing insertion.
Use caution to prevent burns.
1) Insert the ball bearing (149) into the heat-
ing tank and heat them for 10 min. at 100
± 10 ℃ , place them on the holder fitting
(II) (H) and press fit the shaft (102) with
the press (A).
2) Tilt the travel motor 90°

.
3) Fit the shaft into the spindle.
Note:
Be careful to not scratch the lip section
of the oil seal (132) fit into the spindle
when fitting the shaft, and slowly and
gently fit the shaft into the spindle. Be
careful as damage to the lip section
can cause oil leaks and induce early
damage to the travel motor.
4) Fit the swash plate (103) into the spindle

(2).
Note:
Coat the surface that matches with the
swash plate spindle with grease. Align
the swash plate pivot installation holes
with the 2 pivots (167) fit into the spin-
dle and fit the swash plate onto the
spindle.
[7] Assembly of inside of cylinder block

Note:
Place the sharp side of the snap ring
(145) corner facing the inlet side.
For insertion of the washer (110) that
touches the snap ring, have the side of
the washer with sharp corners face the
snap ring side.
1) Insert the washer (110), spring (114),
washer, and snap ring (145) parts in that
order into the cylinder block (104).
37 NSM-13-02-002E
37
Travel Unit
2) Place the cylinder block (104) on the
press work platform.
When attaching the snap ring (145),

be careful as the tip of the pliers can
Caution be misaligned with the snap ring hole
and the snap ring can fly out.
Note:
Spring (114) pressing power 1128 N
or higher
Place a vinyl sheet over the cylinder
block so that the contact surface
between the cylinder block (104) and
timing plate (109) does not get
scratched.
3) Place the holder fitting (I) on the washer
(110) and attach the snap ring (145) into
the snap ring groove of the cylinder block
using the pliers for snap rings while
pressing down on the holder fitting (I) with
the press.
[8] Assembly of hydraulic motor parts
1) Fit the 3 needle pin rollers (151) into the
cylinder block (104) holes and place the
thrust ball (108) on top.
2) Fit the 9 piston assembly parts into the

retainer plate (107).
Note:
After assembly, immerse the the entire
assembly in hydraulic oil.
3) Attach the retainer plate (107) and 9 pis-
ton assembly parts into the cylinder
block.
Note:
Mutually align the spherical surfaces
of the retainer plate and thrust ball
(108).
NSM-13-02-002E 38
38
Travel Unit
4) Insert the cylinder block (104) into the
shaft (102).
Note:
Align the spline hole with the spline
shaft of the shaft and insert the cylin-
der block.
5) After attaching the cylinder block (104),

rotate the cylinder block by hand and
check that there is no backlash. Inspect if
there is backlash.
Note:
Do not lift the cylinder block up after
attachment. Lifting will cause the
thrust ball (108) to become misaligned
and rotation will not be normal.
[9] Assembly of parking brake section

Note:
Install the friction plates (115) after
immersing them in hydraulic oil.
1) Tilt the work platform 90°
.
2) Alternately install the 4 partner plates
(116) and 3 friction plates (115) into the
cylinder block (104).
3) Install the O-rings (135) and (139) into
the piston (112) O-ring groove. At this
time, apply a thin layer of grease to the O-
rings (135) and (139).
4) Install the piston (112) into the spindle
(2).
Note:
If it is difficult to insert the piston into
the spindle due to resistance caused
by the O-rings (135) and (139), lightly
strike the end surface of the piston
with a plastic hammer to insert it.
Be careful not to scratch the O-rings
when installing the piston.
39 NSM-13-02-002E
39
Travel Unit
[10] Attachment of 2nd-speed switchover spool
within the rear flange
1) Insert the spring (366) and spool (363)
into the rear flange (301).
2) Install the O-ring (359) into the plug
(357).
Note:
Coat the O-ring with grease.
3) Screw the plug (357) into the rear flange

(301).
4) Temporarily tighten the plug (357) in the
rear flange (301) with the hexagon
wrench.
[11] Attachment of check ball section

1) Install the 2 O-rings (358) into the 2 plugs
(352).
Note:
Coat the O-rings with grease.
2) Insert the steel balls (353) into the rear
flange (301).
3) Temporarily tighten the plugs (352) in the

wrench.
NSM-13-02-002E 40
40
Travel Unit
[12] Attachment of piston section
1) Install the 2 O-rings (383) into the 2 plugs
(380).
Note:
2) Insert the piston (381) into the rear flange
(301).
3) Temporarily tighten the plugs (380) in the

wrench.
[13] Reassembly of brake valve

1) Insert the spool (323) into the rear flange
(301).
Note:
Coat the spool with hydraulic oil and
insert the spool into the rear flange.
When installing the spool, align the
center of the rear flange hole and cen-
ter of the spool axis to prevent dam-
age to the inner surface of the rear
flange and the outer circumference
surface of the spool due to contact.
If damage occurs in the hole section of
the rear flange or spool outer circum-
ference due to contact, this can cause
internal leaking or a reduction in travel
motor performance after reassembly.
2) Install the O-rings (336) into the plugs
(324).
Note:
3) Install the washers (325) and springs
(328) into the plugs (324).
41 NSM-13-02-002E
41
Travel Unit
4) Screw the 2 plugs (324) into the rear
flange (301).
Note:
When screwing the plugs into the rear
flange, be careful not to cause the
springs (328) to be deformed during
insertion.
5) Temporarily tighten the 2 plugs (324) in
the rear flange (301).
[14] Assembly of parts mounted on rear flange

1) Coat the ball bearing (150) with hydraulic
oil and fit the ball bearing into the rear
flange (301).
2) Fit the parallel pin (341) in the pin hole of
the rear flange (301).
3) Coat the surface of the timing plate (109)
that matches with the rear flange (301).
4) Use the parallel pin (341) as a guide and

install the timing plate (109) on the rear
flange (301).
Note:
Install the timing plate (109) until the
timing plate is attached to the rear
flange (301). The timing plate being
attached to the rear flange prevents
timing plate from falling from the rear
flange when the rear flange is installed
on the spindle (2).
5) Install the 10 springs (113) in the rear

flange (301).
Note:
Thoroughly coat the springs with
grease and secure them so that they
do not fall from the rear flange.
NSM-13-02-002E 42
42
Travel Unit
[15] Connection between rear flange and spin-
dle
1) Install the 2 O-rings (32) and (33) in the
spindle (2) O-ring grooves.
Note:
Install the O-rings (32) and (33) with-
out applying grease. If grease is
applied for reassembly, grease may
ooze out from the matching surface of
the rear flange (301) and spindle (2)
during travel motor operation. This can
be mistaken for an oil leak, so do not
apply grease.
2) Fill the inside of the spindle (2) with 1.0 L
of hydraulic oil.
3) Align the rear flange (301) with the 2 par-
allel pins (34) fit into the spindle (2) and
the rear flange pin hole, and install the
rear flange on the spindle.
4) Temporarily tighten the 10 hexagon
socket bolts (343) in the spindle (2) with
the hexagon wrench.
[16] Tighten each to the specified torque.

1) Tighten the 10 hexagon socket bolts
(343) in the spindle (2) to the specified
torque.
Tightening torque: 102 ± 15.7 N•m
2) Tighten the plugs (324) to the specified

torque.
Tightening torque: 441 ± 39.2 N•m
43 NSM-13-02-002E
43
Travel Unit
torque.
Tightening torque: 58.8 ± 9.81 N•m

torque.
5) Tighten the plug (357) to the specified

torque.
[17] Attachment of relief valve assembly

1) Install the 2 relief valve assemblies (201 -
213).
NSM-13-02-002E 44
44
Travel Unit
2) Tighten the 2 relief valve assemblies (201
- 213) to the specified torque.
[18] Attachment of 2nd stage gears

1) Rotate the work platform and make the
reduction gear side face upwards.
2) Attach the sun gear 2 (8) in the carrier 2
(7).
3) Install eyebolts into the 3 lifting M12 tap
locations of carrier 2 (7), and install the
carrier 2 assembly with a crane.
Note:
When installing the carrier 2 assembly,
straightly align the center axis of the
hub and carrier 2 assembly so that the
internal teeth of the hub (1) are not
scratched by the end surface of the
planetary gears 2 (9), and slowly
install the carrier 2 assembly.
Note:
Arrange the planetary gears 2 (9), rear
flange (301) port (J), and 2-speed pis-
ton hole (K) as shown in the diagram.
[19] Attachment of coupling

1) Attach the coupling (15) in the shaft
(102).
45 NSM-13-02-002E
45
Travel Unit
[20] Attachment of 1st stage gears
1) Install the lifting carrier 1 assembly in the
hub (1).
Note:
When installing the carrier 1 assembly,
straightly align the center axis of the
hub and carrier 2 assembly so that the
internal teeth of the hub (1) are not
scratched by the end surface of the
planetary gears 1 (5), and slowly
install the carrier 1 assembly.
2) Install the sun gear 1 (4) while aligning it

with the coupling (15) spline position.
Note:
If interference occurs between the
spline of sun gear 1 and the tooth tips
of planetary gears 1 (5) due to the
gear positions, slowly lift the carrier 1
assembly until the connection of the
gear coupling with the sun gear 2 (8) is
disconnected and then install sun gear
1 again.
3) Install the thrust plate (13) on carrier 1

(3).
[21] Assembly of cover

1) Coat the hub (1) surface that matches
with the cover (14) with Loctite 515 seal-
ant.
Note:
Coat with sealant so that there are no
discontinuities.
NSM-13-02-002E 46
46
Travel Unit
2) Install eyebolts into the PF1/2 ports and
place the the cover (14) on the hub (1)
while aligning it with the bolt hole posi-
tions.
3) Install hexagon socket head bolts (35)

with the sealant Loctite 242 applied to the
ends and tighten them to the specified
torque.
[22] Lubricating oil feeding

1) Feed with lubricating oil at the feed port.
Note:
Feed 2.1 L of lubricating oil.
2) Install the plugs (30) into each port and

tighten to the specified torque.
47 NSM-13-02-002E
47
Travel Unit
[23] Removal of travel motor
1) Invert the travel motor. (motor faces up)
2) Remove the travel motor installation bolts from the work platform.
3) Tighten the eyebolts (M16) into the spindle (2) threaded holes.
4) Attach hooks and wires to the eyebolts, and remove the travel motor from the work plat-
form with a crane.
NSM-13-02-002E 48
48
Travel Unit
5. Performance Confirmation Test
• After the travel motor maintenance is complete, perform a performance confirmation test accord-
ing the procedure below.
1) Required instruments and tools
1 Pressure gauge for 3.43 MPa 2

2 Measuring cylinder (for 5 L) 1
3 Stop watch 1
2) Test procedure
GM
2
49 NSM-13-02-002E
49
Travel Unit
6. Three-dimensional Disassembly Diagram of Reduction Gear Section
NSM-13-02-002E 50
50
Travel Unit
7. Three-dimensional Disassembly Diagram of Hydraulic Motor Section
51 NSM-13-02-002E
51
Travel Unit
8. Travel Motor Part Table
1 Hub 1 161 Piston 1
2 Spindle 1 162 Shoe 1
3 Carrier 1 1 167 Pivot 2
4 Sun gear 1 1 171 Parallel pin 2
5 Planetary gear 1 3 185 Spring 1
6 Carrier pin 1 3 201 Valve seat 2
7 Carrier 2 1 202 Valve 2
8 Sun gear 2 1 203 Sleeve 2
9 Planetary gear 2 3 204 Collar 2
10 Carrier pin 2 3 205 Plug 2
11 Thrust washer 1 6 206 Spring 2
12 Thrust washer 2 6 207 O-ring 2
13 Thrust plate 1 208 Backup ring 4
14 Cover 1 209 O-ring 2
15 Coupling 1 210 Backup ring 4
22 Lock washer 2 213 Shim 2
23 Shim 1 301 Rear flange 1
24 Angular ball bearing 2 323 Spool 1
27 Needle roller bearing 3 324 Plug 2
28 Needle roller bearing 3 325 Washer 2
29 Floating seal 2 326 Plug 2
30 Plug 3 327 Valve 2
34 Parallel pin 2 331 O-ring 2
35 Hexagon socket head bolt 12 336 O-ring 2
36 Snap ring 1 341 Parallel pin 1
102 Shaft 1 343 Hexagon socket head bolt 10
103 Swash plate 1 352 Plug 3
104 Cylinder block 1 353 Steel ball 2
105 Piston 9 354 Hexagon socket head plug 5
106 Shoe 9 357 Plug 1
107 Retainer plate 1 358 O-ring 3
108 Thrust ball 1 359 O-ring 1
109 Timing plate 1 363 Spool 1
110 Washer 1 366 Spring 1
112 Piston 1 376 Orifice 1
113 Spring 10 377 Filter 1
115 Friction plate 3 379 Plug 1
116 Partner plate 4 380 Plug 2
132 Oil seal 1 381 Piston 1
145 Snap ring 1 396 Hexagon socket head plug 2
149 Ball bearing 1 398 Hexagon socket head plug 8
150 Ball bearing 1 399 Nameplate 1
151 Roller 3
NSM-13-02-002E 52
52
Take-up Roller SH12
Take-up Roller
Take-up Roller
Removal and Installation of Take-up Roller
・ When loosening the grease cylinder check valve, loosen it a little at a time.
・ The pressure inside the cylinder is very high, so there is a danger of grease being expelled
and the plug flying off.The check valve adjustment procedure should not be done in front of
Warning the check valve.
・ Do not get under the machine when the main unit is jacked up.
・ Make sure to place the main unit on wood planks or the like to prevent falling.
・ Align the shoe assembly feed location and stop the engine except when working.
Items to prepare
• Wrench (24 mm)
• Hammer
• Lifting equipment
• Loctite #262
• Striking jig
• Crane
• Crowbar
• Rag
1. Removal of Take-up Roller

[1] Remove the shoe assembly.
See the "Removal and Installation of Shoe
Assembly" procedure.
[2] Use a crowbar (3) to pull off the take-up roller
(1) and recoil spring assembly from the side
frame (2).
[3] Install the lifting equipment (5) on the take-up

roller (1) and recoil spring assembly (4) and
hang them from the side frame (2) with the
crane.
1 NSM-13-03-002E
1
Take-up Roller
[4] Place the take-up roller (1) and recoil spring
assembly (4) onto wood planks (7) as in the dia-
gram. Use a wrench (24 mm) to remove the
take-up roller bolt (6) and separate the roller
and the recoil spring assembly.
2. Installation of Take-up Roller

[1] Use a wrench (24 mm) to fasten the take-up
roller (1) and recoil spring assembly (2) with the
bolt (3).
At this time, be sure to coat the bolt with Loctite
#262.
[2] Install the lifting equipment (6) on the take-up

roller and recoil spring assembly (2) as in the
diagram, lift them up with the crane, and insert
them into the side frame (5).
Push in with the crowbar until the recoil spring
assembly contacts the grease cylinder.
[3] Install the shoe assembly.

For details on installation, see the "Removal and
Installation of Shoe Assembly" procedure.
NSM-13-03-002E 2
2
Take-up Roller
Assembly and Disassembly of Take-up Roller
・ To ensure safe operations, wear protective devices before beginning work and follow all pre-
cautions.
・ When removing devices or positioning devices at the time of installation, use a removal jig
and a hammer or steel rod.
・ Follow the precautions below when suspending the load.
・ The crane must be operated by a qualified operator.
・ Check the weight of the roller to determine whether it can be carried by hand or whether a
crane must be used.
・ Fix the roller to a level surface so it does not roll.
・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
・ If any parts are significantly rusted or dirty, clean them before disassembling.
Caution
・ Any foreign matter entering the equipment during assembly can create a malfunction. There-
fore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and
assemble in a clean location.
・ When assembling sliding parts, be sure to coat them with new hydraulic oil.
・ As a rule, replace all O-rings and other seal parts with new parts.
・ The take-up roller is a heavy object and requires at least 2 workers to handle.
General cautions
・ Be careful not to drop precision parts or let bump them with other parts during work.
・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention
and proceed with caution so as not to damage any parts, create any oil leaks, or compromise
the efficiency of the equipment.
・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the parts from rusting or collecting dust.
Items to prepare
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge
• Seal tape
• Oil pan (drip pan)
• Water container for inspection
3 NSM-13-03-002E
3
Take-up Roller
6
4
3
2
3
5
6 Part name Part number Q'ty

1 Roller KMA1266 1
2 Bushing KNA0447 2
3 Floating seal KHA0041 2
4 Hub KNA11050 1
8 5 O-ring 1A-G50 BHA0956 2
5 6 Hub pin KMA1296 2
9 7 Shaft KMA1267 1
8 Plug with seal nylon KHJ0300 1
9 Hub (without plug) KNA11060 1
Dimension diagram
244
162
9 2 3 5 6
Jig dimension diagram
.5 .5
C0 C0
0.5
40
X
15
30
10
5
20
C3
A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig
NSM-13-03-002E 4
4
Take-up Roller
Disassembly procedure
[1] Stand the roller vertically and use a hexagon
wrench (1) (6 mm) to remove the plug (2).
• The plug is coated with seal nylon, which comes
off when the plug is removed. To reuse the plug,
use seal tape.
[2] Face down the part of the roller from which the
plug was removed and empty the oil from within
the roller.
• It may take a few hours to completely empty the
roller of oil.
• Place an oil pan (3) under the roller to catch the
oil.
[3] Remove the hub pin (4). Tap the pin removal jig
(5) with the hammer (6) from the outside to push
out the hub pin that is already in the roller.
• Securely fasten the roller before doing this work.
• As this pin is very securely fixed, apply lubricant
before tapping it.
[4] Use a gear puller (7), to remove the hub (8).

• If the hub has rusted or is difficult to remove due
to an accumulation of debris, subject it to a
shock, for example by hitting it with a hammer,
to make it easier to move.
• When hitting the collar with a hammer, be care-
ful not to dent it.
5 NSM-13-03-002E
5
Take-up Roller
[5] Check whether the surface of the floating seal
(9) floating seat (11) sliding against the
removed hub has rusted or is damaged. Also
check whether the O-ring (10) is twisted.
• The O-ring cannot be reused. Replace them
with new parts.
• Replace floating seats that have rust, deforma-
tions with new ones.
[6] Remove the floating seal (9) on the roller. As

described in Step [5] above, check whether the
surface of the floating seal sliding against the
roller has rusted or is damaged. Also check
whether the O-ring is twisted.
[7] Remove the O-ring (12) on the shaft (13).

with new parts.
NSM-13-03-002E 6
6
Take-up Roller
[8] +Remove the hub (14) and shaft (13) on the
opposite side.
[9] Secure the shaft (13) in a vise, and as
described in Steps [3] - [5], remove the hub (14)
on the opposite side and check that the sliding
surface of the floating seal floating seat is not
rusted and that the O-ring is not twisted.
[10] As described in Step [6], remove the floating

seal (15) on the opposite side.
[11] Use a micrometer caliper (18), cylinder gauge

(19), and caliper (20) to measure the roller (with
bushing) (17), hubs (9) and (14), and shaft (13)
for wear and deformation. Replace with new
parts as necessary.
7 NSM-13-03-002E
7
Take-up Roller
[12] When replacing the bushing (22), remove it by
placing a striking rod (21) against the end sur-
face and striking that with a hammer (6) uni-
formly left and right as in the diagram.
[13] Invert the roller (17), use jig A (16) to push up

against the bushing (22), and press with a rod-
shaped object (13) (such as a shaft). The bush-
ing comes off.
NSM-13-03-002E 8
8
Take-up Roller
Assembly procedure
[1] Clean all parts.
• Find a clean location.
• Place a rubber plate or cloth on the work sur-
face so as not to damage the parts.
[2] After cleaning the parts (1), air blow them to

remove any remaining cleaning fluid or debris.
[3] If the bushing (3) was removed during disas-

sembly, put it into the roller (2). Use a pressing
machine (4) to press in both the left and right
sides.
9 NSM-13-03-002E
9
Take-up Roller
[4] Use the jigs (5) and (6) attached to the pressing
machine to attach the bushing (3). Use the
pressing machine to press from the opposite
side. Next, use a special fiber cloth to remove all
dust and debris.
[5] Attach the floating seal (8) to the hub (7). Use
jig C (9) to press the floating seal into position.
[6] Use jig C (9) to attach the floating seal (8) to the
roller (2) side.
NSM-13-03-002E 10
10
Take-up Roller
[7] Use a special fiber cloth to thoroughly wipe the
sliding surface of the floating seal to prevent any
dust or scratches.
[8] Apply engine oil to the floating seals (8) on the

hubs.
[9] Attach O-rings (12) to the shaft (11) and mount

them on the roller side.
[10] Install the hubs (7) and (10) on both sides.
11 NSM-13-03-002E
11
Take-up Roller
[11] Hammer the hub pins (13) into the hubs (7) and
(10) with the hammer.
[12] Inject compressed air (0.2 MPa) from the oil fill
port and immerse in water to check that there
are no leaks.
[13] After the hub pins are inserted, fill the engine oil
(120 cc) into the roller main unit.
• The roller main unit can be very unstable, so
give consideration to securing it.
NSM-13-03-002E 12
12
Take-up Roller
[14] After filling the oil, use a hexagon wrench (6
mm) (14) to tighten the plug (15) with the nylon
seal applied.
• To reuse a plug, wrap it with seal tape.
13 NSM-13-03-002E
13
NOTES:
Upper Roller SH120
Upper Roller
Upper Roller
Removal and Installation of Upper Roller
・ When loosening the check valve, loosen it a little at a time and stop when any grease
appears. (The pressure inside the cylinder is very high, so there is the danger of grease
Warning being expelled and the plug flying off if the check valve is loosened too much.）
The check valve adjustment procedure should not be done in front of the check valve.
Items to prepare
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
1. Removal of Upper Roller

[1] Use a box wrench (19 mm) to loosen the grease
cylinder check valve (1), then loosen the shoe
tension.
• Grease drains out, so provide rag (2) close to
the drain port.
[2] Use a jack (3) to lift the top of the shoe, and
then insert wood planks (4) to separate the
shoe (5) and upper roller (6) by about 10 mm.

bolts (7), and then remove the upper roller (6).
1 NSM-13-04-002E
1
Upper Roller
2. Removal of Upper Roller
[1] Perform the reverse of the removal procedure.
Apply Loctite to the bolts and tighten them to the
specified torque.
Installation specified tightening torque
: 521 - 608 N•m

Place a wood plank (2) under the lower frame to
prevent falling.
with A between the frame bottom (3) of the cen-
ter area of the lower side frame and the lowest
hanging part of the top of the shoe plate (4) is
240 - 260 mm.
NSM-13-04-002E 2
2
Upper Roller
Assembly and Disassembly of Upper Roller
cautions.
crane must be used.
advance.
Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling.
・ When assembling touching parts, be sure to coat them with new hydraulic oil.
General cautions
Items to prepare
• Hammer
• Wrenche (13 mm)
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Loctite #262
• Marking pen
• Caliper
3 NSM-13-04-002E
3
Upper Roller
12
11
10
Part name Part number Q'ty
9
1 High strength bolt M10 x 16 102R010Y016N 2
Q'ty
8
2 Loctite #262 KRC5007
reqd.
3 Cover KMA1278 1
7
1 4 Plug with seal nylon KHJ0300 1
5
5 O-ring KRA0232 1
3
6 High strength bolt M8 x 20 102R008 4
7 Thrust plate KMA1285 1
4
8 Shaft KMA1277 1
9 Bushing KMA1270 1
10 Roller KMA1276 1
6 11 Floating seal KHA0038 1
12 Bracket KMA1279 1
Dimension diagram
94.5 59
12
11
1 2
3
4
2 6
7 8 9 10

B Bushing press-fit jig (9)
NSM-13-04-002E 4
4
Upper Roller
wrench (6 mm) (1) to remove the plug (2).
be sure to use seal tape.
the roller.
roller of oil.
oil.

from the cover (5).
[4] Remove the cover (5).

If the cover is difficult to remove, it is possible to
use an air hose (6) with an adapter attached to
apply compressed air or to pry it open by insert-
ing a flathead screwdriver into either end of the
cover.
• When using compressed air, be careful of flying
parts.
5 NSM-13-04-002E
5
Upper Roller
bolts (7) inside the roller, and then remove the
thrust plate (8).
[6] Lift the roller (9) and the shaft (10) comes off.
[7] Remove the floating seal (11) on the

roller.Check whether the sliding surface of the
floating seat (13) has rusted or is damaged.
Also check whether the O-ring (12) is twisted.
with new parts.
[8] Remove the floating seal (11) on the shaft (10).

• The shaft and bracket (14) cannot be removed.
NSM-13-04-002E 6
6
Upper Roller
[9] Remove the O-ring (15) on the cover (16) side.
• Check whether the O-ring is twisted. If it is
twisted, replace it with a new O-ring.
[10] Use a caliper (17), micrometer caliper (18), and

cylinder gauge (19) to measure the roller (with
bushing) (9), bracket (14), and shaft (10) for
wear and deformation. Replace with new parts
as necessary.
[11] When replacing bushing (22), use jig A (21) to

restrain them using the side where the shaft
(10) was removed and press them out with a
pressing machine (20).
7 NSM-13-04-002E
7
Upper Roller
Assembly procedure
[1] Clean all parts.
[2] After cleaning the parts, air blow them to

remove any remaining cleaning fluid (1) or
debris.

sembly, put it into the roller (5).Face up the
thrust plate installation side, restrain from above
using jig B (3), and push in with the pressing
machine (4).
[4] Insert the floating seal (6) into the roller (5) and
bracket (8). Use jig C (7) to press the floating
seal into position.
NSM-13-04-002E 8
8
Upper Roller
[5] Use a special fiber cloth to wipe the surfaces of
the floating seals so as to increase adhesion
and prevent dust from entering.
[6] Apply hydraulic oil to the roller (5).
[7] Attach the shaft (9) to the roller (5).
[8] Use a special fiber cloth to thoroughly wipe the

thrust plate (10) to prevent any dust or
scratches.
9 NSM-13-04-002E
9
Upper Roller
[9] Use a box wrench (17 mm) to fasten the thrust
plate (10) with the 2 bolts (11). Degrease the
bolts well, apply Loctite (12) to the bolt open-
ings, and tighten the bolts. After tightening the
bolts, mark them (13).
• The bolt tightening torque is 62.8 - 72.6 N•m.
[10] Use a wrench (13 mm) to fasten the cover (16)

with the 3 bolts (15). Degrease the bolts, apply
Loctite (12) to the bolt openings, and tighten the
bolts. After tightening the bolts, mark them (14).
• The bolt tightening torque is 31.4 - 37.2 N•m.
[11] Rotate the roller in the direction of the arrow and

check that it rotates smoothly.
are no leaks.
NSM-13-04-002E 10
10
Upper Roller
[13] Fill engine oil (50 - 55 cc) into the roller. After fill-
ing the engine oil, use a hexagon wrench (18) to
tighten the plug (19) (coated with seal nylon).
After tightening the bolts, mark them (17).
This completes the assembly.
11 NSM-13-04-002E
11
NOTES:
Lower Roller SH120
Lower Roller
Lower Roller
Removal and Installation of Lower Roller
・ Do not get under the main unit when it is jacked up.
Make sure to place the main unit on wood planks to prevent falling.
Warning ・ When loosening the grease cylinder check valve, loosen it a little at a time and stop when any
grease appears. (The pressure inside the cylinder is very high, so there is the danger of
grease being expelled and the plug flying off if the check valve is loosened too much.）
Items to prepare
• Rag
• Cleaning fluid
1. Removal of Lower Roller

[1] Use a box wrench (19 mm) to loosen the check
valve (1), and then loosen the shoe tension.
• Grease drains out, so provide rag (2) close to
the drain port.
1 NSM-13-05-002E
1
Lower Roller
[2] Jack up the side frame as in the diagram on the
side where the roller is being replaced.
Jack up so that the shoe is floating about 5 cm
and insert wood planks (3) under the lower
frame to prevent falling.
[3] If it is impossible to insert wood planks (3) under

the lower frame, insert wood planks (4) between
the side frame and the link shoe (5) to separate
the link shoe and lower roller (6) by about 15
mm.

bolts (7), and then remove the lower roller (6).
NSM-13-05-002E 2
2
Lower Roller
2. Installation of Lower Roller
Apply Loctite to the bolts and tighten them to the
specified torque.
Tightening torque: 371 - 432 N•m

Place a wood plank (2) under the lower frame to
prevent falling.
with A between the lower frame (3) of the center
area of the lower side frame and the lowest
hanging part of the shoe plate (4) is 240 - 260
mm.
3 NSM-13-05-002E
3
Lower Roller
Assembly and Disassembly of Lower Roller
cautions.
crane must be used.
advance.
Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling.
・ When assembling sliding parts, be sure to coat them with new hydraulic oil.
General cautions
Items to prepare
• Hammer
• Wire clips
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Loctite
• Caliper
• Cylinder gauge
NSM-13-05-002E 4
4
Lower Roller
8
6
4
5
3
Part name Part number Q'ty

1
1 Roller KNA10930 1
3 2 Shaft KNA0707 1
5
4
3 Bushing KNA0539 2
9 4 Floating seal KMA0755 2
8 5 O-ring 1A-G45 BLA2381 2
6 Collar KNA0708 1
7 Plug with seal nylon KHJ0300 1
8 Wire clip KAA0248 2
9 Collar (without plug) KNA0787 1
Dimension diagram
260
224
9 1 2 3 4 5 6 7 8

B Bushing press-fit jig
5 NSM-13-05-002E
5
Lower Roller
wrench (6 mm) (1) to remove the plug (2).
be sure to use seal tape.
the roller.
roller of oil.
oil.
• Securely fasten so that the roller does not fall
over.
[3] Remove the wire clip (4). Tap another wire (5)
with the hammer (6) from the outside to push
out the wire clip that is already in the roller.
• Place the roller horizontally and secure it so it
does not roll before doing this work.
• The wire in the roller is very securely fixed, so
prepare several wire clips. Also be sure to coat
with lubricant.
[4] Use pliers (7) to remove the pushed out wire

clip (4).
NSM-13-05-002E 6
6
Lower Roller
[5] Use a gear puller (8) to remove the collar (9). If
the collar is difficult to remove, hook the collar
on the bolt and catch the puller on that part.
• If the collar has rusted or is difficult to remove
due to an accumulation of debris, subject it to a
shock, for example by hitting it with a hammer,
to make it easier to move.
• When hitting the collar with a hammer, be care-
ful not to dent it.
[6] Check whether the surface of the floating seal

(10) floating seat (12) sliding against the
removed collar has rusted or is damaged. Also
check whether the O-ring (11) is twisted.
with new parts.
[7] Remove the floating seal (10) on the roller. As

described in Step [6] above, check whether the
surface of the floating seal sliding against the
roller has rusted or is damaged. Also check
whether the O-ring is twisted.
[8] Remove the O-ring (13) on the shaft (14).

with new parts.
7 NSM-13-05-002E
7
Lower Roller
[9] Remove the shaft (14).
[10] As described in Step [7], remove the floating

seal (10) on the opposite side.
[11] Use a caliper (19), micrometer caliper (20), and

cylinder gauge (21) to measure the roller (with
bushing) (17), collars (9) and (18), and shaft
(14) for wear and deformation. Replace with
new parts as necessary.
NSM-13-05-002E 8
8
Lower Roller
[12] When replacing a bushing, insert jig A (15) into
the bushing (16), and use a cylindrical object
(such as a shaft) (14) to push from the top.
The bushing comes off.
Assembly procedure
[1] Clean all parts by immersing them in cleaning
fluid (1).
• Select a clean location.
[2] After cleaning the parts, air blow them to

remove any remaining cleaning fluid or debris.

sembly, put it into the roller (5). Restraining from
above using jig B (3), push in with the pressing
machine (4).
Invert the roller and insert the bushing on the
opposite side in the same manner.
9 NSM-13-05-002E
9
Lower Roller
[4] Use jig C (8) to push the floating seals (6) into
the collar (7) and roller (5).
[5] Use a special fiber cloth to wipe the surfaces of

the floating seals so as to increase adhesion
and prevent dust from entering.
[6] Apply gear oil to the floating seals (6) on the col-
lars (7) and (9).
[7] Attach O-rings (11) to the shaft (10) and mount

into the roller (5).
NSM-13-05-002E 10
10
Lower Roller
[8] Install the collars (7) and (9) on both sides.
[9] Attach the wire clip (12).

• When attaching the wire clip, secure the roller
main unit so that it does not roll.
[10] Turn the main unit and check that the roller
rotates properly.
are no leaks.
11 NSM-13-05-002E
11
Lower Roller
[12] Fill gear oil (125 cc) into the roller. Use a hexa-
gon wrench (6 mm) (14) to tighten the plug (13)
with the nylon seal applied.
• Mobile Gear Oil SHC320 is recommended for
use.
• The plug tightening torque is 24.5 N•m.
NSM-13-05-002E 12
12
Swing Unit SH200-5
Swing Unit
Swing Unit
Removal and Installation of Swing Unit

・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
・ When removing this product from the equipment it is mounted on, stop that equipment sys-
Caution
tem and wait for the surface temperature of this product to fall to about 40 ℃ or below before
removing it. Working on this product while it is still hot can cause burns. Additionally, always
bleed out the pressure before removing any line from this product. Removing a pressurized
line can result in oil spraying out and causing burns and oil leaking.
Items to prepare
• Pliers
• Hammer
• Grease
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Swing Unit

bolts (1), and then remove the air breather (2)
on the hydraulic oil tank.
1 NSM-13-06-002E
1
Swing Unit
[2] Attach the specialty adapter (3) to the area
where the air breather was removed, and set
the vacuum pump.
Create negative pressure in the hydraulic oil
tank using the vacuum pump (4).

(5), and then remove the center cover (6).
[4] Use the wrenches (22 mm, 27 mm, 41 mm) to

remove the hoses (7), (8), (9) and (10) from the
swing motor.
• Mark the swing motor and hoses so that the
connectors can be matched during assembly.
• Attach caps or plugs to the swing motor and
• Clean the swing motor and hoses by spraying
them with a parts cleaner to prevent scratching
and prevent dirt from accumulating on the con-
nectors.
7 Make-up hose (use 41 mm)

8 Drain hose (use 22 mm)
9 Main hose (right) (use 27 mm)
10 Main hose (left) (use 27 mm)
NSM-13-06-002E 2
2
Swing Unit
[5] Use a wrench (19 mm) to remove the grease
hose (11) that feeds grease to the swing motor
reduction gear bearing.


on the drain hose (16) clamp (15).
3 NSM-13-06-002E
3
Swing Unit
on the bracket (17) for the feed port hose, and
use a wrench (22 mm) to remove the hydraulic
hose (19).
• Attach caps or plugs to the swing motor to pre-
vent any entry of water, dust or dirt.

bolts (20) from the swing unit.
NSM-13-06-002E 4
4
Swing Unit
[10] Wrap the wire rope (22) around the swing motor
and lift it with a crane.
• A knock pin (21) is driven into the installation
section of the swing unit. Apply lubricating oil to
the knock pin and pull it out together with the
main unit of the swing motor while hitting with a
hammer.

before lowering the swing unit on wood planks
(23).
• Thoroughly secure the swing unit so that it does
not fall over.
2. Installation of Swing Unit

When installing the swing unit, be careful with
the position of the knock pin.
The tightening torque for the bolts for installing
the swing unit on the swing frame is 280 - 312
N•m.
[2] Before driving, be sure to fill the inside of the
motor casing with hydraulic oil from the drain
port (1).
Thoroughly perform air bleeding from the air
bleed port (2).
Use the level gauge (3) to check that gear oil for
the reduction gear is filled to the stipulated vol-
ume.
5 NSM-13-06-002E
5
Swing Unit
Assembly and Disassembly of Swing Motor
1. Read and understand the contents of this Maintenance Manual before performing disas-
sembly, reassembly, inspection, repair, or other such work of this product.
2. Handle this product according to the separate "Usage Cautions".
3. When removing this product from the equipment it is mounted on, stop that equipment sys-
4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspec-
tion, and repair, etc. of this product. Using an inappropriate tool may result in injury or prod-
Caution uct damage.
5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair,
etc. of this product. This may result in injury or parts damage.
6. Do not directly touch with bare hands the machined edges or threaded sections of parts
during disassembly, reassembly, inspection, or repair etc. of this product. This may result in
injury.
7. Check performance after reassembly. Do not resume use unless performance is fully recov-
ered. Using this product at a sub-par performance level may result in product damage.
8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers.
Always think of safety first during disassembly, inspection, reassembly, repair, or other such
work.
NSM-13-06-002E 6
6
Swing Unit
1. Causes of Trouble and Solutions
This list consists of actions to be taken when an abnormality is sensed or there are problems with
functions during use of the hydraulic motor. Additionally, details concerning disassembly inspection
and reassembly are listed after this, but sufficient caution should be exercised in handling during
these actions so as to prevent scratching of sliding parts of the motor.
Table 1
Symptom Cause External inspection Solution Correction
It is very likely that sliding sec-
tion is damaged when the oil
Internal motor Measure the amount of
fed to the motor is mostly See Table 2.
damage drained oil.
being drained, so disassem-
bly inspection is necessary.
Open the motor inlet and
It is very likely that there is
outlet ports and apply 2.94
internal damage if the output
No rotation MPa of pilot pressure to the Replace damaged
Internal motor shaft does not turn smoothly at
brake release port, and part(s) or motor
damage the torque listed to the left, so
attempt to turn the output assembly.
disassembly inspection is nec-
shaft using about 40 N•m of
essary.
torque.
Setting problem
Measure the load pressure Reset to the correct set pres-
with relief valve
with the pressure gauge. sure.
within the circuit
Wear or damage
The leaking amount is high if
on sliding section
Measure the amount of the amount of drained oil is 5
or high-pressure See Table 2.
drained oil. L/min or more, so disassembly
seal section of
Severe inspection is necessary.
the motor
slipping
High oil tempera-
ture and high Measure the oil tempera-
Lower the oil temperature.
internal motor ture.
leaking
Open the motor inlet and
It is very likely that there is Inspect the parts and
outlet ports and apply 2.94
internal damage if the output bearings in a - e of
Wear or seizing MPa of pilot pressure to the
shaft does not turn smoothly at Table 2, and perform
on motor sliding brake release port, and
the torque listed to the left, so replacement if there
section attempt to turn the output
disassembly inspection is nec- are any abnormali-
shaft using about 40 N•m of
essary. ties.
torque.
Setting problem
Measure the load pressure Reset to the correct set pres-
with relief valve
Abnormal with the pressure gauge. sure.
within the circuit
noise
due to It is very likely that there is
Check for metallic foreign Repair or replace
insufficient internal motor damage if
Internal motor matter in oil drained from damaged part(s).
torque metallic foreign matter is dis-
damage the motor and within the Replace motor
covered, so disassembly
return filter. assembly.
inspection is necessary.
Large amount of Inspect oil within the tank Thoroughly perform air bleed-
air in oil and motor case. ing.
Check for looseness in line
Looseness in fitting, fitting installation Tighten the bolt(s) to the
tightening section bolt, motor installation bolt appropriate torque.
and each bolt on the motor.
7 NSM-13-06-002E
7
Swing Unit
Symptom Cause External inspection Solution Correction
Check for metallic foreign
It is very likely that there is
matter in oil drained from
internal motor damage if
the motor and within the
metallic foreign matter is dis- Repair or replace
Abnormal Seizing in motor return filter. Also, apply
covered or the output shaft damaged part(s).
generation sliding or rotating 2.94 MPa of pilot pressure
does not turn smoothly at the Replace motor
of heat section to the brake release port
torque listed to the left, so disassembly.
and attempt to turn the out-
assembly inspection is neces-
put shaft using about 40
sary.
N•m of torque.
Scratched O-ring Replace O-ring(s).
Oil leaking Repair seal sur-
Scratched seal
from face(s) or replace
surface
matching seal(s).
surface
Looseness in Tighten the bolt(s) to the
Inspect looseness in bolt.
bolt. appropriate torque.
Scratching or
wear on the oil Replace oil seal(s).
seal lip section
Scratching or
Repair part(s) or
wear on the seal
Oil leaking replace the motor
section of the
from oil assembly.
shaft
seal
Lower the internal case pres- Replace oil seal(s).
Check the internal case sure to 0.3 MPa or below. If Repair or replace
Abnormal internal
pressure and amount of the amount of drained oil is damaged part(s).
case pressure
drained oil. high, disassembly inspection Replace motor
is necessary. assembly.
Table 2
No. Inspection part Correction
a Wear on balance plate (22) sliding section Repair or replace part.
b Damage to cam plate (6) sliding section Repair part(s) or replace motor.
c Damage to piston assembly (8) sliding section(s) Repair part(s) or replace motor.
d Wear on piston outer diameters of piston assembly (8) Repair part(s) or replace motor.
e Wear on cylinder (25) piston hole(s) Replace motor.
f Damage to teflon rings (15) and (20) Replace part(s).
NSM-13-06-002E 8
8
Swing Unit
2. Disassembly
[1] Removal of relief assembly
Use a hexagon wrench on the caps (14 mm hex
socket diameter) to remove the relief assem-
blies (34) installed on the motor main unit.
• When reassembling the disassembled relief
assemblies (34), make sure to install them in
their original locations.
[2] Removal of make-up and bypass valve assem-

bly
Loosen and remove the caps (39) (14 mm hex
socket diameter) and remove the springs (38)
and checks (37).
• When reassembling disassembled parts, make
sure to install parts in their original locations.
[3] Making a reference mark on the motor matching

surface
• It is useful for reassembly to make reference
marks with white paint on the matching surface
of the cover (32) and housing (26).
[4] Loosening the tightening bolts

• Loosen and remove the cover (32) and housing
(26) (12 mm hex socket diameter).
9 NSM-13-06-002E
9
Swing Unit
[5] Removal of cover
Place the entire motor with the shaft facing
down, and lift up and remove the cover (32).
[6] Remove the snap ring (24) with the mark-off

pin, and remove the needle bearing (23) inner
race.
[7] Remove the O-rings (13).
[8] Removal of balance plate

Remove the balance plate (22).At this time,
remove the pistons (16) from the balance plate.
• The installation method for the balance plate
(22) in relation to the cover (32) is set (half
groove and circle groove of the high/low pres-
sure switchover section). Before removal, make
sure the phase with the cover (32) is under-
stood.
NSM-13-06-002E 10
10
Swing Unit
[9] Remove the bushings (21) with the teflon rings
(20) attached and the conical springs (19).
[10] Removal of spring (14) (brake section)

Remove the springs (14) from the brake section
piston (12).
• Make sure the spring (14) positions for installa-
tion can be determined.
[11] Removal of brake piston

• When taking the piston (12) out from the hous-
ing (26), sliding resistance occurs due to the
force-fitting effect of O-rings (11) and (13). The
piston is difficult to remove, so use the tap holes
(M6) on the piston (12) as shown in the diagram
to remove the piston.
11 NSM-13-06-002E
11
Swing Unit
[12] Remove the O-ring (11) from the housing (26)
and the O-rings (13) from the piston (12).
[13] Remove the friction plates (9) and partner

plates (10).
[14] Removal of cylinder assembly

Grasp the end of the cylinder (25) by hand and
remove the cylinder assembly from the housing
(26).
• The oil seal (2) and the tapered roller bearing
(3) outer race should be left within the housing.
• The end surface of the cylinder (25) is the slid-
ing surface, so cover this surface with a soft rag
to prevent scratching.
• Place reference marks or numbers on the cylin-
der (25) piston holes and piston assemblies (8)
so that pistons are placed during reassembly in
the same holes they were in at during disas-
sembly.
NSM-13-06-002E 12
12
Swing Unit
[15] Remove the tapered roller bearing (3) outer
race from the housing.
[16] Removal of oil seal

Strike the oil seal (2) using a screwdriver and
hammer to remove it from the housing (26).
• The oil seal cannot be reused.
[17] Disassembly of cylinder assembly

1) Removal of inner race tapered roller bearing
Attach the gear puller to 2 locations on the
tapered roller bearing (3) inner race and the
cylinder (25) spline end, and remove the bear-
ing along with the inner race (1).
13 NSM-13-06-002E
13
Swing Unit
2) Remove the cam plate (6), piston assemblies
(8), and return plate (7) all together from the
cylinder (25).
3) Remove the cam plate (6) so that it slides on

the piston assemblies (8) sliding surfaces.
• Be very careful with handling to prevent
scratching of the cam plate sliding surface.
4) Remove the receiving spring (5) from the cyl-

inder (25).
This completes the disassembly.
NSM-13-06-002E 14
14
Swing Unit
3. Assembly
[1] Preparation before operation
Execute the following preparations before reas-
sembly.
1) Check each part for scratches from use or
from disassembly. If there are any scratches,
remove them with a whetstone or sandpaper
of the necessary grain, clean with cleaning oil,
then dry off with an air blower.
• Replace seal parts with new ones.
• Lap the sliding surfaces of the piston assem-
blies (8), balance plate (22), and cam plate
(6) on a surface plate with #2000 sandpaper.
• When assembling sliding sections, apply
clean hydraulic oil before assembling.
• When installing piston assemblies (8) in the
cylinder (25) piston holes, put the piston
assemblies in the same holes they were in
before disassembly.
15 NSM-13-06-002E
15
Swing Unit
[2] Assembly of cylinder assembly
1) Apply grease to the spherical section (section
touching the receiving spring (5)) of the cylin-
der (25) and install the receiving spring (5).
2) Insert the piston assemblies (8) into the return

plate (7) holes.
3) Install the piston assemblies (8) and return

plate (7) together onto the cylinder (25).
• At this time, install the pistons in the same
holes they were in before disassembly.
• Before installing, apply hydraulic oil to the
cylinder (25) piston holes.
NSM-13-06-002E 16
16
Swing Unit
4) Apply hydraulic oil to the shoe sliding surfaces
of the piston assemblies (8), and then install
the cam plate (6).
5) Install the tapered roller bearing (3) inner race

on the cylinder (25).
6) Lightly coat the installation section of the cylin-

der (25) inner race with Loctite 515 (or 518).
17 NSM-13-06-002E
17
Swing Unit
7) Install the inner race (1) on the cylinder (25).
[3] Installation of oil seal

Coat the outer circumference of the oil seal (2)
with ThreeBond Co.,Ltd. "1211" white and
install it with the seal press-fit jig.
• Coat the oil seal lip part with grease to install it.
[4] Install the tapered roller bearing (3) outer race

on the housing (26).
NSM-13-06-002E 18
18
Swing Unit
[5] Installation of cylinder assembly
Grasp the end surface of the cylinder (25) by
hand and gently install the cylinder assembly
into the housing (26). At this time, use seal pro-
tector on the cylinder spline section.
• When the cylinder assembly is installed, the
spline shaft of the cylinder will stick out from the
bottom surface of the housing, so place an
object of about 30 - 50 mm under the surface.
• Check that the receiving spring (5) is down in
the spot facing section of the return plate (7).
[6] Install the friction plates (9) and partner plates

(10).
• Apply hydraulic oil to both sides of each of these
plates.
[7] Install the O-ring (11) in the housing (26) and

the O-rings (13) in the piston (12).
• Apply grease to the O-rings.
19 NSM-13-06-002E
19
Swing Unit
[8] Installation of brake piston
Apply hydraulic oil to the outer circumference
sliding section of the piston (12) and install it in
the housing (26).
• Stiffness occurs with the piston (12) due to the
force-fitting effect of O-rings (11) and (13), so
lay the entire piston (12) horizontal and push the
piston by hand all at once to install it.
[9] Installation of spring (14) (brake section)

Install the springs (14) in the brake section pis-
ton (12).
• Install the springs (14) in the same locations
they were in before disassembly.
[10] Install bushings (21) with teflon rings (20)

attached and conical springs (19) to the cover
(32) bushing holes.
• Due to the viscosity of the grease, sufficiently
coating both end surfaces and the outer diame-
ter of bushings (21) and the teflon rings (20)
with grease makes it less likely that parts will fall
from the cover when the entire cover is installed
on the housing, which makes assembly easier.
NSM-13-06-002E 20
20
Swing Unit
[11] Sufficiently apply grease to the cover (32) pins
(33) (for balance plate (22) baffling).
[12] Installation of balance plate

Install the pistons (16) in the balance plate (22)
and the balance plate on the cover (32).
[13] Hammer the needle bearing (23) inner race into

the cover (32) and install the snap ring (24).
[14] Install the O-rings (13) onto the cover (32).

• Coat the O-rings with grease.
21 NSM-13-06-002E
21
Swing Unit
[15] Coat with ThreeBond Co.,Ltd. "1211" white to
prevent oil pooled in bolt holes (M14) of the
cover (32) from being recognized as oil leaking.
[16] Installation of cover

Lift the cover (32) and balance plate (22) by
hand and gently install it in the housing (26).
• Be careful that the balance plate (22) and bush-
ings (21) to not fall out from the cover (32) when
installing.
Align the phases of the housing (26) and cover
(32) with the reference marks made before dis-
assembly.
[17] Tighten the tightening bolts (36) (12 mm hex

socket diameter) between the cover (32) and
housing (26) to a tightening torque of 156.9
N•m.
NSM-13-06-002E 22
22
Swing Unit
[18] Installation of make-up
Install the checks (37) and springs (38) on the
cover (32) and tighten the caps (39) (14 mm hex
socket diameter) to a tightening torque of 137.3
N•m.
[19] Installation of relief assembly

Install the relief assemblies (34) (14 mm hex
socket diameter) to the covers (17) tightened to
a tightening torque of 78.5 N•m.
• Be careful with the installation direction.
[20] Assembly confirmation

Open the inlet and outlet ports and apply 2.94
MPa pilot pressure to the brake release port (be
careful as oil will come out from the motor drain
port at this time), and check that the output
shaft rotates smoothly more than once at a
torque of 39.2 N•m.
There is an assembly problem if it does not
rotate, so disassemble the swing unit again and
inspect it.
23 NSM-13-06-002E
23
Swing Unit
4. Jig
Press-fit jig for oil seal (2)
Press-fit jig for tapered roller bearing (3) inner race
Press-fit jig for inner race (1)
NSM-13-06-002E 24
24
5. Swing Motor Internal Structure Diagram
25
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
1 Inner race 1 12 Piston 1 23 Needle bearing 1 34 Relief assembly 2
2 Oil seal 1 13 O-ring 2 24 Locking ring 1 35 O-ring 4
3 Tapered roller bearing 1 14 Spring 16 25 Cylinder 1 36 Hexagon socket head bolt 4
4 Level gauge assembly 1 15 Teflon ring 2 26 Housing 1 37 Check 2
5 Receiving spring 1 16 Piston 2 27 Plug 1 38 Spring 2
6 Cam plate 1 17 Cap 3 28 Cap 2 39 Cap 2
7 Return plate 1 18 O-ring 3 29 Backup ring 2 40 Backup ring 2
8 Piston assembly 9 19 Scrowave spring 4 30 O-ring 2 41 Plug 2
9 Friction plate 2 20 Teflon ring 4 31 O-ring 2
10 Partner plate 2 21 Bushing 4 32 Cover 1
11 O-ring 1 22 Balance plate 1 33 Parallel pin 2
NSM-13-06-002E
Swing Unit
25
Swing Unit
Assembly and Disassembly of Swing Reduction Gear
1. Read and understand the contents of this Maintenance Manual before performing disas-
sembly, reassembly, inspection, repair, or other such work of this product.
2. Handle this product according to the separate "Usage Cautions".
3. When removing this product from the equipment it is mounted on, stop that equipment sys-
4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspec-
tion, and repair, etc. of this product. Using an inappropriate tool may result in injury or prod-
Caution uct damage.
5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair,
etc. of this product. This may result in injury or parts damage.
6. Do not directly touch with bare hands the machined edges or threaded sections of parts
during disassembly, reassembly, inspection, or repair etc. of this product. This may result in
injury.
7. Check performance after reassembly. Do not resume use unless performance is fully recov-
ered. Using this product at a sub-par performance level may result in product damage.
8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers.
Always think of safety first during disassembly, inspection, reassembly, repair, or other such
work.
1. Disassembly
[1] Removal of sun gear and 1st stage holder
assembly
Remove the sun gear (12) and remove the
holder 1 assembly (13).
[2] Removal of spur tooth 4 and 2nd stage holder

assembly
Remove spur tooth 4 (10) and remove the
holder 2 assembly (14).
NSM-13-06-002E 26
26
Swing Unit
[3] Disassembly of 2nd stage holder assembly
Hammer the spring pins (20) into the shafts 2
(15).
• The spring pin cannot be reused.
• Remove the shafts 2 (15) from the holder 2 (16)

while supporting spur teeth 5 (18) by hand.
[4] Removal of ring gear

Remove the ring gear (9) from the gear case
(4).
Liquid packing (ThreeBond Co.,Ltd. "1215"
gray) is applied to prevent gear oil leaks from
the matching surface between the ring gear and
gear case, so lightly strike the ring gear with a
plastic hammer to remove it from the gear case
side.
27 NSM-13-06-002E
27
Swing Unit
[5] Removal of pinion shaft assembly
Remove the collars (8) and apply the gear puller
to the 2 tap hole (M12) thick sections of the gear
case (58) and the pinion shaft (1) end surface.
Remove the pinion shaft (1), plate (2), and
tapered roller bearing (3) as one assembly.
At this time, to ensure the distance that the pin-
ion shaft is removed from the gear case flange
section, use an object of about 200 mm in
height to hold up the gear case.
Remove the tapered roller bearing (7) from the

gear case (4).
Strike the oil seal (6) to remove it from the gear

case (4).
NSM-13-06-002E 28
28
Swing Unit
[6] Disassembly of pinion shaft assembly
Press the output shaft pinion of the pinion shaft
(1) and the opposite side end surface with the
press and remove the tapered roller bearing (3)
and plate (2).
• If abnormalities are found within upper section
parts, replace them as a pinion shaft assembly.
This completes the disassembly.
2. Assembly
[1] Assembly of pinion shaft assembly
Install the plate (2) on the pinion shaft (1).
• Be careful with the installation direction.
Heat the tapered roller bearing (3) to "ambient

temperature + 50 ℃ " and install it on the pinion
shaft (1).
• Do not heat the bearing to 100 ℃ or above.
29 NSM-13-06-002E
29
Swing Unit
[2] Oil seal press fitting
Degrease the oil seal installation section of the
gear case (4) and oil seal (6), apply liquid pack-
ing (ThreeBond Co.,Ltd. "1211" white) to the oil
seal outer diameter, and install the oil seal on
the gear case with the seal press-fit jig.
After press fitting, coat the oil seal lip section
with grease.
[3] Installation of pinion shaft assembly

• Use a seal protector so that the spline side of
the pinion shaft (1) does not scratch the oil seal
lip.
Place the gear case (4) so that the output shaft
is pointing upwards, screw an eyebolt into the
tap hole (M18) on the end surface of the pinion
shaft (1) output shaft to lift the pinion shaft
assembly and install it in the gear case.
[4] Installation of tapered roller bearing

Place the entire gear case so that the output
shaft points downwards, heat the tapered roller
bearing (7) inner race to "ambient temperature
+ 50 ℃ " and install it around the center of the
pinion shaft.
NSM-13-06-002E 30
30
Swing Unit
[5] Installation of ring gear
Degrease the matching surfaces of the gear
case (4) and ring gear (9).
Apply liquid packing (ThreeBond Co.,Ltd.
"1215" gray) to the matching surface of the gear
case.
Install the ring gear (9).
[6] Assembly of holder assembly

Install the bushings 2 (17) in spur teeth 5 (18),
insert it in the holder 2 (16) along with the thrust
plates 2 (19), and insert shafts 2 (15).
• Apply gear oil (NIPPON OIL CORP. HYPOID
GEAR 90 or equivalent) to the spur tooth inner
diameter, inner and outer diameter of the bush-
ings, and outer diameter of the shaft at this time.
31 NSM-13-06-002E
31
Swing Unit
Hammer in the spring pins (20).
• Hammer the spring pins in with the crevice fac-
ing the spur teeth 5 (18) side.
[7] Installation of holder assembly and spur tooth 4

Gently engage the holder assembly with the
inner teeth of the ring gear (9) and lightly rotate
it during insertion to engage it with the pinion
shaft (1) spline.
Gently engage spur tooth 4 (10) with spur teeth

5 (18) and insert.
[8] Installation of sun gear 1st stage holder 1

assembly
Gently engage the holder 1 assembly with the
inner teeth of the ring gear (9) and lightly rotate
it during insertion so that the holder 1 (13) teeth
engages with the spur tooth 4 (10) teeth.
NSM-13-06-002E 32
32
Swing Unit
Gently engage the sun gear (12) with holder 1
assembly spur tooth during insertion.
[9] Rotate the holder 1 assembly (13) by hand and

check that the output shaft rotates smoothly.
33 NSM-13-06-002E
33
Swing Unit
3. Jig
NSM-13-06-002E 34
34
Swing Unit
Seal press-fit jig
Seal protector
35 NSM-13-06-002E
35
Swing Unit
4. Swing Reduction Gear Internal Structure Diagram

1 Pinion shaft 1 13 Holder 1 assembly 1
2 Plate 1 14 Holder 2 assembly 1
3 Tapered roller bearing 1 15 Shaft 2 3
4 Gear case 1 16 Holder 2 1
5 Plug 1 17 Bushing 2 3
6 Oil seal 1 18 Spur tooth 5 3
7 Tapered roller bearing 1 19 Thrust plate 2 3
8 Collar 2 20 Spring pin 3
9 Ring gear 1 21 Parallel pin 2
10 Spur tooth 4 1 22 Plug 1
11 Hexagon socket head bolt 8 23 Plug 1
12 Sun gear 1
NSM-13-06-002E 36
36
Center Joint SH120
Center Joint
Center Joint
Removal and Installation of Center Joint
Items to prepare
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Center Joint

bolts (1), and then remove the air breather (2)
on the hydraulic oil tank.

the vacuum pump (4).
tank using the vacuum pump.
1 NSM-13-07-002E
1
Center Joint
bolts (5), and then remove the lower under cov-
ers (6).
[4] Prepare a waste oil can (7) to receive the oil that
spills out under the center joint.
[5] Use a wrench (36 mm) to remove the travel

hoses (8) and another wrench (27 mm) to
remove the drain hoses (9).
• Mark the center joint and hoses so that the con-
nectors match at the time of assembly.
• Attach caps or plugs to the center joint and
• Clean the center joint and hoses by spraying
nectors.
NSM-13-07-002E 2
2
Center Joint
[6] Use a wrench (19 mm) to remove the pilot
hoses (10) and another wrench (27 mm) to
remove the drain hose (11).
• Attach caps or plugs to the center joint and
• Clean the center joint and hoses by spraying
nectors.

(12), and then remove the center joint lock bar
(13).
[8] Use a wrench (36 mm) to remove the 4 travel

hoses (14).
• Mark the hoses so that the connectors can be
matched during assembly.
• Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
• Clean the hoses by spraying them with a parts
cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
[9] Wrap a wire rope (15) around the center joint

and suspend it with a crane so that the center
joint does not fall during removal and installation
operations.
3 NSM-13-07-002E
3
Center Joint
(16) from the center joint.
[11] Use the wire rope (15) and crane to lift the cen-
ter joint (17).
before lowering the center joint on wood planks.
2. Installation of Center Joint

The tightening torque for the center joint bolts
(1) is 109 - 127 N•m.
[2] The tightening torque for the lock bar (2) bolt (3)
is 88.3 - 107 N•m.
Also, apply Loctite #262 to the bolts.
NSM-13-07-002E 4
4
Counterweight SH120
Counterweight
Counterweight
Removal and Installation of Counterweight
・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
Caution ・ Do not stand or pass under the suspended load.
・ Thoroughly secure the removed counterweight with the wire ropes and crane so that it does
not fall over.
Items to prepare
• Eyebolts (M36)
• Balance lifting device
• Wire rope (with the required breaking load) x 4
• Rag
• Cleaning fluid
1. Removal of Counterweight
[1] Remove the 2 rubber plugs (2) from the top of
the counterweight (1).
[2] Install the 2 eyebolts (M36) (3) in place of the

removed caps.
• Apply lubricating oil to the eyebolts.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
1 NSM-13-08-002E
1
Counterweight
[3] Connect the eyebolts to the shackles (4), and
then use the wire ropes (5) and crane to secure
the counterweight so that it does not fall during
removal and installation operations.

bolts (6) and spacers (7) on the lower section of
the counterweight.
NSM-13-08-002E 2
2
Counterweight
[5] Use the wire ropes and crane to lift and remove
the counterweight.
• Move the counterweight about 50 cm to the rear
while lifting it so that it does not interfere with
the housing, engine parts and pipes.

before lowering the counterweight on wood
planks (8).
• Thoroughly secure the counterweight with the
wire ropes and crane so that it does not fall
over.
2. Installation of Counterweight
The tightening torque for the counterweight bolts is 1078 - 1274 N•m.
Do not apply oil, etc. to the bolts.
3 NSM-13-08-002E
3
NOTES:
Hydraulic Pump SH120
Hydraulic Pump
Hydraulic Pump
Removal and Installation of Hydraulic Pump

Items to prepare
• Hexagon wrenches (8 mm, 10 mm)
• Nylon sling (with the required breaking load)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Hydraulic Pump

[2] Remove the engine hood.

For procedure, see "Removal and Installation of
Engine Hood".
from the top cover.
1 NSM-13-09-002E
1
Hydraulic Pump
from the inside of the top cover.
[5] Remove the top cover (4).

and the 4 bolts (5), then remove the covers (6)
and (7).
NSM-13-09-002E 2
2
Hydraulic Pump
(3), and then remove the 4 covers (8), (9), (10),
and (11).

(12) and 2 nuts (13), and then remove the
exhaust pipe seal clamp (14).

(15), and then remove the muffler installation
bracket (16).
3 NSM-13-09-002E
3
Hydraulic Pump
[10] Remove the muffler (17).
[11] Remove the hoses and connectors that are con-

nected to the pump.
Use a hexagon wrench (8 mm) to remove the 8
hose bolts (18), and remove the pressure hoses
(19).
Use a wrench (36 mm) to remove the drain hose
(20).
Use a wrench (22 mm) to remove the pilot hose
(21).
Use a wrench (30 mm) to remove the suction
hoses (24) and (25).
Remove the connector (23).
Use a wrench (19 mm) to remove the pilot
hoses (22) and (25).
Remove the connector (26).
Use a hexagon wrench (10 mm) to remove the
suction line bolts (27) (2 in front, 2 in back), and
remove the suction line (28).
• Mark the pump and hoses so that the connec-
• Attach caps or plugs to the pump and hoses to
• Clean the pump and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
NSM-13-09-002E 4
4
Hydraulic Pump
[12] Secure the pump with a crane and nylon sling
(29) so that it does not fall during removal and
installation operations.

(30) from the pump.
[14] Use a crane and the nylon sling (29) to pull the
pump out from the shaft and lift the pump.
5 NSM-13-09-002E
5
Hydraulic Pump
before lowering the pump on wood planks (31).
• Thoroughly secure the pump so that it does not
fall over.
2. Installation of Hydraulic Pump

The tightening torque for the pump installation bolt
(1) is 63.7 - 72.6 N•m.
Fill the pump case with hydraulic oil from the drain
port so that no air remains in the pump case.
Additionally, when there is a 2nd option gear pump,
bleed off air from the air bleed port on the top sur-
face of the power take-off case.
NSM-13-09-002E 6
6
Hydraulic Pump
Procedures for Assembly and Disassembly of Pump Main Unit Section
1. Tools
The table below shows the tools required for assembly and disassembly of the K7V pump. The bolts
and plugs may vary by pump type.
Required tools
Tool name and are indicated
with ○ Part name
dimensions
Pump type
Hexagon Mounted ROH plug VP Hexagon
Name B K7V63 socket head valve plug socket head
bolt (PT screw) (PF screw) locking screw
2 - - - M4
2.5 - - - M5
3 - - - M6
4 〇 M5 Rc1/16 - M8
5 〇 M6 Rc1/8 - M10
6 〇 M8 Rc1/4 G1/4 M12 M14
Hexagon wrench 8 〇 M10 Rc3/8 G3/8 M16 M18
10 〇 M12 Rc1/2 G1/2 M20
14 〇 M16 M18 Rc3/4 G3/4 -
17 M20 M22 Rc1 G1 -
19 M24 M27 - - -
21 - - - -
22 M30 - - -
19 〇 M12 - G1/4 -
22 - - G3/8 -
24 〇 M16 - - -
Closed wrench
27 M18 - G1/2 -
Socket wrench
Double-head 30 M20 - - -
(single-head)
36 - - G3/4 -
wrench
41 〇 - - G1 -
50 - - G11/4 -
55 - - G11/2 -
Monkey wrench - 〇 Medium-sized x 1
Screwdriver - 〇 Medium-sized flathead screwdriver x 2
Hammer - 〇 Plastic hammer x 1
Pliers - 〇 For stop ring, TSR-160
Steel rod - 〇 Diameter φ4 or less L=100
Torque wrench - 〇 With adjustable specified torque tightening
7 NSM-13-09-002E
7
Hydraulic Pump
2. Disassembly Procedure
When disassembling the pump, read the disassembly procedure all the way to the end before disas-
sembling according to the sequence below. The numbers in parentheses after the part names are
the part numbers used in the attached diagram 1 pump breakdown diagram.
[1] Select a location for disassembly.
Place a rubber plate or cloth on the work plat-
form so as not to damage the parts.
[2] Use cleaning oil to remove any dirt or rust from
the surface of the pump.
[3] Remove the drain port plugs (468) and drain the
oil from the pump casing (F) (271).
• Remove the plugs from both the front and rear
pumps.
[4] Remove the hexagon socket head bolts (412,
413), and remove the regulator.
• See the manual for the regulator for how to dis-
assemble the regulators.
[5] Place the pump regulator horizontal on the work

platform with the installation surface facedown,
and remove the flange sockets (435) and PTO
unit (05).
• When placing the regulator with the installation
surface face down, be sure to place a rubber
plate or similar material on the work platform so
as not to damage the regulator installation sur-
face.
• See the manual for the PTO unit for how to dis-
assemble the PTO unit.
NSM-13-09-002E 8
8
Hydraulic Pump
[6] Loosen the flange sockets (435) and remove
the gear pump (04).
[7] Loosen the hexagon socket head bolts (401,

402) fastening the pump casing (F) (271), the
pump casing (R) (272), and the valve block
(312) together.
[8] Separate the pump casing (F) (271), the pump

casing (R) (272), and the valve block (312).
• When separating the pump casings and valve
block, remove the 1st gear (116) at the same
time.
9 NSM-13-09-002E
9
Hydraulic Pump
[9] Remove the cylinder blocks (141) out from
pump casing (F) (271) and pump casing (R)
(272) in a straight line in relation to the drive
shafts (111, 113), and remove the piston subas-
semblies (151, 152), holder plates (153), spher-
ical bushings (156), and cylinder springs (157)
at the same time.
• Be careful not to damage the sliding surfaces of
the cylinder blocks, spherical bushings, shoes,
and swash plates.
[10] Remove the hexagon socket head bolts (406)

and remove the seal cover (F) (261).
• The seal cover (F) can be easily removed by
inserting a flathead screwdriver into the notch
groove on the seal cover (F) and then pulling
the screwdriver out.
• The seal cover (F) has an oil seal, so be careful
not to damage the oil seal when removing the
seal cover.
[11] Lightly strike the rear end sections of the drive

shafts (111, 113) to remove them from the
pump casings (271, 272).
NSM-13-09-002E 10
10
Hydraulic Pump
[12] Remove the shoe plates (211) and swash plates
(212) from the pump casings (271, 272).
[13] Insert the needles into the lock release holes

(See diagram.) on the swash plate support
boards (251), then while restraining the rotation
lock pins (255), rotate the swash plate support
boards counter-clockwise, and take them out
from the pump casings.
• When inserting the needles for restraining, be
careful not to mix up the lock release holes and
small holes (for the oil paths) on the arc of the
swash plate support boards.
• Be careful when taking out the swash plate sup-
port boards. The rotation lock pins and set
springs may pop out.
[14] Remove the valve plates (313, 314) from the

valve block (312).
• These can also be removed in Step [7].
[15] If necessary, remove the Q min. plugs (533), stoppers (L) (534), stoppers (S) (535), servo pistons
(532), and tilting pins (531) from the pump casings (271, 272), and remove the needle bearings
(124) from the valve block (312).
• To avoid damaging the heads of the tilting pins, use a jig when removing them.
• Loctite has been applied to the sections where the tilting pins and servo pistons are bonded, so
be careful not to damage the servo pistons.
• Try to avoid removing the needle bearings unless they are at the end of their service life.
• Do not loosen the hexagon nuts of the valve block or Q min. plug. This changes the flow volume
setting.
11 NSM-13-09-002E
11
Hydraulic Pump
3. Assembly Procedure
The assembly procedure is the reverse of the disassembly procedure. However, follow the precau-
tions below.
(1) Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
(2) Thoroughly clean all parts with cleaning oil and air blow them before assembly.
(3) Be sure to apply clean hydraulic oil to sliding parts and bearings before assembly.
(4) As a rule, replace all O-rings, oil seals, and other seal parts with new parts.
(5) Use a torque wrench to tighten all installation bolts and plugs to the torque specified in "Mainte-
nance Standards."
(6) Be careful not to mix up the pump parts for the front and rear of the tandem pump.
[1] Install the set springs (256) and the rotation lock
pins (255) in the pump casing (F) (271). Next,
align the swash plate support boards (251) with
the centering locations of the pump casings,
rotate clockwise, then fasten the swash plate
support boards with the rotation lock pins.
• If the servo pistons, tilting pins, stoppers (L),
and stoppers (S), and Q min. plug have been
removed, install these parts in the pump cas-
ings in advance.
• To avoid damaging the heads of the tilting pins
and the feedback pins, use a jig when tightening
the servo pistons and tilting pins. Also, apply
Loctite (medium strength) to the thread sec-
tions.
NSM-13-09-002E 12
12
Hydraulic Pump
[2] Install the shoe plates (211) on the swash
plates (212). Next fit the swash plate tilting
bushings onto the tilting pins (531) and correctly
mount the swash plates and the shoe plates on
the swash plate support boards (251).
• Use the fingertips of both hands to check that
the swash plates move smoothly.
• Apply grease to sliding sections of swash plates
and swash plate support boards for easier
installation of the drive shafts.
• Be careful not to damage the sliding surfaces of
the shoe plates.
[3] Install the drive shafts (111, 113) with cylinder

roller bearings (123), bearing spacers (127),
and stop rings (824) set on them to the pump
casings (271, 272).
[4] Attach the seal cover (F) (261) to the pump cas-
ing (F) (271), and secure the cover with the
hexagon socket head bolts (406).
• Apply a thin layer of grease to the oil seal inside
the seal cover (F).
• Be careful not to damage the oil seal when
attaching it.
13 NSM-13-09-002E
13
Hydraulic Pump
[5] Assemble the piston cylinder subassemblies
(cylinder blocks (141), piston subassemblies
(151, 152), holder plates (153), spherical bush-
ings (156) and cylinder springs (157)), align the
piston subassemblies with the spherical bush-
ings and cylinder splines, and insert them into
the pump casings.
[6] Align the valve plates (313, 314) with the spring
pins (886) and install on the valve block (312).
• Be careful not to mistake the suction and dis-
charge directions of the valve plates.
[7] Place the pump regulator horizontally on the

work platform with the regulator installation sur-
face facing down and install the pump casings
(271,272) and the valve block (312).
• When placing the regulator with the installation
surface face down, be sure to place a rubber
plate or similar material on the work platform so
as not to damage the regulator installation sur-
face.
• Install the valve block in the correct direction.
(Install the valve block so that the regulator
faces up and the suction flange faces right when
looking at the valve block from the front.)
• When installing the pump casings and valve
block, install the 1st gear at the same time.
NSM-13-09-002E 14
14
Hydraulic Pump
[8] Tighten the valve block (312) and pump casings
(271, 272) with the hexagon socket head bolts
(401, 402).
[9] Tighten the flange sockets (435) and install the

gear pump (04). Tighten the valve block (312)
and pump casings (271, 272) with the hexagon
socket head bolts (401).
[10] Tighten the flange sockets (435) to the valve

block (312) and install the PTO unit (05).
• Be careful with the installation direction of the
PTO unit.
For a pump with no PTO unit, install the cover

(326) with the hexagon socket bolts (414).
15 NSM-13-09-002E
15
Hydraulic Pump
[11] Insert the feedback pins of the tilting pins into
the feedback lever of the regulators, install the
regulators, and tighten the hexagon socket head
bolts (412, 413).
• Install the regulator, making sure not to mistake
the front and the rear of the regulator.
[12] Attach the drain port plugs (467) to finish

assembly.
NSM-13-09-002E 16
16
Hydraulic Pump
Pump Main Unit Section Maintenance Standards
1. Standards for Replacing Worn Parts
If any part exceeds the standard values below and is worn, replace or readjust that part. If, however,
the appearance of the part shows significant damage, replace that part.
Standard value /
recommended replacement value
Part name and inspection item Solution
Pump type
K7V63
Piston and cylinder bore clearance
0.032/0.056 Replace the piston or cylinder.
(D-d)
Piston, shoes, and caulking section
0 - 0.1/0.3 Replace piston and shoe assembly.
backlash (δ)
Shoe thickness (t) 3.9/3.7 Replace piston and shoe assembly.
Free height of cylinder spring (L) 41.1/40.3 Replace cylinder spring.
Assembled height of holder plate Replace holder plate or spherical
17.0/15.7
and spherical bushing (H-h) bushing.
17 NSM-13-09-002E
17
Hydraulic Pump
2. Standards for Repairing Cylinder, Valve Plate, and Swash Plate (Shoe plate)
Valve plate (sliding section) Surface roughness requiring repair 3-Z
Swash plate (shoe plate section)
Cylinder (sliding section) Standard surface roughness
0.4 Z or lower (lapping)
Surface roughness (repair value)
3. Tightening Torque
Tightening torque Tool name
Part name Size
(N•m) (mm)
M5 6.9 B=4
M6 12 B=5
M8 29 B=6
M10 57 B=8
Hexagon socket head bolt
M12 98 B = 10 Hexagon wrench
(material SCM435)
M14 160 B = 12
M16 240 B = 14
M18 330 B = 14
M20 430 B = 17
RC1/16 6.9 B=4
RC1/8 10 B=5
PT plug (material S45C)
Note: Wrap seal tape around the RC1/4 17 B=6 Same as above
plug 1.5 - 2 times.
RC3/8 34 B=8
RC1/2 49 B = 10
ROH plug G1/4 29 B=6
Material G3/8 74 B=8
Same as above
G3/8 or less: S45C G1/2 98 B = 10
G1/2 or more: SCM435 G3/4 150 B = 12
NSM-13-09-002E 18
18
Hydraulic Pump
Attached diagram 1 Pump breakdown diagram

Note
W X Y Z and K L M N in the diagram indicate regulator installation positions.
(See the regulator breakdown diagram.)
19 NSM-13-09-002E
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NSM-13-09-002E
Hydraulic Pump
20
1 Right rotation valve plate
2 Left rotation valve plate
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
Attached diagram 2 Pump assembly cross-section diagram

111 Drive shaft (F) 1 251 Swash plate support board 2 466 ROH plug 2 724 O-ring 12 983 Strike rivet 2
113 Drive shaft (R) 1 255 Rotation lock pin 2 467 ROH plug 2 727 O-ring 4
116 1st gear 1 256 Set spring 2 468 ROH plug 4 732 O-ring 4
123 Cylinder roller bearing 2 261 Seal cover (F) 1 490 Insert plug 9 733 O-ring 2
124 Needle roller bearing 2 271 Pump casing (F) 1 531 Tilting pin 2 774 Oil seal 1
127 Bearing spacer 2 272 Pump casing (R) 1 532 Servo piston 2 789 Backup ring 2
141 Cylinder block 2 312 Valve block 1 533 Q min. plug 2 792 Backup ring 2 Component part no.
Code Part name Q'ty
151 Piston 18 313 Valve plate (R) 1 534 Stopper (L) 2 806 Hexagon nut 2 (quantity) or type
152 Shoe 18 314 Valve plate (L) 1 535 Stopper (S) 2 808 Hexagon nut 2 04 Gear pump 1 set ZX10L7RZ1-07A-V
153 Holder plate 2 326 Cover 1 548 Feedback pin 2 824 Stop ring 2 05 PTO assembly 1 set
156 Spherical bushing 2 401 Hexagon socket head bolt 2 702 O-ring 2 886 Spring pin 4 011 Piston subassembly 2 set 151 (9PC), 152 (9PC)
157 Cylinder spring 12 402 Hexagon socket head bolt 2 710 O-ring 1 901 Eyebolt 2 013 Cylinder subassembly (R) 1 set 141(1PC), 313(1PC)
211 Shoe plate 2 406 Hexagon socket head bolt 4 711 O-ring 1 953 Hexagon socket head locking screw 2 014 Cylinder subassembly (L) 1 set 141(1PC), 314(1PC)
212 Swash plate 2 414 Hexagon socket head bolt 4 717 O-ring 2 954 Locking screw 2 030 Swash plate subassembly 2 set 212 (1PC), 214 (1PC)
214 Tilting bushing 2 435 Flange socket 4 723 O-ring 6 981 Nameplate 1 530 Tilting pin subassembly 2 set 531 (1PC), 548 (1PC)
20
Hydraulic Pump
To main pump

1 Suction port G3/4 Tightening torque: 74 N•m
2 Discharge port G3/4 Tightening torque: 53 N•m
Code Part name Q'ty Code Part name Q'ty Component part no. (q'ty) or type
307 Poppet 1 307 (1PC), 308 (1PC), 351 (1PC)
350 Gear case subassembly 1 set
308 Seat 1 353 （1PC）, 354 （1PC）, 361 （1PC）
309 Ring 1
Code Screw size Tightening torque (N•m)
310 Spring 1
312 M14 x 1.5 29
311 Adjusting screw 1
433, 434
312 Lock nut 1 M8 17
435
351 Gear case 1
466 G1/4 16
353 Drive gear 1
354 Driven gear 1
355 Filter 1
361 Front case 1
435 Flange socket 4
466 VP plug 1
700 Angle ring 1
710 O-ring 1
725 O-ring 1
732 O-ring 1
850 Snap ring 1
Attached diagram 3 Gear pump internal structure diagram
21 NSM-13-09-002E
21
Hydraulic Pump
Explanation of Regulator Operation
1. Regulator Adjustment
It is possible to adjust the maximum flow and the minimum flow with the pump main unit side adjust-
ing screws (953, 954), adjust the horsepower control characteristics with the main regulator adjust-
ing screw (C) (628) and adjusting ring (C) (627), and adjust the flow amount control characteristics
with the hexagon socket head locking screw (924). (Attached table 1 shows the adjustments and
changes that can be made.)
(1) Maximum flow adjustment
(on the pump main unit)
Loosen the hexagon nuts (808) and tighten (or
loosen) the locking screws (954) to adjust the
maximum flow. This only changes the maximum
flow. It does not change the other control char-
acteristics.
(2) Minimum flow adjustment

(on the pump main unit)
Loosen the hexagon nuts (806) and tighten (or
loosen) the hexagon socket head locking
screws (953) to adjust the minimum flow. Similar
to the maximum flow adjustment, this does not
change other control characteristics. However,
the required power may increase at the time of
maximum discharge pressure (during relief) if
the hexagon socket head locking screws are
tightened too much, so adjust these carefully.
(3) Input horsepower adjustment
These regulators use the simultaneous full-
horsepower method. Therefore, when changing
the horsepower setting, adjust the adjusting
screw (C) (628) of both the front and rear pump
to the same amount. The adjusted pressure
value is the value when pressure in both pumps
is simultaneously increased.
[1] Outer spring adjustment
Loosen the lock nut (630) and tighten (or
loosen) the adjusting screw (C) (628) to
adjust the outer springs. As the adjusting
screw (C) (628) are tightened, the control
line graph shifts to the right as shown in the
diagram on the right, and the input horse-
power increases. When the adjusting screw
(C) (628) are rotated N times, the inner
spring (626) settings also change. There-
fore, return the adjusting ring (C) (627) by
rotating it N x A times in the opposite direc-
tion.
NSM-13-09-002E 22
22
Hydraulic Pump
[2] Inner spring adjustment
Loosen the hexagon nut (802) and tighten
(or loosen) the adjusting ring (C) (627) to
adjust the inner springs.As the adjusting
ring (C) (627) is tightened, the flow amount
increases as shown in the diagram on the
right and the input horsepower increases.
(4) Flow control characteristics adjustment

Loosen the hexagon nut (801) and tighten (or
loosen) the hexagon socket head locking screw
(924) to adjust the flow control characteristics.
As the hexagon socket head locking screw
(924) are tightened, the control line graph shifts
to the right as in the diagram on the right.
2. Causes and Solutions for Regulator Trouble

If a malfunction occurs that is thought to be caused by the regulators, disassemble and inspect the
regulators while referring to the Maintenance Procedures.
(1) When the motor overloads
Apply a load to each individual pump and investigate whether there is a problem with the front or
rear pump. If there is a problem with both pumps, see Steps (1) and (2) below. If there is a prob-
lem with only one, start from Step (3).
1) Inspect whether the power shift command milli-
amp value I is correct.
→ Inspect the amp dither.

2) Power shift pressure (Pf) is low. Replace the electromagnetic proportional
pressure reducing valve.
3) Compensation piston (621) and compensation → Disassemble and clean.
rod (623) are sticking.
4) Pin (898) is sticking. → Disassemble and clean.
(2) When maximum flow is not output
1) Check whether the pilot pressure Pi is correct.
2) Pilot piston (643) is sticking. → Disassemble and clean.
3) Spool (652) is sticking. → Disassemble and clean.
(Note) If any parts have deep scratches, replace those parts.
23 NSM-13-09-002E
23
Hydraulic Pump
(3) Attached table and diagram
Type KR76-9Y2C-V KR76-9X2D-V
Rotation speed (min-1) 2000 2200

Adjusting screw (954) tightening
+ 1/4 + 1/4
Maximum flow adjustment amount (rotation)
Flow amount change (L/min) - 3.3 - 3.7
+ 1/4 + 1/4
Minimum flow adjustment amount (rotation)
Flow amount change (L/min) + 2.9 + 3.2
+ 1/4 + 1/4
amount (rotation)
Outer spring Compensation control start pressure

+ 1.88 + 1.88
adjustment change amount (MPa)
Input horse- Input torque change amount (N•m) + 29.3 + 31.1
power adjust-
A 1.90 1.90
ment
Adjusting ring (627) tightening
+ 1/4 + 1/4
amount (rotation)
Inner spring
adjustment Flow amount change (L/min) + 5.4 + 5.9
Input torque change amount (N•m) + 24.8 + 26.7
+ 1/4 + 1/4
amount (rotation)
Flow control characteristics
Flow control start pressure change
adjustment + 0.15 + 0.15
amount (MPa)
Flow amount change (L/min) + 7.5 + 8.2
Attached table 1 Regulator adjustment amount list
NSM-13-09-002E 24
24
Hydraulic Pump
Hydraulic circuit diagram Hydraulic circuit diagram

Front side Rear side
Attached diagram 1 Regulator operation explanation diagram
25 NSM-13-09-002E
25
Hydraulic Pump
Attached diagram 2 Front side regulator breakdown diagram

Note
K L M N in the diagram indicate pump casing installation positions. (See the pump break-
down diagram.)
NSM-13-09-002E 26
26
Hydraulic Pump
Attached diagram 3 Rear side regulator breakdown diagram

Note
W X Y Z in the diagram indicate pump casing installation positions. (See the pump break-
down diagram.)
27 NSM-13-09-002E
27
Hydraulic Pump
Procedures for Assembly and Disassembly of Regulator
1. Tools
The table below shows the tools required for assembly and disassembly of the KR76-9***-V.
Required tools
Tool name and are indicated
with ○ Part name
dimensions
Regulator type
Hexagon ROH plug Hexagon
Mounted valve
Name B KR76-9***-V socket head VP plug socket head
(PT screw)
bolt (PF screw) locking screw
2 - - - M4
2.5 - - - M5
3 - - - M6
4 〇 M5 Rc1/16 - M8
5 〇 M6 Rc1/8 - M10
6 〇 M8 Rc1/4 G1/4 M12 M14
Hexagon wrench 8 〇 M10 Rc3/8 G3/8 M16 M18
10 M12 Rc1/2 G1/2 M20
14 M16 M18 Rc3/4 G3/4 -
17 M20 M22 Rc1 G1 -
19 M24 M27 - - -
21 - - - -
22 M30 - - -
19 M12 - G1/4 -
22 - - G3/8 -
24 M16 - - -
Closed5 wrench 27 M18 G1/2
- -
Socket wrench
Double-head 30 M20 - - -
(single-head)
wrench 36 - - G3/4 -
41 - - G1 -
50 - - G11/4 -
55 - - G11/2 -
Monkey wrench - 〇 Medium-sized x 1
Screwdriver - 〇 Medium-sized flathead screwdriver x 2
Hammer - 〇 Plastic hammer x 1
- 〇 For stop ring, TSR-150
Pliers
- 〇 TRR-150 for snap ring
Steel rod - 〇 Diameter φ4 or less L=100
Torque wrench - 〇 With adjustable specified torque tightening
Bolt to remove
adjusting ring Q - 〇 M4 coarse thread bolt
NSM-13-09-002E 28
28
Hydraulic Pump
2. Disassembly Preparations
[1] These regulators comprise small precision parts, so disassembly and assembly operations are
somewhat complex. When disassembling the pump, read the maintenance procedures all the
way to the end, then disassemble according to the sequence.
[2] The front side regulator and rear side regulator types differ, so mark the regulators when disas-
sembling to differentiate between the drive side and the driven side.
[3] The numbers in the parentheses after the part names indicate codes in attached diagram 1 and 2
assembly cross-section diagrams (page 35, page 37).
• Place a rubber plate or cloth on the work plat-
[2] Use cleaning oil to remove any debris or rust
from the surface of the regulators.
and remove the cover (C) (629).
• The cover (C) is assembled with adjusting
screw (C) (628), adjusting ring (C) (627), lock
nut (630), hexagon nut (801), and hexagon
socket head locking screw (924). Do not loosen
these screws and nuts. Doing so changes the
adjusted pressure-flow setting.
[4] After removing the cover (C) (629) subassem-

blies, remove the outer spring (625), inner
spring (626), and spring seating (C) (624) from
the compensation section, and pull out the
adjusting ring (Q) (645), pilot spring (646), and
spring seating Q (644) from the pilot section.
• The adjusting ring (Q) (644) can be easily
removed by pulling them out with an M4 bolt.

and remove the pilot covers A, B (641). Then,
remove the pilot cover ROH plugs (467), then
remove the Pf sleeve (631) and pin (898).
29 NSM-13-09-002E
29
Hydraulic Pump
[6] Remove the set spring (655) from the pressure
adjustment section.Then remove the stop ring
(814), and remove the spring seating (653),
return spring (654), and sleeve (651).
• The sleeve (651) is assembled with retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) flies out, so be careful not to lose
this part.
[7] Remove the loosening prevention plugs (616)

and remove the fulcrum plug (614) and adjust-
ing plug (615).
• When removing the loosening prevention plugs,
they may be damaged. (Even if there is no loos-
ening prevention plug, this is not a problem with
function.)
[8] Remove the lever (2) (613). Do not pull out the
pins (875).
• These can be easily removed by using a pair of
tweezers.
NSM-13-09-002E 30
30
Hydraulic Pump
[9] Pull out the pins (874) and remove the feedback
lever (611).
• Use a fine steel rod to push out the pins (874)
(pin diameter φ5) from above without touching
the lever (1) (612).
[10] Remove the lever (1) (612). Do not pull out the pins (875).
[11] Pull out the pilot piston (643) and spool (652).
[12] Pull out the piston case (622), compensation piston (621), and compensation rod (623).
• The piston case (622) can be removed by pushing out the compensation rod (623) from the
opposite side of the piston case (622).
[13] For the KR76-9Y2C-V, remove the hexagon socket head bolt (436) and remove the pilot cover A
(641). Remove the electromagnetic proportional pressure reducing valve (079).
For the KR76-9X2D-V, remove the hexagon socket head bolt (436) and remove the pilot cover B
(641). Next, remove the hexagon socket head bolts (439) and remove the valve casing (656).
Remove the electromagnetic proportional pressure reducing valve (079).
• Be careful not to damage the connector section of the electromagnetic proportional pressure
reducing valve (079).
This completes the disassembly of the regulator main units.
(Caution)
The component parts are small, so be very careful not to lose them.
31 NSM-13-09-002E
31
Hydraulic Pump
tions below.
advance.
(2) Any foreign matter entering the equipment can create a malfunction. Therefore, after thor-
oughly cleaning the equipment with cleaning oil, air blow the equipment, and perform assembly
in a clean location.
(3) Be sure to apply clean hydraulic oil to sliding sections before assembly.
(4) As a rule, perform replacement for all O-rings and other seal parts.
(5) Use a torque wrench to tighten all installation bolts and plugs to the torque specified in "Mainte-
nance Standards".
[1] Select a location for assembly.
• Place a rubber plate or cloth on the work platform so as not to damage the parts.
[2] Install the compensation rod (623) into the compensation hole on the casing (601).
[3] Insert the pins (875) press fit in the lever (1) (612) into the grooves on the compensation rod
(623) and install the lever (1) (612) on the pins (875) press fit in the casing (601).
[4] Install the spool (652) and sleeve (651) into the pressure adjustment holes on the casing (601).
• Check that the spool (652) and sleeve (651) slide smoothly in the casing (601) without catching.
• Be careful to assemble the spool (652) in the correct direction.
[5] Install the feedback lever (611), and insert the pins (874) in alignment with the pin holes on the
feedback lever (611).
• Assembly is easier if the pins (874) are inserted into the feedback lever (611) in advance.
• Be careful to assemble the feedback lever (611) in the correct direction.
[6] Install the pilot piston (643) into the pilot hole on the casing (601).
• Check that the pilot piston (643) slide smoothly without catching.
[7] Insert the pins (875) press fit in the lever (2)
(613) into the groove on the pilot piston (643)
and install the lever (2) (613).
NSM-13-09-002E 32
32
Hydraulic Pump
[8] Install the fulcrum plug (614) so that the pins
(875) press fit in the fulcrum plug (614) are
inserted into the pin holes on the lever (2) (613).
[9] Install the adjusting plug (615).Install loosening

prevention plugs (616) as necessary.
• Be careful to insert the fulcrum plug (614) and
adjusting plug (615) into the correct holes.
• At this time, check that the backlash from the
movement of the feedback lever (611) is not too
great and that the feedback levers do not catch
on anything.
[10] Install the return spring (654) and spring seating
(653) into the sleeve (651) and install the stop
ring (814) in the spool (652).
[11] Install the set spring (655) into the pressure

adjustment hole and the compensation piston
(621) and piston case (622) into the compensa-
tion holes.
33 NSM-13-09-002E
33
Hydraulic Pump
[12] Install the Pf sleeve (631), pin (898), and ROH
plugs (467) in each pilot cover (641) and tighten
with the hexagon socket head bolts (436).
Also, for the KR76-9Y2C-V, install the electro-
magnetic proportional pressure reducing valve
(079) in the pilot cover A (641); for the KR76-
9X2D-V install the electromagnetic proportional
pressure reducing valve (079) in the valve cas-
ing (656).
• Check that the pin (898) moves smoothly.
• Be careful not to damage the connector section
of the electromagnetic proportional pressure
reducing valve (079).
[13] Install the spring seating (Q) (644), pilot spring
(646), and adjusting ring (Q) (645) into the pilot
holes, and install the spring seating (C) (624),
inner spring (626), and outer spring (625) into
the compensation holes.
• Be careful to install the spring seating (Q) (644)
and the spring seating (C) (624) in the correct
direction.
[14] Assemble the cover (C) (629) set with the

adjusting screw (C) (628), adjusting screw (Q)
(925), adjusting ring (C) (627), lock nut (630),
hexagon nut (801), and hexagon socket head
locking screw (924), and tighten the hexagon
This completes the assembly of the regulator main units.
NSM-13-09-002E 34
34
Hydraulic Pump
Attached diagram 1 Front side regulator cross-section diagram
NSM-13-09-002E 35
35
Hydraulic Pump
Part number Part name Q'ty Component part no. (q'ty) or type
050 Shuttle valve subassembly 1 set 545 (1PC), 546 (1PC), 547 (1PC)
079 1 set KDRDE5K-31/30C50-102
reducing valve
1 Front side regulator

2 Rear side regulator
Tightening torque
Code Screw size
(N•m)
412, 413 M8 29
418 M5 6.9
436, 437, 438 M6 12
466 G1/4 36
467 G3/8 74
496 NPTF 1/16 8.8
614, 615 M14 x 1.5 27
630 M30 x 1.5 160
801 M8 16
802 M10 19

- Regulator subassembly 1 set 641 Pilot cover A 1
412 Hexagon socket head bolt 2 643 Pilot piston 1
413 Hexagon socket head bolt 2 644 Spring seating Q 1
418 Hexagon socket head bolt 2 645 Adjusting ring Q 1
466 ROH plug 1 653 Spring seating 1
467 ROH plug 1 654 Return spring 1
496 Insert plug 15 655 Set spring 1
546 Seat 1 1 724 O-ring 7
547 Seat 2 1 726 O-ring 2
601 Casing A 1 727 O-ring 1
612 Lever (1) 1 730 O-ring 2
613 Lever (2) 1 734 O-ring 1
621 Compensation piston 1 801 Hexagon nut 1
622 Piston case 1 802 Hexagon nut 1
623 Compensation rod 1 814 Stop ring 1
624 Spring seating C 1 836 Locking ring 1
625 Outer spring 1 874 Pin 1
626 Inner spring 1 875 Pin 4
627 Adjusting ring C 1 887 Pin 1
629 Cover C 1 898 Pin 1
630 Lock nut 1 924 Hexagon socket head locking screw 1
631 Pf sleeve 1
36 NSM-13-09-002E
36
Hydraulic Pump
Attached diagram 2 Rear side regulator cross-section diagram
NSM-13-09-002E 37
37
Hydraulic Pump
Part number Part name Q'ty Component part no. (q'ty) or type
Electromagnetic proportional pres-
079 1 set KDRDE5KR-20/40C13-203A
sure reducing valve
Tightening torque
Code Screw size
(N•m)
412, 413 M8 29
437, 438, 439 M6 12
466 G1/4 36
496 NPTF 1/16 8.8
614, 615 M14 x 1.5 27
630 M30 x 1.5 160
801 M8 16
802 M10 19

- Regulator subassembly 1 set 644 Spring seating Q 1
412 Hexagon socket head bolt 2 645 Adjusting ring Q 1
466 ROH plug 1 654 Return spring 1
496 Insert plug 8 655 Set spring 1
601 Casing B 1 656 Valve casing 1
612 Lever (1) 1 724 O-ring 7
613 Lever (2) 1 726 O-ring 2
623 Compensation rod 1 757 O-ring 1
625 Outer spring 1 802 Hexagon nut 1
627 Adjusting ring C 1 836 Locking ring 1
629 Cover C 1 875 Pin 2
641 Pilot cover B 1 898 Pin 1
643 Pilot piston 1 924 Hexagon socket head locking screw 1
38 NSM-13-09-002E
38
Hydraulic Pump
Procedures for Assembly and Disassembly of PTO Unit
1. Tools
The table below shows the tools required for assembly and disassembly of the PTO unit.
Tool name Dimensions B Part name

Hexagon socket head bolt (0SBM1020)
Hexagon wrench 10
Flange socket (PFSBM1020)
Pliers
- Snap ring (0RR72)
TRR-150
Hexagon socket head bolt (0SBM1020)
Torque wrench -
Flange socket (PFSBM1020)
Flathead screwdriver - Spring pin (0SPV420)
Key - Spring pin (0SPV420)
When disassembling the PTO unit, read the disassembly procedure all the way to the end before
disassembling according to the sequence below.
The numbers in parentheses after the part names are the part numbers used in the attached dia-
gram 2 assembly cross-section diagram.
The diagram shows the aluminum PTO unit.
[2] Use cleaning oil to remove any dirt or rust from
the surface of the pump.
[3] Remove the drain port plug (468) and drain the
oil from the pump casing.
• Remove the plugs from both the front and rear
pumps.
[4] Loosen the flange sockets (435) and remove
the PTO unit.
39 NSM-13-09-002E
39
Hydraulic Pump
[5] Loosen the hexagon socket head bolts (414)
and remove the covers (262).
If the PTO unit has a gear pump, loosen the

flange sockets (435) and remove the gear
pump.
[6] Use a flathead screwdriver and wire cutters to

remove the spring pin (885) securing the idling
shaft (115).
• Be careful not to scratch the gear case.
NSM-13-09-002E 40
40
Hydraulic Pump
[7] Remove the idling shaft (115), and pull out the
2nd gear (117), cylinder roller bearing (126),
and bearing spacers (128).
• The cylinder roller bearing cannot be removed
from the 2nd gear.
[8] Remove the snap ring (825) securing the 3rd

gear (118) and bearing roller (125).
[9] Remove the 3rd gear (118) and bearing rollers

(125) from the gear case (326).
• The bearing roller cannot be removed from the
3rd gear.
41 NSM-13-09-002E
41
Hydraulic Pump
tions below.
advance.
(2) Any foreign matter entering the equipment can create a malfunction. Therefore, after thor-
oughly cleaning the equipment with cleaning oil, air blow the equipment, and perform assembly
in a clean location.
(3) Be sure to apply clean hydraulic oil to sliding sections before assembly.
(4) As a rule, perform replacement for all O-rings and other seal parts and spring pins.
(5) Use a torque wrench to tighten all installation bolts and plugs to the torque specified in
“Maintenance Standards”.
[1] Select a location for assembly.
[2] Install the 3rd gear (118) and bearing rollers
(125) in the gear case (326).
3rd gear.
[3] Install the snap ring (825) that secures the 3rd
gear (118) and bearing rollers (125).
NSM-13-09-002E 42
42
Hydraulic Pump
[4] Install the 2nd gear (117), cylinder roller bearing
(126), and bearing spacers (128), then install
the idling shaft (115).
2nd gear.
• Be careful to install the idling shaft in the correct
direction.
[5] Install the spring pin (885) to secure the idling

shaft (115).
43 NSM-13-09-002E
43
Hydraulic Pump
[6] Secure the covers (262) with the hexagon
If the PTO unit has a gear pump, fasten it with

the flange sockets (435).
[7] Install the PTO unit on the pump main unit with
the flange sockets (435).
PTO unit.
NSM-13-09-002E 44
44
Hydraulic Pump
PTO Unit Maintenance Standards
1. Standards for Replacing Worn Parts
If pitting is occurring (the size of 1 pit is 1 mm or greater or pitting covers 5 % or more of the tooth
surface) on the teeth of the 2nd gear (117) or 3rd gear (118), replace the gear. If, however, the
appearance of the part shows significant damage, replace that part.
2. Tightening Torque
Tightening torque
Gear case material Part name Size
(N•m)
Aluminum (material SCM435) (414) M10 33
Flange socket (435)
Cast metal (material SCM435) (414) M10 57
Flange socket (435)
45 NSM-13-09-002E
45
Hydraulic Pump
Attached diagram 1 PTO unit breakdown diagram
NSM-13-09-002E 46
46
Hydraulic Pump
Code Part name Q'ty Tightening torque

115 Idling shaft 1 Code Screw size
(N•m)
117 2nd gear 1
118 3rd gear 1 415, 435 M10 33
125 Ball bearing 2 468 G3/4 74
126 Roller bearing 1
262 Cover 2
326 Gear case 1
435 Flange socket 4
468 Plug 1
710 O-ring 1
711 O-ring 1
728 O-ring 1
825 Snap ring 1
826 Snap ring 1
885 Spring pin 1
886 Pin 2
Attached diagram 2 PTO unit assembly cross-section diagram
47 NSM-13-09-002E
47
NOTES:
Remote Control Valve SH200-5
Remote Control Valve

Removal and Installation of Operation Remote Control Valve
Items to prepare
• Phillips screwdriver
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Operation Remote Control Valve (Left Side)
[1] Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (2) of the console top
cover.
[2] Use the Phillips screwdriver to remove the 2

screws (3), and then remove the handle of the
tilt lever (4).
1 Boot
2 Bolt
3 Screw
4 Tilt lever
1 RSM-13-10-001E
1
bolts (5), and remove the grip (6) of the gate
lock lever.

screws (7) of the console top cover.
[5] Remove the 3 connectors (8) and remove the

console top cover (9).
5 Bolt
6 Gate lock lever grip
7 Screw
8 Connector
9 Console top cover
RSM-13-10-001E 2
2
[6] Use the Phillips screwdriver or box wrench (10
mm) to remove the 5 bolts (10).
[8] Roll up the boot (12) of the control lever,

remove the connector (13) of the horn switch,
and cut the wire band (14).
[9] While securing the nut (15) with a wrench (22

mm), use another wrench (19 mm) to remove
the lock nut (16) and remove the control lever
(17).
10 Bolt
11 Cover
12 Boot
13 Connector
14 Wire band
15 Nut
16 Lock nut
17 Control lever
3 RSM-13-10-001E
3
[10] Roll back the hose cover (18).
[11] Use a wrench (22 mm) to remove the 6 hoses

(19).
• Mark the joystick remote control valve and
hoses so that the connectors match at the time
of assembly.
• Use caps and plugs to cover the joystick
remote control valve and hoses to prevent any
• Clean the joystick remove control valve and
hoses by spraying them with a parts cleaner to
prevent scratches and prevent dirt from accu-
[12] Use the hexagon wrench (5 mm) to remove the

4 bolts (20).
18 Hose cover
19 Pilot hose
20 Bolt
RSM-13-10-001E 4
4
[13] Remove the joystick remote control valve (21).
5 RSM-13-10-001E
5
2. Removal of Operation Remote Control Valve (Right Side)
[1] Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (2) of the console top
cover.

screws (3), and then remove the handle of the
tilt lever (4).

screws (5) of the console top cover.
1 Boot
2 Bolt
3 Screw
4 Tilt lever
5 Screw
RSM-13-10-001E 6
6
[4] Remove the 3 connectors (6) and remove the
console top cover (7).

mm) to remove the 5 bolts (8).
[7] Roll up the boot (10) of the control lever,

remove the connector (11) of the horn switch,
and cut the wire band (12).
6 Connector
7 Console top cover
8 Bolt
9 Cover
10 Boot
11 Connector
12 Wire band
7 RSM-13-10-001E
7
[8] While securing the nut (13) with a wrench (22
mm), use another wrench (19 mm) to remove
the lock nut (14) and remove the control lever
(15).
[9] Roll back the hose cover (16).

(17).
• Mark the joystick remote control valve and
hoses so that the connectors match at the time
of assembly.
• Use caps and plugs to cover the joystick
remote control valve and hoses to prevent any
• Clean the joystick remove control valve and
hoses by spraying them with a parts cleaner to
prevent scratches and prevent dirt from accu-
13 Nut
14 Lock nut
15 Control lever
16 Hose cover
17 Pilot hose
RSM-13-10-001E 8
8
[11] Use the hexagon wrench (5 mm) to remove the
4 bolts (18) and 4 washers (19).
[12] Remove the joystick remote control valve (20).
18 Bolt
19 Washer
3. Installation of Operation Remote Control Valve

To install, perform the reverse of the removal procedure.
Be careful not to connect the hydraulic hoses in incorrect locations.
Before installing the hoses, check that the hose adapters are not loose and retighten them to the
specified torque.
P port
Hose adapter tightening torque ：28.4 ± 2.9 N•m
Hydraulic hose tightening torque ：49 ± 4.9 N•m
T port, Ports 1 - 4
Hose adapter, hydraulic hose tightening torque ：49 ± 4.9 N•m
9 RSM-13-10-001E
9
Procedures for Assembly and Disassembly of Operation Remote Control Valve
(1) Required tools and tightening torque
Dimensions Tightening torque
Tool Part number Part name Screw size
(mm) (N•m)
22 312 Adjusting nut M14 68.6 ± 4.9
Wrench
32 302 Disk M14
Special jig
(diagram in
Attached
24 301 Joint M14 47.1 ± 2.9
diagram 2. Joint
disassembly jig
page 22)
Other
・ Vapor corrosion inhibitor ・Sandpaper (#1000, #2000)
・White kerosene ・Whetstone
・Heat-resistant grease ・Vice
(2)Maintenance standards
Maintenance
Standard Remarks
inspection item
When handle is in neutral 1000 cc/min or more Conditions
During operation 2000 cc/min or more Primary pressure 2.94 MPa
Leak amount
If either condition occurs, replace the remote
control valve as one unit. Oil viscosity 23 mm2/s
The same approximate

When wear on the sliding sections exceeds wear conditions as those listed above
Spool on the non-sliding sections by 10 μm or more, for leak amount are expected
replace the remote control valve as one unit. when the condition on the left
occurs.
If the end section is worn by 1 mm or more, perform replacement.
Push rod
Replace the operation section disk (302) and joint Make adjustments if the backlash
Operation
section (301) if there is backlash of 2 mm or more is due to looseness in the
section backlash
due to wear. tightening sections.
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be
Operation
resolved with "4. Causes of Trouble and Counter-
stability
measures", replace the remote control valve as
one unit.
Note:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is
acceptable to reuse these after it is confirmed that they are not damaged.
RSM-13-10-001E 10
10
2. Disassembly Procedures
[1] Preparations
1) Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move
during work.
2) Prepare the tools and materials indicated in "1. Maintenance Procedures (1) Required tools
and tightening torque".
3) When disassembling the valve, read the disassembly procedures thoroughly before following
the sequence below.
The numbers in the parentheses after the part names indicate codes in "Attached diagram 1.
Remote control valve assembly cross-section diagram Attached diagram 1. Remote control
valve assembly cross-section diagram”.
[2] General work precautions

1) Each part has been manufactured with a high degree of precision, so be careful not to let parts
bump each other or fall when handling them.
2) If parts are struck or pulled with excessive force during work because they are tight, this may
cause burrs or damage which lead to faulty assembly causing reduction in performance or oil
leaking. Perform work carefully and thoroughly.
3) Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is
abandoned in the middle of disassembly. If work must be halted, be careful about preventing
rust from forming and dust settling on parts.
[3] Disassembly procedure

1) Clean the remote control valve with white
kerosene.
• Place plugs in each port.
2) Use copper plate (or lead plate) to secure the
remote control valve in a vise.
3) Remove the bellows (501).
• Be careful not to tear the bellows.
11 RSM-13-10-001E
11
4) Use a wrench on the bolt width of the adjust-
ing nut (312) and disk (302) to loosen them,
and remove the adjusting nut and disk.
RSM-13-10-001E 12
12
5) Use a jig to rotate the joint (301) to the left
and loosen it.
• The diagram shows the valve with the jig
installed.
• If the return springs (221) are strong, the
plate (151), plugs (211), and push rods
(212) will rise at the same time the joint is
loosened, so be careful of parts flying off
when removing the joint.
6) Remove the plate (151).
7) If the return springs (221) are weak, the

plugs (211) will remain in the casing (101)
due to the sliding resistance of the O-rings
(214), so use a flathead screwdriver to
remove them.
• Use the groove in the outer circumference
of the plugs and remove them while making
sure they are not damaged by an unbal-
anced load.
• Use caution as plugs may fly off when they
are being removed due to the return
springs.
13 RSM-13-10-001E
13
5) Install push rods (212) into the plugs (211).
• Apply hydraulic oil to surface of the push
rods.
6) Install the plug assemblies into the casing

(101).
If the return springs (221) are weak, they will
be stopped by the sliding resistance of the O-
rings (214).
• Be careful not to scratch the casing holes
by forcing in the spools (201).
If the return springs are strong, use the plate

(151) to install all 4 plug assemblies at the
same time and temporarily tighten them with
the joint (301).
• Be careful of the plug assemblies and plate
flying off.
7) Install the plate (151).

8) Use a jig, and tighten the joint (301) to the
casing (101) to the specified torque.
RSM-13-10-001E 18
18
9) Install the disk (302) onto the joint (301).
• Screw the disk in until it is equally touching
each of the 4 push rods (212).
Secondary pressure will cause faulty oper-
ation of the machine if the disk is screwed
in too much, so pay attention to adjustment
of the tightening position.
10)Install the adjusting nut (312), use a wrench

on the bolt width of the disk (302) to secure
it, and tighten the adjusting nut to the speci-
fied torque.
• During tightening, do not move the disk
position.
11)Apply grease to the rotating section of the

joint (301) and to the top of the push rods
(212).
12)Install the bellows (501).

13)Inject vapor corrosion inhibitor into each port and then place plugs in the ports.
19 RSM-13-10-001E
19
3. Assembly Procedures
[1] Preparations
1) As with disassembly, prepare a work platform, tools and materials.

1) Observe the same general work precautions as with disassembly.
2) When performing assembly, remove metal fragments and foreign matter from all parts, and
check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to
remove them.
3) As a rule, replace all O-rings and backup rings with new parts.
4) When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of
grease to ensure smooth installation.)
5) When installing parts, using grease is good for preventing parts from falling.
6) Tighten bolts, etc. to the torque values indicated in page 21 "Attached diagram 1. Remote con-
trol valve assembly cross-section diagram". Use the torque wrench to measure the tightening
torque.
7) After assembly is complete, place plugs in all of the ports to prevent entry of debris.
[3] Assembly procedures

1) Insert washers (217), secondary pressure
springs (241) and spring seatings (216) onto
each of the spools (201) in that order.
Additionally, press in the spring seatings and

move them to the side while bending the sec-
ondary pressure springs to pass the seatings
over the larger holes and install them on
each of the spools.
• Do not lower the spring seatings by 6 mm
or more.
RSM-13-10-001E 16
16
2) Install the return springs (221) in the casing
(101).
Install the pressure reducing valve assem-
blies in the casing.
• Install them in the positions they were in
before disassembly.
3) Install O-rings (214) on the plugs (211).
4) Install seals (213) on the plugs (211).

• Install so that the seal lips are as shown in the diagram below.
*1 Seal
*2 Plug
*3 Push rod
*4 Hydraulic oil application
17 RSM-13-10-001E
17
5) Install push rods (212) into the plugs (211).
• Apply hydraulic oil to surface of the push
rods.
6) Install the plug assemblies into the casing

(101).
If the return springs (221) are weak, they will
be stopped by the sliding resistance of the O-
rings (214).
• Be careful not to scratch the casing holes
by forcing in the spools (201).
If the return springs are strong, use the plate

(151) to install all 4 plug assemblies at the
same time and temporarily tighten them with
the joint (301).
• Be careful of the plug assemblies and plate
flying off.
7) Install the plate (151).

8) Use a jig, and tighten the joint (301) to the
casing (101) to the specified torque.
Tightening torque: 47.1 ± 2.9 N・m
RSM-13-10-001E 18
18
9) Install the disk (302) onto the joint (301).
• Screw the disk in until it is equally touching
each of the 4 push rods (212).
Secondary pressure will cause faulty oper-
ation of the machine if the disk is screwed
in too much, so pay attention to adjustment
of the tightening position.
10)Install the adjusting nut (312), use a wrench

on the bolt width of the disk (302) to secure
it, and tighten the adjusting nut to the speci-
fied torque.
Tightening torque: 68.6 ± 4.9 N・m
• During tightening, do not move the disk
position.
11)Apply grease to the rotating section of the

joint (301) and to the top of the push rods
(212).
12)Install the bellows (501).

13)Inject vapor corrosion inhibitor into each port and then place plugs in the ports.
19 RSM-13-10-001E
19
4. Causes of Trouble and Countermeasures
It is not always easy to find where the source of trouble is located. A few problems that may some-
times occur are listed in the table below. Repair of these problems can be difficult, so see the sug-
gested causes and solutions in the table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the
cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another. Also keep in mind that solutions other than those listed in the
table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further
investigation of problems and causes should be done by an experienced and qualified repair per-
son, as necessary.
Symptom Cause Solution
1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring(s) (241) is 2. Replace it (them) with new
(are) broken or worn. part(s).
Secondary pressure is
not rising. 3. The gap between spool(s) (201) and the 3. Replace the remote control valve
casing (101) is abnormally large. as one unit.
4. There is backlash in the handle section. 4. Disassemble and assemble or
replace the handle section.
1. Sliding parts are sticking. 1. Repair the sticking sections.
Secondary pressure is 2. Tank line pressure is variable. 2. Return directly to the oil tank.
unstable. 3. Air is getting into lines. 3. Perform operation several times
and let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
RSM-13-10-001E 20
20
Attached diagram 1. Remote control valve assembly cross-section diagram

101 Casing 1 217 Washer 4
151 Plate 1 221-1 Return spring (port 1) 1
201 Spool 4 221-2 Return spring (port 3) 1
211 Plug 4 221-3 Return spring (port 2, 4) 2
212-1 Push rod (port 1, 3) 2 241-1 Secondary pressure spring (port 1, 3) 2
212-2 Push rod (port 2, 4) 2 241-2 Secondary pressure spring (port 2, 4) 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating (port 1, 3) 2 312 Adjusting nut 1
216-2 Spring seating (port 2, 4) 2 501 Bellows 1
21 RSM-13-10-001E
21
Attached diagram 2. Joint disassembly jig
RSM-13-10-001E 22
22
Removal and Installation of Travel Remote Control Valve
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Travel Remote Control Valve
[1] Remove the 3 screws (1) on the cover (2) and
remove the cover.
[2] Remove the floor mat (3).
1 Screw
2 Cover
3 Floor mat
23 RSM-13-10-001E
23
bolts (4) on both the left and right sides, and
then remove the left and right travel pedals (5).

bolts (6) on both the left and right sides of the
lever, and then remove the levers (7).

4 Bolt
5 Pedal
6 Bolt
7 Lever
8 Bolt
9 Under cover
RSM-13-10-001E 24
24
(10).
• Mark the valve and hoses so that the connec-
• Attach caps or plugs to the valve and hoses to
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
[7] Use a wrench (19 mm) to remove the 2 hose

adapters (11).

bolts (12) on both the left and right sides of the
travel lever .
10 Pilot hose
11 Hose adapter
12 Bolt
25 RSM-13-10-001E
25
[9] Pull up the travel remote control valve (13) into
the cab, and then remove the travel remote
control valve.
13 Travel remote control valve
2. Installation of Travel Remote Control Valve

Be careful not to connect the hydraulic hoses in incorrect locations.
Before installing the hoses, check that the hose adapters are not loose and retighten them to the
specified torque.
Hose adapter, hydraulic hose tightening torque ：36.3 ± 2.0 N•m
RSM-13-10-001E 26
26
Procedures for Assembly and Disassembly of Travel Remote Control Valve
When disassembling the valve, read the disassembly procedures thoroughly before following the
sequence below. The numbers in the parentheses after the part names indicate codes in page 44
"Attached diagram 1. Remote control valve assembly cross-section diagram".
(1) Disassembly procedures
[1] Preparations
1) Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or
move during work.
2) Prepare tools and materials.
1) Each part has been manufactured with a high degree of precision, so be careful not to let
2) If parts are struck or pulled with excessive force during work because they are tight, this
may cause burrs or damage which may then cause reductions in performance or oil leak-
ing due to faulty assembly. Perform work carefully and thoroughly.
3) Rust may form on parts due to moisture or debris if the valve is left disassembled or if work
is abandoned in the middle of disassembly. If work must be halted, be careful about pre-
venting rust from forming and dust settling on parts.
[3] Disassembly procedure
1) Clean the remote control valve with
white kerosene.
• Place plugs in each port.
2) Use shock plate to secure the remote
control valve in a vise.
Remove the bellows (501) from the cov-
ers (201) and remove the covers by pull-
ing upwards.
4/
3) Use a hexagon wrench on the hexagon

socket head locking screws (423) to
loosen them.
Be careful, as application of Loctite
#241 makes the loosening torque high.
4/
27 RSM-13-10-001E
27
4) Place a round rod (φ8 mm or less)
against one end of the cam shafts (413)
and lightly strike it with a hammer to
remove the shafts.
4/
5) Remove the cams (420) as an assembly

with the locking screws (471) and lock
nuts (472) left attached.
Record the positions of the cams in rela-
tion to the covers (201).
Be careful when removing, as the push
rods (214) may fly off.
4/
6) Use a hexagon wrench on the hexagon

socket head bolts (271) to loosen and
remove them.
4/
7) Remove the covers (201).

Record the positions of the covers in
relation to the casing (101).
Be careful when removing, as the push
rods (214) or plugs (202) may fly off due
to the damping springs (336) and (337).
(The plugs are only kept in the casing by
the sliding resistance of the O-rings
(212).)
4/
RSM-13-10-001E 28
28
8) Remove push rods (214) from the plugs
(202).
Record the positions of the plugs in rela-
tion to the push rods.
Be careful not to scratch the surface of
the push rods.
Be careful when removing, as plugs may
fly off.
4/
9) Remove the plugs (202) with the grease

caps (203) and NHU packings (210) left
attached.
Record the positions of the plugs in rela-
tion to the casing holes.
Be careful when removing, as the pis-
tons (224) may fly off due to the damp-
ing springs (336) and (337).
4/
10)Remove the pistons (224).

Record the positions of the pistons in
relation to the casing holes.
4/
11)Remove the damping springs (336) and

(337) from the casing (101).
Record the positions of the damping
springs in relation to the casing holes.
4/
29 RSM-13-10-001E
29
12)Remove the spring seatings (218) from
the casing (101).
Record the position of the spring seat-
ings in relation to the casing holes.
4/
13)Use a magnet, etc. to remove steel balls

(225).
Be careful not to lose steel balls.
4/
14)Use pliers to remove the locking rings

(221) from the casing (101).
Record the positions of the locking rings
in relation to the casing holes.
Be careful when removing, as the bush-
ings (223) may fly off due to the return
springs (335).
Be careful not to scratch the inner sur-
face of the casing.
4/
15)Use tweezers, etc. to remove the bush-

ings (223) from the casing (101).
Record the positions of the bushings in
4/
RSM-13-10-001E 30
30
16)Remove the pressure reducing valve
assemblies and returns springs (335)
from the casing (101).
Record the positions of these parts in
4/
4/
17)Lay the covers (201) on their sides on a

level surface, place the special tool 1
against the bushings (412), and remove
the bushings by lightly strike them with a
hammer.
4/
18)Secure each cam assembly in a vise,

use a wrench to loosen the lock nuts
(472), and remove the lock nuts and
locking screws (471).
If it is not necessary to adjust, the lock-
ing screws due to backlash occurring
during neutral operation, handle the
cam assembly as one unit without per-
forming disassembly.
4/
31 RSM-13-10-001E
31
19)For disassembly of the pressure reduc-
ing valve assemblies, place the bottom
end of the spools (301) perpendicular
on a level work platform, lower the
spring seatings (311), and use the end
of a small flathead screwdriver to
remove the 2 half-circle washers 1
(215).
Be careful not to scratch the surface of
the spools.
Do not lower the spring seatings by 4 4/
mm or more.
20)Separate the spools (301), spring seat-
ings (311), secondary pressure springs
(324), washers 2 (217), and washers 3
(313).
Handle these parts as assemblies until
assembly of the remote control valve.
Washers 2 are used for pre-set adjust-
ment of the secondary pressure springs,
so thickness is different for each spool
assembly. Additionally, these are some-
times not used, so record the status for 4/
each assembly.
21)Remove the grease cups (203) from the
plugs (202).
4/
22)Remove the NHU packings (210) from

the plugs (202). Use a small flathead
screwdriver, etc. to remove the pack-
ings.
face of the plugs.
4/
RSM-13-10-001E 32
32
23)Remove the O-rings (212) from the
plugs (202).
4/
24)Cleaning parts
• Clean all parts by placing them in a rough cleaning container filled with white kerosene.
(rough cleaning)
25)Scratching can easily occur if cleaning of parts is begun just after parts are immersed in
white kerosene, so let parts sit in white kerosene until debris and grease sufficiently loosen
off from the surface of parts and float to the surface.
If the white kerosene is dirty, this will encourage damage to parts and result in reduced
performance after reassembly. Thoroughly manage the level of cleanliness of the white
kerosene.
• Clean all parts by placing them in a finish cleaning container filled with white kerosene,
and thoroughly clean them up to the interior while slowly rotating them. (finish cleaning)
Use a rag to thoroughly remove white kerosene adhered to parts.
26)Do not dry parts with compressed air, as this will damage parts and cause rust to form due
to debris and moisture being dispersed into the atmosphere.
27)Preventing rust on parts
Apply an anti-rust agent to each part.
Rust will form on parts if they are left as is after cleaning, and this will cause reduced per-
formance of functions after reassemly.
33 RSM-13-10-001E
33
(2)Assembly procedures
[1] Preparations
1) As with disassembly, prepare a work platform, tools and materials.

1) Observe the same general work precautions as with disassembly.
2) When performing assembly, remove metal fragments and foreign matter from all parts, and
check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone
to remove them.
3) As a rule, replace all O-rings and NHU packings.
4) When installing O-rings and NHU packings, be careful not to damage them. (Apply a thin
layer of grease to ensure smooth installation.)
5) When installing parts, using grease is good for preventing parts from falling.
6) Tighten bolts, etc. to the torque values indicated in the assembly cross-section diagram.
7) After assembly is complete, place plugs in all of the ports to prevent entry of debris.
[3] Assembly procedures

1) Install the washers 3 (313), washers 2
(217), secondary pressure springs
(324), and the spring seatings (311)
onto each of spools (301) in that order.
Washers 2 are used for pre-set adjust-
ment of the secondary pressure springs,
so thickness is different for each spool
assembly. Additionally, these are some-
times not used.
Check the status recorded during disas-
sembly and attach parts accordingly. 4/
2) Place the bottom end of the spools

(301) perpendicular on a level work plat-
form, push the spring seatings (311)
down, and install the 2 half-circle wash-
ers 1 (215) onto the spring seatings in
such a way that they are not on top of
each other.
4/
Install the washers 1 so that the sharp

edge side faces up and the washer
catches the head of the spool.
Do not lower the spring seatings by 4
mm or more.
RSM-13-10-001E 34
34
3) Install the return springs (335) in the
casing (101).
Install them in the positions they were in
before disassembly.
4/
4) Install the pressure reducing valve sub-

assemblies assembled in the previous
steps 1) and 2) into the casing (101).
before disassembly.
4/
When installing the pressure reducing

valve subassemblies, be careful not to
strongly strike the casing corners with
the bottom ends of the spools.
5) Install the bushings (223) in the casing

(101) on top of the spring seatings
(311).
before disassembly.
4/
35 RSM-13-10-001E
35
6) Use pliers to temporarily install the lock-
ing rings (221) into the casing holes.
before disassembly.
Place them so that they are horizontal.
face of the casing.
Place the locking rings in such a way
that the sharp edge sides faces up.
4/
7) Set the special tool 2 in each casing

hole, and press in the return springs
(335) and bushings (412) together until
the locking rings (221) click into place in
the grooves.
Slowly press in with caution so as to not
scratch the inner surface of the casing.
4/
8) Install the steel balls (225) into the bush-

ings (412).
4/
9) Install the spring seatings (218) into the

bushings (412).
before disassembly.
4/
RSM-13-10-001E 36
36
10)Install the damping springs (336) in the
casing (101).
before disassembly.
4/
11)Install the damping springs (337) in the

casing (101).
before disassembly.
Be careful that they do not become
entangled with damping springs (336).
4/
12)Install the pistons (224).

before disassembly.
4/
13)Install O-rings (212) on the plugs (202).
4/
37 RSM-13-10-001E
37
14)Install NHU packings (210) into the
plugs (202).
When installing the NHU packings, be
careful of the installation direction. (See
the diagram.)
Before installing NHU packings, apply a
thin layer of grease.
4/
NHU packing
15)Install grease cups (203) into the plugs

(202).
4/
16)Install push rods (214) into the plugs

(202).
Before installing push rods, apply
hydraulic oil to the rod surfaces.
Do not press the rods in strongly, as this
may damage the NHU packing lip sec-
tions.
4/
RSM-13-10-001E 38
38
17)Install the push rod subassemblies
assembled in the previous steps 13),
14), 15), and 16) into the casing (101).
4/
18)Use special tool 1 on the covers (201) to

press down the bushings, and lightly
strike the bushings with a hammer to
press fit them.
Be careful that the ends of the bushings
do not stick out from within the cover.
4/
19)Install the covers (201) on the casing

(101).
before disassembly.
Be careful of the cover rising up due to
the damping springs (336) and (337).
4/
20)Tighten the hexagon socket head bolts

(271) to the specified torque.
Be careful that the covers are horizontal.
4/
39 RSM-13-10-001E
39
21)Temporarily install the locking screws
(471) and lock nuts (472) on the cams
(420).
4/
22)Install the cams (420) on the covers

(201).
before disassembly.
4/
23)While holding the cams (420), insert the

cam shafts (413) from the outside.
4/
24)Apply Loctite #241 or the equivalent to

the surfaces of the hexagon socket head
locking screws (423).
4/
RSM-13-10-001E 40
40
25)Tighten the hexagon socket head lock-
ing screws (423) to the specified torque.
Tightening torque: 6.9 ± 1 N•m
4/
26)Adjust the height of the locking screws

(471) so that the top surface of the cams
(420) and the bottom surface of the cov-
ers (201) are parallel, and tighten the
lock nuts (472) to the specified torque
after rotating the cams left and right to
check if there is any neutral backlash.
Even if the push rods (214) are pressed
in too much by the locking screws, back-
4/
lash during neutral will occur. Use cau-
tion as this may cause the sudden
movement when starting the engine.
27)Tilt the cams (420) and fill the grease
cups (203) of the plugs (202) with
grease while applying grease to the top
of the push rods (214).
For grease application and filling, use a
flat object made of soft material so as to
not scratch the push rod or plug sur-
faces.
4/
28)After mounting the top end of the bel-

lows (501) on the cams (420), mount the
bottom end into the grooves on the cov-
ers (201).
Before mounting the bottom end of the
bellows into the grooves of the covers,
spray anti-rust oil on the parts within the
bellows.
4/
41 RSM-13-10-001E
41
Be careful that the bellows are properly
mounted in the grooves and not twisted,
as this may reduce anti-rust and anti-
moisture protection.
4/
RSM-13-10-001E 42
42
2. Causes of Trouble and Countermeasures
It is not always easy to find where the source of trouble is located. A few problems that may some-
times occur are listed in the table below. Repair of these problems can be difficult, so see the sug-
gested causes and solutions in the table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the
cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another. Also keep in mind that solutions other than those listed in the
table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further
investigation of problems and causes should be done by an experienced and qualified repair per-
son, as necessary.
Symptom Cause Solution
1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring(s) (324) is 2. Replace it (them) with new
(are) worn. part(s).
Secondary pressure is
not rising. 3. The gap between spool(s) and the 3. Replace spool(s) and casing
casing is abnormally large. assembly.
4. There is backlash in the operation 4. Disassemble and assemble or
section. replace operation section parts.
Secondary pressure is 2. Tank line pressure is variable. 2. Return directly to the oil tank.
unstable. 3. Air is getting into lines. 3. Perform operation several times
and let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
1. Air is gathering in the piston chamber. 1. Perform operation several times
2. Sliding parts are sticking. and let out air.
3. Damping spring(s) (336) and/or (337) 2. Repair the sticking sections.
are worn. 3. Replace it (them) with new
Damping is not 4. The gap between piston(s) (224) and part(s).
working. the casing is abnormally large. 4. Replace piston(s) and casing
5. There are check valve operation assembly.
problems. 5. Disassemble and adjust the
6. The piston metering hole(s) is (are) check valve section(s).
abnormally large. 6. Replace piston(s).
Damping torque is high.
2. Piston metering hole(s) is (are) clogged. 2. Repair or replace piston(s).
43 RSM-13-10-001E
43
Note
1. Apply anti-rust oil to the inside of the bellows with a spray.
Attached diagram 1. Remote control valve assembly cross-section diagram
Tightening torque list Code Part name Q'ty Code Part name Q'ty
Code Screw size Tightening torque 101 Casing 1 271 Hexagon socket head bolt 2
151 NPTF1/16 6.9 ± 1 N•m 151 Plug 2 301 Spool 4
271 M12 78.5 ± 9.8 N•m 201 Cover 2 311 Spring seating 4
6.9 ± 1 N•m 202 Plug 4 313 Washer 3 4
423 M6
(Loctite coating) 203 Grease cup 4 324 Secondary pressure spring 4
472 M10 33.3 ± 3.4 N•m 210 NHU packing 4 335 Return spring 4
212 O-ring 4 336 Damping spring 4
214 Push rod 4 337 Damping spring 4
215 Washer 1 8 412 Bushing 4
217 Washer 2 4 413 Camshaft 2
218 Spring seating 4 420 Cam 2
221 Locking ring 4 423 Hexagon socket head locking screw 2
223 Bushing 4 471 Locking screw 4
224 Piston 4 472 Lock nut 4
225 Steel ball 12 501 Bellows 2
RSM-13-10-001E 44
44
[1] Special jig 1 (for bushing removal)
[2] Special jig 2 (for locking ring installation)
Attached diagram 2. Jig for assembly and disassembly
45 RSM-13-10-001E
45
NOTES:
Control Valve SH120
Control Valve
Control Valve
Removal and Installation of Control Valve

Items to prepare
• Wrenches (7 mm, 13 mm, 17 mm, 19 mm, 22 mm, 24 mm, 41 mm)
• Wire cutters
• Eyebolts (M12) x 2
• Wire rope (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Control Valve

[1] Extend the attachment and bring in contact with
the ground.
[2] Drain the oil from the hydraulic oil tank.
(For details, see "Draining Oil from Hydraulic Oil
Tank".)

1 NSM-13-11-002E
1
Control Valve
[5] Use wire cutters to cut the wire band (5).

and then remove the clamp (8).
NSM-13-11-002E 2
2
Control Valve


3 NSM-13-11-002E
3
Control Valve
(16).


tion bolts (19), and then remove the clamp (20).
NSM-13-11-002E 4
4
Control Valve
[15] Use wrenches (19 mm, 22mm, 41 mm) and
hexagon wrenches (8 mm, 10 mm) to remove
the control valve lines and hoses.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps and plugs to cover the lines and
5 NSM-13-11-002E
5
Control Valve
(21) from the control valve.
[17] Use a wrench (19 mm) to remove the bolt (22).
[18] Install the 2 eyebolts (23) (M12) on the control

valve.
[19] Install the shackles (24) on the eyebolts, then

use the crane and wire rope (25) to lift the con-
trol valve (26).
NSM-13-11-002E 6
6
Control Valve
[20] Place the control valve (27) on wood planks
(28).
2. Installation of Control Valve

7 NSM-13-11-002E
7
Control Valve
Assembly and Disassembly Precautions
1. General Precautions
[1] As hydraulic equipment has been manufactured with a high degree of precision and contains
small gaps, perform assembly and disassembly in a clean location with little dust.
Use only clean tools and cleaning oil and handle them with sufficient care.
[2] When the control valve is removed from the machine, thoroughly clean the areas around line
ports and insert plugs to take every precaution to prevent any entry of dust or water.
Also when installing the control valve on the machine, do not remove plugs until lines have been
installed.
[3] Study the structure diagram before starting work and prepare the parts required by the objective
and scope. Also, some parts have to be replaced as part of a subassembly because they cannot
be supplied as single parts, so consult the parts list in advance to prepare for this.
2. Disassembly
[1] Each part has been manufactured with a high degree of precision, so be careful not to let parts
bump each other or fall when handling them.
[2] If parts are struck or pried off with excessive force during work because they are tight, this may
cause burrs, damage or faulty assembly which may then cause oil leaks or reductions in perfor-
mance. Perform work carefully.
[3] Use identification tags to reassemble parts correctly by returning them to their original position
after disassembly.
[4] Do not reuse disassembled O-rings and backup rings.
(Remove them with a wire that has a shoe horn-shaped end and be careful not to scratch the
groove section at this time.)
[5] Rust may form on parts due to moisture or debris if they are left disassembled or if work is aban-
doned in the middle of disassembly. If work must be halted, be careful about preventing rust from
forming and dust settling on parts.
3. Assembly
[1] Observe the same cautions as with disassembly.
[2] When performing assembly, remove metal fragments and foreign matter from parts, and check
that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to remove
them.
[3] Replace O-rings and backup rings with new ones.
[4] When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of
grease to ensure smooth installation.)
[5] Tighten bolts and caps to the specified torque.
NSM-13-11-002E 8
8
Control Valve
Inspection and Handling
Clean each part with pure cleaning oil, and dry each part with compressed air or a soft short-haired
fabric.Parts are easy to mix up and lose, so keep parts organized to make work go smoothly.
External shape inspection Judgment criteria and solution

1. Housing
Perform a visual inspection for scratching, rust and Use #2000 sandpaper or a whetstone to repair
corrosion.Also, inspect the insides using a testing dents, scratching, rusting or corrosion.
agent. ・ In the case of damage to any of the areas below,
* As the valve housing is a part that is not serviced, repair cannot be done.
replace the control valve assembly when there is 1) Housing holes;
damage that cannot be repaired. Flange sliding parts or, in particular, parts that
receive holding pressure
2) Seat section;
Check valve seat surface
3) Port seal section;
O-ring touching section
4) Seal section of each hole including main relief
and overload relief
5) Other damage judged to be a hindrance to nor-
mal functioning
2. Plunger
1) Perform a visual inspection for scratching, seiz- ・ Use #2000 sandpaper or a whetstone to repair dents,
ing, rust and corrosion. scratching, rusting or corrosion.
* If there is scratching on the outer circumference ・ If there is a scratch on the sliding section of the outer
of a plunger, reinspect the fitting hole. circumference that a finger nail could catch on, there
2) Insert the plunger into the housing hole and slide is a defect.
it frontward and backwards while rotating it.
3) Check for damage on the check seat section and ・ Smooth movement means there is no problem.
check valve inside the plunger.
4) Insert the plunger into the check valve and slide it ・ If there is scratching or wear on a seat section, repair
frontward and backwards by hand. or replacement is necessary or the seal will become
5) Inspect regardless of whether there is a spring defective.
abnormality or not. ・ Light, smooth movement without catching means
there is no problem.
・ Replace if damage or scratching is discovered, as this

indicates a defect.
3. Return spring, packing section
Inspect for rust, corrosion, wear, deformation and ・ Replace if there is wear or deformation that cannot be
damage on the springs, spring guides, plunger caps repaired.
and covers.
4. Load check valve, each check valve
1) Inspect for scratches on the check seat section. ・ If there is scratching or wear on a seat section, repair
2) Inspect for spring abnormalities. or replacement is necessary or the seal will become
defective.
・ Replace springs if there is damage or abnormal
scratching.
5. Orifice section
Inspect whether there is something clogging the ori- ・ If there is something causing clogging, remove it with
fice of the valve block or foot relief valve. a wire.
9 NSM-13-11-002E
9
Control Valve
External shape inspection Judgment criteria and solution
6. Shuttle valve
Inspect the shuttle seat surface for damage. ・ If there is scratching or wear on a seat section, repair
or replacement is necessary or the seal will become
defective.
7. Load hold valve, priority valve, regeneration valve
1) Inspect the poppet seat surface for damage. ・ If there is scratching or wear on a seat section, repair
or replacement is necessary or the seal will become
2) Insert the poppet into the sleeve and move it for- defective.
wards and backwards. ・ Smooth movement means there is no problem.
8. Main relief valve, overload relief valve
1) Inspect each seat section for damage.
2) Inspect whether there is something clogging ori- ・ If there is scratching or wear on a seat section, repair
fice holes. or replacement is necessary or the seal will become
3) Insert the poppets and move them. defective.
4) Inspect for spring abnormalities. ・ If there is something causing clogging, remove it with
a wire.
5) Visual inspection of whether the relief valves
(main relief valve, overload relief valve) are in an ・ Smooth movement means there is no problem.
acceptable state is possible, but further inspec- ・ Replace springs if there is damage or abnormal
tion is difficult. For checking functions, judgment scratching.
can be done by sufficiently inspecting the opera-
tion status.
NSM-13-11-002E 10
10
Control Valve
Replacing the Main Plunger
The main plunger was selected to fit with the housing, so this part should not be serviced.Accordingly,
be aware that this part, as a rule, cannot be replaced at the worksite.
If for some reason this part is to be replaced, contact us with the part code and manufacturing number
etched into the nameplate or the distinguishing color.
11 NSM-13-11-002E
11
Control Valve
Accessories
(1) Holder
Material: Brass
φD L B H
For main plunger 21.8 90 35 15.5
NSM-13-11-002E 12
12
Control Valve
External Shape Diagram
13 NSM-13-11-002E
13
Control Valve
Cross-section Structure Diagram
BKT side
1 Plug 4 Housing
2 Bushing 5 Steel ball
3 Cover
NSM-13-11-002E 14
14
Control Valve
SW side
1 Plug 5 Steel ball

2 Cover 6 Cap
3 O-ring 7 Orifice
4 Housing 8 Travel signal switchover spool
15 NSM-13-11-002E
15
Control Valve
Part table
1 Housing 1 40 Backup ring 1
2 Plunger G assembly 1 41 Backup ring 1
3 Plunger M1 assembly 1 42 Spring 1
4 Plunger B3 assembly 1 43 Cap 1
5 Plunger C assembly 1 44 Poppet 1
6 Plunger A1 assembly 1 45 Sleeve 1
9 Main relief assembly 1 48 Poppet 1
10 Cap 1 49 Check 1
11 Check 3 50 Spring 1
12 Backup ring 6 51 Spacer 1
13 Spring 5 52 Cap 3
14 Nylon chip 4 53 O-ring 6
15 Check 5 54 Check 1
16 Cap 1 55 O-ring 1
17 Cap 1 56 Spring 1
18 Cap 2 57 Cap 1
24 O-ring 4 63 Hexagon socket head bolt 4
25 Spring 2 64 Spring washer 4
26 Check 1 65 Bushing 1
27-1 Overload relief assembly 3 66 Check 1
27-2 Overload relief assembly 1 67 Cap 1
30 Cap 5 70 Spool CB 1
31 O-ring 5 71 Cover assembly 1
32 Cap 1 72 Plug 3
34 Check 1 74 Cover assembly 2
35 Hexagon socket head bolt 16 75 Plug 2
36 Cover 3 76 Foot relief assembly 1
37 Cover 1 77 End plate 1 1
38 Hexagon socket head bolt 4 78 Hexagon socket head bolt 4
39 Piston 1
NSM-13-11-002E 16
16
Control Valve
Structure diagrams (each section)
[1] Main plunger section
BKT Plunger
BM-1 Plunger
1 Plunger 1 6 O-ring 1
2 Spring guide 2 7 Spacer 1
4 Plunger cap 1 9 Check 1
5 Cap 1
(Note)
A check is installed at one end of the BM-1 and BKT plungers.
17 NSM-13-11-002E
17
Control Valve
[2] Foot relief valve

1 Poppet 1 4 Sleeve 1
3 Spring 1 6 Cap 1
[3] Main relief valve

1 Sleeve 1 10 Adjusting screw 1
2 Main poppet 1 11 O-ring 1
5 Spring 1 14 Piston 1
6 Cap 1 15 Pilot seat 1
7 Hexagon nut 1 16 O-ring 1
9 Hexagon nut 1 18 Orifice 1
NSM-13-11-002E 18
18
Control Valve
[4] Overload relief valve (AM, BM, BKT)

2 Pilot seat 1 12 Spring 1
4 Cap 1 14 Backup ring 1
5 Hexagon nut 1 15 Piston 1
6 Adjusting screw 1 16 O-ring 1
7 Spring receiver 1 17 Backup ring 1
8 O-ring 1 18 Main seat 1
9 Spring 1 19 Main poppet 1
[5] Center bypass valve

1 Cap 1 3 Spring 1
2 O-ring 1 4 Spool 1
19 NSM-13-11-002E
19
Control Valve
[6] Arm regeneration check

1 Cap 1 3 Spring 1
2 O-ring 1 4 Check 1
[7] Boom back pressure check

1 Cap 1 3 O-ring 1
2 Spring 1 4 Check 1
[8] Load hold valve (AM, BM)

1 Cap 1 11 O-ring 1
2 O-ring 1 12 Cap 1
3 Piston 1 13 Cover 1
6 Sleeve 1 16 Poppet 1
7 Backup ring 1 17 Cap 2
9 Poppet 1 19 Spring 1
10 Spring 1 20 Spacer 1
NSM-13-11-002E 20
20
Control Valve
[9] Boom regeneration check

1 Cap 1 4 Spring 1
3 Spacer 1
[10]Check valve (SW, BM-2, OPT, others)

1 Cap 1 4 Check 1
3 O-ring 1
[11]Check valve [cap orifice diameter varies] (AM-2)

[12]Check valve [cap orifice diameter varies] (BKT)
[13]Check valve [cap orifice diameter varies] (BM-1)
[18]Check valve [cap orifice diameter varies] (AM-1)

1 Cap 1 5 Check 1
4 Nylon chip 1
21 NSM-13-11-002E
21
Control Valve
[14]Check valve (TL)

1 Cap 1 5 Check 1
4 Nylon chip 1 8 Cap 1
[15]Swing priority valve

1 Cap 1 7 Cap 1
2 O-ring 1 8 Cap 2
3 Manifold 1 9 O-ring 2
4 Spool 1 10 Spool 1
6 O-ring 1
NSM-13-11-002E 22
22
Control Valve
[16]Check valve

2 Seat 1 5 Check 1
[17] Arm regeneration valve

1 Piston 1 6 O-ring 1
2 Sleeve 1 7 Cap 1
3 Spool 1 8 Spring receiver 1
5 Cap 1
[19] Check valve (TR)

1 Cap 1 4 Nylon chip 1
2 Backup ring 1 5 Check 1
23 NSM-13-11-002E
23
Control Valve
Main plunger section
This section explains the disassembly procedure.To assemble, perform the reverse of the disassem-
bly procedure.
• During disassembly, manage each part using shipping tags so that they are reassembled prop-
erly.
[1] Remove the socket head bolt (1) and remove the cover (2).
• Socket head bolt
Hex socket diameter: 6
• Be careful as the cover varies depending on the installation location.
• Before installing the cover for reassembly, confirm that there is an O-ring mounted at the housing
opening.
[2] Remove the plunger as a subassembly.

• Do not remove the plunger all at once. Slowly
rotate it while checking the states of contact with
the housing to remove it.
[3] Hold the plunger stationary with a tool (holder)

and then hold the plunger using a vice and
loosen the plunger cap (3).
• Plunger cap
• Sufficiently degrease both the plunger and
holder.
NSM-13-11-002E 24
24
Control Valve
[4] Remove the plunger cap (3) and remove the spring guides (4) and spring (5).
• Be aware that the BM-2 spring is different from other springs.
[5] Remove the opposite side caps (6) of the BM-1 and BKT plungers, and remove the springs (7)
and checks (8).
• Cap
• A spacer (9) is installed in the BKT plunger.
25 NSM-13-11-002E
25
Control Valve
Foot relief valve
bly procedure.
erly.
[1] Remove the cap (1) and remove the poppet (2).
• Cap
Hex diameter: 36
[2] Remove the cap (3) and remove the spring (4).
• Cap (3)
Hex diameter: 27
NSM-13-11-002E 26
26
Control Valve
Main relief valve
Disassembly
Name Hex diameter

1 Adjusting screw 22
2 Hexagon nut 30
3 Hexagon nut 30
4 Cap 30
5 Sleeve 27
[1] Hold the adjusting screw (1) and loosen the hexagon nut (2).
[2] Hold the cap (4) and loosen the hexagon nut (3).
[3] Loosen the cap (4) and remove the cartridge as is.
[4] Remove the poppet subassembly (A), and remove the orifice (9), spring (8), and main poppet
(7) from the sleeve (6).
27 NSM-13-11-002E
27
Control Valve
[5] Remove the sleeve (5).
[6] Remove pressure adjustment subassembly (B) from the cap (4), and remove the spring (10)
and pilot poppet (11).
• Do not disassemble the pilot seat (C) as it is press-fit to the cap.
NSM-13-11-002E 28
28
Control Valve
Assembly and pressure setting
[1] Tighten the adjusting screw (1) until the piston (D) touches the Z surface of the sleeve.
[2] Check the set pressure "0" position.

Place the pressure adjustment subassembly (B) at the bottom and place the spring (10) and
pilot poppet (11) on top of it, and install the cap (4) from the top so that is covers the valve.
Temporarily set the position where the pilot poppet (11) touches the seat section of the pilot
seat (C) as the point where the pressure adjustment spring (10) begins to take effect.
[3] Fit poppet subassembly (A) to assemble the cartridge.

[4] Install the temporarily assembled cartridge to the main unit and tighten the cap (4).
29 NSM-13-11-002E
29
Control Valve
Pressure setting
• If a mistake is made with the relief valve set pressure, this can damage hydraulic devices or invite
danger.
Never raise pressure above the set amount for each model.
1) High-pressure setting
[1] Rotate (right rotation) the sleeve (5) and adjust pressure while watching the pressure gauge.
• 1/4 of a rotation changes the pressure about 10 MPa.
The sensitivity of relief is very strong, so do not suddenly tighten the relief valve for any rea-
son.
[2] Secure the sleeve (5) after pressure setting, and tighten it with the hexagon nut (3).
• Operate the plunger and check the set pressure.
2) Low-pressure setting
[1] After the above mentioned high-pressure setting, adjust the pressure while loosening the
adjusting screw (1) (left rotation).
[2] Secure the adjusting screw (1) after pressure setting, and tighten it with the hexagon nut (2).
• Operate the plunger and check the set pressure.
NSM-13-11-002E 30
30
Control Valve
Overload relief valve
bly procedure.
erly.
• As pressure adjustment with the actual vehicle is difficult, do not disassemble the pressure adjust-
ment section.
[1] Loosen the relief sleeve (1) and remove the cartridge as is.
• Relief sleeve
Hex diameter: 27
• Make sure to reassemble the sleeve in its original location.
[2] Loosen the cap (2), remove the subassembly as is, and remove the spring (3) and the pilot pop-
pet (4).
• Cap
Hex diameter: 24
31 NSM-13-11-002E
31
Control Valve
[3] Remove the pilot seat (5), springs (6) and (7), piston (8), and the main poppet (9).
Center bypass valve

bly procedure.
erly.
[1] Remove the cap (1), spring (2), and spool (3).
• Cap
Hex diameter: 36
NSM-13-11-002E 32
32
Control Valve
Arm regeneration check
bly procedure.
erly.
[1] Remove the cap (1), spring (2), and check (3).
• Cap
Boom back pressure check

bly procedure.
erly.
[1] Remove the cap (1), spring (2), and poppet (3).
• Cap
Hex diameter: 24
33 NSM-13-11-002E
33
Control Valve
Load hold valve
This section explains the disassembly procedure. To assemble, perform the reverse of the disas-
sembly procedure.
erly.
[1] Main unit poppet

1) Remove the socket head bolts (1) and remove the cover assembly (2).
• Before installing the cover for reassembly, confirm that there is an O-ring mounted at the
cover opening.
2) Remove the spring (3) and poppet (4).
NSM-13-11-002E 34
34
Control Valve
[2] Cover section
1) Remove the cap (5), spring (6), and poppet

(7).
• Cap
• For parts that have been in operation for a

long time, the poppet (7) can sometimes not
be removed from the edge of the sleeve seat
surface.Do not force disassembly of parts.
2) Remove the cap (10) and remove the piston
(9).
• Cap
3) Use a pipe with an inner diameter of φ6 and

an outer diameter of φ10 and lightly tap out
the sleeve (8) from the left side.
4) Remove the cap (11), spacer (12), spring (13),

and check (14).
• Cap
35 NSM-13-11-002E
35
Control Valve
Boom regeneration check
bly procedure.
erly.
[1] Remove the cap (1), spacer (2), spring (3), and
check (4).
• Cap
NSM-13-11-002E 36
36
Control Valve
Check valve
This section explains check valve disassembly procedures for the locations listed below.To assem-
ble, perform the reverse of the disassembly procedure.
erly.
Disassembly is explained with the double check valve that is installed on the AM-1 etc.
[1] Remove the cap (1), spring (2), and checks (3)
and (4).
• Cap
• Be careful as the orifice diameter of double
check cap varies depending on the application.
37 NSM-13-11-002E
37
Control Valve
This section explains check valve disassembly procedure for the TL section.To assemble, perform
the reverse of the disassembly procedure.
erly.
[1] Loosen the cap (1) and remove as an assembly.

• Cap
Hex diameter: 30
[2] Remove the cap (2), spring (3), and check (4).
• Cap
NSM-13-11-002E 38
38
Control Valve
Swing priority valve
bly procedure.
erly.
[1] Remove the socket head bolts (1) and remove the priority valve assembly.
• Before installing the assembly for reassembly, confirm that there are O-ring and check part
mounted at the housing opening.
39 NSM-13-11-002E
39
Control Valve
[2] Remove the cap (2), spool (3), and spring (4).
• Cap
• Cap
NSM-13-11-002E 40
40
Control Valve
Check valve (swing priority path)
bly procedure.
erly.
[1] Remove the swing priority valve.

• For removal, see page 39.
[2] Remove the seat (1), check (2), and spring (3).
41 NSM-13-11-002E
41
Control Valve
Arm regeneration valve
bly procedure.
erly.
[1] Remove the cap (1), spring receiver (2), spring

(3), and spool (4).
• Cap
Hex diameter: 24
• There may be a piston (6) attached.
[2] Remove the sleeve (5) and remove the piston

(6).
NSM-13-11-002E 42
42
Control Valve
Travel signal switchover spool
bly procedure.
erly.
• Cap
43 NSM-13-11-002E
43
NOTES:
Other Valves SH200-5
Other Valves
Other Valves
Removal and Installation of Cushion Valve

Items to prepare
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Cushion Valve

the vacuum pump (2).
tank using the vacuum pump.

1 NSM-13-12-002E
1
Other Valves

(6), and then remove the covers (7) and (8).
NSM-13-12-002E 2
2
Other Valves
[6] Use wrenches (17 mm, 19 mm, 22 mm) to
remove the lines (9) and (10).
• Mark the cushion valve and also hoses and
lines so that the connectors match at the time of
assembly.
• Use caps and plugs to cover the cushion valve,
hoses and lines to prevent any entry of water,
dust or dirt.
• Clean the cushion valve, hoses and lines by
spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
12 Wrench (use 17 mm)

3 NSM-13-12-002E
3
Other Valves
(15) on the cushion valve bottom, then remove
the cushion valve.
2. Installation of Cushion Valve

The connections are as follows.
1 Arm in 7 Boom down

2 Boom up 8 Swing left
3 Swing right 9 Bucket open
4 Bucket close 10 Pressure sensor (swing)
5 Heat circuit line 11 Swing priority switching pilot line
6 Arm out 12 Drain line
NSM-13-12-002E 4
4
Other Valves
Assembly and Disassembly of Cushion Valve
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully
selected and fit together, so perform disassembly as little as possible. If assembly and disassembly
is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate the
product warranty.)
[1] Only disassemble in a clean location with minimal dirt.
[2] Use only clean tools and cleaning oil and handle them with care.
[3] Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
[4] Check the internal structure before starting work, and carefully study the disassembly objective
and scope.
(1) Reverse operation spool section
[1] Remove the plugs (1) and O-rings (2).
[2] Remove the springs (3).
[3] Remove the spools (4) with the cap screw and O-ring assembled in them.
Diagram 10
[4] Use a vise to fasten the spools (4) assembly taken out in [3].
[Caution]
Use a piece of wood (jig) to prevent scratches.
5 NSM-13-12-002E
5
Other Valves
[5] Remove the cap screw (1) and O-ring (2).
3 Spool
Diagram 11 4 Piece of wood (jig)
(2) Check plunger section with throttle

[1] Remove the plugs (1) and O-rings (2).
[2] Remove the springs (3) and remove the check plungers (4).
[Caution]
The check plungers have similar shapes, so identify them in such a way that no one will mix
them up with each other.
Diagram 12
NSM-13-12-002E 6
6
Other Valves
(3) Shuttle valve section
[1] Remove the plugs (1) and O-rings (2) and (3).
[2] Remove the steel balls (4).
Diagram 13
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully
selected and fit together, so perform disassembly as little as possible. If assembly and disassembly
is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate the
product warranty.)
[1] Only assemble in a clean location with minimal dirt.
[2] Use only clean tools and cleaning oil and handle them with care.
[3] Clean the disassembled parts and prepared parts.
[4] Study the internal structure before starting the work and prepare the parts required by the disas-
sembly objective and scope.
(1) Reverse operation spool section
[1] Assemble on the spool (3) the cap screw (1) with O-ring (2) attached.
Tightening torque: 9.8 - 14.7 N•m
[Caution]
Use a piece of wood (jig) (4) to prevent scratches.
Diagram 14
7 NSM-13-12-002E
7
Other Valves
[2] Insert the spool assembly (1) assembled in [1] into the body.
[Caution]
The spool assembly is symmetrical left/right, so the insertion direction does not matter.
[3] Insert the springs (2) and assemble the plugs (3) with the O-rings (4) attached.
Diagram 15
(2) Check plunger section with throttle
[1] Insert the check plungers (1).
[Caution]
The check plungers have similar shapes, so be careful to insert each one in its correct posi-
tion.
[2] Insert the springs (2) and assemble the plugs (4) with the O-rings (3) attached.
Diagram 16
NSM-13-12-002E 8
8
Other Valves
(3) Shuttle valve section
[1] Insert the steel balls (1).
[2] Assemble the plugs (2) with the O-rings (3) and (4) attached.
Diagram 17
3. Written Materials
[1] Check plunger table
Orifice diameter
Part number Name Remarks
(φ)
65301-11705 Check plunger 0.5
65301-11706 Check plunger 0.6 SH130-5
65301-11707 Check plunger 0.7 SH130-5, SH240-5
65301-11708 Check plunger 0.8 SH130-5, SH210-5
65301-11709 Check plunger 0.9 SH130-5, SH210/240-5
65301-11711 Check plunger 1.1 SH240-5
9 NSM-13-12-002E
9
Other Valves
[2] Cushion valve assembly diagram
External shape diagram
Cross-section diagram
Code Part name Code Part name Code Part name
1 Body 9 Check plunger 17 Plug
2 Spool 10 Check plunger 18 O-ring
3 Spring 11 Check plunger 19 Name plate
4 Plug 12 Check plunger 20 Drive screw
5 O-ring 13 Spring 21 Plug
6 Cap screw 14 Plug 22 Plug
7 O-ring 15 O-ring
8 Plug 16 Steel ball
NSM-13-12-002E 10
10
Radiator and Oil Cooler SH120
Radiator and Oil Cooler

Removal and Installation of Radiator
・ Do not remove the radiator cap when the radiator coolant temperature is high. Hot liquid
Warning could spray out.

Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 19 mm)
• Pliers
• Wire rope (with the required breaking load)
• Caps
• Plugs
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
1. Removal of Radiator
1 NSM-13-13-002E
1
[2] Install the drain hose (3), and then prepare the
drain tank (4).
[3] To make it easier to drain the coolant, remove

the radiator cap (5).
[4] Loosen the drain plug (6), and then drain the
coolant.
NSM-13-13-002E 2
2

3 NSM-13-13-002E
3
bolts (11) from the radiator cover.

(12), and then remove the upper hose (13) and
lower hose (14) from the radiator.
• Use caps to cover the radiator and hoses to pre-
[9] Remove the drain plug (15), loosen the hose

band (17), and then remove the hose (16).
NSM-13-13-002E 4
4
[10] Loosen the hose band (19), and then remove
the hose (18) from the radiator cap.
• Attach caps or plugs to the hose to prevent any
[11] Turn up the rubber band (20) on the fan.

(21), and then remove the hose (23) from the
hose bracket (22).
• Use caps to cover the hoses and line to prevent
5 NSM-13-13-002E
5
[13] Remove the connector (24) from the sensor.

(25), and then remove the fan shroud (26).

from the fan guard (28), and then move the fan
guard towards the engine.
NSM-13-13-002E 6
6
(29), remove the 2 washers (30), and then
remove the radiator cover (31).
[17] Remove the 2 butterfly bolts (32), and then

remove the front anti-insect net (33).
[18] Install the 2 shackles (34) to the top of the radia-

tor, and then use the wire rope (35) and crane to
lift the radiator.
7 NSM-13-13-002E
7
[19] Lift the radiator together with the radiator cover
(37) until the fixtures (36) at the bottom of the
radiator become disconnected.

before lowering the radiator on square wooden
pieces.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (36).
2. Installation of Radiator
For details on the method for coolant filling, see the Engine Shop Manual.
Coolant capacity is 14.6 L.
Finally, check that the level of coolant is correct.
NSM-13-13-002E 8
8
Removal and Installation of Oil Cooler

Items to prepare
• Hexagon wench (6 mm)
• Pliers
• Screwdriver
• Wire rope (with the required breaking load)
• Caps
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Oil Cooler

[1] Drain the hydraulic oil from the hydraulic oil
tank.
See "Draining Oil from Hydraulic Oil Tank"for
details of thie procedure.
9 NSM-13-13-002E
9
[4] Remove the 2 butterfly bolts (4), and then

remove the anti-insect net (5).
[5] Use a wrench (8 mm) to remove the hose

clamps (6), and then remove the hose (7).

bolts (8), and then remove the line (9).
• Use caps to cover the oil cooler and lines to pre-
NSM-13-13-002E 10
10
[7] Use a wrench (17 mm) to remove the 2 upper
bolts (10) and 2 lower bolts (10) securing the oil
cooler.
[8] Install the 2 eyebolts (M8) (11) on the top of the

oil cooler.
by a half turn.
[9] Use a screwdriver to push in the connecting

part of the line at the bottom of the oil cooler by
about 5 cm.
11 NSM-13-13-002E
11
[10] Install the 2 shackles (12) to the eyebolts, and
then use the wire rope (13) and crane to lift the
oil cooler main unit.

before lowering the oil cooler on wood planks,
etc.
2. Installation of Oil Cooler

NSM-13-13-002E 12
12
Tank SH120
Tank
Tank
Removal and Installation of Hydraulic Oil Tank
・ Bleed off the pressure in the hydraulic oil tank before beginning work.
Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until
the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work.

Items to prepare
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Hydraulic Oil Tank

[1] Drain the oil from the hydraulic oil tank. (For
details, see "Draining Oil from Hydraulic Oil
Tank")
[3] Prepare a waste oil can (3) under the hydraulic

oil tank.
1 NSM-13-14-002E
1
Tank
• Use caps to cover the hose to prevent any entry


(8), and then remove the drain hoses (9) and
(10).
• Use caps to cover the lines to prevent any entry
NSM-13-14-002E 2
2
Tank
remove the drain hoses.
• Mark the hydraulic oil tank and hoses so that
the connectors match at the time of assembly.
• Attach caps or plugs to the hydraulic oil tank
and hoses to prevent any entry of water, dust or
dirt.
• Clean the hydraulic oil tank and hoses by spray-
ing them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
11 Drain hose (use 27 mm wrench)

3 NSM-13-14-002E
3
Tank
[8] Cut the hose bands on the tank side, and tie the
hoses together.

(20), and then remove the top cover (21) from

(22) and 4 spacers (23) from the bottom of the
hydraulic oil tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the location where
they are and how many.

(24) from the fuel tank front cover (tank) (25),
and then remove the cover (tank).
NSM-13-14-002E 4
4
Tank
(26) from the fuel tank side cover, and then
remove the side cover (27).

(28), and then remove the side cover (tank)
(29).
[14] Install the 2 eyebolts (M12) (30) to the top of the

hydraulic oil tank, and then use the shackles
(31), wire rope (32) and crane to lift the hydrau-
lic oil tank (33).
• When lifting, be careful that the level gauge (34)
does not interfere with the frame at the side of
by a half turn.
5 NSM-13-14-002E
5
Tank
before lowering the hydraulic oil tank on wood
planks (35).
• Thoroughly secure the hydraulic oil tank so that
it does not fall down.
2. Installation of Hydraulic Oil Tank

For the tightening torque, check the "Bolt tightening torque list" in the Service Text.
The stipulated capacity of the hydraulic oil tank is 82 L.
After checking operation, check the oil quantity with the level gauge.
NSM-13-14-002E 6
6
Tank
Removal and Installation of Fuel Tank

Items to prepare
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
Removal of fuel tank

[1] Remove the cap (1) and filter (2).
[2] Drain out all the fuel from the fuel tank into a
drum can.
7 NSM-13-14-002E
7
Tank
[3] Use the drain cock (3) on the bottom of the tank
to drain out any fuel that does not drain out but
remains at the bottom of the tank.

(4), and then remove the top cover (5).

from the fuel tank front cover (tank) (7), and
then remove the cover (tank).
NSM-13-14-002E 8
8
Tank
and clamp (9), and then remove the handle
(10).

(11) from the fuel tank side cover (12), and then
remove the side cover.

9 NSM-13-14-002E
9
Tank
[9] Loosen the hose band (15), and then remove
the hose (16).
• Mark the fuel tank and hose so that the connec-
• Attach caps or plugs to the fuel tank and hose to

(18) and 4 collars (19) from the bottom of the
hydraulic oil tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the location where
they are and how many.

(20), and then remove the side cover (tank)
(21).
NSM-13-14-002E 10
10
Tank
[13] Install the 4 eyebolts (M12) (22) on top of the
fuel tank.
by a half turn.
[14] Connect the 4 shackles (23) to the eyebolts,

then use the wire ropes (24) and crane to lift the
fuel tank.
before lowering the fuel tank (25) on wood
planks.
Installation of fuel tank

Finally, carefully check for any fuel leaks.
For the tightening torque, check the "Bolt tightening torque list" in the Service Text .
11 NSM-13-14-002E
11
NOTES:
Attachments SH120
Attachments
Attachments
Removal and Installation of Bucket
・ Stop the machine on a level location with good footing.
・ When working together with others, always be sure to exchange signals and pay adequate
Caution attention to safety.
・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• Hammer
• Striking rod
• Screwdriver
• Grease
• Rag
• Cleaning fluid
1. Removal of Bucket
[1] Place the back of the bucket parallel to the
ground.
[2] Use a screwdriver to remove the pin (2) rings
(1), and then remove the bucket side and boom
side pins.
1 NSM-13-15-002E
1
Attachments
the bucket side pin (6) and arm side pin (5) out,
and then remove the bucket (7).
• If a pin is hard to remove, there is a load on the
pin.
Do not force it. Adjust the bucket position.
• When removing the pins, be careful not to dam-
age the O-rings or dust seals.
2. Installation of Bucket
• Clean each pin and pin hole.
• If a pin is hard to insert, do not force it. Adjust the bucket position.
• When insetting pins, be careful not to damage the O-rings or dust seals.
• As the final step, always grease up.
NSM-13-15-002E 2
2
Attachments
Removal and Installation of Bucket Link
Caution attention to safety.
・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• 2 wrenches (24 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
1. Removal of Bucket Link

[1] Remove the bucket. (For details, see "Removal
and Installation of Bucket".)
[2] Place the bucket link (1) parallel to the ground.
[3] Use 2 wrenches (24 mm) to remove the double

nuts (2), and then pull out the bolts (3) and (4).
3 NSM-13-15-002E
3
Attachments
the pin (7) out and remove the bucket link (8).

the pin (9) out and remove the left arm link (10)
and right arm link (11).
pin.
NSM-13-15-002E 4
4
Attachments
2. Installation of Bucket Link
5 NSM-13-15-002E
5
Attachments
Removal and Installation of Bucket Cylinder
attention to safety.
Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
・ Be sure to inspect the nylon sling and other lifting equipment before beginning work.
Items to prepare
• Hammer
• Striking rod
• Nylon sling (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of Bucket Cylinder

[2] Remove the bucket link. (For details, see
"Removal and Installation of Bucket".)
[3] Bring the arm top in contact with the ground.
Retract the bucket cylinder rod.
[4] Tie the cylinder rod with wire (2) so that it can-
not come out.
NSM-13-15-002E 6
6
Attachments
[5] Switch the key switch (3) OFF to stop the
engine. Switch the key switch ON again, and
then turn the control lever (4) about 10 times to
bleed off any pressure.
Note:
Do not operate the bucket at this time.
[6] Move the travel lever (5) back and forth about 5
[7] Return the key switch to OFF.
[8] Press the air breather button (6) on top of the

the tank.
7 NSM-13-15-002E
7
Attachments
[9] Use 2 wrenches (36 mm) to remove the hoses
(7) and (8).
• Use caps and plugs to cover the hoses and
• Clean the hoses and line by spraying them with
a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
[10] Use a crane and nylon sling (9) to secure the

bucket cylinder (10).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.

and washer (12).
NSM-13-15-002E 8
8
Attachments
the pin (15) out.
pin.
[13] Lift the bucket cylinder (10) and remove it.

[14] Place the bucket cylinder on crossties.
2. Installation of Bucket Cylinder

• When inserting pins, be careful not to damage the dust seals.
9 NSM-13-15-002E
9
Attachments
Removal and Installation of Arm Cylinder
with a hammer.
Items to prepare
• Caps
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of Arm Cylinder

arm cylinder (2).

and washer (4).
NSM-13-15-002E 10
10
Attachments
[3] Use a hammer (5) and striking rod (6) to remove
the pin (7). Be careful. The arm and arm cylin-
der rod may come out of place.
[4] Start the engine, move the arm out at idle, and
retract the arm cylinder (2) rod.
not come out.
11 NSM-13-15-002E
11
Attachments
Do not operate the arm at this time.
[8] Switch the key switch OFF.

the tank.
NSM-13-15-002E 12
12
Attachments
[10] Use a wrench (41 mm) to remove the hose (13)
and use a wrench (36 mm) to remove the hose
(14).

hose (15).

and washer (17).

the pin (20) out.
pin.
13 NSM-13-15-002E
13
Attachments
[14] Lift the arm cylinder (2).
[15] Place the arm cylinder (2) on crossties.
2. Installation of Arm Cylinder

NSM-13-15-002E 14
14
Attachments
Removal and Installation of Arm
with a hammer.
Items to prepare
• Wrench (19 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
1. Removal of Arm
[2] Remove the bucket cylinder. (For details, see
"Removal and Installation of Bucket Cylinder".)
[3] Remove the arm cylinder. (For details, see
"Removal and Installation of Arm Cylinder".)
[4] Bring the arm (1) top in contact with the ground
and use a crane and nylon sling (2) to secure it.
At this time, insert the arm cylinder pin (3) and
secure with the nylon sling.

and washer (5).
15 NSM-13-15-002E
15
Attachments
the pin (8) out and remove the arm (9).
pin.
• Be very careful. When the pin is removed, the
arm may fall slightly.
• Be very careful. The arm may fall over to the
side.
[7] Lift the arm.

[8] Place the arm on crossties.
2. Installation of Arm
NSM-13-15-002E 16
16
Attachments
Removal and Installation of Boom Cylinder
with a hammer.
Items to prepare
• Crowbar
• Wire rope (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of Boom Cylinder

• When removing only the boom cylinder, put the attachments in the temporary decommissioning
posture.
• When removing as far as the boom, first remove the bucket, bucket cylinder, arm, and arm cylinder
according to their respective removal procedures.
Bring the boom top in contact with the ground.
right boom cylinder (2).
17 NSM-13-15-002E
17
Attachments
hose (3).
[3] Use 2 wrenches (24 mm) to remove the 2 dou-

ble nuts (4) and bolt (5), and then remove the
fastening ring (6).

the pin (9) out.
[5] Start the engine, lower the boom at idle, and
retract the boom cylinder rod.
NSM-13-15-002E 18
18
Attachments
not come out.

[9] Switch the key switch OFF.
19 NSM-13-15-002E
19
Attachments
the tank.
[11] Use a wrench (36 mm) to remove the hose (15).

• Mark the lines and hoses so that the connectors

and washer (17).
[13] Use a crowbar to remove the pin (18).
NSM-13-15-002E 20
20
Attachments
[14] Use a crane and nylon sling (1) to lift the right
boom cylinder (2) and remove it.
[15] Place the right boom cylinder (2) on crossties.
[16] Remove the cab side left cylinder (19) with the
same procedure.
2. Installation of Boom Cylinder

21 NSM-13-15-002E
21
Attachments
Removal and Installation of Boom
with a hammer.
Items to prepare
• Slide hammer (24 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Batten
• Square wooden pieces
• Wire
1. Removal of Boom
[2] Remove the bucket cylinder. (For details, see
"Removal and Installation of Bucket Cylinder".)
[3] Remove the arm cylinder. (For details, see
"Removal and Installation of Arm Cylinder".)
[4] Remove the arm.(For details, see "Removal and
Installation of Arm".)
[5] When removing the boom cylinder too, see
"Removal and Installation of Boom Cylinder".
[6] This section explains the procedure for when
not removing the boom cylinder.
Bring the boom (1) top in contact with the
ground.
NSM-13-15-002E 22
22
Attachments
hose (2).
[8] Use a wrench (24 mm) to remove the double

nuts (3) and bolt (4), and then remove the fas-
tening ring (5).

the pin (8) out.
Use a crane and nylon sling (9) to hold the
boom cylinder so that it does not fall.
not come out.
23 NSM-13-15-002E
23
Attachments
nipple (11), and then secure the base of the
boom cylinder with the batten (12).
[12] Lower the boom cylinder and let it rest on the

batten (12).
[13] Remove the cab side boom cylinder from the
boom in the same way.
[14] Install the pin (8) removed in Step [9].

Use a wrench (24 mm) to install the bolt (4) with
the 2 double nuts (3), and then install the fasten-
ing ring (5).
[15] Wrap the nylon sling (9) around the pin installed
in Step [13] and secure with the crane.
NSM-13-15-002E 24
24
Attachments
remove the hoses (13), (14), (15), (16), (17) and
(18).
• Mark the hoses and lines so that the connectors
13 Bucket hose (use 36 mm wrench)

14 Bucket hose (use 36 mm wrench)
15 Arm hose (use 36 mm wrench)
16 Arm hose (use 41 mm wrench)
17 2nd option hose (use 22mm wrench)
18 2nd option hose (use 22mm wrench)

and washer (20).
[18] Use a slide hammer (21) (24 mm) to remove the

pin (22).
25 NSM-13-15-002E
25
Attachments
[19] Back up the machine and remove the boom (1).
2. Installation of Boom Cylinder

NSM-13-15-002E 26
26
Attachments
Removal and Installation of Arm HBCV
・ Stop the machine in the temporary decommissioning posture on a level location with good
footing.
Caution ・ When working together with others, always be sure to exchange signals and pay adequate
Items to prepare
• Wrench (22 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Arm HBCV

[1] Use a wrench (22 mm) to remove the pilot hose
(1) and drain hose (2).
• Mark the HBCV and hoses so that the connec-
HBCV to prevent any entry of water, dust or dirt.
• Clean the hoses and HBCV by spraying them
tors.

hexagon socket head bolts (3), and then remove
the line (4).
• Use caps and plugs to cover the HBCV and
• Clean the HBCV and lines by spraying them
tors.
27 NSM-13-15-002E
27
Attachments
the arm HBCV (6).
2. Installation of Arm HBCV

The tightening torque for line installation and HBCV installation is 51.2 ± 9.6 N•m.
NSM-13-15-002E 28
28
Attachments
Removal and Installation of Boom HBCV
Caution ・ When working together with others, always be sure to exchange signals and pay adequate
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Crossties
1. Removal of Boom HBCV

[1] Use wrenches (19 mm, 22 mm) to remove the
hoses (1), (2), (3) and (4) from the tool box side
boom HBCV.
tors.
1 Pilot hose (use 19 mm wrench)


the line (6).
tors.
29 NSM-13-15-002E
29
Attachments
the boom HBCV (8).
[4] Use wrenches (19 mm, 22 mm) to remove the

hoses (1), (3), (4) and (9) from the cab side
boom HBCV in Step [1].
[5] Use a wrench (27 mm) to remove the boom bot-
tom pressure sensor (10).
tors.

hexagon socket head bolts (11), and then
remove the line (12).
tors.
NSM-13-15-002E 30
30
Attachments
hexagon socket head bolts (13), and then
remove the boom HBCV (14).
2. Installation of Arm HBCV

Line installation bolt tightening torque: 26.3 ± 4.9 N•m
HBCV installation bolt tightening torque: 51.2 ± 9.6 N•m
31 NSM-13-15-002E
31
Attachments
Operation and Assembly/Disassembly of Hydraulic Cylinder
1. Specifications and Structure Diagram (including the assembly diagram and parts table)
This manual explains the KCH-6 model construction machine hydraulic cylinder, which has a struc-
ture typical of such cylinders.
For details on the specifications and structure of the product being used, see the delivery diagram
(including the assembly diagram and parts table) given separately.
2. Operation Explanation
(1) Basic functions
Hydraulic cylinders are a type of hydraulic actuator. A hydraulic cylinder converts the energy of
pressure supplied from the hydraulic pump into a large force of linear motion. By operating the
hydraulic pressure direction switchover valve, one can switch the direction of operation between
extension and retraction. This linear motion with large force and the switchover of the operation
direction are the basic functions.
(2) Function of each location
This manual explains the functions of each section of the cylinder using one of our products with
a typical structure. There may be some slight differences with the product being used, but the
functions are the same.
1) Cylinder head assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4)
press fit into the interior diameter of the cylinder head (3). The seal system of the interior diam-
eter of the cylinder head prevents oil from leaking to the outside and prevents foreign matter
from getting into the cylinder. The cylinder head assembly also has the function of supplying
and discharging high-pressure oil from inside the cylinder tube to the retraction side port.
1 Cylinder tube 7 U-ring

2 Piston rod 8 Backup ring
3 Cylinder head 9 Wiper ring
4 Bushing 10 O-ring
5 O-ring 11 Backup ring
6 Buffer ring 12 Installation bolt
• Bushing
Press fit to the inside surface of the cylinder head (3) and contacts the piston rod (2). Together
with the slide rings (18) and (19) on the outer circumference of the piston, the bushing divides
the lateral load applied to the cylinder and moves linearly relative to the piston rod. Further-
more, it supports one end of the piston rod and has the function of minimizing eccentricity
which has a negative impact on the sealing.
• Buffer ring
The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7)
by the hydraulic oil to improve durability.
NSM-13-15-002E 32
32
Attachments
• U-ring and backup ring
The U-ring (7) seals the pressurized oil within the cylinder. The U-ring also has the function of
forming an appropriate oil film on the surface of the piston rod in order to prevent rust of the
piston rod (2). The backup ring (8) has the function of suppressing extrusion of the U-ring into
the gap between the piston rod and the cylinder head (3) when the pressure operates and of
improving durability.
• Wiper ring
The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and
goes into the cylinder and prevents dust and water from getting into the cylinder from the out-
side. It also has the function of wiping off any mud sticking to the surface of the piston rod as
the piston rod moves.
2) Piston assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring
(16) is mounted on the center of the piston (15) to prevent the flow of pressurized oil from either
the left or right chamber to the other chamber. There are slide rings (18) and (19) mounted at
each end of the seal ring. They have the function of a bearing to receive the cylinder lateral
load.
1 Cylinder tube 19 Slide ring

2 Piston rod 20 Locking screw
13 Cushion ring 21 Steel ball
14 Cushion seal 22 Cushion ring
15 Piston 23 Cushion seal
16 Seal ring 24 Stopper
17 Backup ring 25 Snap ring
18 Slide ring
33 NSM-13-15-002E
33
Attachments
For some cylinder sizes, the piston (15) and nut (21) are separate.
1 Cylinder tube 20 Shim

2 Piston rod 21 Nut
13 Cushion ring 22 Locking screw
14 Cushion seal 23 Steel ball
15 Piston 24 Cushion ring
16 Seal ring 25 Cushion seal
17 Backup ring 26 Stopper
18 Slide ring 27 Snap ring
19 Slide ring
Example of parts numbers for separated piston and nut

• Seal ring and backup ring
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of
the O-ring to seal the ring-shaped gap between the piston and the cylinder tube (1) and form
chambers with a high-pressure side and a low-pressure side with the piston as the boundary.
The backup ring (17) has the function of suppressing extrusion of the seal ring into the gap
between the piston and the cylinder tube when the pressure operates and of improving dura-
bility.
• Slide ring
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of
the cylinder tube (1). Together with the bushing (4) positioned on the inside surface of the cyl-
inder head (3), the slide ring divides the lateral load applied to the cylinder and moves linearly
relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing
eccentricity, which has a negative impact on the sealing, and buries and captures any impuri-
ties trapped between the cylinder tube and the slide rings (18) and (19).
• Cushion ring
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together.
When it is fully retracted, the cylinder bottom and the cushion ring fit together. In both cases,
this forms a ring-shaped gap and squeezes the oil to reduce the cylinder collision speed at full
extension or full retraction and thus soften the impact.
NSM-13-15-002E 34
34
Attachments
3) Pipe assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder
tube assembly. It has the function of supplying and discharging high-pressure oil by connecting
with the hydraulic circuits of the machine body.
28 Pipe assembly
29 Pipe assembly
35 NSM-13-15-002E
35
Attachments
3. Handling Precautions
(1) Precautions for installing the cylinder on the machine body
• When installing the cylinder on the machine body or removing it from the machine body, secure
the piston rod at the fully retracted position, check safety, and suspend.
Never suspend the cylinder from the line section. This would not only pose the danger of falling
but could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state. If the piston rod is not in the fully
Caution retracted state, it could be easily damaged. This could create the need for repair or make the
piston rod unusable. Also, not securing the piston rod is dangerous because the piston rod
might fly out unexpectedly.
• Do not weld after the cylinder has been mounted on the machine body.
Electric welding on the cylinder or even at a position separated from the cylinder can generate
Caution a spark within the cylinder and damage parts. This could cause extensive damage, making it
necessary to replace parts or replace the cylinder.
• When painting the machine body, mask the piston rod and wiper ring.
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the
wiper ring does not function adequately, greatly interfering with cylinder functions. For example,
Caution dirt and paint from the outside may get into the cylinder easily and damage seal parts and
cause an oil leak.
• Clean the cylinder before installing it.
(2) Usage cautions

• Use under the determined conditions.
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to
seal parts. If the relief valve is set to a value higher than that on the assembly diagram, there is
a danger of this leading to cylinder damage.
General sealing materials cannot handle high ambient temperature (about 100 ℃ or higher) or
low ambient temperature (-20 ℃ or lower), so the cylinder would be damaged if used at such
Caution temperatures. Such temperatures require special seal materials, so check if the cylinder being
used complies with this requirement.
The number one cause of cylinder trouble is oil leaks due to piston rod scratches. Operate very
carefully to avoid scratching the piston rod.
If the piston rod is scratched, handle this according to "Trouble Diagnostics".
• Warm up the equipment adequately before work.
After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck
to the metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
A new cylinder or one that has been left unused for a long time has much air built up inside, so
it does not operate smoothly. Also, if one suddenly operates or pressurizes the cylinder without
Caution bleeding out the air, the adiabatic compression of the air generates high temperatures, which
may burn and carbonize seal parts, leading to a drastic drop in functioning.
Before starting work, always warm up the cylinder by moving slowly through a few full strokes
under no load to bleed off any air in the cylinder.
NSM-13-15-002E 36
36
Attachments
• Always put the machine in a safely secured posture when stopping it temporarily or storing it.
When extended, the cylinder cannot hold a load for a long time in a fixed position. This is
because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil tempera-
Caution ture variation. This results in the danger of machine moving unexpectedly, which can lead to
serious accidents.
Always put the machine in a safely secured position before stopping it temporarily or storing it.
(3) Maintenance and inspection cautions

• Always carry out daily maintenance inspections.
The most important point for realizing the cylinder functions for a longer time is "daily mainte-
nance inspections".In order to ensure adequate cylinder functioning, execute "4. Maintenance
Inspection and Service".
Caution Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the
piston rod in a clean state. However, do not use water or the like to clean the wiper ring section
and seal section. Wipe with a rag. When leaving the machine unused for a week or longer,
apply anti-rust oil to the surface of the piston rod in order to prevent rusting.
• Use genuine KYB parts for replacement parts.
If replacement parts are used that are not genuine KYB parts, adequate functioning cannot be
attained. Always use genuine KYB parts.
Caution Specialty jigs have been produced so that assembly work and disassembly work can be done
safely and quickly, so order them.
• Be careful about assembly and disassembly too.
Disassembling a cylinder still installed on the machine body is extremely dangerous because it
can cause unexpected movement of the machine body. Always remove the cylinder from the
machine body before disassembling it.
Caution Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder
service life but also damage other hydraulic equipment. Assemble under clean conditions.
Use the thread part tightening torque indicated in the diagram. If the torque is either too low or
too high, this can cause thread damage.
• Strictly observe the cylinder storage standards.
Caution Execute according to "7. Assembly and Disassembly Procedures".
37 NSM-13-15-002E
37
Attachments
4. Maintenance Inspection and Service
In order to ensure a hydraulic cylinder functions properly for a long time, periodically carry out main-
tenance inspection and service based on the "Autonomous inspection table". Repair any trouble
locations quickly based on the trouble diagnostics.
For periodic inspection and service, first work to prevent any hazard to operators. Strive to pre-
Caution vent hazards by working with an attitude based on good sense.
Inspection
and service Inspection and service detail Daily Monthly Yearly Remarks
location
Is the cylinder clean (especially rod sliding sec-
tions)? ○
Appearance Is any oil leaking from line installation sections or

other fixed sections? ○
Is there missing or peeling paint, or rust? ○

Is operation smooth and free of abnormal noise
and any other abnormality? ○
Is the responsiveness good? ○

Operation Is any oil leaking from sliding sections? ○
Are there internal leaks? ○
Is the pressure used normal? ○
Is the overload relief valve set pressure normal? ○
Is hydraulic oil dirty or deteriorated? ○
Hydraulic oil Is hydraulic oil replaced periodically? ○
Are filters inspected periodically? ○
Is the supply of grease to pins adequate? ○
Do pin sections have any abnormal noises or seiz-
ing? ○
Main unit
installation Do pin sections have any backlash or wear? ○
section Are pin seals normal? ○
Are any installation screws loose or fallen out? ○
Retighten installation screws. ○
Are sliding sections worn? ○ When leaving piston
Are sliding sections scratched or dented? ○ rod sliding sections
Piston rod exposed for long
section
Is sliding section plating peeling off? ○ periods, apply anti-
Are sliding sections bent? ○ rust oil to the piston
rod.
Are there any welding section cracks or damage? ○
Are there any loose bolts or nuts (threaded parts)? ○
Cylinder Retighten threaded installation parts (bolts and
tube section nuts (threaded parts)). ○
(including
line sections) Are there any welding section cracks or damage? ○
Are there large dents on the tube? ○
NSM-13-15-002E 38
38
Attachments
5. Trouble Diagnostics
Hydraulic cylinder trouble, countermeasure and solution
It is not easy to discover trouble locations. The table below shows general symptoms, suggested
causes and also solutions.
For repairs, see the possible causes and solutions in the table.
The cause of machine problems are often not rooted in just a single part. Problems are often due to
the relationship of one part with another. In some cases, solutions are required other than those
given in the table. In such a case, contact with our company to investigate the problem and its cause
further and take appropriate measures.
Item Symptom
Piston rod sliding section oil leak
1
(For the judgment values, see "7. (4) Inspection after assembly".)
2 Cylinder head matching section oil leak
3 Pipe and cylinder tube welding section oil leak
4 Operation defect
Item Symptom Related part Symptom Countermeasure and solution
(1) Remove the scratches with a whetstone to make the

sliding surface smooth (1.5 s max.). If the oil leak
continues, the rod scratches may have damaged the
A sliding surface has rust
U-ring or other seal, so disassemble and inspect.
and scratches that catch
on a fingernail. (2) If the scratches or rust cover too large an area to be
Piston rod repaired with a whetstone, replace the piston rod
and the U-ring, wiper ring, or other seal and the pis-
ton rod bearing part.
(1) Replate or replace the piston rod.

Plating is peeling off. (2) At this time, inspect the seals and piston rod bearing
part as well and replace any that are damaged.
There is foreign matter
(1) Remove the foreign matter.
caught in the interior or
exterior diameter section. (2) If the packing is damaged, replace it.
There are scratches on
the interior or exterior Replace the part.
diameter section.
Piston rod sliding (1) This may be scorching due to adiabatic compres-
1
section oil leak The lips and groove sec- sion of air remaining in the cylinder.
tion are locally carbon- (2) When operating the cylinder for the first time after
ized (scorched). replacing a packing, run at low pressure and low
speed to adequately bleed off the air.
Rod packing The packing has lost its (1) Replace the part.
(Buffer ring and rubber elasticity and is in (2) This may be the end of the packing service life,
U-ring) tatters. deterioration of the hydraulic oil, or high temperature
of the hydraulic oil.
a. Replace the hydraulic oil.
The lip section is defec- b. Check the temperature of the hydraulic oil. (The
tive all the way around. oil temperature should be no higher than 80 ℃ .)
c. Check for local high temperature.
(1) Replace the part.

(2) Abnormally high pressure may be operating on the
There is major extrusion packing.
of the packing heel sec- a. Check the pressure during operation.
tion. b. There may be trouble with the buffer ring sec-
tion.
Inspect the buffer ring section.
39 NSM-13-15-002E
39
Attachments
(1) As a rule, replace the rod packing too at the same

time.
The part is greatly
Backup ring (2) Abnormally high pressure is often the cause. The
deformed.
check items for this are the same as those given
above for packing heel section extrusion.
There is foreign matter
Remove the foreign matter.
caught in the lip.
Wiper ring The lip is damaged.
There is other abnormal Replace the part.
damage.
Piston rod sliding There is major wear of
1
section oil leak the bushing and the gap
with the piston rod
Replace the part.
exceeds the limit on inte-
Bearing part rior diameter wear in "7.
(bushing) (9) Usage limits".
(1) Replace the part.

There are large scratches
on a sliding surface. (2) Inspect the piston rod sliding surfaces for scratches
and rust.
(1) Remove the scratches or rust with a whetstone.

A seal mounting section
Cylinder head (2) If the repair does not solve the problem, replace the
has scratches and rust.
cylinder head.
(1) Remove the foreign matter.

(2) If the O-ring is damaged, replace it.
(3) Tube interior surface inspection: If there are any
There is foreign matter scratches or rust, use a whetstone to make the sur-
caught in the interior or face smooth.
O-ring
exterior diameter. There (4) Cylinder head O-ring groove inspection: Same as
is damage to the O-ring. above
(5) Backup ring inspection: If the backup ring is
deformed or extruded, replace it.
Check the above and replace the O-ring.
The part is deformed or
Backup ring Replace the backup ring together with the O-ring.
extruded.
Cylinder head
2 matching section (1) Disassemble the cylinder head and inspect the O-
oil leak ring and backup ring. If there is damage, replace.
(2) Check the tube and cylinder head threads for dam-
Cylinder
A part is loose. age and if there is any damage, replace.
head
(3) When the inspection is complete, tighten to the
specified torque.See "7. (7) Assembly procedure".
(4) Stop rotation.
There is looseness,
Bolt Replace all the bolts and tighten to the specified torque.
stretching or breakage.
(1) Replace with a new one.

There is abnormal swell- (2) Oil leaks at matching sections may be caused by
Cylinder tube abnormally high pressure (including cushion pres-
ing.
sure), so if the tube is swollen or deformed, replace
it with a new one. Also inspect the circuit pressure.
NSM-13-15-002E 40
40
Attachments
Replace with a new one.
Caution (See page 41)

Pipe and cylinder
Pipe and cylin- There are cracks on the
tube welding sec-
der tube welding section. The crack progresses and ultimately the part fractures.
tion oil leak
A fracture is extremely dangerous, so if a crack is seen,
quickly stop work and replace that part.
3 Welding over a crack is ineffective.
Line fastening bolt is Tighten to the specified torque according to the work
loose. procedure.
Oil leak from cylin-
der line connec- Pipe assembly The line is bent. Replace with a new one.
tion section
There are scratches on a (1) Use a whetstone to make the surface smooth.
contact surface. (2) If the oil leak does not stop, replace.
The bending is large and
exceeds the stipulated
Piston rod (2) There may also be damage to seals and sliding
bend warp.
Cylinder tube parts, so inspect them. If there is any abnormality,
(Bend warp: See "7. (3)
Maintenance standards".) replace.
Operation defect Replace with a new one. Inspect the seal and sliding
Cylinder tube There are dents.
Movement is not parts the same as above.
smooth.
Abnormal wear of sliding
Inspect the seal and sliding parts the same as
Piston rod parts and damaged pis-
above.
Cylinder tube ton section or foreign
Sliding parts matter caught at the cyl- (2) Remove the foreign matter.
inder head sliding section Inspect the seal and sliding parts the same as
above.
There are scratches, Replace with a new one.
Piston seal
wear, or other damage. Also inspect the cylinder tube interior surfaces.
Internal oil leak (1) Use honing or a whetstone to eliminate the

The piston rod scratches and rust and make the surface smooth. If
There are scratches and
extends and Cylinder tube the scratches cover too large an area to be repaired,
rust on interior surface.
retracts on its own replace the cylinder tube with a new one.
4 and drops abnor- (2) Replace with a new piston seal.
mally during oper- (1) Tighten to the specified torque.See "7. (7) Assembly
ation. procedure".
Also, the stipu-
Piston nut Tightening is insufficient. (2) The piston rod thread section could be stretched.
lated speed is not
Measure the diameter where the rod and piston fit
output.
together and if this area is tapered, replace the pis-
ton rod assembly.
Valves Leak from valve. Inspect the amount of valve leakage and service.
Bleed out the air.
a. Cylinder with no air bleeding
Bleed out the air by moving the cylinder back and
forth at few times at low pressure and low speed.
b. Cylinder with air bleeding (air breather)
After securing the machine so that the cylinder does
Operation is There is air remaining in
Air not move, bleed the air from the air breather.
unsteady. the cylinder.
[Tip]
The cylinder extends or retracts somewhat when the
cylinder stops suddenly. This phenomenon occurs
due to the compressibility of the hydraulic oil. This
occurs particularly easily for cylinders with long
strokes.
41 NSM-13-15-002E
41
Attachments
The impact is high
The gap between the
when switching
Pin bushing installation section and Measure the pin and pin bushing dimensions and
over between
Pin the pin bushing is replace any part that exceeds its stipulated dimension.
extension and
enlarged.
retraction.
The oil or grease feed is
Cylinder sliding Apply oil or grease.
Pin bushing inadequate.
4 operations make
Pin There is seizing at
sounds. Replace with a new part and apply oil or grease.
matching section.
Caution
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.
NSM-13-15-002E 42
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Attachments
6. Storage Standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent
trouble during storage and to extend the product service life, pay attention to the following items.
1) Storing the cylinder alone (In principle, store indoors.)
• Store the cylinder off the floor and do not store in any location with high temperature and
humidity, corrosive gas or liquids.
• Before shipment, we operates the cylinder with hydraulic oil to which a fixed quantity of vapor-
izing anti-rust agent has been added (in order to prevent rust within the cylinder), carries out
the pre-shipping inspection, then retracts the piston rod with ultra-dry air (condensation point -
35 ℃ or lower) (in order to prevent condensation due to temperature difference), and then puts
caps on the ports and line joints before shipping the cylinder.
• Any product that has been storage in our product warehouse longer than the standard storage
period is disassembled and inspected before being shipped. Therefore, do not store or leave a
cylinder unused with a cap removed or with the remaining oil in the cylinder drained.
Storage for 1 month Storage for 6 months or longer
Storage for 1 year or longer
or longer (3 months for cylinder alone)
Clean any dust from the Operate the cylinder back and
Since there is a danger of packing
cylinder, and then apply forth with clear hydraulic oil, and
deterioration, disassemble,
anti-rust oil to the pin bush- then pour anti-rust oil into the cyl-
(1) inspect, and replace packings.
ings, flange sections, pis- inder and store in compliance
Also, check for rust inside the cyl-
ton rod, and other sections with the items on the left for stor-
inder.
that rust easily. age of 1 month.
If a cylinder that has been stored
If the cylinder cannot be oper- for a long time is used as is, oil
(2) -
ated, seal in anti-rust oil. may leak due to temporary run-
ning-in defects of seals.
(3) When storing a cylinder, be extremely careful not to drop it, let it collide with anything, strike it.
2) Mounted on vehicle body

(1) Operate the cylinder at least once per month
(2) Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply
anti-rust oil at least once per month to the exposed part of the piston rod.
(3) Handle carefully to absolutely avoid scratching the piston rod.
(4) When putting the cylinder into an environment where rust occurs particularly easily, for example due
to exposure to sea breezes during export, always apply anti-rust oil to the piston rod and as much as
possible protect with polyethylene sheets or VCI paper (vaporizing anti-rust paper).
(5) Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully
and as much as possible keep it off dust seals etc.(For details on anti-rust oil to select, see "6. 3) Rec-
ommended anti-rust oil".)
3) Recommended anti-rust oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
b. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 % - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked surfaces other
Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
than parts with oil sealed in
43 NSM-13-15-002E
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Attachments
7. Assembly and Disassembly Procedures
(1) Preparations ......................Prepare the following before starting disassembly.
[1] Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or
move during work.
[2] Tool and materials preparation
Prepare the tools and materials shown on the following pages.
[1] Clean any dirt or mud from the outside walls of the cylinder before starting disassembly.
[2] Each part has been manufactured with a high degree of precision, so be careful not to let
[3] If parts are struck or pried off with excessive force during work because they are tight, this
may cause burrs or damage which causing reduction in performance or oil leaking. Perform
work carefully and thoroughly.
[4] If a cylinder is left disassembled, humidity and dirt can cause rust on parts. If a pause in the
work is unavoidable, be careful to prevent rust and keep off dust.
(3) Maintenance standards
Replace sliding parts and seal parts as follows.
[1] Bushing ........................When 1/4 of the circumference is worn brown over the entire length
[2] Seals and slide rings ....Replace with new parts when the cylinder is disassembled.
[3] Pin bushing ...................When there is severe seizing
[4] Piston rod .....................When the piston rod is bent more than 0.5 mm / 1 m
NSM-13-15-002E 44
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Attachments
(4) Inspection after assembly
Dimension
Check the fully retracted length and stroke as instructed on the diagram.
inspection
Pressure
Check for looseness, permanent deformation, and external leaks when the test pres-
withstand
sure instructed on the diagram is applied to each stroke end for at least 3 min.
inspection
Check the amount of oil leak at the rod section.
・ Judgment value for rod section oil leak
Move the piston rod back and forth 20 times with the oil at a temperature from 20 ℃
to 40 ℃ , and then judge by the state of the oil ring formed on the rod surface. If the
oil ring is in a broken down A state, this is judged to be trouble.See "5. Trouble Diag-
nostics" for information on how to solve this.
External leak
inspection
Oil leak amount unit: ml/10 min

Interior Interior Interior
Oil leak Oil leak Oil leak
diameter diameter diameter
amount amount amount
(mm) (mm) (mm)
Internal leak 32 0.4 160 10.0
inspection
40 0.6 100 4.0 180 12.6
50 1.0 125 5.6 200 15.6
63 1.6 140 6.0 220 20.0
80 2.3 250 22.0
45 NSM-13-15-002E
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Attachments
(5) Required tools
1) General tools
No. Tool name Q'ty
Screwdriver
1 1
(flathead screwdriver)
2 Hexagon wrench 1 set
3 Vise 1
Wrench
4 1 set
(for piston nuts)
5 Punch 1
6 Torque wrench 1 set
Hammer
7 1
(plastic hammer)
8 Monkey wrench 1
9 Scoop 1 set
NSM-13-15-002E 46
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Attachments
2) Special jig
Cylinder assembly requires the following special jigs.
Jig name Sketch
For bushing removal and press fitting
For wiper ring press fitting
Seal ring insertion jig
Seal ring calibration jig
For cylinder head insertion
For piston insertion
Consult with our company about jigs.

(The following page has a list of jig part numbers.)
47 NSM-13-15-002E
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Attachments
3) Special jigs part number list
[1] Select jigs for the cylinder head according to the rod diameter.
[2] Select jigs for the piston according to the cylinder bore.
Applicable rod diameter Set part number

65 3006J-56001
70 3007J-06001
75 3007J-56001
80 3008J-06001
85 3008J-56001
Cylinder head assembly and
90 3009J-06001
disassembly jig
95 3009J-56001
100 3010J-06001
105 3010J-56001
110 3011J-06001
115 3011J-56001
120 3012J-06001
Applicable cylinder bore Set part number
95 3009J-51001
100 3010J-01001
105 3010J-51001
110 3011J-01001
115 3011J-51001
120 3012J-01001
Seal ring insertion and cali-
125 3012J-51001
bration jig
130 3013J-01001
135 3013J-51001
140 3014J-01001
145 3014J-51001
150 3015J-01001
160 3016J-01001
170 3017J-01001
NSM-13-15-002E 48
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Attachments
(6) Disassembly Procedure
1) Drain the oil.
2) Secure the cylinder.
Secure the cylinder in a vertical or horizontal
position. A vertical position makes assembly
and disassembly easier. Secure the cylinder
using the bottom pin hole and stop rotation
and secure the axis position.
(When securing the cylinder, if a line or the
like interferes, remove it.)
3) Removal of cylinder head
Use a hexagon wrench to loosen the cylinder
head tightening bolts and remove them.
Passing a pipe through the hexagon wrench
as in the diagram below makes the work eas-
ier.
49 NSM-13-15-002E
49
Attachments
4) Pull out the piston rod.
[1] Check that the line caps are removed.
[2] Put the oil pan at the retraction side (cylinder head side) port.
[3] With the piston rod pulled out all the way, slowly pull out the cylinder head and remove it.
[4] Pull out the piston rod together with the cylinder head and place them on crossties.
・ When assembling and disassembling with the cylinder secured

vertically, work paying particular attention to the following
points.
In the work of removing the piston rod, the cylinder head may
come out of the cylinder tube ahead of the piston due to fric-
Caution tion with the packing, creating a condition in which there is
space between the cylinder head and the piston.
If the work is done in that state, the cylinder head may sud-
denly slip out and injure the operator. Always work with the cyl-
inder head touching the piston.
Working in the vertical state
Working in the horizontal state

・ When assembling and disassembling with
the cylinder secured horizontally, work pay-
ing particular attention to the following
points.
In the work of removing the piston rod,
Caution there is a danger of the piston rod falling
and damaging parts right after it is
removed.
Work carefully while holding the rod hori-
zontal and in contact with the crossties.
Beware of falling
5) Secure the piston rod.
Use the rod head bolt width or pin hole to set
up a rotation stopper.
NSM-13-15-002E 50
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Attachments
6) Remove the piston nut.
[1] Remove the locking screw (3).
Locking screw is caulked in with a punch at
2 locations on the outer circumference.
Cut away the caulked sections with a hand
drill (1), and then loosen the locking screw.
[2] Remove the steel ball (2) at the bottom of
the locking screw (3).
[3] Remove the piston nut.

• The piston nut is tightened with the torque
specified in the assembly diagram.
• Loosening a piston nut requires about 1.5
times that torque. Prepare the power
wrench (6) that uses the hydraulic jack (4)
and hydraulic cylinder (5).
* For a one piece piston and nut, apply
the wrench to the hexagonal section of
the piston and loosen the piston directly.
7) Removal of piston etc.

Remove the piston (9), cushion ring (8), and cylinder head (7) in that order.
51 NSM-13-15-002E
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Attachments
8) Retraction side cushion ring disassembly
10 Rod threaded section

[1] Remove the piston nut. The cushion ring cannot be disassembled with the piston nut
attached.
[2] Remove the snap ring (12). Remove by gently tapping with a plastic hammer in such a way
as to not scratch the piston rod (11) or cushion ring (14).
[3] When the cushion ring (14) is slid to the piston rod thread (11) side, the stopper (split in two)
(15) can be removed.
[4] Remove the cushion ring (14).
[5] The cushion seal (13) has a split opening, so spread the opening wide and remove the cush-
ion seal.
9) Removal of the piston seal.
[1] The slide rings (22) and backup ring (20)
can be removed easily by hand.
[2] As in the diagram on the right, secure the
piston (17) in a vise (18) using hardwood
(21) and stand up a flathead screwdriver
(23) and tap on it with a hammer to cut
through the seal ring (16) and remove it.
[3] Pull out the O-ring (19) with a scoop.
* The removed seal parts cannot be
reused.
NSM-13-15-002E 52
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Attachments
10)Disassembly of buffer ring
[1] The buffer ring (27) is mounted in the
groove on the interior diameter of the cylin-
der head. When removing this seal, stick in
a sharp tool and lift it up, and then insert a
scoop and take it out.
* The removed seal parts cannot be
reused.
31 Bushing
11)Disassembly of U-ring and wiper ring

[1] Use a screwdriver to remove the U-ring (26) and backup ring (25).
[2] The wiper ring (24) is press fit.
Stick a screwdriver straight down into the rubber and tap it to remove the wiper ring.
* The removed seal parts cannot be reused.
12)Removal of O-ring and backup ring

[1] Pull out the O-ring (29) and backup ring
(30) with a scoop.
13)Disassembly of bushing
[1] Raise the snap ring (28) with a screwdriver,
and then remove it from the cylinder head.
[2] For the bushing (33), use the bushing
removal jig (32) as in the diagram on the
right and press out the bushing with a
press.
14)Removal of pin bushing

[1] Remove the wiper ring (24) from the tube
and piston rod. Remove it by using a
screwdriver in the same manner as for the
cylinder head.
[2] As in the diagram on the right, use a press
(34) and jig (36), and place a metal pin (35)
in place to remove the pin bushing (37).
15)Cleaning and storage

Clean the removed parts with white kerosene, and then apply hydraulic oil, cover the parts, and
store them.
If they are left disassembled, there is a danger of their collecting rust and dust and not being
able to function adequately after they are assembled again.
53 NSM-13-15-002E
53
Attachments
(7) Assembly procedure
If a part with peeling paint is assembled, the peeled off paint can get inside the cylinder.
Caution This causes oil leaks, so work being very careful to prevent this.
1) Installation of pin bushing

[1] Use the press (1) and installation jig (2) to press fit the pin bushing (3) to the piston rod (4)
and tube.
(Apply hydraulic oil in advance.)
[2] Use the metal block (5) to install the wiper ring (6).
2) Replacement of seal
[1] When reassembling the cylinder, replace
all the seals.
[2] O-rings
• Mount the backup ring (7) and O-ring (8)
after thoroughly cleaning the cylinder head
(9) O-ring mounting groove.
Foreign matter in the grove section would
cause an oil leak.
• Be careful about the location of the backup
ring.
• Apply grease or hydraulic oil to the backup
ring and O-ring so that they slide easily,
and then attach them. If they are sliding
poorly, O-ring may become twisted during
assembly, which causes oil leaks.
NSM-13-15-002E 54
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Attachments
3) Assembly of cylinder head assembly
[1] Place the cylinder head (12) on the pressing base (13) and use the bushing press-fit jig (10)
to press fit the bushing (11) to the press (14).
Apply hydraulic oil to the inside surface of the cylinder head in advance and after press fit-
ting, check that there is no level difference at the bushing.
[2] Use the wiper ring press fit jig (15) to press fit the wiper ring (16).
[3] Mount the backup ring (18) and U-ring (19) in the U-ring groove (17) in that order.
• Check the assembly direction of the U-ring and mount it carefully so as not to scratch it.
Installing the U-ring backwards would cause an oil leak.
• After mounting, check that there are no wrinkles or other permanent deformation remaining
in the U-ring.
[4] Mount the buffer ring (20).

Be careful with the attachment directions of the seals.
If the seal is installed backwards, extraordinarily high pressure will be generated between
the seal and the U-ring (19), causing deformation and breakage of the cylinder.
[5] Assemble the bushing retainer snap ring (21).
55 NSM-13-15-002E
55
Attachments
4) Assembly of piston assembly
[1] Assemble the seal ring (24).
• Attach the back-up ring (23) for one side
and the O-ring (25) on the piston (26) in
advance, place the piston on the press
platform, place the seal ring insertion jig
(22) against the metal block (28), and use
the press (29) to attach the seal ring.
[2] Correct the seal ring.
• Mount the seal ring (24) and the other
backup ring (23), and then immediately
correct with the seal ring calibration jig (27)
so that the seal ring does not remain
expanded. (Strictly observe this instruc-
tion.)
Since the seal ring is stretched when it is
mounted, if it is not calibrated, "6) Insertion
of piston rod into the tube" is not possible.
[3] Assemble the slide ring.
• Spread the cut section of the slide ring the
minimum with both hands and install from
the axial direction.
If it is spread too wide, it cannot be
mounted.
* Consult with our company about jigs.
5) Assembly of piston rod assembly
[1] Secure the piston rod (31).
[2] Assemble the cylinder head (32) on the pis-
ton rod (31).
Be careful that the wiper ring and U-ring
lips do not catch on the stepped section.
Use the cylinder head insertion jig (30) as
in the diagram on the right to assemble the
cylinder head on the piston rod.
• Apply grease or oil and assemble being
careful not to scratch the packing.
[3] If there is a cushion on the extension side,
assemble the cushion ring (33) and cush-
ion seal (34) with the following procedure.
1) Insert the cushion seal into the groove
with the surface of the cushion seal that
has a slit (*2) facing the piston side.
2) Attach the part of the cushion ring pro-
cessed to be flat (*1) facing as in the dia-
gram.
3) Attach the piston (35).
NSM-13-15-002E 56
56
Attachments
[4] When there is a cushion on the retraction
side
Assemble the cushion ring (39) and cush-
ion seal (38) with the following procedure.
1) Assemble the cushion ring before assem-
bling the piston nut.
The cushion ring cannot be assembled
with the piston nut attached.
2) Mount the cushion seal in the groove with
the surface of the cushion seal that has a
slit (*3) facing the piston rod threaded
side (36).
3) Attach the part of the cushion ring pro-
cessed to be flat facing as in the right dia-
gram.
4) Insert the stopper (40) into the groove.
Press the cushion ring (39) all the way to
the stopper and strike in the snap ring
(37). Strike gently with a plastic hammer
in such a way as to not scratch the piston
rod (4) or cushion ring.
Make sure that the cushion seal and cushion ring face the correct direction.
If they are installed backwards, the cushion will not be effective.
Caution After installing the cushions, check that the extension and retraction cushion rings move up and
down and left and right.
[5] Tighten the piston nut.

• Always tighten the piston nut to the speci-
fied torque given on the assembly diagram.
• If the tightening torque is insufficient, this
causes internal leaks, nut looseness, and
thread cutting
• Also, if the tightening torque is excessive,
extension side cushion ring swelling and
piston contact surface deformation occur.
• In order to tighten correctly, clean and
degrease the piston and nut and piston rod
thread section adequately (with paint thin-
ner) before tightening the nut.
[6] Stop the piston from turning.
• After tightening the piston nut, put in the
steel ball (43), tighten the locking screw
(42) to the specified torque given on the
assembly diagram, and then caulk (41) with
the punch (44) at 2 locations on the outer
circumference.
57 NSM-13-15-002E
57
Attachments
6) Insertion of piston rod into the tube
[1] Secure the tube (47) vertically or horizon-
tally.
[2] Place the jig (45) (made of nylon pipe, split
in two) on the tube, and insert the piston
rod (4) in the tube (47).
• If the tube is secured vertically, the piston
rod enters the tube due to its own weight.
• When the piston section is entering the
tube, be careful that the slide rings (46) do
not fall out.
• Shift the abutment phase 180°from one
ring to the next to mount the rings.
7) Cylinder head tightening

Align the cylinder head with the position on the assembly diagram, and then tighten the bolts to
the specified torque given on the assembly diagram in the order shown in the diagram below.
The number of bolts varies according to the cylinder type, but the installation procedure is ess-
sentially the same.
Bolt tightening order
NSM-13-15-002E 58
58
Attachments
8) Installation of line
[1] Check that the O-ring is in the groove correctly.
[2] Tighten the port section bolts (*5) to the specified torque given on the assembly diagram.
• When installing lines, be careful that lines are not twisted or catching on something.（*6）
[3] Tighten the bands for securing the line (*10) equally on both sides to the torque indicated in
the assembly diagram so that no abutment (*7) gap occurs.
• Normal state (*8)
• Gap present state (*9)
When installing the cylinder lines and the machine body rubber hoses, nipples, etc., assemble
Caution securing the cylinder line port section with a wrench. If one tightens without securing the port
section, the line may bend, oil may leak, and the machine body may get in the way.
(8) Test operation

[1] In order to fill the inside of the cylinder with oil, after it is installed on the machine body, move
the cylinder through its full stroke slowly 8 times or more. If the cylinder is suddenly moved
from the start, the hydraulic oil may be aerated.
[2] If the cylinder has air bleeding, pressurize so that the air bleed side is the pressure side
(return oil side) and bleed off the air.
[3] Apply oil and grease to the pins at both ends.
(9) Usage limits

Below are the usage limits for sliding sections. Use them for reference for maintenance.
• Piston rod exterior diameter wear limit
Nominal diameter Minimum outer
Solution
(mm) diameter (mm)
65 - 80 -0.023 Replace or replate.
85 - 120 -0.027 Replace or replate.
59 NSM-13-15-002E
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Attachments
• Rod bushing interior diameter wear limit
Nominal diameter Standard interior Maximum inner
Solution
(mm) diameter (mm) diameter (mm)
55 - 75 +0.060 - +0.190 +0.30 Replace the bushing.
80 - 120 +0.060 - +0.195 +0.30 Replace the bushing.
• Piston slide ring thickness wear limit
Nominal diameter Standard thickness Minimum thickness

Solution
(mm) (mm) (mm)
95 - 160 t2.42 - 2.48 t2.37 Replace the slide ring.
165 - 250 t2.92 - 2.98 t2.87 Replace the slide ring.
NSM-13-15-002E 60
60
Lights SH160
Lights
Lights
Removal and Installation of Boom Light
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid

spring washer (3), and washer (4), and then
remove the boom light (5).
1 NSM-13-16-002E
1
Lights
Removal and Installation of Tool Box Light
Items to prepare
• Wrench (13 mm)
• Rag
• Cleaning fluid
[1] Open the tool box (1).
[3] Remove the lamp bracket (3).

and then remove the tool box light (5).
NSM-13-16-002E 2
2
Procedures for Removal and Installation of Cab Inner and Outer Parts SH200-5
Procedures for Removal and Installation of Cab Inner and Outer Parts
Removal and Installation of Cab Assembly
Items to prepare
• Box wrenches (10 mm, 13 mm, 19 mm)
• Eyebolt (M24) x 4
• Chains (wire ropes) (with the required breaking load)
• Lubricating oil
• Rag
• Cleaning fluid
1. Removal of Cab Assembly
[1] Remove the operator's seat.
Operator's Seat".)
bolts (1) and another box wrench (13 mm) to
remove the 2 bolts (2), and then remove the
rear cover (3).

bolts (4), and then remove the air conditioner
ducts on both sides (5).
1 Bolt
2 Bolt
3 Rear cover
4 Bolt
5 Duct
1 RSM-13-17-001E
1
[4] Remove the air conditioner ducts (6) and (7) by
pulling them forward.

(8), and then remove the brackets (9).
[6] Remove the air conditioner duct (10).
6 Duct
7 Duct
8 Bolt
9 Bracket
10 Duct
RSM-13-17-001E 2
2
[7] Remove the radio antenna (11).
[8] Use a wrench (13 mm) to remove the bolts

(12) for the ground wire (13) connecting the
cab and frame.
11 Radio antenna
12 Bolt
13 Ground wire
14 Connector
15 Connector
3 RSM-13-17-001E
3
[10] Remove the washer fluid hose (16).

(17) each, and then remove the rear brackets
(right and left) (18) and (19).
[12] Remove the 3 butterfly screws (20), and then

remove the cover (21).
16 Hose
17 Bolt
18 Rear bracket (right)
19 Rear bracket (left)
20 Butterfly screw
21 Cover
RSM-13-17-001E 4
4
[13] Remove the 2 butterfly screws (22), and then
open the cover (23) of the outside air filter.
[14] Remove the outside air filter (24).

Slide the suction duct connected with the air
conditioner unit in the cab from the duct flange
and remove it.
[15] Remove the 4 caps (25) from the top of the

cab.
22 Butterfly screw
23 Cover
24 Filter
25 Cap
5 RSM-13-17-001E
5
[16] Install the 4 eyebolts (M24) (26) in place of the
removed caps.
• Fully tighten the eyebolts, and then loosen
them by a half turn.
[17] Use chains (27) and crane to secure the cab.
[18] Use a Phillips screwdriver to remove the 3

screws (28), and then remove the cover (29).
26 Eyebolt
27 Chain
28 Screw
29 Cover
RSM-13-17-001E 6
6
(30) from the cab.
[20] Use chains (32) and crane to remove the cab

(31).
30 Bolt
31 Cab
32 Chain
7 RSM-13-17-001E
7
before lowering the cab on wood planks (33).
• Thoroughly secure the cab with the chains and
crane so that it does not fall down.
33 Wood plank
2. Installation of Cab Assembly

The tightening torque for the cab assembly installation bolts is 157 N•m.
RSM-13-17-001E 8
8
Removal and Installation of Operator's Seat
Items to prepare
• Wrench (13 mm)
1. Removal of Operator's Seat
[1] Pull the slide lever (1) to slide the seat (2) to
the rear.
(3) from the front of the seat.
[3] Pull the slide lever (1) to slide the seat forward,
and then pull the reclining lever (4) to fold the
seatback forward.

(5) from the rear of the seat.
1 Slide lever
2 Seat
3 Bolt
4 Reclining lever
5 Bolt
9 RSM-13-17-001E
9
[5] Remove the operator's seat (6).
6 Operator's seat
2. Installation of Operator's Seat

The tightening torque for the seat installation bolts is 19.6 N•m.
RSM-13-17-001E 10
10
Removal and Installation of Wiper
Items to prepare
• Wrench (17 mm)
1. Removal of Wiper
and then remove the wiper arm (2).
[2] Use the Phillips screwdriver to remove the

screw (3), and then remove the wiper (4).
1 Nut
2 Wiper arm
3 Screw
4 Wiper
2. Installation of Wiper
11 RSM-13-17-001E
11
Removal and Installation of Wiper Controller
Items to prepare
• Wrench (10 mm)
• Flathead screwdriver
1. Removal of Wiper Controller
installation screws (2) for the side upper trim (1).
[2] Lift the side upper trim (1), remove the connec-
tors (3), and then remove the side upper trim.
Some models have no connector.

turn clips (4) and the 4 bolts (5), and then
remove the side rear cover (6).
1 Side upper trim

2 Screw
3 Connector
4 Turn clip
5 Bolt
6 Side rear cover
RSM-13-17-001E 12
12
mm) to remove the 4 bolts (7), and then
remove the side rear B trim (8).

(9), and then remove the side lower trim (10).

mm) to remove the 4 bolts (11), and then
remove the side rear A trim (12).
7 Bolt
8 Side rear B trim
9 Bolt
10 Side lower trim
11 Bolt
12 Side rear A trim
13 RSM-13-17-001E
13
[7] Remove the connector (14) from the wiper
controller (13).
[8] Use a flathead screwdriver to slightly bend the

4 installation clips (15), and then remove the
wiper controller (13).
13 Wiper controller
14 Connector
15 Installation clip
2. Installation of Wiper Controller

RSM-13-17-001E 14
14
Removal and Installation of Wiper Motor
Items to prepare
• Flathead screwdriver (longnose pliers)
1. Removal of Wiper Motor
(1), and then remove the side lower trim (2).
[2] Use a flathead screwdriver or longnose pliers

to remove the clip pins (3), and then remove
ducts B (4).
1 Bolt
2 Side lower trim
3 Clip pin
4 Duct B
15 RSM-13-17-001E
15
[3] Use a Phillips screwdriver or box wrench (10
mm) to remove the 3 bolts (5). Use a hexagon
wrench (4 mm) to remove the 3 bolts (6).
Remove the front upper trim assembly (7).
[4] Lift the front upper trim assembly (7), and then
remove the connector (8).
5 Bolt
6 Bolt
7 Front upper trim
8 Connector
9 Connector
RSM-13-17-001E 16
16

and then remove the wiper arm (13).
[8] Use a wrench (17 mm) to remove the nut (14).
10 Bolt
11 Cover
12 Nut
13 Wiper arm
14 Nut
17 RSM-13-17-001E
17
bolts (15) and 2 nuts (16), and then remove the
wiper motor assembly (17).
15 Bolt
16 Nut
17 Wiper motor
2. Installation of Wiper Motor

• Be careful about the wiper link and wiper arm installation location.
• Check the wiper arm wipe location and stop location.
RSM-13-17-001E 18
18
Removal and Installation of Monitor
Items to prepare
• Wrench (10 mm)

on the monitor (2).
[2] Lift the monitor main unit (2), and then remove
the connector (3) underneath.
1 Bolt
2 Monitor
3 Connector
19 RSM-13-17-001E
19
Removal and Installation of Cab Front Glass
Reinforced glass is used for the front window.
Caution Be extremely careful not to damage it when touching it during removal or installation.
Items to prepare
• Wrench (10 mm)
• Rag
• Cleaning fluid

(1) each, and then remove the brackets (2) and
(3).
[2] Remove the covers (4) and (5) for the bracket.
1 Bolt
2 Bracket
3 Bracket
4 Cover
5 Cover
RSM-13-17-001E 20
20
(6), and then remove the front glass left lower
bracket (7).

(8), and then remove the front glass right lower
bracket (9).
[5] Move the front glass right upper bracket (11) to

a position where the wire (10) is not pulled on.
6 Bolt
7 Bracket
8 Bolt
9 Bracket
10 Wire
11 Bracket
21 RSM-13-17-001E
21
[6] Remove the cab front glass (12).
12 Cab front glass
RSM-13-17-001E 22
22
Procedure for Window Lock Adjustment
Items to prepare
• Wrench (10 mm)
• Rag
• Cleaning fluid

(2).
[3] Set the cab front glass (3) in place.
1 Cover
2 Bolt
3 Cab front glass
23 RSM-13-17-001E
23
[4] Use a wrench (10 mm) to retighten the 3 bolts
(2).
2 Bolt
RSM-13-17-001E 24
24
Hydraulic Equipment-related Parts SH120
Hydraulic Equipment-related Parts

Accumulator
Warning ・ Be sure to release the hydraulic pressure in the circuits.
Items to prepare
• Wrench (30 mm)
• Rag
• Cleaning fluid
[1] Use a wrench (30 mm) to remove the accumula-

tor (1).
1 NSM-13-18-002E
1
Suction Filter
・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank.
Caution ・ When replacing the hydraulic oil, always replace with new oil.
Items to prepare
• Wrench (17 mm)
• Rag
• Cleaning fluid

the tank.

(2), and then remove the feed port cover (3).
[3] Drain the oil from the hydraulic oil tank. (For
details, see "Draining Oil from Hydraulic Oil
Tank".)
[4] Remove the O-ring (4).
NSM-13-18-002E 2
2
[5] Remove the suction filter (5).
[6] Clean the suction filter (5) with clean cleaning

fluid, dry it well, and then inspect it. If there is
any damage on the surface, replace the suction
filter with a new one.
• If the O-ring on the rear of the cover is worn or
• To install, perform the reverse of the removal
procedure.
• Always replace the suction filter with a new one
every 5000 hr. and when replacing the hydraulic
oil.
3 NSM-13-18-002E
3
Return Filter
・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank.
Caution ・ When replacing the hydraulic oil, always replace with new oil.
Items to prepare
• Wrench (17 mm)
• Rag
• Cleaning fluid

the tank.

• There is a spring inside the cover, so restrain
the spring by hand and remove the cover.
NSM-13-18-002E 4
4
[3] Remove the O-ring (4).
Take the spring (5) and valve (6) out from the
tank.
[4] Take the return filter (7) out from the tank and
replace it.
• If the O-ring on the rear of the cover is worn or
• To install, perform the reverse of the removal
procedure.
5 NSM-13-18-002E
5
Pilot Filter
Warning ・ Be sure to release the hydraulic pressure in the circuits.
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid
[1] Use a wrench (19 mm) to remove the pilot filter

(1).
NSM-13-18-002E 6
6
Other SH120
Other
Other
Removal and Installation of Side Door
Items to prepare
• Wrench (19 mm)

(1), and then remove the side door (left) (2).

(1), and then remove the side door (right) (3).
1 NSM-13-19-002E
1
Other
Draining Oil from Hydraulic Oil Tank
Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until
the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work.
Items to prepare
• Feed pump (power source for feed pump)
• Extension cable
• Waste oil tank
• Waste oil can
• Rag
• Cleaning fluid

hydraulic oil tank to bleed off the pressure in the
tank.

(2), and then remove the feed port cover (3).
NSM-13-19-002E 2
2
Other
[3] Insert the feed pump (4) into the feed port.
[4] Operate the feed pump (4) and transfer the oil
inside the hydraulic oil tank to the waste oil tank
(5).

[6] Prepare a waste oil can (8) under the hydraulic

oil tank.
3 NSM-13-19-002E
3
Other
[7] Use a wrench (36 mm) to remove the drain plug
(9).
[8] Drain any remaining oil that has settled at the

bottom of the hydraulic oil tank.
NSM-13-19-002E 4
4

Lbx130x2 Service Manual

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Lbx130x2 Service Manual

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Table of Contens SH120

130 X2 Service Text Table of Contents

Heaped 0.62 m3 (0.81 yd3)

3. Main Body Dimensions

9. Travel Lower Body

2. Control Valve, Cylinder

2. Hydraulic Oil Filters

Take measures to ensure safe operation

Use wire ropes with safety factor 6 or greater.

We: Frontal rating load

Ws: Lateral rating load

MAX: Rating load at height point H and

(Maximum working reach: 25.366 ft) (Units; Ib)

We: Frontal rating load

Ws: Lateral rating load

MAX: Rating load at height point H and

(Maximum working reach: 26.879 ft) (Units; Ib)

We: Frontal rating load

Ws: Lateral rating load

MAX: Rating load at height point H and

(Maximum working reach: 25.366 ft) (Units; Ib)

We: Frontal rating load

Ws: Lateral rating load

MAX: Rating load at height point H and

(Maximum working reach: 26.879 ft) (Units; Ib)

2. Long Arm 118.5 in.(3.01 m)

2. Long Arm 118.5 in. (3.01 m)

Work Range Diagram

Main Equipment Table

3. Air Cleaner (double element)

2. Solenoid Valve (4 stack)

5. Valve for travel operation

8. Travel remote control valve control diagram

10.Selector Valve (option)

Arm cylinder 130X2/130X2 (Blade)

Bucket cylinder 130X2/130X2 (Blade)

Blade cylinder 130X2 130X2 (Blade)

Bucket capacity (m3) 0.37 0.45 0.5 0.55 0.65

Equipment Layout Diagram

1 Engine 7 Swing motor 13 Fuel tank

Standard Machine Option List

Front guard, mesh (full)

OPG Level 1 (with cab seating) ● FB strengthened guard

+ Strengthened bucket linkage,

Hydraulic Equipment Layout

1 Left side housing

1 Hydraulic pump 7 P1 pressure sensor

1 Cushion valve (with heat circuit)

1 Travel remote control valve

Main Equipment Structure and Operation Explanation

No. PART NAME QTY. Tightening torque

Leads to Cl port servo piston

Part Component part number

1 Front side regulator

Code Part name Q'ty Code Part name Q'ty

Part Component part number

Code Part name Q'ty Code Part name Q'ty

1 Suction port G3/4 Tightening torque: 54.6 lb-ft (74 N•m)

Component part number

Code Part name Q'ty Code Part name Q'ty

(2)Structure and operation explanation

Figure 1 Motor structural diagram

Automatic 2nd-speed type