ZX140W-3 Full Service Manual

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
• This manual contains the revision information
to the 12, June 2009.
ADDITIONAL REFERENCES
• Please refer to the other materials (operator’s

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

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

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SECTION AND GROUP
SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
TECHNICAL MANUAL Group 2 Control System
Group 3 ECM System
(Operational Principle) Group 4 Hydraulic System
Group 5 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Electric Lever
Group 6 Transmission
Group 7 Axle
Group 8 Travel Motor
Group 9 Signal Control Valve
Group 10 Steering Valve
All information, illustrations and speci- Group 11 Brake Valve
fications in this manual are based on
the latest product information available
Group 12 Others (Upperstructure)
at the time of publication. The right is Group 13 Others (Undercarriage)
reserved to make changes at any time
without notice.
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Monitor Unit
Group 2 Standard Group 3 Dr. ZX
Group 3 Engine Test Group 4 ICF
COPYRIGHT(C)2007 Group 4 Excavator Test Group 5 Component Layout
Hitachi Construction Machinery Co., Ltd. Group 5 Component Test Group 6 Troubleshooting A
Tokyo, Japan Group 7 Troubleshooting B
All rights reserved Group 8 Electrical System Inspection
←これ以下
記載しない
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Motor
Group 2 Tightening Torque Group 3 Center Joint
Group 3 Painting Group 4 Transmission
Group 4 Bleeding Air from Hydrau- Group 5 Axle
lic Oil Tank Group 6 Axle Lock Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Operate Check Valve
Group 1 Cab (Axle Lock Cylinder)
Group 2 Counterweight SECTION 4 FRONT ATTACHMENT
Group 3 Main Frame Group 1 Front Attachment
Group 4 Pump Device Group 2 Cylinder
Group 5 Control Valve Group 3 Hose Rupture Valve
Group 6 Swing Device Group 4 Operate Check Valve
Group 7 Pilot Valve (Blade/Outrigger)
Group 9 Pilot Shut-Off Solenoid Valve
Group 11 Travel Shockless Valve
Group 12 Swing Shockless Valve
Group 13 Solenoid Valve
Group 15 Brake Valve
Group 16 Accumulator Charging Valve
SECTION 1
GENERAL
CONTENTS
Group 1 Specifications
Specifications........................................................................ T1-1-1
Working Ranges.................................................................T1-1-11
Main Component Layout.................................................. T1-2-1
Electrical System (Overview)........................................... T1-2-6
Electrical System
(Monitors and Switches).............................................. T1-2-8
Electrical System
(Controllers and Relays).............................................T1-2-11
Engine....................................................................................T1-2-13
Pump Device.......................................................................T1-2-14
Swing Device.......................................................................T1-2-14
Signal Control Valve..........................................................T1-2-14
Control Valve.......................................................................T1-2-15
Brake Valve...........................................................................T1-2-15
3-Spool Solenoid Valve Unit...........................................T1-2-15
Solenoid Valve Unit (For Electric Lover).....................T1-2-15
Travel Shockless Valve......................................................T1-2-16
Transmission
Changeover Solenoid Valve......................................T1-2-16
Travel Device.......................................................................T1-2-16
Filter........................................................................................T1-2-16
Engine...................................................................................... T1-3-1
Engine Accessories.............................................................. T1-3-5
Hydraulic Component........................................................ T1-3-7
Electrical Component.......................................................T1-3-14
CEBT-1-1
(Blank)
CEBT-1-2
SECTION 1 GENERAL
Specifications
ZX140W-3 (Standard Chassis, Rear Blade)
ZX140W-3: Up to serial No 005000
ZX140W-3-AMS: Up to serial No 050000
C
H D
B
G
P
F
E N
K J O L
Q I R A
MCGB-12-001
Type of Front-End Attachment Monoblock Boom 2-Piece Boom

Type of Arm 2.52m (8 ft 3 in) 2.52m (8 ft 3 in)
Bucket Capacity (Heaped) PCSA 0.50 m3 (0.65 yd3), CECE 0.45 m3
Operating Weight kg (lb) 14700 (32400) 15200 (33500)
Basic Machine Weight kg (lb) 12500 (27600) 12500 (27600)
Engine ISUZU AI-4JJ1X
Engine Power SAE J1349 net
ISO 9249 net 90.2 kW/2200 min-1 (123 PS/2200 rpm)
EEC 80/1269 net
A: Overall Width (Excluding Rearview Mirrors) mm (ft·in) 2530 (8' 4")
B: Cab Height mm (ft·in) 3130 (10' 3")
C: Rear End Swing Radius mm (ft·in) 2120 (7' 0")
D: Rear End Length mm (ft·in) 2120 (7' 0")
E: Minimum Ground Clearance mm (ft·in) 350 (1' 2”)
F: Counterweight Clearance mm (ft·in) 1215 (4' 0")
G: Engine Cover Height mm (ft·in) 2360 (7' 9")
H: Overall Width of Upperstructure mm (ft·in) 2480 (8' 2")
I: Wheelbase mm (ft·in) 2550 (8' 4")
J: Swing-Center to Rear Axle mm (ft·in) 1000 (3' 3")
K: Front Wheel Tread mm (ft·in) 1875 (6' 2")
L: Rear Wheel Tread mm (ft·in) 1875 (6' 2")
M: Outrigger Spread mm (ft·in) -
N: Max. Raising Height mm (ft·in) 445 (1' 6")
O: Max. Digging Depth mm (ft·in) 145 (6")
P: Blade Height mm (ft·in) 590 (1' 11")
Q: Front Axle to Front of Chassis mm (ft·in) 570 (1' 10")
R: Rear Axle to Rear of Chassis mm (ft·in) 980 (3' 3")
Tire Size 10.00-20 16PR
Swing Speed min-1 (rpm) 13.7
Travel Speed (Fast / Slow / Creeper) * km/h (mph) 35/8.6/2.2 (21.7/5.3/1.4)
Gradeability Degree (%) 35 (70)
fNOTE: “*” The specification not matching the local regulation is excluded.
T1-1-1
SECTION 1 GENERAL
ZX140W-3 (Standard Chassis, Rear Blade)

ZX140W-3: Serial No 005001 and up
ZX140W-3-AMS: Serial No 050001 and up
H C
D
B
G
P
F
E N
J L
O
K Q I R A
TCEB-01-01-001

Type of Arm 2.52m (8 ft 3 in) 2.52m (8 ft 3 in)
EEC 80/1269 net
M: Outrigger Spread mm (ft·in) -
T1-1-2
SECTION 1 GENERAL
ZX140W-3 (Standard Chassis, Rear Outrigger)

H D
B
G
F
E
K J
L
A Q I R M
MCGB-12-002

Type of Arm 2.52 m (8 ft 3 in) 2.52 m (8 ft 3 in)
Engine Power SAE J1349 net 90.2 kW/2200 min-1 (123 PS/2200 rpm)
ISO 9249 net
EEC 80/1269 net
A: Overall Width (Excluding Rearview Mirrors) mm (ft·in) 2480 (8' 2”)
M: Outrigger Spread mm (ft·in) 3380 (11' 1")
N: Max. Raising Height mm (ft·in) -
O: Max. Digging Depth mm (ft·in) -
P: Blade Height mm (ft·in) -
R: Rear Axle to Rear of Chassis mm (ft·in) 1070 (3' 6”)
T1-1-3
SECTION 1 GENERAL
ZX140W-3 (Standard Chassis, Rear Outrigger)

H C
D
B
G
F
E
K J L
A Q I R M
TCEB-01-01-002

EEC 80/1269 net
R: Rear Axle to Rear of Chassis mm (ft·in) 1060 (3' 6”)
T1-1-4
SECTION 1 GENERAL
ZX140W-3 (Front Blade Rear Outrigger)

C
H D
B
G
P
F
N E
K O J L
A Q I R M
MCGB-12-003

Engine ISUZU ISUZU AI-4JJ1X
EEC 80/1269 net
T1-1-5
SECTION 1 GENERAL
ZX140W-3 (Front Blade Rear Outrigger)

H C
D
B
G
P F
N E
O J
K L
A Q I R M
TCEB-01-01-003

EEC 80/1269 net
T1-1-6
SECTION 1 GENERAL
ZX140W-3 (Front Outrigger Rear Blade)

C
H
D
B
G
P
F
E N
K J O L
M
A Q I R
MCGB-12-004

EEC 80/1269 net
E: Minimum Ground Clearance mm (ft·in) 350 (1' 2")
T1-1-7
SECTION 1 GENERAL
ZX140W-3 (Front Outrigger Rear Blade)

H C
D
B
G
P F
E N
J
O
K L
M Q I R A
TCEB-01-01-004

EEC 80/1269 net
T1-1-8
SECTION 1 GENERAL
ZX140W-3 (Front Outrigger Rear Outrigger)

C
H
D
B
G
F
E
K J L
A Q I R M
MCGB-12-005

EEC 80/1269 net
T1-1-9
SECTION 1 GENERAL
ZX140W-3 (Front Outrigger Rear Outrigger)

H C
D
B
G
F
E
J L
K
Q I R M
A
TCEB-01-01-005

EEC 80/1269 net
T1-1-10
SECTION 1 GENERAL
Working Ranges
ZX140W-3
Monoblock Boom
G
MCGB-12-006
Type of Front-End Attachment Monoblock Boom

Category 2.10 m (6 ft 11 in) Arm 2.52 m (8 ft 3 in) Arm 3.01 m (9 ft 11 in) Arm
Item Backhoe Backhoe Backhoe
A: Maximum Digging Reach mm (ft·in) 8040 (26' 5") 8410 (27' 7") 8870 (29' 1")
B: Maximum Digging Depth mm (ft·in) 4610 (15' 2") 5030 (16' 6") 5520 (18' 1")
C: Maximum Cutting Height mm (ft·in) 8660 (28' 5") 8850 (29' 0") 9160 (30' 1")
D: Maximum Dumping Height mm (ft·in) 6240 (20' 6") 6440 (21' 2") 6760 (22' 2")
E: Transport Height mm (ft·in) 3130 (10' 3") 3130 (10' 3") 3240 (10' 8")
F: Overall Transport Length
Std. Chassis Rear BL. mm (ft·in) * 7690 (25' 3") * 7730 (25' 4") * 7710 (25' 4")
Std. Chassis Rear O/R. mm (ft·in) * 7690 (25' 3") * 7730 (25' 4") * 7710 (25' 4")
Front BL. Rear O/R. mm (ft·in) * 8140 (26' 9") * 8180 (26' 10") * 8160 (26' 9")
Front O/R. Rear BL. mm (ft·in) * 8235 (27' 0") * 8275 (27' 2") * 8255 (27' 1")
Front O/R. Rear O/R. mm (ft·in) *8235 (27' 0") * 8275 (27' 2") * 8255 (27' 1")
G: Minimum Swing Radius mm (ft·in) 2610 (8' 7") 2650 (8' 8") 2910 (9' 7")
fNOTE: “*” Transport the machine with the rear side facing forward.
BL: Blade, O/R: Outrigger
T1-1-11
SECTION 1 GENERAL
Working Ranges
ZX140W-3
Monoblock Boom
ZX140W-3-AMS: Serial No 050001 and up G
B A
TCEB-01-01-006
Type of Front-End Attachment Monoblock Boom

Front O/R. Rear O/R. mm (ft·in) *8170 (26' 10") * 8210 (26' 11") * 8190 (26' 10")
T1-1-12
SECTION 1 GENERAL
ZX140W-3
2-Piece Boom
ZX140W-3-AMS: Up to serial No 050000 G
MCGB-12-007
Type of Front-End Attachment 2-Piece Boom

Front O/R. Rear O/R. mm (ft·in) * 8735 (28' 8") * 8745 (28' 8") * 8715 (28' 7")
T1-1-13
SECTION 1 GENERAL
ZX140W-3
2-Piece Boom
ZX140W-3-AMS: Serial No 050001 and up G
TCEB-01-01-007
Type of Front-End Attachment 2-Piece Boom

Front O/R. Rear O/R. mm (ft·in) * 8670 (28' 5") * 8680 (28' 6") * 8650 (28' 5")
T1-1-14
SECTION 1 GENERAL
Main Component Layout

Upperstructure (1)
1
2
3
8
9
10
24 11
12
23 13
14
22 15
21 16
17
20 TCEB-01-02-002
19 18
1- Rear Camera 8- Battery 14- Travel Shockless Valve 20- Steering Valve
2- Radiator 9- Fuel Cooler 15- Pilot Valve (Left) 21- Brake Valve
3- Inter Cooler 10- Washer Tank 16- Pilot Shut-Off Solenoid Valve 22- Travel Pilot Valve
4- Reserve Tank 11- ECM (Engine Controller) 17- Center Joint 23- Pilot Valve (Right)
5- Air Conditioner Condenser 12- Solenoid Valve Unit (For 18- Accumulator Charging Valve 24- Blade / Outrigger Electric
6- Receiver Drier Electric Lever) 19- Auxiliary / Positioning Electric Lever
7- Air Cleaner 13- Oil Cooler Lever
T1-2-1
SECTION 1 GENERAL
Upperstructure (2)
42
41
40
39
38
37
36
35 25
34
33 26
32 27
31 28
30
TCEB-01-02-003
29
25- Positioning Control Valve 30- Automatic Fueling Switch 35- Engine Oil Filter 40- Steering Filter
26- Shuttle Valve 31- Control Valve 36- Pump Device 41- Pilot Filter
27- Signal Control Valve 32- Automatic Fueling Pump 37- Fuel Pre Filter 42- Engine
28- Heat Circuit Cut Solenoid Valve 33- 3-Spool Solenoid Valve Unit 38- Fuel Main Filter
29- Swing Shockless Valve 34- Swing Device 39- Solenoid Pump
T1-2-2
SECTION 1 GENERAL
Undercarriage
1 2 3
4 5
9 6
8
7
TCEB-01-02-001
1- Blade Cylinder 3- 2-Spool Solenoid Valve Unit 5- Front Axle 8- Transmission

2- Rear Axle (Blade / Outrigger Cylinder) 6- Outrigger Cylinder 9- Transmission Changeover
4- Axle Lock Cylinder 7- Travel Motor Solenoid Valve
T1-2-3
SECTION 1 GENERAL
Undercarriage
1 2 3
4 5
8
7
6
TCJB-01-02-011

T1-2-4
SECTION 1 GENERAL
Front Attachment
 2-Piece Boom  Monoblock Boom
3 1
4
2
7
7
1
6 4
T1F3-01-02-003 6 T1F3-01-02-004
1- Bucket Cylinder 3- Positioning Cylinder 5- Hose Rupture Valve 6- Hose Rupture Valve (Boom)
2- Arm Cylinder 4- Boom Cylinder (Positioning) 7- Hose Rupture Valve (Arm)
T1-2-5
SECTION 1 GENERAL
Electrical System (Overview)
Pump Device (Refer to T1-2-14.) Filter (Refer to T1-2-16.)

· Pump 1 Delivery Pressure Sensor · Steering Pump Delivery Pressure Sensor
· Pump 2 Delivery Pressure Sensor
· Pump 1 Control Pressure Sensor
· Pump 1 Maximum Flow Rate Limit Control Solenoid Valve Engine (Refer to T1-2-13.)
· Pump 2 Maximum Flow Rate Limit Control Solenoid Valve
· Torque Control Solenoid Valve
13
1
12
2
3
4
7 6
8
9
10
Travel Shockless Valve (Refer to T1-2-16.)

· Pressure Sensor (Travel Forward)
11
· Pressure Sensor (Travel Reverse)
TCEB-01-02-002
Brake Valve (Refer to T1-2-15.)
· Brake Pressure Sensor
· Work Brake Release Switch
· Brake Remain Pressure Sensor
1- Fresh Air Temperature Sensor 5- Battery 8- Solenoid Valve Unit (For 11- Pilot Shut-Off Solenoid Valve
2- Starter Relay 6- ECM Electric Lever) 12- Fuel Sensor
3- Battery Relay 7- Intake Air Temperature Sensor 9- Atmosphere Pressure Sensor 13- Hydraulic Oil Temperature
4- Glow Plug Relay 10- Air Cleaner Restriction Switch Sensor (Main)
T1-2-6
SECTION 1 GENERAL
Swing Device (Refer to T1-2-14.)

· Pressure Sensor (Front) 14
18 15
16
17
Control Valve (Refer to T1-2-15.) TCEB-01-02-003
· Pressure Sensor (Boom Raise) Signal Control Valve (Refer to T1-2-14.)
· Pressure Sensor (Arm Roll-In) · Pressure Sensor (Swing)
· Pressure Sensor (Auxiliary)
14- Horn 16- Pressure Sensor (Positioning) 18- 3-Spool Solenoid Valve Unit
15- Slip Ring 17- Heat Circuit Cut Solenoid Valve
T1-2-7
SECTION 1 GENERAL
Electrical System (Monitors and Switches)
5 6 7
2
4 3 12
TCJB-01-02-006 11 10 9 8 TCJB-01-02-014
14
15
22
16 13 23
34 24
25
26
27
17 28
18
19 33
20 32
TCJB-01-02-007
31 30 29
21
TCJB-01-02-008
1- Monitor Unit (Refer to T1-2-9.) 9- Brake Pedal 17- Hazard Switch 26- Travel Speed Mode Switch
2- Swing Lock Lever 10- Steering Column Monitor 18- Electrical Control Main Switch 27- Engine Speed Control Mode
3- Blade/Outrigger Lever (Refer to T1-2-10.) (Optional) Selection Switch
4- Pilot Shut-Off Lever 11- Auxiliary/Positioning Pedal 19- Blade/Outrigger Front-Rear 28- Power Mode Switch
5- Engine Stop Switch (Optional) Selector Switch 29- Key Switch
6- Combination Switch 12- Horn Switch 20- Outrigger Left-Right Selector 30- Blade/Outrigger Selector
· Turn Signal Switch 13- Left Analog Switch (Auxiliary) Switch Switch
· Light Switch 14- Horn Switch 21- Heater Seat Switch (Optional) 31- Auto-Idle Switch
· Dimmer Switch 15- Positioning Pedal Selection 22- FNR Switch 32- Work Light Switch
· Passing Switch Switch 23- Auxiliary 33- Wiper/Washer Switch
7- Brake Switch 16- Auxiliary Pedal Selection 24- Auxiliary 34- Right Analog Switch (Assist)
8- Accelerator Pedal Switch 25- Engine Control Dial (Optional)
T1-2-8
SECTION 1 GENERAL
Monitor Unit
8
1 2 3 4 5 6 9
10
11
12
13
14
15
16
17
18
35 34
21 20 19
33
32 31 30 29 28 27 26 25 24 23 22
TCJB-05-02-043
1- Work Mode Display 10- Parking Brake Display 17- Mail Display (Optional) 27- Mail Selection (Optional)
2- Auto-Idle Display 11- Work Brake Display 18- Clock 28- Work Mode Display
3- Overload Alarm Display 12- Axle Lock Display 19- Trip Meter Display 29- Auxiliary Selection
(Optional) 13- Work Light Display 20- Odometer Display 30- Coolant Temperature Gauge
4- Auto Axle Lock Display 14- Auxiliary 2 (Positioning) 21- Hour Meter Display 31- Work Mode Selection
5- Auxiliary Selection Display 22- Back Monitor Selection 32- Return to Primary Screen
6- Glow Signal Display 15- Auxiliary 1 (Attachment) 23- Menu 33- Brake Oil Pressure Gauge
7- Trip Meter Selection Display 24- Meter Display Selection 34- Speedometer
8- Odometer 16- Blade/Outrigger Settings and 25- Fuel Gauge 35- Tachometer
9- Hour Meter Brake Mode Display 26- Auxiliary
T1-2-9
SECTION 1 GENERAL
Steering Column Monitor
1 2
12
11 4
5
10 6
9 7
TCJB-02-01-008
8
1- Travel Forward Indicator 5- Travel Reverse Indicator 8- Travel Slow Speed Indicator 12- Turn Signal Indicator (Left)
2- Turn Signal Indicator (Right) 6- Hazard Light Indicator 9- Auxiliary
3- Neutral Indicator 7- Auto-Cruise Indicator 10- Clearance Light Indicator
4- Pilot Cut Indicator (Optional) 11- High Beam Indicator
T1-2-10
SECTION 1 GENERAL
Electrical System (Controllers and Relays)
1 2 3
6 5 TCJB-01-02-015
1- MC (Main Controller) 3- Fuse Box 5- Option Controller

2- Satellite Communication 4- Dr.ZX Connector (Use as 6- ICF (Information Controller)
Terminal (Optional) Download Connector) 7- Flasher
T1-2-11
SECTION 1 GENERAL
Relays Position
TCJB-01-02-009
Option Controller
Dr.ZX Connector Fuse Box TCJB-01-02-010
1- High Beam Relay 19- Pilot Shut-Off Relay 33- Heater Seat Relay (OP) 45- Twin Wiper Relay 3 (OP)
2- Clearance Light Relay (Left) 20- Security Horn Relay 34- Room Lamp Controller Relay 46- Twin Wiper Relay 4 (OP)
3- Clearance Light Relay (Right) 21- Starter Cut Relay (OP) 47- Twin Wiper Relay 5 (OP)
4- Head Light Relay (Left) 22- Security Relay 35- Assist Relay 1 (OP) 48- Twin Wiper Relay 6 (OP)
5- Head Light Relay (Right) 23- Travel Fast Selection Relay 36- Assist Relay 2 (OP) 49- Swing Alarm Relay (OP)
6- Travel Slow Selection Relay 24- Blade/Outrigger Relay (Rear) 37- Assist Flow Rate Control Relay 50- Rear Head Light Relay (OP)
7- Compressor Relay (A/C) 25- Blade/Outrigger Relay (Front) (OP) 51- Additional Front Head Light
8- Heater Relay (A/C) 26- Blade/Outrigger Relay (Rear- 38- Blank (OP)
9- MAX-Hi Relay (A/C) Right) 39- Auxiliary/Positioning Selection 52- Additional Front Head Light
10- ECM Main Relay 27- Blade/Outrigger Relay (Rear- Relay 1 (OP) (OP)
11- Turn Signal Light Relay (Left) Left) 40- Auxiliary/Positioning Selection 53- Revolving Light Relay (OP)
12- Turn Signal Light Relay (Right) 28- Blade/Outrigger Relay (Main 2) Relay 2 (OP) 54- Immobilizer 1 (OP)
13- Wiper Relay 29- Blade/Outrigger Relay (Front- 41- Auxiliary/Positioning Selection 55- Immobilizer 2 (OP)
14- Boom Light Relay Right) Relay 3 (OP) 56- Immobilizer 3 (OP)
15- Stop Light Relay 30- Blade/Outrigger Relay (Front- 42- Auxiliary/Positioning Selection
16- Washer Relay Left) Relay 4 (OP)
17- Horn Relay 31- Blade/Outrigger Relay (Main 1) 43- Twin Wiper Relay 1 (OP)
18- Load Dump Relay 32- Auto-Cruise Relay (OP) 44- Twin Wiper Relay 2 (OP)
fNOTE: OP: Optional
T1-2-12
SECTION 1 GENERAL
Engine
1
2
T1T1-01-02-005 5 6
3 4
7
T1T1-01-02-003 13 12 11 10 T1T1-01-02-004
1- EGR Valve 5- Overheat Switch 9- Common Rail Pressure Sensor 13- Supply Pump Actuator
2- Glow Plug 6- Injector 10- Crank Speed Sensor
3- Cam Angle Sensor 7- Boost Pressure Sensor 11- Engine Oil Pressure Sensor
4- Coolant Temperature Sensor 8- Boost Temperature Sensor 12- Fuel Temperature Sensor
T1-2-13
SECTION 1 GENERAL
Pump Device
5 6
2 1
7
11
10
9 8
4 3 TCEB-03-01-003 TCEB-03-01-001
Swing Device Signal Control Valve
13
12
19
18 14
15
16
17
TCEB-01-02-004 TCEB-01-02-005
1- Pump 1 6- Steering Pump 10- Torque Control Solenoid Valve 16- Heat Circuit Cut Solenoid Valve
2- Pump 2 7- Pump 2 Control Pressure 11- Pump 2 Maximum Flow Rate 17- Swing Shockless Valve
3- Pump 1 Delivery Pressure Sensor Limit Control Solenoid Valve 18- Pressure Sensor (Swing)
Sensor 8- Pump 1 Control Pressure 12- Pressure Sensor (Front) 19- Pressure Sensor (Auxiliary)
4- Pump 2 Delivery Pressure Sensor 13- Signal Control Valve
Sensor 9- Pump 1 Maximum Flow Rate 14- Pressure Sensor (Positioning)
5- Pilot Pump Limit Control Solenoid Valve 15- Shuttle Valve
T1-2-14
SECTION 1 GENERAL
Control Valve Brake Valve

1 2 4
7
6
TCGB-01-02-003 TCJB-01-02-017
3
3-Spool Solenoid Valve Unit Solenoid Valve Unit (For Electric Lever)
9 10 11
20
12
19
13
18
14
17
15
16
TCGB-03-12-001 TCJB-01-02-018
1- Main Relief Valve 7- Brake Pressure Sensor 13- Auxiliary Solenoid Valve 17- Blade / Outrigger Solenoid
2- Pressure Sensor (Arm Roll-In) 8- Brake Valve 14- Blade / Outrigger Solenoid Valve
3- Pressure Sensor (Boom Raise) 9- Solenoid Valve Unit (SC) Valve 18- Auxiliary Solenoid Valve
4- Accumulator Charging Valve 10- Solenoid Valve Unit (SF) 15- Travel Make-Up Solenoid Valve 19- Positioning / Assist Solenoid
5- Brake Remain Pressure Sensor 11- Solenoid Valve Unit (SI) 16- Hydraulic Oil Temperature Valve
6- Stop Light / Work Brake 12- Positioning / Assist Solenoid Sensor (For Electric Lever) 20- Swing Parking Brake Release
Release Switch Valve Solenoid Valve
T1-2-15
SECTION 1 GENERAL
Travel Shockless Valve Transmission Changeover Solenoid Valve
5 6
2
TCJB-01-02-019 TCJB-05-07-002
4
Travel Device Filter

11 12 13
7 8
TCJB-01-02-020
10 9
15 14 TCEB-01-02-006
1- Pressure Sensor (Travel 4- Pressure Sensor (Travel 8- Transmission 12- Steering Filter
Forward) Reverse) 9- Travel N Sensor 13- Pilot Filter
2- Travel Forward Pi Cut Solenoid 5- Travel Mode Selector Solenoid 10- Travel Motor Displacement 14- Fuel Pre Filter
Valve Valve Control Solenoid Valve 15- Fuel Main Filter
3- Travel Reverse Pi Cut Solenoid 6- Pressure Reducing Valve 11- Steering Pump Delivery
Valve 7- Travel Motor Pressure Sensor
T1-2-16
SECTION 1 GENERAL
Engine
Manufacturer ISUZU
Model 4JJ1XYSA
Type Diesel, 4-Cycle, Water-Cooled, Direct Injection Type, Exhaust Turbo Charged Type
Cyl. No.- Bore × Stroke 4-95.4 mm × 104.9 mm
Total Displacement 2999 cm3
83±3.3 kW/2000 min-1 (113±4.5 PS/2000 rpm) HP Mode: 90.2+1.5-3.9 kW/2200 min-1 (123+2-5.3
Rated Output
PS/2200 rpm)
Compression Ratio 17.5
Dry Weight 320 kg (710 lb)
Firing Order 1-3-4-2
Direction of Rotation Clockwise (Viewed from Fan Side)
Dimensions: Length ×
963 × 813 × 918 mm
Width × Height
T1-3-1
SECTION 1 GENERAL
Diameter 650 mm (25.6 in), 5 Blades, Synthetic Resin, Intake

Cooling Fan
Type with Fan Ring Safety Net
Fan Pulley Ratio Belt Driven Rotation Ratio: 0.87
COOLING SYSTEM
Cracking Opening at Atmospheric Pressure: 85 °C (185 °F)
Thermostat
Full Open (Stroke: 10mm or More): 100 °C (212 °F)
Water Pump Centrifugal Swirl Pump
Lubrication Pump Type Gear Pump
LUBRICATING SYSTEM Filter Full-Flow Paper Element Type with Bypass
Cooler Water Cooled Integral 4-Stage Type
Electric Motor Magnetic Pinion Shift Reduction Type
STARTING SYSTEM
Voltage and Output 24 V·4 kW
PREHEAT SYSTEM Type Glow Plug (24 V, QOS II)
ENGINE STOP SYSTEM Type Fuel Shut-Off (Electronic Control)
Type Regulator Integrated AC Type, Brushless
ALTERNATOR
Voltage and Output 24 V·50 A
SUPERCHARGING
Type Exhaust-Turbocharger Type RHF5 Type with No Waste Gate
SYSTEM
Type Common Rail Type, HP3 Type
FUEL SYSTEM Governor Electronic All Speed Control
Injection Nozzle Electrical Multi-Hole Injector
T1-3-2
SECTION 1 GENERAL
Performance (New Engine)

IMPORTANT : This list shows design specifications, which are not servicing standards.
220±11 g/kW·h (299±15 g/PS·h) @ 90.2+1.5-3.9 kW (at Full Load: 2200 min-1)
Fuel Consumption Ratio
220±11 g/kW·h (299±15 g/PS·h) @ 83±3.3 kW (at Working Load: 2000 min-1)
Maximum Output Torque 402±20 N·m (41±2 kgf·m, 300±15 lbf·ft) @ Approx. 1800 min-1
Compression Pressure 3 MPa (31 kgf/cm2, 440 psi) @ 200 min-1
Valve Clearance (Intake/
0.15/0.15 mm (Cold)
Exhaust)
Slow: (at Full Load) 800±20 min-1
No Load Speed Fast: (at Full Load) 2200±20 min-1
(at Working Load) 2000±20 min-1
T1-3-3
SECTION 1 GENERAL
Engine Performance Curve (4JJ1XYSA)

Test conditions:
1. In conformity with JIS D1005 (Performance Test 2. Equipped with fan and alternator.
Method for Diesel Engine Used for Construction
Machinery) under standard atmospheric pressure.
Torque
(N·m)
Output
(kW)
Fuel
Consumption
Ratio (g/kW·h)
Engine Speed min-1 (rpm) TCEB-01-03-001
T1-3-4
SECTION 1 GENERAL
Engine Accessories
Type In-line Type

RADIATOR ASSEMBLY
Weight 73 kg (165 lb)
Radiator Oil Cooler Intercooler

Core Size (Height × Width ×
770 × 808.3 × 53 mm 710 × 725.2 × 40 mm 620 × 400 × 65 mm
Thickness)
No. of Core Lines 1 1 1
Fin Pitch 3.5 3.0 5.0
Fin Shape Corrugated T-CW Corrugated T-CW Corrugated T-CW
Capacity 7.8 L 18.0 L 7.2 L
Heat Dissipation Area 38.20 m 2
22.33 m 2
10.15 m2
100 kPa (1.02 kgf/cm2, 14.5 1500 kPa (15.3 kgf/cm2,
Air-Tight Test Pressure 250 kPa (2.55 kgf/cm2, 36 psi)
psi) 218 psi)
Cap Opening Pressure 49 kPa (0.5 kgf/cm2, 7.1 psi) − −
T1-3-5
SECTION 1 GENERAL
Core Size (Height × Width ×

224 × 137.8 × 32 mm
Thickness)
Fin Pitch 4.0 mm
Fin Shape Wavy Fin
FUEL COOLER
Capacity 0.2 L
Heat Dissipation Area 0.865 m2
Resisting Pressure 45 kPa (0.5 kgf/cm2, 6.5 psi)
Weight 0.7 kg (1.5 lb)
Nominal Voltage 12 V
Capacity 70 Ah or More (5-Hour Rate)
Discharging Characteristic
More than 4.5 Min.
(-15 °C (5 °F)·300 A) Duration
BATTERY
30-Second Voltage 9.9 V or More
Dimensions (Height ×
223 × 171 × 301 mm
Width × Length)
Weight 21 kg (47 lb) × 2
SOLENOID PUMP Rated Voltage DC24 V
T1-3-6
SECTION 1 GENERAL
Hydraulic Component
 Upperstructure
Speed Ratio Main Pump: 1, Pilot Pump: 1, Steering Pump: 1
PUMP DEVICE
Type Bent-Axis Type Variable Displacement Axial Plunger Pump
Theoretical Displacement Pump 1: 100 cm3/rev, Pump 2: 75 cm3/rev
MAIN PUMP
Maximum Oil Flow Rate
Pump 1: 220 L/min, Pump 2: 165 L/min
(Theoretical)
REGULATOR Type Hydraulic Pressure Operated Type
Type Constant Capacity Type Gear Pump
PILOT PUMP, STEERING Theoretical Displacement 16.8 cm3/rev
PUMP Maximum Oil Flow Rate
31.9 L/min (HP Mode: 35.3 L/min)
(Theoretical)
Type Pilot Pressure Operated Type (4-Spool + 5-Spool)
Main Relief Set Pressure 34.3 MPa (350 kgf/cm2, 4990 psi) @ 110 L/min
37.2 MPa (379 kgf/cm2, 5410 psi) @ 50 L/min (Boom Lower,
Arm Roll-In, Bucket Roll-In, Blade / Outrigger Raise, Blade /
CONTROL VALVE Outrigger Lower)
Overload Relief Set Pressure
39.2 MPa (400 kgf/cm2, 5700 psi) @ 50 L/min (Boom Raise,
Arm Roll-Out, Bucket Roll-Out)
28.0 MPa (286 kgf/cm2, 4070 psi) @ 135 L/min (Auxiliary)
Type Pilot Pressure Operated Type (Single-Spool)
AUXILIARY CONTROL
Overload Relief Set Pressure 39.2 MPa (400 kgf/cm2, 5700 psi) @ 50 L/min
VALVE
Weight 12.6 kg (28 lb)
T1-3-7
SECTION 1 GENERAL
Type 2-Stage Planetary Gear Reduction

SWING DEVICE Reduction Ratio 16.155
Type Swash Plate Type Constant Displacement Axial Plunger Motor
Model M5 × 130CHB
SWING MOTOR Theoretical Displacement
72.0 cm3/rev
Capacity
Type Non Counterbalance Valve Type
VALVE UNIT
Relief Set Pressure 29.3 MPa (299 kgf/cm2, 4260 psi) @ 110 L/min
Type Multi-Disc Wet Negative Type
SWING PARKING BRAKE
Release Pressure 1.9 to 2.8 MPa (19 to 28 kgf/cm2, 276 to 407 psi)
FRONT ATTACHMENT 1, 3 port: 7.0±0.5 mm
Plunger Stroke
PILOT VALVE 2, 4 port: 5.9±0.5 mm
TRAVEL PILOT VALVE Plunger Stroke 1, 2 port: 4.0±0.5 mm
POSITIONING / Model HEL02B-101
AUXILIARY ELECTRIC Operating Torque 1, 2 port: 3.47 to 6.10 N·m
LEVER Lever Tilting Angle 12.5 °
Model HEL02A-101
OUTRIGGER / ASSIST
Operating Torque 1.28 to 3.90 N·m
ELECTRIC LEVER
Lever Tilting Angle 12.5 °
T1-3-8
SECTION 1 GENERAL
· SC: For Arm Regenerative Control

4-SPOOL SOLENOID
Function · SF: For Brake Valve Control
VALVE UNIT
· SI: For Operate Check Valve (Axle Lock Cylinder) Control
AUXILIARY SOLENOID
VALVE UNIT (AUXILIARY
Function For Auxiliary Flow Rate Control
FLOW RATE CONTROL)
(OPTIONAL)
2-SPOOL SOLENOID
VALVE (FOR BLADE / Function For Operate Check Valve (Blade / Outrigger Cylinder) Control
OUTRIGGER)
· Shockless (For Boom Lower)
· Pump Flow Rate Control
SIGNAL CONTROL VALVE Function
· Bucket Flow Rate Control
· Swing Parking Brake Release
PILOT SHUT-OFF
Type ON/OFF Solenoid Valve
SOLENOID VALVE
PILOT RELIEF VALVE Relief Set Pressure 3.7 MPa (37.7 kgf/cm2, 538 psi) @ 40 L/min
Gerotor Displacement 159 cm3/rev
STEERING VALVE (WITH Steering Valve: 17.2 MPa (175 kgf/cm2, 2500 psi)
Relief Set Pressure
PRIORITY VALVE) Priority Valve: 20.6 MPa (210 kgf/cm2, 2990 psi)
Overload Relief Set Pressure 22.6 MPa (230 kgf/cm2, 3290 psi)
Brake Start-Up Threshold 2.5±0.5 to 4.9±0.5 MPa (25.5±5 to 50±5 kgf/cm2, 363±73 to
BRAKE VALVE
Pressure 712±73 psi)
T1-3-9
SECTION 1 GENERAL
Accumulation Starting
14.5 MPa (148 kgf/cm2, 2108 psi)
ACCUMULATOR Pressure (Cut-In)
CHARGING VALVE Accumulattion Stopping
17.7 MPa (180 kgf/cm2, 2573 psi)
Pressure (Cut-Out)
TRAVEL SHOCKLESS
Type Flow Regulator Type (With 2-Spool Solenoid Valve)
VALVE
TRANSMISSION
Pressure Reducing Valve Set
CHANGEOVER SOLENOID 3.7 MPa (37.7 kgf/cm2, 538 psi)
Pressure
VALVE
OIL COOLER BYPASS
Cracking Pressure 250±15 kPa (2.55±0.153 kgf/cm2, 36±2 psi) @ 5 L/min
CHECK VALVE
BYPASS CHECK VALVE Cracking Pressure 600 kPa (6.1 kgf/cm2, 87 psi)
T1-3-10
SECTION 1 GENERAL
 Undercarriage
TRAVEL MOTOR Type Bent-Axis Type Variable Displacement Axial Plunger Motor
(ZX140W-3: Up to serial Theoretical Displacement 140/59.7 cm3/rev (Travel Speed 20 km/h or More)
No 005000, ZX140W- (Max./Min.) 140/105.3 cm3/rev (Travel Speed 20 km/h or Less)
3-AMS: Up to serial No
050000) Weight 80 kg (177 lb)
TRAVEL MOTOR Type Bent-Axis Type Variable Displacement Axial Plunger Motor
(ZX140W-3: Serial No Theoretical Displacement 140/54.8 cm3/rev (Travel Speed 20 km/h or More)
005001 and up, ZX140W- (Max./Min.) 140/94.5 cm3/rev (Travel Speed 20 km/h or Less)
3-AMS: Serial No 050001
and up) Weight 80 kg (177 lb)
Type Counterbalance Valve Type
TRAVEL BRAKE VALVE
Relief Set Pressure 42 MPa (428 kgf/cm2, 6110 psi)
Type 2-Axis Planetary Gear Reduction
Fast: 1.19
TRANSMISSION Reduction Ratio
Slow: 4.87
Weight 135 kg (298 lb) (Including Oil)
T1-3-11
SECTION 1 GENERAL
Front: Steering Drive Axle with Hub Reduction

Type
STANDARD AXLE (Front, Rear: Full Rigid Drive Axle with Hub Reduction
Rear) (ZX140W-3: Up Brake Type Wet-Type Multi-Disc Brake
to serial No 005000,
ZX140W-3-AMS: Up to Final Reduction Ratio 13.714
serial No 050000) Front: 630 kg (1390 lb)
Weight
Rear: 550 kg (1220 lb)
Front: Steering Drive Axle with Hub Reduction
Type
STANDARD AXLE (Front, Rear: Full Rigid Drive Axle with Hub Reduction
Rear) (ZX140W-3: Serial Brake Type Wet-Type Multi-Disc Brake
No 005001 and up,
ZX140W-3-AMS: Serial Final Reduction Ratio 16.0
No 050001 and up) Front: 637 kg (1410 lb) (Including Oil)
Weight
Rear: 592 kg (1310 lb) (Including Oil)
Rod Outer Diameter 100 mm (3.9 in)
AXLE LOCK CYLINDER Stroke 160 mm (6.3 in)
T1-3-12
SECTION 1 GENERAL
 Front Attachment
Boom Arm Bucket
Rod Outer Diameter 70 mm (2.8") 80 mm (3.1") 70 mm (2.8")
Tube Inner Diameter 105 mm (4.1") 115 mm (4.5") 100 mm (3.9")
Stroke 941 mm (3' 1") 1120 mm (3' 8") 875 mm (2' 10")
Monoblock Boom
Fully Retracted Length 1448 mm (4' 9") 1650 mm (5' 5") 1350 mm (4' 5")
Plating Thickness 30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight 107 kg (236 lb) 151 kg (333 lb) 100 kg (221 lb)
CYLINDER
Rod Outer Diameter 75 mm (3.0") 80 mm (3.1") 70 mm (2.8")
Tube Inner Diameter 105 mm (4.1") 115 mm (4.5") 100 mm (3.9")
Stroke 877 mm (2' 11") 1120 mm (3' 8") 875 mm (2' 10")
2-Piece Boom
Fully Retracted Length 1700 mm (5' 7") 1650 mm (5' 5") 1350 mm (4' 5")
Plating Thickness 30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight 123 kg (272 lb) 151 kg (333 lb) 100 kg (221 lb)
Positioning
Rod Outer Diameter 95 mm (3.7")
Tube Inner Diameter 150 mm (5.9")
Stroke 710 mm (2' 4")
CYLINDER 2-Piece Boom
Fully Retracted Length 1215 mm (3' 12")
Plating Thickness 30 µm (1.18 µin)
Blade Outrigger
Rod Outer Diameter 60 mm (2.4") 60 mm (2.4")
Tube Inner Diameter 105 mm (4.1") 854 mm (2' 10")
CYLINDER Optional
Plating Thickness 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight 47 kg (104 lb) 67 kg (148 lb)
T1-3-13
SECTION 1 GENERAL
Electrical Component
BATTERY RELAY Voltage and Current 24 V·100 A

STARTER RELAY Voltage 24 V
GLOW PLUG RELAY Voltage 24 V
Specification 24 V·2.5+0.5-1 A
HORN
Sound Pressure 113±5 dB (A) @ 2 m
Specification 24 V·Max. 2.3 A
SECURITY HORN
Sound Pressure 115±5 dB (A) @ 2 m
BUZZER (OPTIONAL) Sound Pressure 112 dB
Work Light : Halogen 24 V, 70 W
Cab Light : 24 V, 10 W
Head Light : Halogen 24 V, 62/62 W
Turn Signal Light : 24 V, 21 W
ILLUMINATION Specification
Clearance Light : 24 V, 4 W
Licence Plate Light : 24 V, 12 W × 2 Used
Tail Light : 24 V, 10 W
Stop Light : 24 V, 21 W
T1-3-14
SECTION 1 GENERAL
Refrigerant 134a
Cooling Ability 16.7 MJ/h (4000 kcal/h) or More
Cool Air Volume 550 m3/h or More
Heating Ability 19.8 MJ/h (4720 kcal/h) or More
AIR CONDITIONER Warm Air Volume 400 m3/h or More
Temperature Adjusting
Electronic Type
System
Refrigerant Quantity 850±50 g
Compressor Oil Quantity 210 cm3
T1-3-15
SECTION 1 GENERAL
(Blank)
T1-3-16
SECTION 2
SYSTEM
CONTENTS
Group 1 Controller Group 4 Hydraulic System
Outline .....................................................T2-1-1 Outline .....................................................T2-4-1
Can: Controller Area Network Pilot Circuit...............................................T2-4-2
(Network Provided for Machine) .............T2-1-2 Service Brake Circuit ..............................T2-4-18
MC: Main Controller .................................T2-1-3 Steering Circuit.......................................T2-4-19
ECM: Engine Control Module .................T2-1-12 Main Circuit ............................................T2-4-20
ICF: Information Controller .....................T2-1-14
Group 5 Electrical System
Monitor Unit............................................T2-1-16
Outline .....................................................T2-5-1
Option Controller ....................................T2-1-31
Main Circuit ..............................................T2-5-2
Steering Column Monitor ........................T2-1-36
Electric Power Circuit (Key Switch: OFF) ..T2-5-4
Group 2 Control System Accessory Circuit......................................T2-5-6
Outline .....................................................T2-2-1 Starting Circuit (Key Switch: START) ........T2-5-8
Engine Control .........................................T2-2-4 Charging Circuit (Key Switch: ON) ..........T2-5-14
Pump Control .........................................T2-2-32 Serge Voltage Prevention Circuit ............T2-5-18
Valve Control..........................................T2-2-50 Pilot Shut-Off Circuit (Key Switch: ON) ...T2-5-20
Other Controls........................................T2-2-69 Security Lock Circuit...............................T2-5-22
Option Controller Control........................T2-2-95 Engine Stop Circuit (Key Switch: OFF) ...T2-5-24
Electric and Hydraulic Security Horn Circuit...............................T2-5-26
Composite Circuit Control................... T2-2-112 Wiper/Washer Circuit .............................T2-5-28
Light Circuit ............................................T2-5-30
Group 3 ECM System
Outline .....................................................T2-3-1
Fuel Injection Control ...............................T2-3-2
Fuel Injection Amount Correction Control...T2-3-10
Preheating Control ................................. T2-3-11
EGR (Exhaust Gas Recirculation)
Control .................................................T2-3-12
Engine Stop Control ...............................T2-3-14
CEBT-2-1
(Blank)
CEBT-2-2
SYSTEM / Controller
OUTLINE
The controllers are provided for each control respec-
tively.
Each controller is connected by using CAN (Controller
Area Network) in order to display on the monitor unit in
cab or the monitoring of machine overall condition
including the engine.
• MC: Main Controller

• ECM: Engine Control Module
• ICF: Information Controller
• Monitor Unit
• Option Controller
• Steering Column Monitor
Satellite Terminal Dr. ZX

(Option)
Monitor Unit
ICF
Option Controller
MC
CAN Bus Line
Steering Column ECM

Monitor
TCJB-02-01-001
NOTE: CAN (CAN Bus Line)
T2-1-1
SYSTEM / Controller
CAN: Controller Area Network (NETWORK
PROVIDED FOR MACHINE)
MC, ECM, ICF, monitor unit, option controller and
steering column monitor are connected by using CAN
bus line and communicate the signal and data each
other.
CAN bus line consists of two wires, CAN High and

CAN Low.
Each controller judges the CAN bus line level due to
potential difference between CAN High and CAN Low.
Each Controller arranges the CAN bus line level and
sends the signal and data to other controllers.
Satellite Terminal Dr. ZX

(Option)
Monitor Unit
ICF
CAN High
Option Controller
MC
CAN Low
CAN Bus Line
Steering Column ECM

Monitor
TCJB-02-01-001
T2-1-2
SYSTEM / Controller
MC: MAIN CONTROLLER
Function Outline
The signals from engine control dial, sensors and
switches are input to MC. Information from ECM, ICF,
monitor unit and option controller are input to MC by
using CAN.
MC processes the input signals in the logic circuit
and sends the signal equal to target engine speed to
ECM (Engine Control Module) by using CAN com-
munication in order to control the engine.
MC drives the solenoid valve unit and pump control
solenoid valve in order to control the pump and valve.
MC has the controls as follows.

• Engine Control
• Pump Control
• Valve Control
• Other Control
NOTE: As for details on each control, refer to the

SYSTEM / Control System group.
T2-1-3
SYSTEM / Controller
• Engine Control
• Engine Control Dial Control • Auto-Idle Control
Controls the engine speed according to the rota- Reduces the engine speed when all the control
tion angle of engine control dial. levers are in neutral. Therefore, fuel consumption
-1
Reduces the engine speed by 100 min in order and noise level can be reduced.
to reduce fuel consumption and noise level when
all the control levers are in neutral. • Hydraulic Oil Temperature Auto-Warming Up
Control
• Travel Accelerator Control Automatically warms up the hydraulic system.
Controls engine speed according to the accel-
erator pedal depressing amount when the ma- • Coolant Temperature Auto-Warming Up Control
chine travels. Automatically warms up the engine.
In addition, controls engine speed according to
pump load when engine speed increases and the • Idle Speed-Up Control
machine climbs the slope so that the machine can Prevents the engine from hunting when the en-
travel at fuel-efficient engine speed. gine runs at slow idle.
• Working Accelerator Control • Heater Control

Controls engine speed during digging operation Increases the rising temperature speed of the
by the accelerator pedal or the engine control dial. heater in cab while increasing the engine speed
at the low temperature.
• Engine Speed Holding Control When Decelerat-
ing • Attachment Operation Speed Increase Control
When the machine decelerates (when the travel (Optional)
pilot valve returns to the neutral position) and if Set attachment operation speed (breaker, pul-
travel speed is fast, engine speed is kept at fast verizer, crusher and vibrating hammer) to in-
idle. In addition, engine speed decreases ac- crease (+) with Dr. ZX. When operating the at-
cording to deceleration of travel speed in order to tachment, engine speed increases to the attach-
prevent cavitation in the travel motor. ment operating speed set by Dr. ZX.
• HP Mode Control • Attachment Operation Speed Decrease Control

Slightly increases digging power such as arm (Optional)
roll-in operation while excavating deeply. Set attachment operation speed (breaker, pul-
verizer, crusher and vibrating hammer) to de-
• E Mode Control crease (-) with Dr. ZX. When the attachment
Reduces the engine speed set by the engine mode is selected, engine speed decreases to the
control dial according to pump control pressure attachment operating speed set by Dr. ZX.
and average pump delivery pressure in order to
reduce fuel consumption.
T2-1-4
SYSTEM / Controller
Accelerator
Travel N Sensor
Pedal
Hydraulic Oil
Pilot Shut-Off Temperature Pressure Sensor
Switch Sensor Travel Forward
Travel Reverse
Key Switch Front Attachment

Swing
Boom Raise
Arm Roll-In
Engine
Control Auxiliary (OP)
Dial Arm Roll-Out (OP)
Auto-Idle
Switch
CAN Monitor Unit Attachment Mode
Communication 1 to 5
Coolant
Temperature
Sensor
Power Mode
Switch
Digging Mode Dr. ZX
HP
Mode
E
Mode ICF
P
Mode
Pump 1
Travel Speed Delivery
Mode Switch Pump 2 Delivery Pressure
ECM Pressure Sensor Sensor
Fast
Slow
Engine Speed
Control Mode
Selection Switch
Pedal
Dial
Pump 2 Pump 1
Creeper Control Control
Brake Pressure Pressure
Switch Sensor Sensor
FNR Switch
Parking Brake
Forward
Axle Lock
Neutral
Auto Axle Lock
Reverse OFF
TCJB-02-02-001
NOTE: OP: Optional
T2-1-5
SYSTEM / Controller
• Pump Control
• Speed Sensing Control (Normal)
Controls the pump flow rate in response to engine
speed changes due to variations in load so that
the engine output can be utilized more efficiently.
Engine stall is prevented when the machine op-
erates under adverse conditions such as operat-
ing at high altitude.
• Travel Speed Sensing Control

Controls the pump flow rate in response to engine
speed changes due to variations in travel load so
that the engine output can be utilized more effi-
ciently.
• Pump 1 Flow Rate Limit Control in Superfine

Travel Speed Mode
Limits the maximum flow rate of pump 1 during
the creeper mode.
• Pumps 1, 2 Flow Rate Limit Control

Reduces the maximum pump flow rate when
traveling at slow speed and improves the com-
bined operation of front attachment and swing.
• Pumps 1, 2 Flow Rate Control

Controls the maximum flow rate of pumps 1, 2
when traveling at fast speed and increases travel
speed.
• Steering Pump Torque Reduction Control

Reduces pumps 1, 2 driving torque in order to
prevent the engine from stalling and utilize the
engine output efficiently when the steering pump
driving torque increases.
• Pump 1 Flow Rate Limit Control (Optional)

Combines pressure oils from pumps 1, 2 and
supplies pressure oil to the actuator when the at-
tachment (mainly vibrating hammer) is used and if
pump 2 flow rate is lacking.
At this time, combined pump 1 flow rate is regu-
lated and the required pump flow rate is add in
order to operate the attachment.
• Pump 2 Flow Rate Limit Control (Optional)

Limits maximum pump 2 flow rate when the at-
tachment (mainly a breaker) is used.
T2-1-6
SYSTEM / Controller
Accelerator Pedal
Travel N Sensor
Pressure Sensor
Travel Forward
Engine
Control Dial Travel Reverse
Auxiliary (optional)
Travel Speed Brake Pressure Sensor

Mode Switch Work Brake Release Switch
Fast Monitor Unit Brake Pedal

CAN
Communication
Slow
Attachment Mode
1 to 5
Digging Mode
Engine Speed
Control Mode
Selection Switch
ICF
Pedal
Pump 2 Pump 1
Dial Delivery Delivery Steering Pump
Pressure Pressure Delivery Pressure
Sensor Sensor Sensor
Creeper
ECM
FNR Switch
Forward
Neutral
Reverse
Brake Switch Torque Control

Parking Solenoid Valve
Brake
Axle Lock
Auto
Axle Lock
OFF
Pump 2 Maximum Pump 1 Maximum TCJB-02-02-016

Flow Rate Limit Flow Rate Limit
Solenoid Valve Solenoid Valve
T2-1-7
SYSTEM / Controller
• Valve Control
• Arm Regenerative Control
Increases arm roll-in speed and prevents hesita-
tion when the arm is rolled in.
• Work Brake Control

Applies the front/rear brakes in order to make the
machine stable during digging operation.
• Auto Axle Lock Control

Automatically activates the auto-axle lock when
the machine stops. In addition, automatically de-
activates the axle lock and reduces vibration
when traveling.
• Travel Motor Displacement Angle Selection Con-

trol
Shifts the travel motor to the minimum displace-
ment angle when the machine travels at level
ground and reduces fuel consumption.
• Superfine Travel Speed Control

Turns travel speed into the ultraslow speed mode.
• Travel Motor Excessive Rotation Control

Protects the travel motor in order not to overrun
when the machine descends the slope.
• Pulverizer Control (Optional)

Increases the pulverizer operating speed.
When operating combined operation of arm
roll-out, arm roll-out + boom raise, swing or travel
and pulverizer, flow rate to the auxiliary spool is
restricted and operation of the arm, boom, swing
or travel is improved.
• Crusher Control (Optional)

Increases the crusher operating speed.
When operating combined operation of arm
roll-out, arm roll-out + boom raise, swing or travel
and crusher, flow rate to the auxiliary spool is re-
stricted and operation of the arm, boom, swing or
travel is improved.
T2-1-8
SYSTEM / Controller
Digging Mode Attachment Mode1 to 5

Brake Pedal
Key Switch Travel N sensor
Monitor
Unit Pressure Sensor
Brake Pressure
Travel Forward Sensor
Travel Reverse Work Brake
Front Release Switch
Engine Control Dial ICF Swing Pump 2 Pump 1
Boom Raise Delivery Delivery
Pressure Pressure
Power Digging Arm Roll-In Sensor Sensor
Switch Arm Roll-Out (OP)
ECM Auxiliary (OP)
P2 P1
Engine Speed Control
Mode Selection Switch
Pedal
Dial Hydraulic Oil

Temperature
Creeper Sensor
Travel Motor
Travel Speed Pump 2 Control

Mode Switch Pressure Sensor
Pump 1 Control
Fast Pressure Sensor
Solenoid Valve Unit

Slow Travel Motor Displacement
SI
Main Relief Valve Control Solenoid Valve
SF
SC
FNR Switch Auxiliary Flow

Auxiliary Flow
Rate Control
Rate Control
Forward Solenoid
Valve
Valve (OP)
Neutral
Reverse
Brake
Valve
Operate
Check Valve
Axle Lock
Cylinder
Brake Switch
Parking
Brake
Axle Lock
Auto
Axle Lock
Brake (Front)
Arm Regenerative Valve
OFF
P2 P1
Brake (Rear)
TCGB-02-02-003
T2-1-9
SYSTEM / Controller
• Other Control
• Forward/Reverse Shifting Restriction Control • Rear Monitoring Display Selection Control
If the travel direction is changed to the opposite Switches the screen of monitor unit into that of the
direction while traveling, adverse effects may back-screen.
occur in the travel circuit and components. In or-
der to protect the circuit and components from • Screen Forcible Transition Control
being damaged, the opposite travel direction side Controls so that the monitor unit screen is dis-
pilot pressure is temporarily interrupted so that played as the primary screen (speedometer)
the opposite direction system is deactivated dur- when the machine travels. In addition, makes the
ing travel operation. monitor unit operation disabled.
• Travel Pilot Pressure Cut Control • Work Mode Control

Cuts off the forward or reverse travel pilot pres- The work mode control consists of digging and
sure when the FNR switch is in the N (neutral) attachment 1 to 5.
position so that the machine cannot travel al- The mode can be selected by using the monitor
though the travel pilot valve is operated. unit.
• Travel Mode Selection Control • Swing Alarm Control (Optional)

Selects the transmission solenoid valve by shift- Sounds the buzzer (optional) and turns the bea-
ing the travel speed mode switch and shifts con light during swing operation.
high/low of the transmission. In addition, lights the
indicator in steering column monitor. • Travel Alarm Control (Optional)
Sounds the buzzer (optional) while the machine
• Parking Brake Selection Control travels.
Applies or release the parking brake in transmis-
sion by shifting the brake switch. • Auto-Cruise Control (Optional)
Secures the accelerator pedal in the stroke end
• Parking Brake Alarm Control during fast-forward travel operation and controls
Sounds the buzzer in order to protect the trans- that the machine automatically can travel at fast
mission when operating the front attachment although the accelerator pedal is released.
while the parking brake is applied.
• Brake Dragging Prevention Control

Prevents the machine traveling operation while
the parking brake and work brake are applied.
T2-1-10
SYSTEM / Controller
Monitor Unit
Back Monitor
Buzzer
MC
Key Switch
CAN Bus Line
Travel
N Sensor
Pressure Sensor To ICF
Travel Forward
Travel Reverse
Front Attachment Steering

ECM Column
Swing Monitor
Brake Pressure
Sensor From Fuse #28
Brake Remain From Fuse #29
Pressure Sensor
Hydraulic Oil Fast Speed
Temperature Sensor Shift Relay
Auto Cruise
Switch (OP) Slow Speed
Shift Relay
Work Brake
Release Switch
FNR Switch Travel Reverse Pi Cut

Solenoid Valve
Forward Travel Forward Pi Cut
Solenoid Valve
Neutral Travel Alarm Device
(Optional)
Buzzer Deactivation
Reverse Switch (Optional)
Buzzer
Travel Speed
Mode Switch
Fast
Swing Alarm Relay
(Optional)
Buzzer
(Optional)
Revolving Light
(Optional)
Brake Switch
Parking
Brake
TCJB-02-01-002
T2-1-11
SYSTEM / Controller
ECM: ENGINE CONTROL MODULE
Function Outline
ECM (Engine Control Module) receives the signals
from sensors and MC
ECM processes and drives the two-way valve, suc-
tion control valve and EGR (Exhaust Gas Recircula-
tion) motor in order to control the supply pump, in-
jector pump and EGR valve.
ECM has the controls as follows.

• Fuel Injection Control
ECM detects the engine operating condition ac-
cording to the signals from each sensor and MC
and controls the fuel injection.
• Fuel Injection Amount Correction

ECM adjusts fuel injection amount according to
the signal of atmospheric pressure sensor.
• Preheating Control
ECM controls time for continuity of electrical cur-
rent for the glow plug according to coolant tem-
perature and improves the starting of engine.
• EGR Control
ECM decides EGR gas amount according to en-
gine speed, fuel flow rate, coolant temperature,
atmospheric pressure and intake-air temperature.
ECM opens EGR valve and re-circulates exhaust
gas, amount of which is equal to EGR gas amount,
in the intake manifold. EGR gas is combined with
intake-air so that combustion temperature is low-
ered and NOx is reduced.
• Engine Stop Control

When the emergency stop switch is turned to the
ON position, ECM stops the fuel injection of in-
jector and stops the engine.
NOTE: As for details on each control, refer to the

SYSTEM / ECM System group.
T2-1-12
SYSTEM / Controller
From Fuse #16
From Battery
ECM
Crank Speed Sensor
Engine Stop
Glow Plug Relay Switch Cam Angle Sensor
Atmospheric Pressure Sensor
Fuel Temperature Sensor
Intake-Air Temperature Sensor
Glow Plug Boost Pressure Sensor
Boost Temperature Sensor

CAN Bus Line
Engine Oil Pressure Sensor
EGR Motor Position Sensor
MC
EGR Motor
Two-Way
Valve
Common Rail
Pressure Sensor
Monitor Unit
Suction Control
Valve
Common Rail
Coolant Supply Pump

Temperature
Sensor
Fuel Tank
Injector
TCJB-02-01-003
T2-1-13
SYSTEM / Controller
ICF: INFORMATION CONTROLLER
Function Outline
• Operating Hours Management
The built-in clock is provided for ICF.
ICF sends data of built-in clock to the monitor unit
by using CAN bus line.
• Alarm, Fault Code Memory

ICF memorizes the alarm and fault code from
each controller by using CAN bus line in the time
series.
The memorized alarm and fault code are sent to
the center server by the satellite terminal (op-
tional).
Engine oil pressure alarm and overheat alarm are
sent to the center server whenever these occur.
Other alarm and fault code are sent to the center
server once a day.
• Fault Code Display

ICF displays the fault code sent from each con-
troller by using CAN bus line on Dr. ZX.
• Maintenance History
When the maintenance key is pushed on the
monitor unit, time is recorded.
• Daily Report Data Making

ICF records operating hours, fuel level and fuel
amount of use during daily operation, and makes
the daily report data.
The daily report data can be sent to the center
server by using the satellite terminal (optional).
• Frequency Distribution Data Making

ICF makes the frequency distribution data every
100 hours.
The frequency distribution data can be sent to the
center server by using the satellite terminal (op-
tional).
• Cumulative Operating Hours Record

ICF records all hours when the machine is oper-
ated.
The cumulative operating hours can be
downloaded to Dr. ZX.
• Mail Data Making (Optional)

ICF records the mails sent from the monitor unit
and sends them to the center server by the satel-
lite terminal.
T2-1-14
SYSTEM / Controller
ICF
CAN Bus Line
MC Communication
• Built-In Clock
ECM
Satellite Terminal
(Optional)
• GPS
Monitor Unit
Center Server
Dr. ZX
T1V1-02-01-049
T2-1-15
SYSTEM / Controller
MONITOR UNIT
Primary Screen
7
1 2 3 4 5 6 8
9
10
11
12
13
14
15
16
17
18
35 34
20 20 19
TCJB-05-02-043
33 32 31 30 29 28 27 26 25 24 23 22
1 - Work Mode Display 10 - Parking Brake Display 19 - Trip Meter Display 28 - Work Mode Display
2 - Auto-Idle Display 11 - Work Brake Display 20 - Odometer Display 29 - Auxiliary Selection
3 - Overload Alarm Display 12 - Axle Lock Display 21 - Hour Meter Display 30 - Coolant Temperature
(Optional) Gauge
4 - Auto Axle Lock Display 13 - Work Light Display 22 - Back Monitor Selection 31 - Work Mode Selection
5 - Auxiliary 14 - Auxiliary 2 (Positioning) 23 - Menu 32 - Return to Primary Screen
Selection Display
6 - Glow Signal Display 15 - Auxiliary 1 (Attachment) 24 - Meter Display Selection 33 - Brake Oil Pressure Gauge
Selection Display
7 - Trip Meter 16 - Blade/Outrigger Settings 25 - Fuel Gauge 34 - Speedometer
and Brake Mode Display
8 - Odometer 17 - Mail Display (Optional) 26 - Auxiliary 35 - Tachometer
9 - Hour Meter 18 - Clock 27 - Mail Selection (Optional)
T2-1-16
SYSTEM / Controller
7
• Display of Meters
Data to be displayed on each meter are displayed on
the monitor unit according to the input signal from
sensor, the signal received from ICF by using CAN
and the internal data of monitor unit.
Items to be displayed 18
7. Trip Meter (Signal received from MC by using CAN)

8. Odometer (Signal received from MC by using CAN)
9. Hour Meter (Internal data of the monitor unit)
18. Clock (Signal received from ICF by using CAN)
25. Fuel Gauge (Input signal from the fuel sensor)
30. Coolant Temperature Gauge (Input signal from the
coolant temperature sensor) 8 TCJB-05-02-057
34 33 30 25
33. Brake Oil Pressure Gauge (Signal received from
MC by using CAN)
34. Speedometer (Signal received from MC by using
CAN)
35. Tachometer (Signal received through MC from
ECM by using CAN)
TCJB-05-02-056
9
TCJB-05-02-042
35 TCJB-05-02-041
T2-1-17
SYSTEM / Controller
• Work Mode Display (1) 1 7
The attachments being used are displayed accord-
ing to the signals received from MC by using CAN.
Digging Mode
18
T1V1-05-01-108
Attachment Mode
Breaker
T1V1-05-01-104
Pulverizer
TCJB-05-02-057
34 33 30 25
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibrating Hammer
T1V1-05-01-107
Others
T1V1-05-02-003
NOTE: The items on monitor unit and HITACHI

pattern are same.
Monitor Unit HITACHI pattern
Breaker1 Hydraulic Breaker1
Pulverizer1 Secondary Crusher1
Crusher1 Primary Crusher1
T2-1-18
SYSTEM / Controller
• Auto-Idle Display (2)
2 3 4 6
When the auto-idle switch on switch panel is turned
ON, the data is displayed.
When the key switch is turned ON with the auto-idle
switch ON, the data blinks for 10 seconds.
• Overload Alarm (3)
TCJB-05-02-061
The system measures the load of suspended load

from the boom cylinder bottom pressure sensor.
When overload is detected, an alarm is displayed.
• Auto Axle Lock Display (4)

The data is displayed when the brake switch in the
auto axle lock position. TCJB-05-02-042
• Glow Signal Display (5)

While ECM is supplying current to the glow plug, the
data is displayed according to the signal from ECM.
T2-1-19
SYSTEM / Controller
30 25
• Fuel Gauge (25)
The data of fuel level is displayed.
• Coolant Temperature Gauge (30)

Temperature of engine coolant is displayed.
TCJB-05-02-064
• Brake Oil Pressure Gauge (33) 34 33

Pressure in the brake circuit is displayed.
• Speedometer (34)
Travel speed is displayed.
NOTE: When the machine travels forward and al-

though other setting on the monitor unit is
done, the primary screen is displayed.
(Screen Forcible Transition Control)
(Refer to the SYSTEM / Control System
group.)
TCJB-05-02-064
35
• Tachometer (35)
Engine speed is displayed.
NOTE: Speedometer (34) or tachometer (35) is

displayed on the monitor screen due to the
setting.
TCJB-05-02-065
T2-1-20
SYSTEM / Controller
• Parking Brake Display (10)
When the parking brake is applied, the red indicator 4 10 11 12
lights.
(Brake Switch: P (Parking Brake) Position
• Work Brake Display (11)

When the work brake is applied (under the work
brake control), the red indicator lights.
(Refer to the SYSTEM/Control System group.)
• Axle Lock Display (12)

When the axle lock is operated, the red indicator
lights. (Brake Switch: Axle Lock or Auto Axle Lock
position)
NOTE: When the brake switch is in the auto axle

TCJB-05-02-042
lock position and the lever is in neural, auto
axle lock display (4) or axle lock display
(12) lights.
At this time, the accelerator pedal is de-
pressed, the axle lock is released by the
axle lock control and axle lock display (12)
goes off.
As the brake switch is in the auto axle lock
position, auto axle lock display (4) is kept to
light.
(Refer to the SYSTEM/Control System
group.)
T2-1-21
SYSTEM / Controller
• Work Light Display (13)
The work light switch is turned ON, the green indi- 15 14
cator lights.
• Auxiliary 2 (Positioning) Selection Display (14) 13

When the auxiliary/positioning selection switch is in 16
the Positioning position, the green indicator lights.
• Auxiliary 1 (Attachment) Selection Display (15)

When the auxiliary/positioning selection switch is in
the Auxiliary (Attachment) position, the green indi-
cator lights.
• Blade/Outrigger Setup and Brake Mode Display (16)

The combination data of blade/outrigger is displayed.
When the parking brake, work brake or TCJB-05-02-042
blade/outrigger is operated, the green indicator re-
lated to the operated function lights.
When applying parking brake
NOTE: The illustration shows the screen on the
front outrigger and rear blade specification.
Green indicator
lights.
TCJB-05-02-074
When applying work brake
Green indicator Green indicator

lights. lights.
TCJB-05-02-075
When operating blade/outrigger

lights. lights.
TCJB-05-02-102
T2-1-22
SYSTEM / Controller
• Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
Sensor Error Display Display
TCJB-05-02-104
When the fuel sensor is faulty or if the harness be-

tween fuel sensor and monitor unit is open circuit,
the data is displayed on the fuel gauge.
• Coolant Temperature Sensor Error Display
TCJB-05-02-103
When the coolant temperature sensor is faulty, the

data is displayed on the coolant temperature gauge.
TCJB-05-02-045
• Alarm and Remedy Displays against Alarm

Alarm marks are displayed on bottom of the screen
according to the alarm signals from pilot shut-off
lever, overheat switch, fuel sensor, hydraulic oil filter,
alarm switch (optional), air cleaner restriction switch,
alternator, battery system and ECM and the alarm
signals received from MC by using CAN. The rem-
edy for each alarm is displayed by key operation.
Alarm Display TCJB-05-02-049
Remedy Display against T1V5-05-01-013
Alarm
T2-1-23
SYSTEM / Controller
Main Menu
• Time Setting
Time is set.
Time Set Screen T1V5-05-01-021
• Operating Conditions
This screen displays machine operating hour, fuel
usage and fuel consumption rate registered by the
monitor unit.
Operating Conditions Screen T1V5-05-01-025
• Attachment Selection (Work Mode)

(Only machines equipped with optional parts)
Selects digging mode and attachment mode set by
Dr. ZX on this screen.
NOTE: In attachment mode, the following four

modes are set by default.
1 - Digging
2 - Breaker 1
3 - Breaker 2
4 - Pulverizer 1
5 - Crusher 1
NOTE: The items on monitor unit and HITACHI 1 2 3 4 5 T1V5-05-01-109
pattern are same.

Attachment Selection Screen
T2-1-24
SYSTEM / Controller
• Pump 2 Flow Rate Adjustment (Attachment Adjust- Figure 1
ment)
When using the attachments, fine adjust flow rate of
pump 2 by keys 1 and 2 operation.
The signals from monitor unit are sent to MC by us-
ing CAN.
When breaker 1 or 2 is used, MC adjusts maximum
flow rate of pump 2 while controlling maximum pump
2 flow rate limit control solenoid valve. (Figure 1)
(Pump 2 Flow Rate Limit Control) Key 1
When pulverizer 1 or crusher 1 is used, MC adjusts
flow rate of pressure oil that flows from pump 2 to Key 2
pulverizer or crusher while controlling the auxiliary
flow rate control solenoid valve. (Figure 2) (Pulver- When using Breaker 1 T1V5-05-01-111
izer / Crusher Control) Figure 2

(Refer to the SYSTEM / Control System group.)
NOTE: When the 2-speed selector circuit is OFF,

maximum flow rate of pump 2 can be ad-
justed while controlling the maximum pump
2 flow rate limit control solenoid valve.
(Figure 1)
When the 2-speed selector circuit is ON,
flow rate of pressure oil that flows from Key 1
pump 2 to the attachments can be adjusted
while controlling the auxiliary flow rate con- Key 2
trol solenoid valve. (Figure 2) T1V5-05-01-024
The table blow shows the default. When using Pulverizer 1
Type of 2-Speed Valve Selector Accumulator Secondary

Attachments Display Selector Circuit Circuit Circuit Hydraulic
Relief Selector
Circuit
Breaker 1 Figure 1 OFF O/T OFF ON
Breaker 2 Figure 1 OFF O/T ON OFF
Pulverizer 1 Figure 2 ON C/V OFF OFF
Crusher 1 Figure 2 ON C/V OFF OFF
NOTE: O/T: Hydraulic Oil Tank
C/V: Control Valve

pattern are same.
Breaker 1 Hydraulic Breaker 1
Pulverizer 1 Secondary Crusher 1
Crusher 1 Primary Crusher 1
T2-1-25
SYSTEM / Controller
• Maintenance Settings
The data; date of the last replacement, hour meter,
the remaining hours until the next replacement and
the replacement interval are displayed.
As the items to be replaced are displayed in a list,
record performed replacement by selecting an item
from the list.
• Interval ON/OFF Settings

Set change interval for each item to be replaced.
• Items included in Maintenance Settings

Engine Oil Maintenance Setup Screen T1V5-05-01-049
Engine Oil Filter
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Filter
Pump Transmission Oil
Swing Reduction Gear Oil
Swing Bearing Grease
Hydraulic Oil Brake Steering Filter
Travel Device Transmission Oil
Axle Gear Oil (Front, Rear, each Hub)
Drive Shaft Greasing
Front Axle King Pin Greasing
Front Axle Center Pin Greasing
Wheel Nut Torque Check Interval ON/OFF Setup Screen T1V5-05-01-052
Air Filter
Engine/Air Conditioner V-belt
Fuel Filter
Air Conditioner Filter
User Setting (TRIP 1)
T2-1-26
SYSTEM / Controller
• Mail (Optional Function)
Sends requests such as general, fuel replenishment,
service maintenance and forwarding requests in the
mail switch screen.
Contents of mails are registered in ICF, and are sent
to the central server by a satellite terminal.
Mail Switch Screen T1V5-05-01-037
• Meter Display Selection (HOUR↔ODO↔TRIP)

The meter display; hour meter, odometer and trip
meter on primary screen is switched.
The selected item is displayed on the primary
screen.
When the key switch is turned OFF, the item is reset
into the meter combination setting.
Meter Display Selection Screen TCJB-05-02-072
• Back Monitor Settings

By key operation, image display ON/OFF of
Auto-Control for switching image of the back monitor
while the machine travels backward.
T1V5-05-01-173
T2-1-27
SYSTEM / Controller
• Language Settings
Select a language to be used in screens from
among preset languages, according to work envi-
ronment.
Language Setup Screen T1V1-05-01-137
• Meter Combination Settings (km/h↔min-1)

-1
Speedometer (km/h), tachometer (min ), hour meter,
odometer and trip meter on the primary screen are
combined and set respectively.
(Default: Speedometer+Hour Meter)
TCJB-05-02-068
Meter Combination Setup Screen
• Unit Setting (km↔mile)

The units; km and mile, in the primary screen are
set.
TCJB-05-02-016
Unit Setup Screen
T2-1-28
SYSTEM / Controller
• Service Menu (Built-In Diagnosing System)
• Troubleshooting
This screen displays the fault codes according to
the signals received from each controller by using
CAN.
• Monitoring Fault Code Display T1V5-05-01-097
This screen displays temperature and pressure

data received from each controller by using CAN.
By key operation, the displayed data can be hold.
Monitoring Screen T1V5-05-01-087
• Controller Version
This screen displays the version of MC, ICF,
monitor unit, steering column monitor and option
controller.
NOTE: The version of ECM is not displayed.
Controller Version Display TCHB-05-02-008
• Blade/Outrigger Settings
Combination of blade and outrigger displayed on
the primary screen is set.
Blade/Outrigger Setup Screen TCHB-05-02-009
T2-1-29
SYSTEM / Controller
• Overload Alarm
(Only the machines equipped with optional parts) Overload Alarm
IMPORTANT: When using overload alarm, make

overload alarm available by using Dr.
ZX.
1. MC detects load of the suspended load by the

signal from the boom bottom pressure sensor.
2. When the overload alarm switch (optional) is
turned ON and load of the suspended load be-
comes overloaded, the monitor unit displays an
alarm message on the primary screen and rings a
buzzer according to the signal from MC by using
CAN.
3. If overload of the suspended load is dissolved, the
alarm message disappears and the buzzer stops Primary Screen TCJB-05-02-042
ringing.
Overload Alarm Switch
(Optional)
NOTE: Even if the work is done while displaying a
screen except the primary screen, when an
overload condition is reached, the screen
of monitor unit is switched to the primary
screen, an alarm message is displayed and
a buzzer is rung.
Even after the overload alarm is dissolved,
the monitor unit keeps on displaying the
primary screen without returning to the
screen while the work is done.
T1V1-05-02-004
T2-1-30
SYSTEM / Controller
OPTION CONTROLLER
Function Outline
The signals from electric levers of blade/outrigger,
auxiliary, positioning, assist (optional) are input to the
option controller.
Information from MC, ECM, ICF and the monitor unit is
input to the option controller by using CAN.
The option controller activates the solenoid valve cor-
responding to the signals from electric levers and con-
trols each actuator.
The option controller control consists of the followings.

• Auxiliary and Positioning Control (Optional)
• Blade/Outrigger Control
• Assist Control (Optional)
• Auxiliary and Blade/Outrigger Output Monitoring
Control (Optional)
• Positioning and Assist Output Monitoring Control
(Optional)
• Electric Lever Pilot Cut Control
• HSB Breaker Control (Optional)
• Overload Alarm Control (Optional)
NOTE: As for details of each control, refer to the

SYSTEM/Control System group.
T2-1-31
SYSTEM / Controller
• Auxiliary and Positioning Control • Overload Alarm Control (Optional)
Selects each function by using the auxiliary and Rings the buzzer and displays the overload alarm
positioning selection switch and activates the re- when boom raise operation like as suspending is
lated solenoid valve according to operation. overloaded.
Activates the blade/outrigger solenoid valve ac-
cording to electric lever operation.
• Assist Control
Activates the assist solenoid valve according to
assist switch operation.

Control
The option controller compares electric lever op-
eration with the detected value of pressure sensor.
If the option controller recognizes abnormality, the
auxiliary and blade/outrigger stop.
• Positioning and Assist Output Monitoring Control

If the option controller recognizes abnormality, the
positioning and assist stop.

If the option controller recognizes abnormality, all
the solenoid valves stop.
T2-1-32
SYSTEM / Controller
Electric Lever Operation Circuit, Overload Alarm Circuit

Boom Bottom Pressure Sensor
Pressure Sensor
Auxiliary Pedal
Auxiliary
Positioning
Positioning
Pedal Dr.ZX
Blade/Outrigger
Lever ICF
Overload Alarm
Assist Switch From Fuse #19
Buzzer
Option Controller
Blade/Outrigger
Switch CAN Communication
Left Analog
Switch Monitor Unit
(Optional)
Swing Parking Brake

Release Solenoid
Valve
Pilot Pump Swing Motor
Auxiliary Sole- Positioning Assist Sole-

noid Valve Solenoid noid Valve
Valve
Swing Parking
Brake
Positioning Con- Assist Control
Control Valve trol Valve Valve
TCJB-02-01-005
T2-1-33
SYSTEM / Controller
• HSB Breaker Control (Optional)
When the work mode on monitor unit is turned
into Attachment Mode (Breaker 1), the option
controller activates the selector valve control so-
lenoid valve and secondary pilot relief pressure
control solenoid valve in order to control flow rate
of pressure oil to the actuator from pump 2.
T2-1-34
SYSTEM / Controller
Breaker Control Circuit
Attachment Mode Breaker

Accumulator Accumulator
1 to 5
Monitor Unit Control Valve (High Pressure)
Dr. ZX
ICF
CAN Communication
MC Option Con-
troller
Accumulator
(Low Pressure)
Selector Valve
Secondary Pilot
Relief Pressure
Control Valve Secondary Pilot
Relief Pressure
Valve
Accumulator
Control Sole- Selector Secondary
noid Valve
Valve Con- Pilot Relief
trol Solenoid Pressure
Valve Control
Solenoid
Valve
From Pilot
Pump
Pump 2 Maximum Flow

Rate Limit Control Solenoid
Valve
From Pump 2 Pump 2

Flow Rate Control
Valve in Signal
Control Valve
TCJB-02-01-007
T2-1-35
SYSTEM / Controller
STEERING COLUMN MONITOR
Function Outline
The steering column monitor turns on or off the related
indicator by switching each switch.
The steering column monitor rings the buzzer by the
signal from brake pressure switch.
1 2
12 3
4
11
5
10 6
9 7
8
TCJB-02-01-008
1- Travel Forward Indicator 4 - Pilot Cut Indicator 7 - Auto-Cruise Indicator (Op- 10 - Clearance Light Indicator
tional)
2- Turn Signal Indicator 5 - Travel Reverse Indicator 8 - Travel Slow Speed Indica- 11 - High Beam Indicator
(Right) tor
3 - Neutral Indicator 6 - Hazard Light Indicator 9 - Auxiliary 12 - Turn Signal Indicator (Left)
T2-1-36
SYSTEM / Control System
OUTLINE
MC (Main Controller) is used to control the machine The option controller drives the blade/outrigger, auxil-
operations. The signals from engine control dial, vari- iary, positioning, assist (optional) and swing parking
ous sensors and switches are sent to MC and proc- brake release solenoid valve according to the electric
essed in the logic circuit. lever operation and controls each actuator.
MC sends the signals equivalent to the target engine
speed to ECM (Engine Control Module) by using CAN
communication in order to control the engine. (Refer to
the SYSTEM / ECM System group.) MC drives the
solenoid valve unit and torque control solenoid valve in
order to control the pump and valve.
Input Signal Output Signal

• Engine Control Dial → Engine Control (ECM)
• Pump 1 Control Pressure Sensor → Engine Control Dial Control
• Pump 2 Control Pressure Sensor → Travel Accelerator Control
• Pump 1 Delivery Pressure Sensor → Working Accelerator Control
• Pump 2 Delivery Pressure Sensor → Engine Speed Holding Control when Decelerating
• Steering Pump Delivery Pressure Sensor → HP Mode Control
• Travel N Sensor → E Mode Control
• Pressure Sensor (Travel Forward) → Auto-Idle Control
• Pressure Sensor (Travel Reverse) → Hydraulic Oil Temperature Auto-Warming Up Control
• Pressure Sensor (Front Attachment) → Coolant Temperature Auto-Warming Up Control
• Pressure Sensor (Swing) → Idle Speed-Up Control
• Pressure Sensor (Boom Raise) → Heater Control
• Pressure Sensor (Arm Roll-In) → MC * Attachment Operation Speed Increase Control
• Pressure Sensor (Auxiliary) (Optional) → * Attachment Operation Speed Limit Control
• Pressure Sensor (Arm Roll-Out) (Optional) →
• Hydraulic Oil Temperature Sensor → Pump Control (Torque Control Solenoid Valve)
• Auto-Idle Switch → Speed Sensing Control
• Pilot Shut-Off Switch → Travel Speed Sensing Control
• Brake Pressure Sensor → Pump 1 Flow Rate Limit Control in Superfine Travel
• Brake Remain Pressure Sensor → Speed Mode
Pumps 1, 2 Flow Rate Limit Control
Pumps 1, 2 Flow Rate Control
Steering Pump Torque Decrease Control
* Pump 1 Flow Rate Limit Control
* Pump 2 Flow Rate Limit Control
Continued to T2-2-2
NOTE: *: This control is for only the machine with

optional parts equipped.
T2-2-1
Continued from T2-2-1
Input Signal Output

• Power Mode Switch (HP/E/P) → Valve Control (Solenoid Valve Unit)
• FNR Switch (F/N/R) → Arm Regenerative Control
• Travel Speed Mode Switch (Fast/Slow) → Work Brake Control
• Engine Speed Control Mode Selection Switch Auto Axle Lock Control
(Pedal/Dial/Creeper) → Travel Motor Displacement Angle Control
• Brake Switch → Superfine Travel Speed Control
• Work Brake Release Switch → Travel Motor Excessive Rotation Control
• Key Switch → * Pulverizer Control
• Auto Cruise Switch (Optional) → * Crusher Control
CAN Communication
• Crank Speed ← Target Engine Other Control
Sensor → Speed Forward/Reverse Shifting Restriction Control
• Cam Angle Sensor → Travel Pilot Pressure Cut Control
• Coolant Temperature Actual Engine Travel Mode Selection Control
Sensor → ECM Speed → Parking Brake Selection Control
Coolant Parking Brake Alarm Control
Temperature → Brake Dragging Prevention Control
Rear Monitoring Display Selection Control
Screen Forcible Transition Control
Work Mode Control
Work Mode * Swing Alarm Control
Monitor
(Digging/Attachment) → * Travel Alarm Control
Unit
* Auto-Cruise Control
CAN Communication
• Electrical Lever (for Positioning / Blade / Option Controller Control

Outrigger / Assist (Optional)) → * Auxiliary and Positioning Control
• Auxiliary / Positioning Selection Switch → Blade/Outrigger Control
• Assist Switch (Optional) → * Assist Control
• Assist Selection Switch → * Auxiliary and Blade/Outrigger Output
• Outrigger Control Switch →
Option
Monitoring Control
• Left Grip Analog Switch (Optional) →
Controller
* Positioning and Assist Output Monitoring
• Overload Alarm Switch (Optional) → Control
Electric Lever Pilot Cut Control
* HSB Braaker Control
* Overload Alarm Control

T2-2-2
(Blank)
T2-2-3
ENGINE CONTROL
The engine control consists of the following functions.
• Engine Control Dial Control

• Travel Accelerator Control
• Working Accelerator Control
• Engine Speed Holding Control when Decelerating
• HP Mode Control
• E Mode Control
• Auto-Idle Control
• Hydraulic Oil Temperature Auto-Warming Up
Control
• Coolant Temperature Auto-Warming Up Control
• Idle Speed-Up Control
• Heater Control
• * Attachment Operation Speed Increase Control
• * Attachment Operation Speed Limit Control

T2-2-4
Engine Control System Layout
Accelerator
Travel N Sensor
Pedal
Hydraulic Oil
Pilot Shut-Off Temperature Pressure Sensor
Switch Sensor Travel Forward
Travel Reverse
Key Switch Front Attachment

Swing
Boom Raise
Arm Roll-In
Engine
Control Auxiliary (OP)
Dial Arm Roll-Out (OP)
Auto-Idle
Switch
Monitor Unit Attachment Mode
1 to 5
Coolant
CAN Communi- Temperature
cation Sensor
Power Mode
Switch
Digging Mode Dr. ZX
HP
Mode
E
Mode ICF
P
Mode
Pump 1
Travel Speed Delivery
Mode Switch Pump 2 Delivery Pressure
ECM Pressure Sensor Sensor
Fast
Slow
Engine Speed
Control Mode
Selection Switch
Pedal
Dial
Pump 2 Pump 1
Creeper Control Control
Brake Pressure Pressure
Switch Sensor Sensor
FNR Switch
Parking Brake
Forward
Axle Lock
Neutral
Auto Axle Lock
Reverse OFF
TCJB-02-02-001
NOTE: OP: Optional
T2-2-5
Engine Control Dial Control
Engine speed is
Purpose: Controls the engine speed according to the reduced by 100
rotation angle of engine control dial. Engine min-1 when the
-1 Speed
Reduces the engine speed by 100 min from control levers are in
neutral.
fast idle speed in order to reduce fuel con-
sumption and noise level when all the control
levers are in neutral.
Operation:
1. MC sends the signals equivalent to target engine
speed to ECM by using CAN communication ac-
cording to rotation angle of the engine control dial.
Engine Con-
2. ECM controls the engine speed according to CAN trol Dial Posi-
communication. Slow Idle Fast Idle tion
3. When the following conditions exist and all the
control levers are turned to the neutral position
(pressure sensors (travel forward/reverse, front
attachment): OFF), MC sends the signal to ECM
by using CAN communication after one second.
-1
4. ECM reduces the engine speed by 100 min from
fast idle speed (P mode engine speed).
Condition:
• Engine Control Dial: P-90 min-1 or more
• Engine Speed Control Mode Selection Switch:
Dial mode or Creeper mode
• Power Mode Switch: HP or P
NOTE: When the engine speed set by the engine

control dial is already slower than the fast
-1
speed idle by 100 min , the engine speed
does not change.
This control is done regardless of whether
the auto-idle control is done or not.
The fast idle speed (P mode engine speed)
of engine can be corrected by Dr. ZX.
IMPORTANT: The control in operation steps 3, 4 is

deactivated by Dr. ZX temporarily or
permanently.
T2-2-6
Pressure Sensor
Travel Forward
Travel Reverse
Front Attachment
Engine Con-
trol Dial
CAN Commu-
Power Mode nication
Switch
HP
Mode Dr. ZX
E
ICF
Mode
P
Mode
ECM
Engine Speed
Control Mode
Selection Switch
Pedal
Dial
Creeper
TCJB-02-02-002
T2-2-7
Travel Accelerator Control
Purpose: Controls engine speed according to the ac-

celerator pedal depressing amount when the
machine travels.
In addition, controls engine speed according
to pump load when engine speed increases
and the machine climbs the slope so that the
machine can travel at fuel-efficient engine
speed.
Operation:
1. When the following conditions exist, MC sends
the signal to ECM by using CAN communication.
2. ECM calculates these information and controls in
order to get the best engine speed.
Condition:
• Brake Switch: OFF, Axle lock or Auto axle lock
Pedal mode
• Travel Speed Mode Switch:
Fast or Slow
• FNR Switch: F (Forward) or R (Reverse)
• Travel Speed: 25 km/h or faster
• Pump 1 Delivery Pressure: Output
T2-2-8
Accelerator Pedal
Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse
CAN Commu-
nication
Pump 1 Delivery
Travel Speed
Pressure Sensor
Mode Switch
ECM
Fast
Slow

Pedal
Brake
Switch
FNR Switch
Parking Brake
Forward
Axle Lock
Neutral
Auto Axle Lock
Reverse OFF
TCJB-02-02-003
NOTE: The illustration shows the operation when

the switches are in the following positions.
Travel Speed Mode Switch: Fast
FNR Switch: F (Forward)
Brake Switch: OFF
T2-2-9
Working Accelerator Control
Purpose: Make engine speed during digging operation

by the accelerator pedal as well as the en-
gine control dial.
Operation:
1. When the following conditions exist, MC sends
the signal to equivalent to accelerator pedal op-
eration (pressure detected by the travel forward
pressure sensor) to ECM by using CAN commu-
nication.
2. ECM controls engine speed according to CAN
communication.
NOTE: Fast idle speed of the engine can be

changed by the accelerator pedal at the
pedal mode.
Condition:
• Work Brake: Operable
• FNR Switch: N (Neutral)
Pedal mode
T2-2-10
Accelerator Pedal Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse
Brake Pressure Sensor

Work Brake Release
Switch
CAN Communication
ECM

Pedal
Brake
Switch
FNR Switch
Parking Brake
Forward
Axle Lock
Neutral
Auto Axle Lock
Reverse OFF
TCJB-02-02-004

Brake Switch: Axle Lock position
T2-2-11
Engine Speed Holding Control When Decelerat-
ing
Purpose: When the machine decelerates (when the

travel pilot valve returns to the neutral posi-
tion) and if travel speed is fast, engine speed Travel Pilot Valve: Neutral
is kept at fast idle. In addition, engine speed
decreases according to deceleration of travel Engine
speed in order to prevent cavitation in the Speed
travel motor. Fast Idle
Operation:
1. When the following conditions exist and travel
speed is fast, MC sends the signal to ECM by
using CAN communication.
2. ECM keeps engine speed at fast idle speed ac-
cording to CAN communication.
3. When travel speed is reduced, engine speed de- Slow Idle
creases to travel idle speed gradually. Travel
Speed (Fast) Speed (Slow) Speed
Condition:
• Travel N Sensor: Output
• Accelerator Pedal: After fully operating travel
(Forward or Reverse) for 4 seconds or longer
(pilot pressure: 2.8 MPa or higher), the accelera-
tor pedal returns to the neutral position.
T2-2-12
Accelerator Pedal Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse
CAN Commu-
nication
ECM
FNR
Switch
Forward
Neutral
Reverse
TCJB-02-02-005

T2-2-13
HP Mode Control
Purpose: Slightly increases digging power such as

arm roll-in operation while excavating deeply. Engine
Speed
1650 min-1 Increasing
Operation: Range of Fast
1. When the power mode switch is in the HP mode About Idle
1500 min-1
position and all the following conditions exist, MC
sends the signals equivalent to the target engine
speed to ECM by using CAN communication.
2. ECM slightly increases the engine speed set by
the engine control dial in order to increase engine
power.
Engine Con-
Condition: trol Dial Posi-
tion
• Engine Control Dial: Set at about 1500 min-1 or Slow Idle Fast Idle
faster.
• Boom Raise or Arm Roll-In Operation: Operated
• Average Delivery Pressure of Pumps 1 and 2:
High
2
(Reference: 25 MPa (255 kgf/cm , 3635 psi))
NOTE: HP control can be made operable or inop-

erable by Dr. ZX. Although the key is turned
OFF, the setting is kept.
T2-2-14
Pressure Sensor
Boom Raise
Arm Roll-In
Engine Con-
trol Dial
CAN Commu-
Power Mode nication
Switch
HP
Mode
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
ECM Sensor Sensor
TCJB-02-02-006
T2-2-15
E Mode Control
Purpose: Reduces the engine speed set by the engine

control dial according to the pump control Engine Speed
Engine Set by E Operation
pressure (lever operation) and the average Steps 1, 2
Speed Mode Control
pump delivery pressure in order to reduce
fuel consumption. Engine speed in-
crease by 200 min-1.
Operation Steps 3, 4
Operation:
1. When the required engine speed by the engine
control dial is faster than the engine speed set by
E mode control and the power mode switch is in
the E mode position, and if the pump control P Mode
pressure and the average pump delivery pressure Speed
are within the following conditions, MC sends the Engine Con-
signals equivalent to the target engine speed to trol Dial Posi-
Slow Idle Fast Idle tion
ECM by using CAN communication.
2. ECM reduces the engine speed from the required
engine speed set by the engine control dial.
3. If the pump control pressure is high and the av-
erage pump delivery pressure is low, MC sends
the signal equivalent to the target engine speed to
ECM by using CAN communication.
-1
4. ECM increases the engine speed by 200 min .
Condition:
• Engine speed is reduced lower than the required
engine speed by the engine control dial:
Control Pressure of Pump 1 or 2: Low of either
2
(Reference: 3 MPa (31 kgf/cm , 436 psi) or less)
and Average Pump Delivery Pressure: High
2
(Reference: 9.8 MPa (100 kgf/cm , 1425 psi))
• Engine speed is increased to P mode speed

Control Pressure of Pump 1 or 2: High of either
2
(Reference: 3 MPa (31 kgf/cm , 436 psi) or more)
and Average Pump Delivery Pressure: Low (Ref-
2
erence: Less than 9.8 MPa (100 kgf/cm , 1425
psi))
T2-2-16
Engine Con-
trol Dial
CAN Commu-
Power Mode nication
Switch
E
Mode
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
ECM Sensor Sensor
Pump 2 Control Pump 1 Control

Pressure Sensor Pressure Sensor
TCJB-02-02-007
T2-2-17
Auto-Idle Control
Purpose: Reduces the engine speed when all the

control levers are in neutral in order to re-
duce fuel consumption and noise level.
Operation:
1. Approx. 3.5 seconds after the control lever is
turned to neutral with the auto-idle switch ON, MC Engine speed is
sends the signals equivalent to the auto-idle reduced to the
Engine auto-idle speed
speed to ECM by using CAN communication. Speed after 3.5 seconds.
2. ECM changes the engine speed into the auto-idle
speed. Fast Idle
3. As soon as either control lever is moved (pres-
sure sensors (travel forward/reverse, front at-
tachment): ON), MC returns the signals sending Auto-Idle
to ECM into those equivalent to the target engine Speed
speed set by the engine control dial.
4. ECM returns the engine speed into the original 1200 min-1
engine speed.
Engine Con-
trol Dial Posi-
Auto-Idle Deactivation Requirements: Slow Idle Fast Idle tion
• Control Lever: Operated (pressure sensor (travel
or front attachment): ON)
• Power Mode Switch: When the E mode is
changed to P mode or P mode is changed to E
mode
• Engine Control Dial: When the engine speed is
changed
NOTE: Auto-idle speed can be adjusted by Dr. ZX.
T2-2-18
Pressure Sensor
Travel Forward
Travel Reverse
Front Attachment
Engine Con-
trol Dial
Auto-Idle
Switch
CAN Commu-
Power Mode nication
Switch
HP
Mode
E
Mode
P
Mode
ECM
TCJB-02-02-008
T2-2-19
Hydraulic Oil Temperature Auto-Warming Up
Control
Purpose: Automatically warms up the hydraulic sys- Engine

tem. Speed
Operation: Fast Idle

1. When the key switch is turned ON or when hy-
1400 min-1
draulic oil temperature is below 0 °C, MC sends
the signals equivalent to the target engine speed
to ECM by using CAN communication according
Auto-Warming Increasing
to the signals from key switch and hydraulic oil Speed
Up Speed
temperature sensor. Slow Idle
2. ECM increases the engine speed to the Engine Con-
auto-warming up speed. trol Dial Posi-
3. In 12 minutes after the key switch is turned ON or Slow Idle Fast Idle tion
the engine starts, or when hydraulic oil tempera-
ture is 2 °C or higher, MC deactivates the hydrau-
lic oil temperature auto-warming up control.
4. Therefore, ECM returns engine speed to the
original engine speed.
IMPORTANT: When adjusting the auto-idle speed,

deactivate the auto-warming up
control by using Dr. ZX. Wait ad-
justment until 12 minutes after the
engine starts.
Auto-warming up control can be
deactivated temporarily by Dr. ZX.
Once the key switch is turned OFF,
auto-warming up control is operable
again.
IMPORTANT: Auto-warming up speed can be ad-

justed by Dr. ZX.
T2-2-20
Hydraulic Oil
Temperature
Sensor
Key Switch
CAN
Communication
Dr. ZX
ICF
ECM
TCJB-02-02-009
T2-2-21
Coolant Temperature Auto-Warming Up Control
1500 min-1
Purpose: Automatically warms up the engine. (Radiator Coolant Temperature Less than 35 °C)
Engine
Speed 1300 min-1
Operation: (Radiator Coolant Temperature
1. After the engine starts, ECM send the signals More than 35 °C, Less than 50 °C)
equivalent to radiator coolant temperature to MC. Fast Idle
2. MC sends the signals equivalent to target engine
speed to ECM by using CAN communication
according to the CAN signal of radiator coolant Auto-Warming
temperature from ECM. Up Speed
Increasing
3. ECM increases the engine speed to the radiator Speed
coolant temperature auto-warming up speed. Slow Idle
Engine
IMPORTANT: MC selects the higher target engine Control Dial
Slow Idle Fast Idle Position
speed control; hydraulic oil
temperature auto-warming up 900 min-1
(Radiator Coolant Temperature
control or radiator coolant More than 50 °C)
temperature auto-warming up
control. MC sends the signal to ECM
Engine
by using CAN communication. Speed
(min-1)
IMPORTANT: The radiator coolant temperature
auto-warming up speed is changed
due to radiator coolant temperature.
Although the engine is set at slow 1500
idle speed with radiator coolant 1300
temperature beyond 50 °C and when 900
radiator coolant temperature
decreases, the engine speed
increases again. Radiator
0 35 50 (°C) Coolant
Temperature
IMPORTANT: The radiator coolant temperature
auto-warming up control can be
deactivated temporarily by Dr.ZX.
When the radiator coolant
temperature auto-warming up
control is deactivated, contact with
the service manager.
When the hydraulic oil temperature
auto-warming up control is
deactivated temporarily, the radiator
coolant temperature auto-warming
up control is deactivated at the same
time. Once the key switch is turned
OFF, the hydraulic oil temperature
auto-warming up control and the
radiator coolant temperature
auto-warming up control are
operable again.
T2-2-22
Key Switch
CAN
Communication Monitor Unit
Coolant
Temperature
Sensor
ECM
TCJB-02-02-010
T2-2-23
Idle Speed-Up Control
Purpose: Prevents the engine from hunting when the Engine

Speed
engine runs at slow speed.
Operation:
1. When the travel or front attachment is operated 1050 min-1
while the engine is running at a speed between
slow idle and idle speed-up speed, MC sends the Idle Speed-Up
Control
signals equivalent to the target engine speed to
ECM by using CAN communication. Increasing
2. ECM increases the engine speed to the idle Speed
speed-up speed. Engine
Control Dial
T2-2-24
Pressure Sensor
Travel Forward
Travel Reverse
Front Attachment
Engine
Control Dial
CAN
Communication
ECM
TCJB-02-02-012
T2-2-25
Heater Control
Purpose: Increases the rising temperature speed of the

heater in cab while increasing the engine
speed at the low temperature.
Engine
Speed
Operation: Increasing
1. When the following conditions exist and the Range of Fast
engine starts, MC sends the signals equivalent to Idle
the target engine speed to ECM by using CAN
communication.
2. ECM increases the engine speed beyond fast idle
speed.
Condition:
Engine
• Engine Control Dial: Set the engine speed at fast Control Dial
idle speed position. Slow Idle Fast Idle Position
• Coolant Temperature: Less than 5 °C (41 °F).
• Control Lever: Neutral (Front Attachment/Travel)
• Pilot Shut-Off Switch: OFF
(Pilot Shut-Off Lever: Lock position)
• Brake Switch: P (Parking Brake) position Increasing Range of Fast
Model
Idle Speed
ZX140W-3 100 min−1
T2-2-26
Pilot Shut-Off Pressure Sensor

Switch Travel Forward
Travel Reverse
Front Attachment
Engine
Control Dial
CAN
Coolant
Temperature
Sensor
ECM
Brake
Switch
Parking Brake
TCJB-02-02-013
T2-2-27
Attachment Operation Speed Increase Control
(Only Machine Equipped with Attachment Parts)
Purpose: Increases the maximum engine speed to

the attachment (breaker, pulverizer, crusher When all
conditions exist,
or vibrating hammer) operating engine Engine Speed
the maximum
speed set by Dr. ZX when the attachment is engine speed is
operated. increased to the
speed set by Dr.
ZX.
Operation:
1. When the following conditions exist and the
attachment is operated, MC sends the signals
equivalent to the target engine speed set by Dr.
ZX to ECM by using CAN communication.
2. ECM increases engine speed to the attachment Engine
operating speed set by Dr. ZX. Control Dial
Conditions:
• Dr. ZX: Resets the maximum engine speed to a
faster (+) attachment (breaker, pulverizer, crusher
or vibrating hammer) operating speed in the
service mode. NOTE: When P mode engine speed is preset to a
• Engine Control Dial: Fast Idle Speed Position slower speed in Dr. ZX service mode, the
• Power Mode Switch: HP Mode maximum engine speed will not be
• Auxiliary: Operated increased when operating the attachment.
• Work Mode: Attachment Mode
Attachment selected by using the attachment
mode monitor unit is set (+) by Dr. ZX.
T2-2-28
Pressure Sensor
Engine Auxiliary (Optional)

Control Dial
CAN
Attachment
Power Mode Mode 1 to 5
Switch
HP
Mode Dr. ZX
ICF
ECM
TCJB-02-02-014
T2-2-29
Attachment Operation Speed Limit Control
(Only Machine Equipped with Attachment Parts)
Purpose: Decreases the maximum engine speed to Engine

the attachment (breaker, pulverizer, Speed
crusher or vibrating hammer) operating
engine speed set by Dr. ZX when the When all
conditions exist,
attachment mode is selected. the maximum
engine speed is
Operation: reduced to the
speed set by Dr.
1. When the following conditions exist and the ZX.
attachment is operated, MC sends the signals
equivalent to the target engine speed set by Dr.
ZX to ECM by using CAN communication. Engine
2. ECM increases engine speed to the attachment Control Dial
operating speed set by Dr. ZX. Slow Idle Fast Idle
Position
Conditions:
• Dr. ZX: Resets the maximum engine speed to a
slower (−) attachment (breaker, pulverizer,
crusher or vibrating hammer) operating speed in
the service mode.
• Work Mode: Attachment Mode
Attachment selected by using the monitor unit is
set (−) by Dr. ZX
T2-2-30
CAN
Attachment
Mode 1 to 5
Dr. ZX
ICF
ECM
TCJB-02-02-015
T2-2-31
PUMP CONTROL
The pump control system has the following functions:

• Pump 1 Flow Rate Limit Control in Superfine
Travel Speed Mode
• Pumps 1, 2 Flow Rate Limit Control
• Pumps 1, 2 Flow Rate Control
• Steering Pump Torque Reduction Control
• * Pump 1 Flow Rate Limit Control (Optional)
• * Pump 2 Flow Rate Limit Control (Optional)

T2-2-32
Pump Control System Layout
Accelerator Pedal
Travel N Sensor
Pressure Sensor
Travel Forward
Engine
Auxiliary (optional)
Travel Speed Brake Pressure Sensor

Mode Switch Work Brake Release Switch
Fast Monitor Unit Brake Pedal

CAN
Communication
Slow
Attachment Mode
1 to 5
Digging Mode
Engine Speed
Control Mode
Selection Switch
ICF
Pedal
Pump 2 Pump 1
Dial Delivery Delivery Steering Pump
Pressure Pressure Delivery Pressure
Sensor Sensor Sensor
Creeper
ECM
FNR Switch
Forward
Neutral
Reverse
Brake Switch Torque Control

Parking Solenoid Valve
Brake
Axle Lock
Auto
Axle Lock
OFF
Pump 2 Maximum Pump 1 Maximum TCJB-02-02-016

Flow Rate Limit Flow Rate Limit
Solenoid Valve Solenoid Valve
T2-2-33
Speed Sensing Control (Normal)
Purpose: Controls the pump flow rate in response to

engine speed changes due to variations in
load so that the engine output can be utilized
more efficiently.
Engine stall is prevented when the machine
operates under adverse conditions such as
operating at high altitude.
Q
Operation:
1. The target engine operating speed is set by Flow Rate
controlling the engine control dial.
2. When the following conditions exist, MC Pump P-Q Curve
calculates the difference in speed between the
target engine speed and the actual engine speed
monitored by CAN communication from ECM.
Then, MC sends signals to the torque control
solenoid valve.
3. The torque control solenoid valve delivers pilot
pressure oil in response to the received signals to
the pump regulator and controls the pump
delivery flow rate.
4. If the engine load increases and the actual engine
speed becomes slower than the target engine Pressure P
speed, the pump swash angle is reduced so that
pump flow rate will be reduced. Therefore, the
engine load is reduced and engine stall is
prevented.
5. If the actual engine speed becomes faster than
the target engine speed, the pump swash angle is
increased so that pump flow rate will increase.
Therefore, the engine output can be utilized more
efficiently.
Condition:
• FNR Switch: N (Neutral) position
• Brake Switch: P (Parking Brake) position
• Travel Forward or Reverse Not Operation
• Work Brake: Operable
T2-2-34
Pressure Sensor
Travel Forward
Engine

Work Brake Release Switch
Brake Pedal
CAN
Communication
Pump 2 Delivery Pump 1 Delivery

Pressure Sensor Pressure Sensor
ECM
FNR Switch
Forward
Neutral
Reverse
Brake Switch
Parking
Brake
Axle Lock
Auto Axle Torque Control

Lock Solenoid Valve
OFF
TCJB-02-02-017
T2-2-35
Travel Speed Sensing Control
Function: The pump flow rate is controlled in response

to variations in engine speed due to travel
load changes in order to use the engine
power effectively.
Operation:
1. MC determines the engine target running speed
corresponding to sensing signals detected by the Q
engine control dial or the pressure sensor (travel Flow
forward or reverse). Rate
2. When the following conditions exist, MC
calculates the difference between the target Pump P-Q Curve
engine speed and actual engine speed detected
by ECM by using CAN communication and sends
the signals to the torque control solenoid valve.
3. In response to the signals from MC, the torque
control solenoid valve sends pilot pressure to the
pump regulators in order to control the pump flow
rate.
4. When the actual engine speed becomes slower
than the target engine speed as the load to the
engine increases, the pump displacement angle
is reduced in order to reduce the delivery flow rate. Pressure P
Therefore, the load to the engine is reduced and
the engine is prevented from stalling.
5. If the actual engine speed becomes faster than
the target engine speed, the pump displacement
angle is increased in order to effectively utilize the
engine power.
Condition:
• Travel Forward or Reverse Operation
• Brake Switch: Axle Lock, Auto Axle Lock or OFF
position
• Work Brake: Inoperable
T2-2-36
Accelerator Pedal
Pressure Sensor
Engine Travel Forward

CAN
Communication
ECM
FNR Switch
Forward
Neutral
Reverse
Brake Switch
Parking
Brake
Axle Lock
Auto Axle Torque Control

Lock Solenoid Valve
OFF
TCJB-02-02-018

Brake Switch: Axle Lock
T2-2-37
Pump 1 Flow Rate Limit Control in Superfine
Travel Speed Mode
Function: Limits the maximum pump 1 flow rate at the

Q
creeper mode.
Flow Maximum flow rate is reduced.
Rate
Operation:
1. When the creeper mode is selected, the signal
from engine speed control mode selection switch
is sent to MC. Normal Pump P-Q Curve
2. If either travel forward or reverse operation is
made at this time, MC activates the pump 1
maximum flow rate limit control solenoid valve
and reduces maximum pump flow rate.
NOTE: The pump 1 maximum displacement can

be adjusted by using Dr. ZX in the service
mode.
Pressure P
T2-2-38
Pressure Sensor
Travel Forward
Travel Reverse
CAN
Communication
Dr. ZX
ICF
Creeper
ECM
FNR Switch
Forward
Reverse
Brake Switch
Axle Lock
Auto Axle Pump 1 Maximum
Lock Flow Rate Limit Control
Solenoid Valve
TCJB-02-02-019

Brake Switch: Axle Lock
T2-2-39
Pumps 1, 2 Flow Rate Limit Control
Purpose: Reduces the maximum pump flow rate when

traveling at slow speed and improves the
combined operation of front attachment and
swing.
Operation:
1. When the following conditions exist, MC
recognizes that the machine travels at slow
speed.
2. MC activates the pump 1, 2 maximum flow rate
limit control solenoid valves and reduces
maximum flow rate of pumps 1, 2.
Condition:
Creeper mode
• Travel Forward or Reverse Pressure Sensor:
0.5 MPa or less
• Travel Speed: 1.1 km/h or less
T2-2-40
Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse

Creeper
FNR Switch
Forward
Reverse
Pump 2 Maximum Flow Rate Pump 1 Maximum Flow Rate TCGB-02-02-002

Limit Control Solenoid Valve Limit Control Solenoid Valve

T2-2-41
Pumps 1, 2 Flow Rate Control
Purpose: Controls the maximum flow rate of pumps 1,

2 when traveling at fast speed and increases
travel speed.
Operation:
1. When the following conditions exist, MC recog-
nizes that the machine travels at fast speed.
2. MC activates the pump 1, 2 maximum flow rate
limit control solenoid valves and makes flow rate
of pumps 1, 2 maximum.
Condition:
Pedal mode or Dial mode
• Travel Forward or Reverse Pressure Sensor:
0.7 MPa or more
• Travel Speed: 2.0 km/h or more
NOTE: As the engine speed control mode selec-

tion switch is not in the pedal mode and
creeper mode positions, MC recognizes
that the engine speed control mode selec-
tion switch is in the dial position.
T2-2-42
Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse

Pedal
Dial
Creeper
FNR Switch
Forward
Reverse
Pump 2 Maximum Flow Rate Pump 1 Maximum Flow Rate TCGB-02-02-001

Limit Control Solenoid Valve Limit Control Solenoid Valve

Engine Speed Control Mode Selection
Switch: Pedal mode
T2-2-43
Steering Pump Torque Reduction Control
Function: When load to the steering pump increases, Q

loads to pump 1 and 2 are reduced so that Flow
engine stall is prevented and the engine Rate Pump P-Q Curve is reduced in
proportion to the steering pump
power is used efficiently. delivery pressure.
Operation:
1. When the following conditions exist and MC re- Normal Pump P-Q Curve
ceives the signals from the steering pump delivery
pressure sensor, MC activates the torque control
solenoid valve so that the pumps 1 and 2 delivery
flow rate is reduced.
2. Accordingly, the total driving power of pumps 1, 2
and the steering pump is controlled in order not to
exceed the engine output power. Therefore, the
engine power can be used efficiently.
Pressure P
Condition:
• Travel Forward or Reverse Operation
T2-2-44
Accelerator Pedal
Pressure Sensor
Travel Forward
Travel Reverse

Brake Pedal
ICF
Steering Pump Delivery

Pressure Sensor
ECM
FNR Switch
Forward
Neutral
Reverse
Brake Switch
Parking
Brake
Axle Lock
Torque Control
Solenoid Valve
Auto Axle
Lock
OFF
TCJB-02-02-057

Brake Switch: OFF
T2-2-45
Pump 1 Flow Rate Limit Control (Only Machine
Equipped with Attachment)
Purpose: Combines pressure oil pump 1, 2 and deliv-

ers combined pressure oil to the actuator
when attachment (mainly a vibrating ham-
mer) is used and pump 2 flow rate is lack.
(Refer to the SYSTEM / Hydraulic system
group.)
At this time, limits the combined pump 1 flow
rate and make up for pump flow rate for at-
tachment operation.
Operation:
1. When the attachment is used with the accelerator
pedal in neutral, MC receives the signals from
pressure sensor (auxiliary) (optional).
2. In response to attachment control operation, MC
drives the pump 1 maximum flow rate limit control
solenoid valve and controls pump 1 flow rate.
NOTE: The minimum pump swash set-angle on

monitor unit for a attachment (breaker 1 to
5, pulverizer 1 to 5, crusher 1 to 5 or vi-
brating hammer 1 to 5) can be adjusted
within 50 % set in the service mode of Dr.
ZX.
T2-2-46
Accelerator Pedal
Pressure Sensor
Travel Forward
Travel Reverse
Auxiliary (Optional)
CAN Monitor Unit

Communication
Attachment
Mode 1 to 5
Dr. ZX
ICF
Pump 1 Maximum Flow

Rate Limit Control
Solenoid Valve
TCJB-02-02-021
T2-2-47
Pump 2 Flow Rate Limit Control (Only Machine
Equipped with Attachment)
Purpose: Limits pump 2 maximum flow rate when a

attachment (mainly a hydraulic breaker) is Q
used. Maximum Flow Rate
Flow Rate
Operation:
1. When attachment is used with the accelerator
pedal in neutral, MC receives the signals from Normal Pump P-Q Curve
pressure sensor (auxiliary) (optional).
2. In response to attachment control operation, MC
drives the pump 2 maximum flow rate limit control
solenoid valve and reduces maximum pump flow
rate.
NOTE: In proportion to the attachment control op-

eration, maximum pump flow rated is re-
duced. The minimum pump swash Pressure P
set-angle on monitor unit for a attachment
(breaker 1 to 5, pulverizer 1 to 5, crusher 1
to 5 or vibrating hammer 1 to 5) can be
adjusted with 50 % in the service mode of
Dr. ZX.
NOTE: When the auxiliary flow combining solenoid

valve stops, pump 2 flow rate can be ad-
justed finely by the monitor unit.
T2-2-48
Accelerator Pedal
Pressure Sensor
Travel Forward
Travel Reverse
Auxiliary (Optional)
CAN
Communication
Attachment
Mode 1 to 5
Dr. ZX
ICF
Auxiliary Flow Combiner

Pump 2 Maximum Flow Control Solenoid Valve
Rate Limit Control Sole-
noid Valve TCJB-02-02-022
T2-2-49
VALVE CONTROL
The valve control system functions as follows:

• Travel Motor Displacement Angle Control
• Superfine Travel Speed Control
• * Pulverizer Control
• * Crusher Control

T2-2-50
Valve Control System Layout
Digging Mode Attachment Mode 1 to 5
Brake Pedal
Key Switch Travel N sensor
Monitor
Unit Pressure Sensor
Brake Pressure
Travel Forward Sensor
Travel Reverse Work Brake
Front Release Switch
Engine Control Dial ICF Swing Pump 2 Pump 1
Pressure Pressure
Arm Roll-In Sensor Sensor
Arm Roll-Out (OP)
ECM Auxiliary (OP)
P2 P1
Pedal
Dial Hydraulic Oil

Temperature
Creeper Sensor
Travel Motor
Travel Speed
Mode Switch
Pump 2 Control Pump 1 Control
Fast Pressure Sensor Pressure Sensor
Solenoid Valve Unit

Slow Travel Motor Displacement
SI
SF Control Solenoid Valve
SC
FNR Switch Auxiliary Flow

Rate Control
Forward Solenoid
Valve (OP) Auxiliary Flow
Rate Control
Neutral Valve
Reverse
Brake
Valve
Operate
Check Valve
Axle Lock
Cylinder
Brake Switch
Parking
Brake
Axle Lock
Auto
Axle Lock
Brake (Front)
OFF Arm Regrenerative

Valve P2 P1
Brake (Rear) TCGB-02-02-003
T2-2-51
Arm Regenerative Control
Purpose: Accelerates the arm roll-in speed in order to

prevent arm hesitation during arm roll-in op-
eration.
Operation:
1. MC activates solenoid valve unit (SC) so that so-
lenoid valve unit (SC) delivers pilot pressure when
the signals from pump 1, 2 delivery pressure
sensors, swing pressure sensor, arm roll-in
pressure sensor and boom raise pressure sensor
meet the following conditions.
2. This pilot pressure shifts the arm regenerative
valve and the return circuit from arm cylinder rod
side to the hydraulic oil tank is closed.
3. Then, return oil from the arm cylinder rod side is
combined with pressure oil from the pump and is
routed to the cylinder bottom side so that arm
roll-in speed increases and prevents arm hesita-
tion. (Refer to the COMPONENT OPERATION /
Control Valve group.)
Conditions:
• Pump 1 and 2 Delivery Pressure Sensors:
Either pump 1 or 2 delivery pressure is low. (The
arm does not need much power to operate.)
2
(Reference: 16.5 MPa (168 kgf/cm , 2400 psi) or
less)
• Arm Roll-In Pressure Sensor: High output. (The
arm control lever stroke is large.) (Reference: 0.5
2
MPa (5.1 kgf/cm , 73 psi) or more)
• Swing or Boom Raise Pressure Sensor: Output-
ting signal.
NOTE: In order to improve the arm roll-in operation,

MC gradually activates solenoid valve unit
(SC) when hydraulic oil temperature is
between 0 and 10 °C.
T2-2-52
Pressure Sensor
Swing
Pump 2 Pump 1
Arm Roll-In Pressure Pressure
Sensor Sensor
Hydraulic Oil
Temperature
Sensor
SC
Solenoid Valve Unit
Arm Regrenerative
Valve
TCGB-02-02-004
T2-2-53
Work Brake Control
Purpose: The front and rear brakes are applied during

excavation work in order to stabilize the
machine vehicle.
Operation:
1. When the following conditions exist and the brake
pedal is depressed, the work brake release switch
is activated so that MC shifts solenoid valve unit
(SF).
2. When solenoid valve unit (SF) is shifted, pilot
pressure shifts the brake valve.
3. When the brake valve is shifted, pressure oil from
the brake valve flows to the front and rear brakes
and the brakes are applied.
Condition:
• Brake Switch: Axle Lock or Auto Axle Lock posi-
tion
• Engine: Running
• Travel Speed: 3 km/h or less
• Brake Pressure : 6.6 MPa or more
NOTE: A slight time-lag will occur due to difference

in operation start time of solenoid valves
when the brake switch is shifted to the P
(parking brake) position. MC activates the
work brake control for four seconds after
the brake switch has been shifted to the
parking brake position.
Therefore, the machine is prevented from
descending the slope when the machine
stops on the slope.
NOTE: When the brake pedal is depressed once

and released, the work brake switch is
turned OFF and the work brake is applied.
When the brake pedal is depressed again,
the work brake switch is turned ON and the
work brake is released.
T2-2-54
Travel N Sensor Brake Pedal
Brake Pressure
Sensor
Work Brake
Release Switch
CAN
Communication
ECM
SF
Solenoid Valve Unit
Brake
Valve
Brake Switch
Parking
Brake
Axle Lock
Auto Axle
Lock Brake (Front)
OFF
Brake (Rear)
TCGB-02-02-005
T2-2-55
Auto Axle Lock Control
Purpose: Automatically activates the auto axle lock Brake Switch Position Axle Lock
when the machine stops. In addition, auto-
P (Parking Brake) Operation
matically deactivates the axle lock and re-
Axle Lock Operation
duces vibration when traveling.
OFF Release
Operation:
1. When the following axle lock operated conditions
exist, MC blocks the signal to solenoid valve unit
(SI).
2. Therefore, the operate check valve in axle lock
cylinder is closed and the axle lock is activated.
3. When the accelerator pedal is depressed and the
axle lock released conditions exist, MC shifts so-
lenoid valve unit (SI).
4. When solenoid valve unit (SI) is shifted, pilot
pressure shifts the operate check valve in axle
lock cylinder.
5. Therefore, the axle lock cylinder is connected to
the hydraulic oil tank and the axle lock cylinder
can be operated.
Axle Lock Operated Conditions:

• Brake Switch: Auto Axle Lock position
• Travel Speed: Less than 3 km/h
• Travel Forward or Reverse Not Operation
Axle Lock Released Conditions:

• Brake Switch: OFF position
• Travel Speed: 3 km/h or faster
• Travel Forward or Reverse Pilot Pressure: 0.7
MPa or more
NOTE: Operating time of the auto axle lock control

can be changed every 0.5 seconds be-
tween 0.0 and 10.0 seconds by using Dr.
ZX. (Default: 0.0 second)
T2-2-56
Dr. ZX Travel N Sensor

Pressure Sensor
Travel Forward
Travel Reverse
ICF
SI
Solenoid Valve Unit
Operate
Check Valve
Brake Switch Axle

Lock
Cylinder
Auto Axle
Lock
TCGB-02-02-006
T2-2-57
Travel Motor Displacement Angle Selection Con-
trol
Purpose: Shifts the travel motor to the minimum dis-

placement angle when the machine travels
at level ground and reduces fuel consump-
tion.
Operation:
1. When the following conditions exist, MC shifts the
travel motor displacement angle control solenoid
valve.
2. When the travel motor displacement angle control
solenoid valve is shifted, pressure oil from pump 1
flows to the small and large chambers in servo
piston so that travel motor displacement angle
decreases.
(Refer to the COMPONENT OPERATION / Travel
Motor group.)
3. Therefore, as required oil is reduced, the engine
load is reduced and fuel consumption is im-
proved.
Conditions:
• Travel Speed: 17 km/h or more
• Travel Forward or Reverse Pilot Pressure: 1.5
MPa or more
T2-2-58
Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse
Travel Motor
Travel Motor
Displacement Control
Solenoid Valve
Servo Piston
TCGB-02-02-007
T2-2-59
Superfine Travel Speed Control
Function: The machine is driven in the superfine

travel speed mode.
Operation:
1. When the following conditions exist, MC activates
the travel motor displacement control solenoid
valve.
2. When pressure oil in the large chamber in servo
piston flows to the hydraulic oil tank and the travel
motor displacement angle increases.
3. The machine travels at the superfine speed.
Condition:
Creeper Position
• Travel N sensor: Less than 1500 min-1 (travel
motor speed).
NOTE: When the output signal from travel N sen-

-1
sor is 1500 min or more MC does not op-
erate this system in order to prevent cavi-
tation from occurring in the travel motor.
T2-2-60
Travel N Sensor

Creeper
Travel Motor
Travel Motor Dis-

placement Control
Solenoid Valve Servo Piston
TCGB-02-02-008
T2-2-61
Travel Motor Excessive Rotation Control
Function: The machine is prevented from running

away while descending slopes and protects
the travel motor from damage.
Operation:
1. The output signal from travel N sensor is sent to
MC.
2. When the signal value from travel N sensor ex-
ceeds the specified value, MC activates the travel
motor displacement control solenoid valve.
3. When the travel motor displacement control so-
lenoid valve is shifted, pressure oil in the large
chamber in servo piston flows to the hydraulic oil
tank and the travel motor displacement angle in-
creases.
NOTE: The travel motor displacement control so-
lenoid valve is the proportional solenoid
valve. When the travel motor displacement
angle is suddenly increased, cavitation
may occur in the travel motor. Therefore,
MC activates the travel motor displacement
control solenoid vale slowly so that the
travel motor displacement angle changes
slowly in order to prevent the occurrence of
cavitation.
4. As the travel motor displacement angle increases,

the motor displacement increases and braking
force occurs to the travel motor.
5. Thereby, excessive rotation of the travel motor is
prevented and travel speed decreases.
T2-2-62
Travel N Sensor
Travel Motor
Travel Motor Dis-

placement Control
Solenoid Valve Servo Piston
TCGB-02-02-009
T2-2-63
Pulverizer Control (Optional)
IMPORTANT: Pulverizer 1 is set at pulverizer 1 of During Combined Operation

attachment mode in monitor unit
when the machine is carried out. Operation:
When pulverizer 2 to 5 is used, set 1. When the following conditions exist, MC drives
the setting by using Dr. ZX. the auxiliary flow rate control solenoid valve MC
controls restricted flow rate of the auxiliary flow
Purpose: Increases operating speed of the pulverizer. rate control solenoid valve and reduces pressure
Reduces flow rate through the auxiliary spool oil which flows to the pulverizer through the aux-
and improve arm, boom, swing or travel op- iliary spool from pump 2.
eration during combined operation of arm 2. As pressure oil which flows to arm roll-out, arm
roll-out, arm roll-out+ boom raise, swing or roll-out+ boom raise, swing or travel from pump 2
travel and secondary crusher. increases, arm roll-out, arm roll-out+ boom raise,
swing or travel operation is improved.
Operation:
1. When selecting pulverizer 1 in the monitor unit, Condition:
MC drives the auxiliary flow combiner control so- • Auxiliary Pressure Sensor: Output ting signal
lenoid valve. Arm Roll-Out Pressure Sensor: Outputting signal
2. When operating the pulverizer, pressure oil from • Auxiliary Pressure Sensor: Outputting signal
the auxiliary solenoid valve flows through the Arm Roll-Out and Boom Raise Pressure Sensors:
auxiliary flow combiner control solenoid valve and Outputting signal
shifts the bypass shut-out valve and auxiliary flow • Auxiliary Pressure Sensor: Outputting signal
combiner valve. Swing Pressure Sensor: Outputting signal
3. As the neutral circuit in 4-spool side is blocked by • Auxiliary Pressure Sensor: Putputting signal
the bypass shut-out valve, pressure oil from pump Travel Pressure Seonsor: Outputting signal
1 through the auxiliary flow combiner valve is
combined with pressure oil from pump 2 so that
combined pressure oil is supplied to the auxiliary
spool. Therefore, operating speed of the pulver-
izer increases.
4. Flow rate of the auxiliary flow rate control solenoid
valve can be adjusted finely in the monitor unit.
T1V5-05-01-024
T2-2-64
Pressure Sensor
Travel Forward Pulverizer Cylinder
Monitor Unit Travel Reverse

Swing
Boom Raise
Arm Roll-Out
Auxiliary
Dr. ZX
CAN
Communication ICF
MC
Auxiliary Flow Com-

Auxiliary Flow Rate
biner Valve
Control Solenoid Valve
Auxiliary Flow
From Pilot Rate Control
Pump Valve
Auxiliary Flow
Combiner Control
Solenoid Valve
Pump 2 Pump 1
From Auxiliary
Solenoid Valve
TCJB-02-02-034
T2-2-65
Crusher Control (Optional)
IMPORTANT: Crusher 1 is set at crusher 1 of at- During Combined Operation

tachment mode in monitor unit when Operation:
the machine is carried out. 1. When the following conditions exist, MC drives
When crusher 2 to 5 is used, set the the auxiliary flow rate control solenoid valve. MC
setting by using Dr. ZX. controls restricted flow rate of the auxiliary flow
Purpose: Increases operating speed of the crusher. rate control solenoid valve and reduces pressure
Reduces flow rate through the auxiliary spool oil which flows to the crusher through the auxiliary
and improve arm, boom, swing or travel spool from pump 2.
operation during combined operation of arm 2. As the primary crusher is heavier than the pul-
roll-out, arm roll-out+ boom raise, swing or verizer, restricted flow rate increases of the aux-
travel and crusher. iliary flow rate control valve and gives priority to
arm roll-out or arm roll-out+ boom raise during
Operation: combined operation of arm roll-out or arm
1. When selecting crusher 1 in the monitor unit, MC roll-out+ boom raise and crusher.
drives the auxiliary flow combiner control solenoid
valve. Condition:
2. When operating the crusher, pressure oil from the • Auxiliary Pressure Sensor: Outputting signal
auxiliary solenoid valve flows through the auxiliary Arm Roll-Out Pressure Sensor: Outputting signal
flow combiner control solenoid valve and shifts • Auxiliary Pressure Sensor Outputting signal
the bypass shut-out valve and auxiliary flow Arm Roll-Out and Boom Raise Pressure Sensors:
combiner valve. Outputting signal
3. As the neutral circuit in 4-spool side is blocked by • Auxiliary Pressure Sensor: Outputting signal
the bypass shut-out valve, pressure oil from pump Swing Pressure Sensor: Outputting signal
1 through the auxiliary flow combiner valve is • Auxiliary Pressure Sensor: Outputting signal
combined with pressure oil from pump 2 so that Travel Pressure Sensor: Outputting signal
spool. Therefore, operating speed of the crusher
increases.
4. Flow rate of the auxiliary flow rate control solenoid
valve can be adjusted finely in the monitor unit.
T1V5-05-01-113
T2-2-66
Pressure Sensor
Travel Forward Pulverizer Cylinder
Monitor Unit Travel Reverse

Swing
Boom Raise
Arm Roll-Out
Auxiliary
Dr. ZX
CAN
Communication ICF
MC

Auxiliary Flow Rate Valve
Auxiliary Flow
From Pilot Rate Control
Valve Valve
Auxiliary Flow
Combiner Control
Solenoid Valve
Pump 2 Pump 1
From Auxiliary
Solenoid Valve
TCJB-02-02-034
T2-2-67
(Blank)
T2-2-68
OTHER CONTROLS
Other control systems consist of the following systems.
• Forward/Reverse Shifting Restriction Control

• Travel Pilot Pressure Cut Control
• Travel Mode Selection Control
• Parking Brake Selection Control
• Parking Brake Alarm Control
• Brake Dragging Prevention Control
• Rear Monitoring Display Selection Control
• Screen Forcible Transition Control
• Work Mode Control
• * Swing Alarm Control
• * Travel Alarm Control
• * Auto-Cruise Control

T2-2-69
Forward/Reverse Shifting Restriction Control
Purpose: If the travel direction is changed to the op-

posite direction while traveling, adverse ef-
fects may occur in the travel circuit and
components. In order to protect the circuit
and components from being damaged, the
opposite travel direction side pilot pressure is
temporarily interrupted so that the opposite
direction system is deactivated during travel
operation.
Condition:
• Travel N Sensor: Output signal when traveling
• Travel Forward or Reverse Pilot Pressure:
0.7 MPa or more
Operation: MC judges that the machine is traveling

forward or reverse when the above condi-
tions exist.
• When traveling forward (travel reverse pilot pressure • When traveling reverse (travel forward pilot pressure
is temporarily interrupted): is interrupted):
1. When signals from the travel forward pilot pres- 1. When signals from the travel reverse pilot pres-
sure sensor arrives at MC, MC judges that the sure sensor arrive at MC, MC judges that the
machine is traveling forward and grounds terminal machine is traveling in reverse and grounds to
#B24 in MC. terminal #B22 in MC.
2. As terminal #B24 is grounded, the travel reverse 2. As terminal #B22 is grounded, the travel forward
Pi cut solenoid valve, which is connected to ter- Pi cut solenoid valve, which is connected to ter-
minal #B24, is magnetized. minal #B22, is magnetized.
3. The travel reverse Pi cut solenoid valve operates 3. The travel forward Pi cut solenoid valve operates
and the travel reverse operation circuit is deacti- and the travel forward operation circuit is deacti-
vated. vated.
T2-2-70
Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse
FNR Switch
Forward
Neutral
Reverse B22 B24
From Fuse #29
Travel Pilot Valve
Travel Forward Pi
Cut Solenoid
Valve
Travel Reverse
Pi Cut Solenoid
Valve
Signal Control Valve
TCJB-02-02-035

T2-2-71
Travel Pilot Pressure Cut Control
Purpose: Cuts off the forward or reverse travel pilot

pressure when the forward/reverse switch is
in the N position (neutral) so that the ma-
chine cannot travel although the travel pilot
valve is operated.
Operation:
1. When the FNR switch is in the neutral position,
MC grounds to terminals #B22 and #B24 in MC.
2. Therefore, the travel forward Pi cut solenoid valve
and travel reverse Pi cut solenoid valve are
magnetized.
3. The solenoid valves operate and the operation
circuit from travel pilot valve is deactivated.
T2-2-72
Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse
FNR Switch
Forward
Neutral
Reverse B22 B24
From Fuse #29
Travel Pilot Valve
Travel Forward Pi
Cut Solenoid
Valve
Travel Reverse
Pi Cut Solenoid
Valve
Signal Control Valve TCJB-02-02-036
T2-2-73
Travel Mode Selection Control
Purpose: Selects the travel mode selector solenoid

valve by shifting the travel speed mode
switch and shifts fast/slow of the transmis-
sion. In addition, lights the indicator in steer-
ing column monitor.
Operation:
• Travel Speed Mode Switch: Fast
1. When the travel speed mode switch is turned into
fast position, MC grounds to terminal #A26 in MC.
2. Therefore, the fast speed selection relay is mag-
netized.
3. Current from fuse #28 flows to the travel mode
selector solenoid valve in transmission change-
over solenoid valve through the fast speed selec-
tion relay and the travel mode selector solenoid
valve is shifted.
4. Pressure oil from the pilot pump flows to the fast
side port in transmission through the pressure
reducing valve and travel mode selector solenoid
valve in transmission changeover solenoid valve.
5. The disc brake side in transmission is released by
pressure oil and the transmission is shifted to the
fast side.
6. When the travel speed mode switch is in the fast
position, MC sends the signal to the steering
column monitor by using CAN communication.
7. The steering column monitor turns the travel slow
speed indicator off.
T2-2-74
From Fuse #28
Transmission
Changeover Solenoid
Valve
Key Switch Fast Speed Pilot Pump

Selection Relay
Travel Mode Selector

Solenoid Valve
Pressure
Reducing
Valve
A26
MC
Travel Speed
Mode Switch
Fast CAN ECM

Communication
Transmission
Steering Column Disc Brake

Monitor
Brake Switch
Parking
Brake
Travel Slow
Speed Indicator
TCJB-02-02-037
T2-2-75
• Travel Speed Mode Switch: Slow
1. When the travel speed mode switch is turned into
slow position, MC grounds to terminal #A27 in
MC.
2. Therefore, the slow speed selection relay is
magnetized.
3. Current from fuse #28 flows to the travel mode
selector solenoid valve in transmission change-
over solenoid valve through the slow speed se-
lection relay and the travel mode selector sole-
noid valve is shifted.
4. Pressure oil from the pilot pump flows to the slow
side port in transmission through the pressure
reducing valve and travel mode selector solenoid
valve in transmission changeover solenoid valve.
5. The disc clutch side in transmission is released by
pressure oil and the transmission is shifted to the
slow side.
6. When the travel speed mode switch is in the slow
position, MC sends the signal to the steering
7. The steering column monitor turns the travel slow
speed indicator on.
T2-2-76
From Fuse #28
Transmission
Changeover Solenoid
Valve
Slow Speed
Key Switch Selection Pilot Pump
Relay
Travel Mode Selector
Solenoid Valve
Pressure
Reducing
Valve
A27
MC
Travel Speed
Mode Switch
Fast CAN ECM

Communication
Transmission
Slow
Steering Column Disc Clutch

Monitor
Brake Switch
Parking
Brake
Travel Slow
Speed Indicator
TCJB-02-02-038
T2-2-77
Parking Brake Selector Control
Purpose: Applies or releases the parking brake in

transmission by shifting the brake switch.
Operation:
1. When some conditions in the followings exist, MC
deactivates the ground connection to terminal
#A26 and #A27.
2. As the slow speed selection relay and fast speed
selection relay are turned OFF, current from fuse
#28 is blocked by each relay.
3. The spool in travel mode selector solenoid valve
moves to the position where the spool is balanced
with spring force.
4. Therefore, pressure oil from the pilot pump is
blocked by the travel mode selector solenoid
valve.
5. As pressure oil from the pilot pump is blocked and
does not act on the transmission, the transmission
activates the disc brake and disc clutch.
6. As the disc brake and disc clutch in transmission
are activated, the output shaft in transmission is
locked and the parking brake is applied.
Condition:
• Key Switch OFF
• Brake Remained Pressure: 5.2 MPa or less
• Engine: Stopped
T2-2-78
From Fuse #28
Transmission
Changeover Solenoid
Valve
Slow Speed Fast Speed Pilot Pump

Key Switch Selection Selection Relay
Relay
Travel Mode
Selector
Solenoid Valve
A27 A26
MC
CAN ECM
Communication
Transmission
Steering Column Disc Brake Disc Clutch

Monitor
Brake Switch
Parking
Brake
Brake Remain
Pressure Sensor
From Steering
Valve Accumulator
Charging Valve
TCJB-02-02-039
T2-2-79
Parking Brake Alarm Control
Function: The buzzer sounds when the front attach-

ment is operated with the parking brake
applied in order to protect the transmission.
Operation:
1. When the brake switch is in the P (parking brake)
position and MC receives the signals from pres-
sure sensors (front attachment, boom raise, arm
roll-in and swing), MC sends the signals to the
monitor unit by using CAN communication.
NOTE: Even if the same operation is made, the
sensing pressure may differ depending on
oil temperature. MC judges that the front
attachment is being operated when the oil
temperature and the pilot pressure match
the values shown in the following table.
Oil Temperature Pilot Pressure Input Sensor

10 °C or more 0.7 MPa Front
Attachment
0 °C up to 10 °C 1 MPa Boom Raise
Arm Roll-In
Swing
Below 0 °C 1.5 MPa ↑
2. Terminal #A9 is grounded by the monitor unit.

3. Therefore, current from fuse #19 flows to the
buzzer and the buzzer sounds.
T2-2-80
Pressure Sensor
Front Attachment
Swing
Boom Raise
Arm Roll-In
Brake Switch
Parking Brake
Hydraulic Oil
Axle Lock Temperature
Sensor
Auto Axle Lock
OFF
CAN Communication
Buzzer
Monitor Unit A9 From Fuse #19
TCJB-02-02-040
NOTE: This illustration shows the operation when

the front attachment is operated.
T2-2-81
Brake Dragging Prevention Control
Function: When the parking brake and work brake are

applied, travel system is deactivated.
Operation:
1. When the work brake is operable or the brake
switch is in the P (parking brake) position, MC
grounds terminals #B22 and #B24 in MC.
2. Current from fuse #29 flows energizes the travel
forward Pi cut solenoid valve and travel reverse Pi
cut solenoid valve.
3. Therefore, as pilot pressure from the travel pilot
valve is interrupted with the solenoid valves, the
machine cannot travel.
T2-2-82
Travel N Sensor
Brake Pedal

Brake Switch CAN

Communi-
Parking Brake cation
Axle Lock
B22 B24
Auto Axle Lock
OFF From Fuse #29
Travel Pilot Valve
Travel Forward Pi
Cut Solenoid
Valve
Travel Reverse
Pi Cut Solenoid
Valve
Signal Control Valve TCJB-02-02-041

the switch is in the following position.
Brake Switch: P (Parking Brake) position
T2-2-83
Rear View Image Selection Control
Purpose: Changes the display of monitor unit into the

image of rearview monitor.
Operation:
1. When the FNR switch is turned into the R (re-
verse) position with rear view monitor auto selec-
tion ON, MC sends the signal to shift the display
to the monitor unit by using CAN communication.
2. The monitor unit changes the image of rearview
monitor.
3. When the FNR switch is turned into the F (for-
ward) or N (neutral) position, the image of rear-
view is displayed for three seconds and then the
primary screen is automatically displayed.
NOTE: The function rear view monitor auto selec-

tion on monitor unit is set OFF when the
machine is delivered.
NOTE: Although the FNR switch is turned into the

F (forward) or N (neutral) position after the
image of rearview is displayed on the
monitor unit, the image of rearview is dis-
played for three seconds.
When the following operations are done
within three seconds after the image of
rearview is displayed, the image of rear-
view is not displayed on the monitor unit.
1. Change the image of rearview into the
primary screen.
2. Turn the FNR switch into the R (reverse)
position.
(If the FNR is kept in the R (reverse) posi-
tion, the image of rearview is not displayed.
If step 1 above is done, the image of rear-
view is displayed in three seconds or
longer.
T2-2-84
Rear View Monitor
Image
FNR Switch
Monitor Unit
Forward CAN Communication
Neutral
Reverse
Setup Menu Back Monitor

Selection Switch
TCJB-02-02-042
T2-2-85
Screen Forcible Transition Control
Purpose: Controls so that the monitor unit screen is

displayed as the primary screen (speed-
ometer) when the machine travels. In addi-
tion, makes the monitor unit operation dis-
abled.
Operation:
1. When the following conditions exist, MC judges
that the machine can travel forward and sends the
signal to the monitor unit by using CAN commu-
nication.
2. The monitor unit displays the primary screen
(speedometer) for one second due to the signal
from MC and makes all operations of monitor unit
disabled.
3. If the travel forward operation is not done, the
monitor unit can be operated in one second.
4. When some following conditions exist while the
machine travels, MC judges that the machine
travels forward and sends the signal to the moni-
tor unit by using CAN communication.
5. The monitor unit displays the primary screen
(speedometer) for one second due to the signal
from MC and makes all operations of monitor unit
disabled.
Conditions when traveling:

• FNR Switch: F (Forward)
position
Conditions while traveling:

• Travel Forward Pilot Pressure: 0.7 MPa or more
• Travel Speed (Forward): 3.0 km/h or faster
T2-2-86
Accelerator Pedal
Travel N Sensor
Pressure Sensor
Travel Forward
Travel Reverse
FNR Switch
Forward
Neutral Brake Pedal
Reverse Brake Pressure Sensor

Brake Switch
Parking Brake
Axle Lock
Monitor Unit
Auto Axle Lock
OFF
CAN
Communication
Speedometer
TCJB-02-02-043

the switch is in the following position.
Brake Switch: OFF
T2-2-87
Work Mode Control
The work modes include digging and front attachment
1 to 5 and are selected by the work mode on monitor
unit.
• Digging Mode:
Normal control is performed.
• Front Attachment Mode:

Functions only when the attachment in the op-
tional kit is operated.
In response to attachment control operation, in-
creasing or decreasing of engine speed (refer to
T2-2-28, 30.), increasing or decreasing pump flow
rate (refer to T2-2-46, 48.) and valve selection
(refer to T2-2-64, 66 and 108) are controlled.
The engine speed and pump flow rate control
settings are made by using Dr. ZX.
NOTE: As the attachment mode, one to five at-

tachment modes can be selected from
breaker 1 to 5, pulverizer 1 to 5, crusher 1
to 5 and vibrating hammer 1 to 5 by using
Dr. ZX.
T2-2-88
Swing Alarm Control (Only Machines Equipped
with Optional Parts)
Purpose: Sounds the buzzer (optional) and turn on the

beacon light (optional) during swing opera-
tion.
Operation: MC receives the signals from swing pres-

sure sensor when swing operation is made.
As long as MC receives this signal, MC
sends the signals to the swing alarm device,
sounds the buzzer (optional) and turn on
the beacon light (optional).
NOTE: The buzzer (optional) can be stopped by

using the buzzer deactivation switch (op-
tional).
Pressure Sensor
Swing
Buzzer Deactivation
Swing Alarm Switch (Optional)
Relay (Optional)
Buzzer
(Optional)
Beacon Light
(Optional)
T178-02-01-026
T2-2-89
Travel Alarm Control (Only Machines Equipped
with Optional parts)
Purpose: Sounds the buzzer (optional) while traveling.
Operation: As long as MC receives the signals from

the travel forward/reverse pressure sensor
when travel operation is made, MC sends
the signals to the travel alarm device so
that the buzzer (optional) sounds.
NOTE: After traveling continuously for more than

13 seconds, the buzzer (optional) can be
stopped with the buzzer deactivation switch
(optional).
NOTE: In order to prevent the buzzer (optional)

from sounding when operation other than
traveling (such as work accelerator opera-
tion) is made, MC does not activate the
buzzer (optional) when one of the following
condition is established:
FNR Switch: N (Neutral)
Brake Switch: P (parking brake) position
NOTE: If the FNR switch is not in the F (forward) or

R (reverse) position, MC judges that the
FNR switch is in the N (neutral) position.
T2-2-90
Accelerator Pedal
FNR Switch Pressure Sensor
Travel Forward
Forward
Travel Reverse
Neutral
Reverse
Brake Switch
Parking Brake
Axle Lock
Travel Alarm Device
(Optional)
Auto Axle Lock
Buzzer Deactivation
OFF Switch (Optional)
Buzzer (Optional) TCJB-02-02-044
T2-2-91
Auto-Cruise Control (Only Machines Equipped
with Optional Parts)
Purpose: Secures the accelerator pedal in the stroke

end during fast-forward travel operation and
controls that the machine automatically can
travel at fast although the accelerator pedal
is released.
Operation:
1. When the following conditions exist, MC flows
current to the electromagnet (optional) in auto
cruise, which is installed to the lower side of ac-
celerator pedal.
2. Therefore, the accelerator pedal is moved toward
the electromagnet (optional).
3. Consequently, although the accelerator pedal is
released, the accelerator pedal secured at the
full-stroke position.
4. At this time, MC sends the signal to the steering
5. The steering column monitor turns the auto cruise
indicator on due to the signal from MC.
6. When some conditions in the following exist, MC
blocks current to the electromagnet (optional) in
auto cruise.
7. Therefore, the accelerator pedal becomes free
and returns to original condition.
Condition:
• Auto Cruise Switch (Optional): ON
• Travel Forward Full Operation
• Travel Speed: Certain speed or faster
Auto Cruise Released Conditions:

• Auto Cruise Switch (Optional): OFF
• Travel Forward Not Operated
• Work Brake Release Switch: ON
• Brake Pressure Sensor: Certain pressure or more
T2-2-92
Auto Cruise Switch

Accelerator Pedal
(Optional)
Travel N Sensor
Travel Forward
Electromagnet (Optional)
Travel Speed
Mode Switch
Brake Pedal
Fast
Slow Work Brake Release Switch
FNR Switch CAN Communication
Forward
Neutral
Steering Column
Monitor
Reverse
Auto Cruise Indicator

(Optional)
TCJB-02-02-045
T2-2-93
(Blank)
T2-2-94
OPTION CONTROLLER CONTROL
The option controller control system functions as fol-
lows:
• * Auxiliary and Positioning Control

• * Assist Control
Control
• * Positioning and Assist Output Monitoring Control
• * HSB Breaker Control
• * Overload Alarm Control

T2-2-95
Auxiliary and Positioning Control
Purpose: Selects each function by using the auxiliary NOTE: If the left analog switch is set in the posi-
and positioning selection switch and acti- tioning by Dr.ZX, the left analog switch op-
vates the related solenoid valve according to eration is prioritized and the positioning
operation. pedal operation is disabled.
NOTE: The operation is explained when the posi- NOTE: The default of auxiliary/positioning selector
tioning is operated here. switch is in the positioning.
When the auxiliary is selected and although
Operation: the key switch is turned OFF, the position-
1. When the auxiliary/positioning selector switch is ing is selected next time when the key
turned into the positioning and the positioning switch is turned ON.
pedal is operated, the optional controller activates
the positioning solenoid valve according to opera-
tion.
2. Pressure oil from the pilot pump flows to the con-
trol valve spools through the positioning solenoid
valve.
3. The optional controller sends the selection infor-
mation of auxiliary/positioning selector switch by
(The positioning is selected here.)
4. The monitor unit displays the positioning selection
on primary screen.
5. In case the positioning is operated, the optional
controller activates the positioning solenoid valve
and swing parking brake release solenoid valve at
the same time.
6. Therefore, pressure oil from the pilot pump flows
to the swing parking brake so that the swing
parking brake is released.
T2-2-96
Auxiliary
Pedal
Front Attachment Positioning Se-

Selection Display lection Display
Positioning Monitor Unit

Pedal
CAN Communi-
Auxiliary/ cation
Positioning Option Controller
Selector
Switch
Swing Parking Brake

Release Solenoid Valve
Pilot Pump
Auxiliary Solenoid Positioning

Valve Solenoid
Valve Swing Motor
Swing Parking
Control Valve Positioning Control
Brake
Valve
TCJB-02-02-046

the positioning is operated.
T2-2-97
Blade/Outrigger Control
Purpose: Activates the blade/outrigger solenoid valve NOTE: If the left analog switch is set in the
according to electric lever or left analog blade/outrigger by Dr.ZX, the left analog
switch operation. switch operation is prioritized and the
blade/outrigger lever operation is disabled.
Operation:
1. When the blade/outrigger lever or blade/outrigger
switch is operated, the option controller activates
the blade/outrigger solenoid valve according to
operation.
trol valve spools through the blade/outrigger so-
lenoid valve.
NOTE: As for the blade/Outrigger operation circuit,

refer to the pages for Blade/Outrigger Con-
trol (Operation Circuit).
3. The option controller sends the blade/outrigger

operating signal to the monitor unit by using CAN
communication.
4. The monitor unit turns on the related indicator
(green) on the Blade/Outrigger Setup Screen due
to the signal from option controller.
NOTE: The blade/outrigger is shifted by the

blade/outrigger selector switch which is in-
stalled to the left console.
T2-2-98
Blade/Outrigger
Lever
Monitor Unit
CAN Communi-
cation
Blade/Outrigger
Option Controller
Switch (Left Analog
Switch)
Blade/Outrigger
Settings Display
Pilot Pump
Blade/Outrigger
Solenoid Valve
Control Valve
TCJB-02-02-047

the blade/outrigger raise is operated.
T2-2-99
Assist Control
Purpose: Activates the assist solenoid valve according

to assist switch or left analog switch opera-
tion.
Operation:
1. When the assist switch or left analog switch is
operated, the option controller activates the assist
solenoid valve according to operation.
trol valve spools through the assist solenoid
valve.
3. The option controller activates the assist solenoid
valve and swing parking brake release solenoid
valve at the same time.
4. Therefore, pressure oil from the pilot pump flows
to the swing parking brake so that the swing
NOTE: Assist is installed when the attachment like

tilt bucket or 360° swing type grapple is
used, which requires another circuit for
small flow rate.
NOTE: If the left analog switch is set in the assist

by Dr.ZX, the left analog switch operation is
prioritized and the assist switch (right grip)
operation is disabled.
T2-2-100
Assist Switch
Assist Switch Option Controller

(Left Analog
Switch)
Swing Parking Brake

Release Solenoid Valve
Pilot Pump
Assist Sole-
noid Valve Swing Motor
Assist Control Swing Parking

Valve Brake
TCJB-02-02-048
T2-2-101
Auxiliary and Blade/Outrigger Output Monitoring
Control
Purpose: The option controller compares auxiliary

pedal, blade/outrigger lever and
blade/outrigger switch operations with the
detected value of pressure sensor. If the op-
tion controller recognizes abnormality, the
auxiliary and blade/outrigger stop.
Operation:
1. Auxiliary pedal, blade/outrigger lever,
blade/outrigger switch operations and the de-
tected value of pressure sensor are input to the
option controller.
2. When the option controller compares the input
signals and detects error beyond 0.5 MPa in 200
ms (0.2 seconds), the option controller blocks
current to the auxiliary and blade/outrigger sole-
noid valves.
3. Therefore, as the auxiliary and blade/outrigger
solenoid valves are turned OFF and pressure oil
from the pilot pump is blocked by the solenoid
valves, the actuators stop.
NOTE: If hydraulic oil temperature is low, the re-

quired time when the option controller de-
tects the signal is 0.2 second longer.
T2-2-102
Auxiliary Pedal
Blade/Outrigger
Lever
Blade/Outrigger Option Controller

Switch (Left Analog
Switch)
Pilot Pump
Auxiliary Solenoid Blade/Outrigger

Valve Solenoid Valve
Pressure Sensor
(Auxiliary)
Control Valve
TCJB-02-02-050
T2-2-103
Positioning and Assist Output Monitoring Control
Purpose: The option controller compares positioning

pedal and assist switch operations with the
detected value of pressure sensor. If the op-
tional controller recognizes abnormality, the
positioning and assist stop.
Operation:
1. Positioning pedal, assist switch operations and
the detected value of pressure sensor (position-
ing) are input to the option controller.
2. When the option controller compares the input
signals and detects error beyond 0.5 MPa in 200
ms (0.2 seconds), the option controller blocks
current to the positioning, assist and swing park-
ing brake release solenoid valve.
3. Therefore, as the positioning and assist sole-
noid valves are turned OFF and pressure oil from
the pilot pump is blocked by the solenoid valves,
the actuators stop.
NOTE: If hydraulic oil temperature is low, the re-

quired time when the option controller de-
tects the signal is 0.2 second longer.
T2-2-104
Positioning
Pedal
Assist Switch
Option Controller
Assist Switch
(Left Analog
Switch)
Swing Parking Brake

Release Solenoid
Valve
Pilot Pump
Assist Solenoid Positioning

Swing Motor
Pressure Sensor
(Positioning) Assist Control Positioning Control Swing Parking
Valve Valve Brake
TCJB-02-02-051
T2-2-105
Electric Lever Pilot Cut Control
Purpose: The option controller compares electric lever

(auxiliary pedal, positioning pedal,
blade/outrigger lever), blade/outrigger switch
and assist switch operations with the de-
tected value of pressure sensor. If the op-
tional controller recognizes abnormality, all
the solenoid valves stop.
Operation:
1. When error beyond 0.1 MPa between the electric
lever operation and the detected value of pres-
sure sensor is detected in 50 ms (0.5 seconds)
after some conditions in the following exist, the
option controller stops all solenoid valves.
2. Therefore, all operations by the electric levers and
switches become disabled and bungle is pre-
vented from occurring by output abnormality.
3. At this time, the option controller connects termi-
nal #A27 to the ground inside.
4. When the security relay is turned ON, the pilot
shut-off solenoid valve is turned OFF so that the
ground circuit in pilot shut-off solenoid valve may
be blocked.
5. Consequently, the front attachment/swing opera-
tion is disabled.
Condition:
Control: ON
• Positioning and Assist Output Monitoring Control:
ON
T2-2-106
Blade/Outrigger Assist Switch

Positioning Switch (Left (Left Analog Blade/Outrigger
Auxiliary Pedal Pedal Analog Switch) Switch) Assist Switch Lever
From
Fuse #4
Security
Relay
A27 Option Controller

Positioning
Solenoid Valve
Pilot
Shut-Off
Solenoid
Valve
Swing Parking Brake
Release Solenoid
Valve
Pilot Pump Swing Motor
Assist Sole-
Blade/Outrigger noid Valve
Auxiliary
Solenoid Valve Solenoid
Valve
Pressure Sensor
(Auxiliary)
Swing Parking Brake
Control Valve Positioning Assist Control
Control Valve Valve
Pressure Sensor TCJB-02-02-052
(Positioning)
T2-2-107
HSB Breaker Control (Optional)
IMPORTANT: HSB breaker is set at breaker 1 of

attachment mode in monitor unit
when the machine is delivered.
When breaker 3 to 5 is used, set the
setting by using Dr. ZX.
Operation:
1. When selecting breaker 1 in monitor unit, the op-
tion controller activates the selector valve control
solenoid valve.
2. Pressure oil from the pilot pump flows through the
selector valve control solenoid valve, shifts the
selector valve, and the return circuit in breaker is
connected to the hydraulic oil tank.
3. At the same time, the option controller activates
the secondary relief control solenoid valve.
4. Pressure oil from the pilot pump flows the sec-
ondary pilot relief pressure control solenoid valve,
shifts the secondary pilot relief pressure control
valve, and reduces relief set pressure in breaker
circuit. T1V5-05-01-111
5. When the maximum pump 2 flow rate limit control

solenoid valve is activated in the monitor unit,
pump 2 flow rate can be adjusted finely.
T2-2-108
Attachment Breaker
Mode 1to 5
Monitor Unit
Dr. ZX
ICF
CAN Communication
MC Option Controller
Secondary Pilot Relief
Pressure Control Valve
Selector Valve
Secondary Pilot
Selector Valve Pressure Relief
Control Solenoid Secondary Pilot Valve
Valve Relief Pressure
Control Solenoid
Valve
From Pilot
Pump
Pump 2 Maximum
Flow Rate Limit Con-
trol Solenoid Valve
From Pump 2 Flow Rate Pump 2

Control Valve in Signal
Control Valve
TCJB-02-02-032
T2-2-109
Overload Alarm Control (Only Machines
Equipped with Optional Parts)
Purpose: Sounds the buzzer and displays the overload

alarm when boom raise operation like as
suspending is overloaded. Overload Alarm
Switch (Optional)
Operation:
1. When the following conditions exist, the optional
controller sends the signal to the monitor unit by
2. While receiving the signal from the optional con-
troller, the monitor unit grounds terminal #A9 in-
side.
3. The monitor unit sounds the buzzer and the
overload alarm is displayed.
Condition:
• Boom Bottom Pressure Sensor: Output signal M1J1-03-001
beyond the specification
• Overload Alarm Switch: ON
NOTE: Make overload alarm available by using Dr.

ZX.
NOTE: The alarm pressure setting of load on MC

can be adjusted in Dr.ZX.
T2-2-110
Overload Alarm
Switch: ON Dr. ZX
ICF
Boom Bottom
Pressure Sensor
Overload Alarm
Monitor Unit
Option Controller
CAN Communication
A9
Buzzer
From Fuse
#19
TCJB-02-02-053
T2-2-111
ELECTRIC AND HYDRAULIC COMPOSITE
CIRCUIT CONTROL
Blade/Outrigger Control (Operation Circuit)
Purpose: Operates the operate check valve for

blade/outrigger by the solenoid valve and
makes each blade/outrigger cylinder oper-
able.
NOTE: Independent circuits operate each cylinder

and are similar. Therefore, the front-right
outrigger cylinder operation is explained
here as an example.
Operation:
1. When the blade/outrigger selector switch is in the 5. Current from fuse #29 shifts the 2-spool solenoid
blade/outrigger ON position, current from fuse valve for outrigger relay (front-right) through
#29 magnetizes blade/outrigger main relay 1. blade/outrigger relay (front-right).
2. At this time, when the blade/outrigger lever is op- 6. As the 2-spool solenoid valve for outrigger relay
erated, the option controller grounds terminal (front-right) is shifted, pressure oil from the pilot
#B20 inside. pump shifts the operate check valve through the
solenoid valve.
NOTE: When the blade/outrigger lever is in neutral,
7. The operate check valve is opened and the out-
the option controller blocks the ground
rigger cylinder (front-right) can be operated.
connection to terminal #B20.
8. When the blade/outrigger lever is operated under
Therefore, blade/outrigger main relay 2 is
these conditions, the outrigger cylinder
turned OFF.
(front-right) is operated by pressure oil from the
control valve.
3. Current from fuse #29 magnetizes blade/outrigger
9. As terminals #B11 and #B13 are grounded, the
main relay 2 through blade/outrigger main relay 1.
option controller recognizes that the outrigger
4. When the left-right selector switch is in the right
cylinder (front-right) is operated.
and the front-rear selector switch is in the front,
10. The option controller sends the operating signal of
current from fuse #29 magnetizes blade/outrigger
blade/outrigger to the monitor unit by using CAN
relays (front-left), (rear-left) and (rear).
communication.
11. The monitor unit turns on the related indicator
(front-right) (green) on the Blade/Outrigger Setup
Screen.
T2-2-112
From Fuse
#29
Blade/Outrigger
Main Relay 1
Blade/Outrigger
Selector Switch Blade/Outrigger
Main Relay 2
Blade/Outrigger
Blade/Outrigger: Blade/ Outrigger Relay (Rear-Right)
Relay (Rear) Blade/Outrigger
ON
Relay (Front)
Blade/Outrigger
Relay (Rear-Left)
Blade/Outrigger
Relay (Front-Right)
Blade/Outrigger
Relay (Front-Left)
Front-Rear Left-Right Selector

Selector Switch
Switch
F R R L
Monitor Unit
CAN B20 B13 B4 B1 B11

Communi-
cation
Option Controller
Pilot Pump
Outrigger
Blade/Outrigger Cylinder
Setting Display (Front-Right)
2-Spool Solenoid Valve
(For Outrigger)
Control Valve Operate

Check Valve
TCJB-02-02-055
T2-2-113
Pilot Cut Control
Purpose: Prevents the front attachment and swing

operations from operating while the machine
travels by turning the blade/outrigger selec-
tor switch to the pilot cut position when the
machine travels with the pilot shut-off lever in
the UNLOCK position.
Operation:
1. When the pilot shut-off lever is in the UNLOCK 7. When the blade/outrigger selector switch is in the
position, the pilot shut-off relay is magnetized and pilot cut position, terminals #2 in blade/outrigger
current from fuse #4 flows to the ground through relays (front) and (rear) are grounded.
the pilot shut-off solenoid valve, pilot shut-off relay 8. Therefore, although the blade/outrigger selector
and security relay. switch and blade/outrigger main relay 1 becomes
2. Therefore, the pilot shut-off solenoid valve is faulty and current from fuse #29 flows into, the
shifted and the front attachment and swing op- blade/outrigger operation is prevented.
erations can be operated.
(Refer to the SYSTEM / Electrical System group.)
3. At this time, when the blade/outrigger selector
switch is in the pilot cut position, current from fuse
#4 magnetizes the security relay and turns on the
lock indicator in steering column console.
4. As the security relay is turned ON, current from
the pilot shut-off relay is blocked.
5. Therefore, as the pilot shut-off solenoid valve is
not shifted, pressure oil from the pilot pump is
blocked by the pilot shut-off solenoid valve.
6. Consequently, although the front attachment and
swing operations are operated, these operations
are inoperable.
T2-2-114
From Fuse
#29
Blade/Outrigger
Main Relay 1
Pilot Cut Position
Blade/Outrigger
Selector Switch
Blade/Outrigger
Relay (Rear) Blade/Outrigger
2 Relay (Front)
2
From Fuse #4
Pilot Shut-Off
Solenoid
Valve
Pilot
Shift-Off
Relay Security
Relay
Monitor
Unit
Steering
Column
Monitor
B20 B13 B4 B1 B11
Option Controller
Pilot Cut Indicator
TCJB-02-02-056
T2-2-115
(Blank)
T2-2-116
SYSTEM / ECM System
OUTLINE
ECM (Engine Control Module) receives the signals • The supply pump is driven by the engine and
from sensors and MC. produces high-pressure fuel.
ECM processes and drives the two-way valve, suction • The common rail distributes high-pressure fuel
control valve and EGR (Exhaust Gas Recirculation) produced by the supply pump to the injector in
motor in order to control the supply pump, injector each engine cylinder.
pump and EGR valve. • The injector injects high-pressure from the com-
mon rail.
• Fuel Injection Control
• Fuel Injection Amount Correction
• Preheating Control
• EGR Control
• Engine Stop Control
Crank Speed Sensor
Cam Angle Sensor
Coolant Temperature Sensor
Boost Pressure Sensor

CAN EGR Motor Position Sensor
EGR Motor
MC ECM
Two-Way Valve
Common Rail
Pressure Sensor
Suction Control
Valve
Common Rail
Supply Pump
Injector
Fuel Tank
T1GR-02-02-001
T2-3-1
SYSTEM / ECM System
FUEL INJECTION CONTROL
ECM detects the engine running condition according to
the signals from each sensor and MC and controls fuel
injection amount, injection pressure, injection timing
and injection rate.
• Fuel Injection Amount Control

• Fuel Injection Pressure Control
• Fuel Injection Timing Control
• Fuel Injection Rate Control
NOTE: Two-way valve controls:

•Fuel Injection Amount Control
•Fuel Injection Timing Control
•Fuel Injection Rate Control
Suction control valve controls:
•Fuel Injection Pressure Control
T2-3-2
SYSTEM / ECM System
Crank Speed Sensor
Cam Angle Sensor

EGR Motor
MC ECM
Common Rail Two-Way Valve

Pressure Sensor
Suction Control
Valve
Common Rail
Supply Pump
Injector
Fuel Tank
T1GR-02-02-001
T2-3-3
SYSTEM / ECM System
Fuel Injection Amount Control
Purpose: Controls the best fuel injection amount.
Operation:
1. ECM detects the engine speed according to the
signals from the crank speed sensor and cam
angle sensor.
2. MC calculates the target engine speed according
to the signals from the engine control dial, sen-
sors and switches and sends the signals to ECM.
3. ECM mainly controls fuel injection amount by
turning ON/OFF for two-way valve in injector ac-
cording to the engine speed and the signals from
MC.
T2-3-4
SYSTEM / ECM System
Crank Speed Sensor

Hydraulic Oil
Pressure Cam Angle Sensor
Temperature
Sensor Sensor Atmospheric Pressure
Sensor
Fuel Temperature
Engine
Sensor
Control Dial
Coolant Temperature
Sensor
Intake-Air Temperature
Sensor
Auto-Idle
Switch Boost Pressure Sensor
Boost Temperature
Sensor
Engine Oil Pressure
Sensor
Power Mode EGR Motor Position
Switch Sensor
EGR Motor
HP Mode
MC ECM
E Mode
P Mode
Pressure Sensor
Engine Speed Control Monitor Unit

Pedal
Digging Attachment
Dial Mode Mode Common Rail
Creeper
FNR Switch
Forward
Pump 2 Delivery
Neutral Pressure Sensor
Fuel Tank Supply Injector
Reverse Pump
Brake Switch
Parking
Brake
Pump 1 Delivery
Axle Lock Pressure Sensor
Auto-Axle
Lock
Pump 1 Control Pressure Sensor
OFF
TCJB-02-03-002
NOTE: The illustration shows when sending the

signals of target engine speed are sent to
ECM from MC.
T2-3-5
SYSTEM / ECM System
Fuel Injection Pressure Control
Purpose: Controls fuel pressure in the common rail in

order to control fuel injection pressure.
Operation:
1. ECM calculates fuel injection amount according to
the engine speed and the signals from MC by
using CAN communication. (Refer to the page on
Fuel Injection Amount Control.)
2. The common rail pressure sensor sends the sig-
nals according to pressure in the common rail to
ECM.
3. ECM calculates the best fuel pressure in common
rail according to the engine speed, fuel injection
amount and the signals of common rail pressure.
4. ECM drives the suction control valve in supply
pump and supplies the best pressure of fuel to the
common rail.
5. Fuel according to fuel pressure in the common rail
is supplied to the injector from the common rail.
T2-3-6
SYSTEM / ECM System
Crank Speed Sensor
Hydraulic Oil Cam Angle Sensor

Pressure Temperature
Sensor Sensor Atmospheric Pressure
Sensor
Fuel Temperature
Engine Sensor
Control Dial Coolant Temperature
Sensor
Intake-Air Temperature
Sensor
Auto-Idle Boost Pressure Sensor
Switch
Boost Temperature
Sensor
Engine Oil Pressure
Sensor
EGR Motor Position
Power Mode
Sensor
Switch
EGR Motor
HP Mode
MC ECM
E Mode
P Mode
Pressure Sensor
Engine Speed Control Monitor Unit

Pedal
Digging Attachment
Dial Mode Mode Common Rail
Creeper
Suction Control
Valve
FNR Switch
Forward
Pump 2 Delivery
Neutral Pressure Sensor
Fuel Tank Supply Injector
Reverse Pump
Brake Switch
Parking
Brake
Pump 1 Delivery
Axle Lock Pressure Sensor
Auto-Axle
Lock
OFF
TCJB-02-03-003
T2-3-7
SYSTEM / ECM System
Fuel Injection Timing Control
Purpose: Calculates the best fuel injection timing.
Operation:
1. ECM calculates the fuel injection timing according
to engine speed and fuel injection amount.
2. ECM controls the two-way valve in injector by
turning ON/OFF according to fuel injection timing.
Fuel Injection Rate Control
Purpose: Improves combustion in the engine cylinder.
Operation:
1. The injector injects small amount of fuel (pilot in-
jection) first and ignites.
2. After igniting, the injector injects fuel (main injec-
tion).
3. ECM controls fuel injection timing and fuel injec-
tion amount by turning the two-way valve in in-
jector ON/OFF.
• Fuel Injection Operation

1. The nozzle in injector is always pressured.
2. When the two-way valve is turned ON,
high-pressure fuel in the control chamber flows
through orifice 1.
3. Therefore, the hydraulic pressure piston is raised
and the nozzle opens so that the injection starts.
4. When the two-way valve is turned OFF,
high-pressure fuel from the common rail flows to
the control chamber through orifice 2.
5. Therefore, when high-pressure flows to the con-
trol chamber, the hydraulic pressure piston is
lowered.
6. Consequently, the nozzle is closed and injection
stops.
T2-3-8
SYSTEM / ECM System
1. Two-Way Valve: ON 2. Injection Start
From ECM From ECM
Two-Way Valve
Two-Way Valve
Returning to Fuel Tank Returning to Fuel Tank

From Common From Common
Rail Rail
Orifice 1
Control Cham-
ber
Control Cham-
ber
Hydraulic Pres-
sure Piston
Nozzle Nozzle
3. Two-Way Valve: OFF 4. Injection Stop
From ECM From ECM
Two-Way Valve Two-Way Valve
From Common From Common

Rail Rail
Orifice 2
Hydraulic Hydraulic
Pressure Piston Pressure Piston
Nozzle Nozzle
T1GR-02-02-012
T2-3-9
SYSTEM / ECM System
FUEL INJECTION AMOUNT CORRECTION
CONTROL
Purpose: Corrects fuel injection amount to the best
fuel injection timing and amount.
1. When the engine starts and engine speed is lower

than the engine start correction speed (550 min−1),
ECM corrects fuel injection amount. (Start Cor-
rection)
2. ECM corrects fuel injection amount according to
the signals from the atmospheric pressure sensor.
(High Altitude Correction)
3. ECM controls the two-way valve in injector and
controls the best fuel injection amount.
Crank Speed Sensor
Cam Angle Sensor
Coolant temperature sensor

EGR Motor
ECM
MC
Two-Way Valve
Common Rail
Pressure Sensor
Suction Control
Valve
Common Rail
Supply Pump
Fuel Tank Injector
T1J1-02-03-003
T2-3-10
SYSTEM / ECM System
PREHEATING CONTROL
From Terminal M
Coolant Temperature
in Key Switch
Purpose: Warm the engine, makes the engine start, Sensor
and reduces white smoke and noise when
starting the engine. Preheats after the engine
starts and makes idling immediately when
the engine starts.
Operation: Fuse Box

1. The signal from the coolant temperature sensor is
sent to the ECM. ECM
2. When the key switch is turned ON, electrical cur-
rent from terminal M in the key switch flows to the
glow plug relay.
3. ECM connects the ground circuit of glow plug re-
lay according to the signals from coolant tem-
perature sensor and controls time for continuity of
electrical current for the glow plug.
From Battery
Glow Plug Relay
Glow Plug TCJB-02-03-008
T2-3-11
SYSTEM / ECM System
EGR (EXHAUST GAS RECIRCULATION)
CONTROL
Purpose: Re-circulates a part of exhaust gas in the
intake manifold and combines it with in-
take-air. Therefore, combustion temperature
is lowered and generation of oxide of nitro-
gen (NOx) is controlled.
Operation:
• EGR Gas Amount Control
1. ECM decides EGR gas amount according to en-
gine speed, fuel flow rate, coolant temperature,
atmospheric pressure and intake-air temperature.
2. ECM drives EGR motor, opens EGR valve and
exhausts EGR gas in response to engine condi-
tion so that EGR gas is combined with intake-air.
3. At the same time, ECM detects the opening
amount of EGR valve by using EGR motor posi-
tion sensor.
• EGR Gas Cooling

1. EGR gas is cooled by the cooling system in EGR
gas passage.
2. Cooled EGR gas is combined with intake-air so
that combustion temperature is lowered and NOx
is generated lower.
• Lead Valve
1. The lead valve prevents fresh air from entering
into the EGR gas passage and EGR gas from
flowing in reverse direction.
2. Therefore, EGR gas flows to one direction and
EGR gas amount increases.
T2-3-12
SYSTEM / ECM System
To Intercooler
Exhaust
From Air Cleaner
Outlet of Coolant
Cooling System
Engine
Inlet of Coolant
EGR Valve
Intake Manifold
EGR Motor
Position Sensor
From Suction
Intercooler EGR Motor
Lead Valve
ECM
Crank Speed Sensor
Cam Angle Sensor
Common Rail Pressure Sensor

T1V1-02-02-007
T2-3-13
SYSTEM / ECM System
ENGINE STOP CONTROL
• Although the keys witch is turned to OFF, the engine

does not stop. (Emergency Stop)
When the engine does not stop due to some troubles

that the machine is broken or damaged with the key
switch OFF, turn (lower) the engine stop switch to the
ON position. Then, the engine stops. After that, return
(raise) the engine stop switch to the OFF position.
CAUTION: Do not use the engine stop switch

except when unavoidable. When the machine
stops due to the machine breakdown, do not
start the machine until repair is completed.
1. When the engine stop switch is turned to the ON

position, electrical current from fuse #8 flows to
terminal #47 in ECM.
2. ECM stops fuel injection of the injector and stops
the engine.
3. At the same time, ECM turns the ECM main relay
OFF.
4. After the ECM main relay is turned OFF, ECM is
turned OFF.
T2-3-14
SYSTEM / ECM System
From Battery
Engine Stop Switch
ECM Main Relay
47
ECM
Injector
TCJB-02-03-007
T2-3-15
SYSTEM / ECM System
(Blank)
T2-3-16
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system is broadly divided into four
circuits, the pilot circuit, the service brake circuit, the
steering circuit and the main circuit.
Pilot Circuit:
Power Source Controller Pilot Circuit

Pilot Pumps → Front Attachment Pilot Valve → Front Attachment Operation Circuit
Travel Pilot Valve Travel Operation Circuit
Pump Regulator Pump Control Circuit
3-Spool Solenoid Valve Unit Valve Control Circuit
Max. Pump 2 Flow Rate Hydraulic Oil Heat Circuit
Limit Solenoid Valve Swing Parking Brake Release Circuit
Signal Control Valve Travel Mode Selector Control Circuit
Transmission Changeover Work Brake Circuit
Solenoid Valve Blade/Outrigger Operation Circuit
Blade/Outrigger Solenoid
Valve
Service Brake Circuit / Steering Circuit:
Power Source Controller Actuator

Steering Pump → Steering Valve → Steering Cylinder
Accumulator Charging
Valve
↓
Brake Valve → Front Brake
Rear Brake
Main Circuit:
Power Source Controller Actuator

Main Pumps → Control Valves → Motors
Cylinders
Front Attachments (Optional)
T2-4-1
PILOT CIRCUIT
Outline:
Pressure oil from the pilot pump is used as operation
pressure as follows.
• Operation Circuit (Front Attachment, Travel,

Blade/Outrigger)
• Swing Parking Brake Release Circuit
• Valve Control Circuit
• Hydraulic Oil Heat Circuit
• Work Brake Circuit
• Axle Lock Circuit
• Travel Mode Selector Circuit
• Blade/Outrigger Circuit
• Pump Control Circuit
• Front Attachment Operation Circuit
• Positioning Control Circuit
T2-4-2
Front Attachment, Travel, Blade / Outrigger
Operation Circuits, Swing Parking Brake Release
Circuit, Valve Control Circuit, Hydraulic Oil Heat
Circuit, Work Brake Circuit and Axle Lock
Release Circuit
Operation Control Circuit
Travel Pilot Valve Left Pilot Valve Right Pilot Valve Blade/Outrigger
Solenoid Valve
Travel
Shockless Valve Swing
Shockless Valve
Pilot Shut-Off Swing

Solenoid Valve Parking
Signal Control Valve Brake
Release To Control Valve
Circuit Spool
Swing Motor
Hydraulic Oil To Control Valve
Heat Circuit Spool
Bucket Flow Rate Control Valve Hose Rupture Valve (Boom)
Boom Anti-Drift Valve

Arm Anti-Drift Valve
Bypass Shut-Out Valve
Solenoid Valve Unit Hose Rupture Valve (Arm)
SI Arm Regenerative Valve

SF
SC
Control Valve
Brake Valve Axle Lock Valve Control

Work Brake Cylinder Circuit
Circuit Hydraulic
Oil Tank
Axle Lock Operation Check
Release Circuit Valve
Suction
Filter
Pilot Relief
Valve
Pilot Pump
Pilot Filter
TCGB-02-04-001
T2-4-3
Pump Control Circuit, Blade/Outrigger Circuit
and Travel Mode Selector Circuit
Travel Pilot Valve Left Pilot Valve Right Pilot Valve Blade/Outrigger
Solenoid Valve
Travel
Shockless Swing
Valve Shockless Valve
Pilot Shut-Off
Solenoid
Valve
Maximum Pump 2 Flow

Rate Limit Control Solenoid
Valve Torque Control
Shuttle Solenoid Valve
Valve
Maximum Pump 2
Flow Rate Limit
Control Solenoid
Valve
SA SB ST
Blade/
Outrigger Blade/Outrigger
Cylinder Cylinder
Solenoid Solenoid Valve Maximum
Valve Pump 1 Flow
Rate Limit
Control 1 2
Operation Operation Solenoid
Check Valve Check Valve Valve
Cylinder
Cylinder
Regulator
Blade/Outrigger Circuit Pump Control

Circuit Hydraulic
Travel Mode Selector Circuit Oil Tank
Transmission
Changeover Suction
Solenoid Valve Filter
Transmission
Pilot Pump
Pilot Relief
Valve
Pilot Filter
TCGB-02-04-002
T2-4-4
Front Attachment Operation Circuit (Optional)
and Valve Control Circuit Operation Control Circuit
Travel Pilot Valve Left Pilot Valve Right Pilot Valve

Auxiliary Solenoid
Valve
Travel
Swing
Shockless Valve
Shockless Valve
Pilot Shut-Off
Solenoid Valve
Signal Control Valve To Control Valve

Spool
Auxiliary Flow
Combiner
Control
Solenoid Valve
Pressure
Reducing
Valve
Auxiliary Shuttle
Flow Rate Valve
Control
Solenoid Auxiliary Flow Combiner
Valve Valve
Auxiliary Flow Rate
Secondary Control Valve
Pilot Relief
Pressure Shuttle Bypass Shut-Out Valve
Control Valve Valve
Selector Control Valve

Valve
Valve Control Circuit
Hydraulic
Oil Tank
Selector Valve
Control Solenoid
Valve
Suction
Filter
Secondary Pilot
Relief Pressure Pilot Pump
Pilot Relief
Control
Valve
Solenoid Valve
Pilot Filter
TCGB-02-04-003
T2-4-5
Positioning Control Circuit (2-Piece Boom Only)
and Valve Control Circuit
Positioning
Solenoid Valve
Positioning Control
Valve
Operation
Control
Circuit
Shuttle
Valve
Pilot Shut-Off Hose Rupture Valve
Solenoid (Positioning)
Valve
Signal Control
Valve
Bypass Shut-Out
Valve
Control Valve
Valve Control Circuit
Hydraulic Oil
Tank
Suction
Filter
Pilot Pump
Pilot Relief
Valve
Pilot Filter
T21W-02-04-004
T2-4-6
(Blank)
T2-4-7
Front Attachment, Travel Operation Circuits
• Each pilot valve controls pressure oil from the

pilot pump and operates the spools in control
valve.
• A signal control valve is located in the circuit
between front attachment and travel pilot valves
and the control valve. The shockless valve built in
boom raise circuit in signal control valve buffers
movement of the spool in control valve. (Refer to
the COMPONENT OPERATION / Signal Control
Valve group.)
• A travel shockless valve is located in the travel
operation circuit.
A swing shockless valve is located in the swing
operation circuit.
A slow return valve (swing shockless valve) is
located in the arm roll-out operation (arm roll-in
return) circuit.
Each valve is in order to buffer movement of the
spools in control valve. (Refer to the
COMPONENT OPERATION / Others
(Upperstructure) group.)
T2-4-8
Travel
Pilot Left Pilot Right Pilot
Valve Valve Valve
Slow Return Valve
Swing Shockless
Valve
Signal Control
Valve
11 12 4 1 8 7 6 5 Control Valve
Travel Shockless 3 2
Valve
12 11
7 8
2
1
1
4
3
3
Pilot Pump
5 6
TCGB-02-04-009
1- Boom Raise 4- Arm Roll-In 7- Bucket Roll-In 11 - Travel Reverse

2- Boom Lower 5- Left Swing 8- Bucket Roll-Out 12 - Travel Forward
3- Arm Roll-Out 6- Right Swing
T2-4-9
Blade/Outrigger, Auxiliary, Positioning Control
Circuits
• The blade/outrigger, auxiliary and positioning are

the electric levers. When each electric lever is
operated, the option controller activates each
solenoid valve of the blade/outrigger, auxiliary or
positioning. Therefore, pressure oil from the pilot
pump flows to the control valve through each
solenoid valve and moves the control valve
spools. (Refer to the SYSTEM / Control System
group.)
T2-4-10
Blade/Outrigger Blade/Outrigger Auxiliary Positioning
Switch Lever Pedal Pedal
Optional Controller
9 10 13 14 31 32
Blade/Outrigger Auxiliary
Positioning
Solenoid Valve
Valve
Control Valve
9 10
13 14
Pilot Pump
31
32
Positioning Control
Valve TCGB-02-04-010
9 - Blade/Outrigger Lower 13 - Auxiliary (Open) 31 - Positioning Lower 32 - Positioning Raise

10 - Blade/Outrigger Raise 14 - Auxiliary (Close)
T2-4-11
Pump Control Circuit (Refer to the COMPONENT
OPERATION/Pump Device group.)
• Pump Delivery Flow Rate Control by Flow Rate

Control Pressure Pi
• Pilot pressure from the control valve is selected
by the shuttle valve in signal control valve and the
pump 1 flow rate control valve or pump 2 flow
rate control valve in signal control valve is shifted.
• Pilot pressure from the positioning is selected by
the external shuttle valve and the pump 1 flow
rate control valve in signal control valve is shifted.
• Pilot pressure oil from the pilot pump is supplied
to main pump 1 or 2 through the max. pump 1
and 2 flow rate limit control valves as flow rate
control pressure Pi by shifting the pump 1 flow
rate control valve or pump 2 flow rate control
valve.
NOTE: When operating boom raise/lower, arm

roll-out/in, bucket roll-in/out, travel
(forward/reverse) and positioning, flow rate
control pressure Pi is supplied to main
pump 1.
When operating boom raise, arm roll-out/in,
swing (right/left), blade/outrigger and
auxiliary, flow rate control pressure Pi is
supplied to main pump 2.
• Pump Control by Torque Control Solenoid Valve

• Pilot pressure from the pilot pump is controlled by
the torque control solenoid valve and supplied to
main pumps 1 and 2 as torque control pressure
Pps.
T2-4-12
Travel Pilot Left Pilot Right Pilot

Valve Valve Valve
Blade/
Outrigger Auxiliary Positioning
Solenoid Solenoid Solenoid
Valve Valve Valve
Shuttle Valve
Signal Control
Valve
Shuttle Valve
Pump 1 Flow
Rate Control
Valve Pump 2 Flow Rate
Control Valve
Control Valve
Flow Rate
Control
Pressure
(Pressure Pi)
Torque Control
Torque Control Pressure
Solenoid Valve (Pressure Pps)
Pilot Pump
Maximum Pump 2 TCGB-02-04-005
Maximum Pump 1 Flow Flow Rate Limit
Rate Limit Control Control Solenoid
Solenoid Valve Valve
T2-4-13
Valve Control Circuit (Refer to the COMPONENT
OPERATION/Control Valve group.)
• Pilot pressure from the pilot valve, solenoid valve

units (SC), bucket flow rate control valve control
spool in signal control valve controls the valves
below.
• Boom lower pilot pressure: Boom anti-drift valve,

bypass shut-out valve and hose rupture valve
(boom)
• Arm roll-in pilot pressure: Arm anti-drift valve,
hose rupture valve (arm) and bucket flow rate
control valve control spool
• Positioning lower pilot pressure: Bypass shut-out
valve, hose rupture valve (positioning)
• Solenoid valve unit (SC): Arm regenerative valve
• Bucket flow rate control valve spool: Bucket flow
rate control valve
(Optional)
• Auxiliary flow combiner control solenoid valve:
Auxiliary flow combiner valve, bypass shut-out
valve
• Auxiliary flow rate control solenoid valve: Auxiliary
flow rate control valve
• Pressure reducing valve (front attachment, travel
pilot pressures): Auxiliary flow combiner valve
T2-4-14
Arm Boom
Roll-In Lower Bucket Flow Rate
Control Valve Spool
Auxiliary Positioning
Valve
32
Shuttle Valve
Auxiliary Flow
Combiner Control
Solenoid Valve
Auxiliary Flow
Rate Control
Solenoid Valve
Signal Control Pressure

Valve 4 2 Reducing Valve
Shuttle Valve
Auxiliary Flow
Combiner Valve
Auxiliary Flow
Rate Control
Valve
Bucket Flow Rate

Control Valve
2
To Hose Rupture Boom Anti-Drift
Valve (Arm) Valve
To Hose Rupture
SC Valve (Boom)
4
Arm Anti-Drift
Valve
Arm Regenerative
Valve
Bypass
Shut-Out Valve
32
To Hose Rupture
Valve (Positioning) TCGB-02-04-006
T2-4-15
Swing Parking Brake Release Circuit (Refer to the
COMPONENT OPERATION / Swing Device
group.)
• When operating the front attachment, swing,

blade/outrigger or auxiliary, pilot pressure is
selected by the shuttle valve in signal control
valve and shifts the swing parking brake release
spool.
• When operating the positioning or assist
(optional), shifts the swing parking brake release
solenoid valve.
• As a result, the release signal pressure is
supplied to the swing motor and the swing
Axle Lock Release Circuit (Refer to the

COMPONENT OPERATION / Travel Device
group.)
• Pilot pressure from solenoid valve unit (SI) shifts

the operation check valve in axle lock cylinder.
• Consequently, the axle lock cylinder can oscillate
and releases the axle lock.
Hydraulic Oil Heat Circuit (Refer to the

COMPONENT OPERATION / Others
(Upperstructure) group.)
• When the pilot shut-off solenoid valve is closed,

the pilot pressure oil is routed to the signal control
valve so that hydraulic oil is warmed while
passing through the orifice in the signal control
valve.
• The warmed pilot pressure oil flows to the signal
control valve and pilot valves so that the pilot
system components are warmed.
Work Brake Circuit
• Pilot pressure from solenoid valve unit (SF) shifts

the brake valve.
• Pressure oil from the accumulator charging valve
acts on the front brake and rear brake through the
brake valve by shifting the brake valve.
• Consequently, the brake is applied.
T2-4-16
Left Pilot Right Pilot

Valve Valve
Blade/Outrigger Auxiliary Swing Parking

Solenoid Valve Solenoid Brake Release
Pilot Shut-Off
Solenoid Valve
Swing Motor
Signal
Control
Valve
Swing Parking Brake

Operation
Release Spool
Solenoid Valve Check Valve
Unit
SI
SF
Axle Lock Cylinder
Brake Valve
Front Brake
Pilot Steering
Pump Pump
Accumulator
Charging
Valve
Rear Brake
TCGB-02-04-007
T2-4-17
SERVICE BRAKE CIRCUIT
• Pressure oil from the steering pump acts on the NOTE: Pressure in the service brake circuit is kept
brake valve through the steering valve (priority for a specified period of time due to
valve) and accumulator charging valve. functions of the accumulator and check
(Refer to the COMPONENT OPERATION / valve with the engine stopped.
Steering Valve group.)
• Pressure oil from the accumulator charging valve
acts on the front brake and rear brake and
operates the brakes by operating the brake valve.
Steering Valve
Front Brake
Priority Valve
Accumulator
Brake Valve
Accumulator
Charging Valve
Steering Filter
Check Valve Accumulator
Steering Pump
Rear Brake
TCJB-02-04-012
T2-4-18
STEERING CIRCUIT
• Pressure oil from the steering pump flows to the

steering valve through the steering filter and
priority valve.
(Refer to the COMPONENT OPERATION /
Steering Valve group.)
• The steering valve is actuated by rotation of the
steering wheel and pressure oil flows to the
steering cylinder so that the front wheels changes
their directions.
Steering Valve
Priority Valve Steering Cylinder
Accumulator
Charging Valve
Steering Filter
Steering Pump
TCJB-02-04-013
T2-4-19
MAIN CIRCUIT
Outline
• Main pumps 1 and 2 draw hydraulic oil from the
hydraulic oil tank. Main pump 1 and main pump 2
deliver pressure oil to the 4-spool control valve
and the 5-spool control valve respectively.
• Pressure oil from the parallel circuit in 4-spool
control valve is routed to the auxiliary control
valve.
• Delivered hydraulic oil is routed to the motor or
cylinder in response to operation of the control
valve spool.
• Return oil from the motor and/or cylinder flows
back to the hydraulic oil tank through the control
valve and/or oil cooler.
• When oil temperature is low (high viscosity), oil
flow resistance increases in the oil cooler, which
opens the bypass check valve and hydraulic oil
directly returns to the hydraulic oil tank.
T2-4-20
Blade/Outrigger
Cylinder
Travel Motor
Bucket Cylinder
Optional
Attachment
Control Valve
Boom Cylinder
4-Spool
Arm Cylinder Section
Blade/Outrigger Travel
Auxiliary Bucket
Boom 2 Boom 1
Arm 1 Arm 2 Positioning

Control Valve
Swing
Positioning
5-Spool
Section
Bypass
Check Valve
Swing Motor
Main Main
Pump 2 Pump 1
Oil Cooler
Suction Filter Hydraulic

Oil Tank
Positioning
Cylinder
T16W-02-04-004
T2-4-21
Neutral Circuit
• When the control lever is in neutral, pressure oil
from the main pump passes through the control
valve and returns to the hydraulic oil tank.
• The parallel circuit is located in the 4-spool
section and 5-spool section respectively so that
combined operation is possible.
Single Operation Circuit

• Pressure oil from main pump 1 is routed to the
4-spool control valve and is further routed to each
spool of travel, bucket, boom 1 and arm 2.
• Pressure oil from main pump 2 is routed to the
5-spool control valve and is further routed to each
spool of swing, arm 1, boom 2, auxiliary and
blade/outrigger.
• The boom and arm are actuated by pressure oil
from two main pumps. Pressure oil from each
main pump is combined and supplied together.
T2-4-22
Blade/Outrigger
Cylinder
Travel Motor
Blade/Outrigger Parallel Circuit
5-Spool Section 4-Spool Section
Travel
Optional Bucket
Attachment Cylinder
Auxiliary
Neutral Circuit
Bucket
Arm Cylinder
Boom 2
Boom 1 Neutral Circuit
Swing Motor
Arm 1 Boom Cylinder
Arm 2
Swing
Flow Combiner
Circuit
Parallel Circuit
Pump 2 Pump 1
T16W-03-03-042
T2-4-23
Positioning Circuit (2-Piece Boom)
When operating boom lower and positioning, pressure

oil from each pilot valve flows to the bypass shut-out
valve through the shuttle valve. Therefore, the bypass
shut-out valve is switched.
• During Single Operation:
As the bypass shut-out valve is switched, the
neutral circuit in 4-spool section of control valve is
blocked and pressure oil from pump 1 is supplied
to the positioning control valve.
• During Combined Operation:
When operating combined operation of boom,
arm or bucket and positioning, the neutral circuit
in 4-spool is blocked by each spool.
Pressure oil from pump 1 is supplied to the
positioning control valve through the 4-spool
section parallel circuit.
T2-4-24
4-Spool Section
Parallel Circuit
4-Spool Section
Neutral Circuit
Pilot Pressure
from Attachment
or Positioning
Bypass
Shut-Out Valve
Positioning
Cylinder
Pump 1
Positioning Control TCGB-03-03-003

Valve
T2-4-25
Combined Operation Circuit
• Swing and Boom Raise Operation

• When the boom is raised while swinging, pilot
pressure shifts the spools of swing, booms 1 and
2.
• Pressure oil from pump 1 flows to the boom
cylinder through the parallel circuit, boom flow
rate control valve and boom 1 spool so that the
boom is raised.
• Pressure oil from pump 2 flows to the swing
motor through the swing spool and swings.
• At the same time, pressure oil flows to the boom
cylinder through the parallel circuit, boom 2 spool
and is combined with pressure oil from pump 1 so
that the boom is raised.
T2-4-26
Parallel Circuit
Boom 2 Boom
Boom 1 Cylinder
Swing Motor
Swing
Parallel Circuit
Pump 2 Pump 1 T16W-02-04-005
T2-4-27
Auxiliary Flow Combiner Circuit (Only the
machines equipped with the optional parts)
• When the front attachment as a hydraulic breaker
is operated, pilot pressure from the auxiliary flow
combiner selector solenoid valve shifts the
auxiliary flow combiner valve and bypass shut-out
valve.
• When the bypass shut-out valve is shifted, the
neutral circuit in 4-spool section is blocked.
• Consequently, pressure oil from pump 1 flows
through the auxiliary flow combiner valve and is
combined with that from pump 2 so that
spool.
NOTE: During operation of boom raise/lower, arm

roll-in/out, bucket roll-in/out and right /left
travel, operating pressure for each from the
signal control valve (port SN) acts on the
auxiliary flow combiner valve (port SN).
This operating pressure pushed back the
auxiliary flow combiner valve and blocks
pressure oil from pump 1.
As the pressure reducing valve decreases
operating pressure above, combined oil
flow rate to the auxiliary circuit can be
adjusted.
NOTE: During combined operation of attachment

(pulverizer, crusher) and front attachment,
MC activates the auxiliary flow rate control
solenoid valve and shifts the auxiliary flow
rate control valve.
Therefore, as pressure oil to the
attachment decreases and that to the front
attachment increases, operability of the
front attachment is improved. (Refer to the
SYSTEM/Control System group.)
T2-4-28
Pressure Front Attachment,

Reducing Valve Travel Pilot Valve Front Attachment
(Optional) Pressures Pilot Pressure

(Optional)
Auxiliary Flow
Combiner Valve
SN SM
Optional
Neutral Circuit
Attachment
Auxiliary
From Auxiliary Flow

Rate Control
Solenoid Valve
Auxiliary
Flow Rate
Control
Valve
SJ
Bypass
Shut-Out Valve
Pump 2 Pump 1
TCGB-02-04-011
T2-4-29
(Blank)
T2-4-30
SYSTEM / Electrical System
OUTLINE
The electrical circuit is broadly divided into the main
circuit, monitor circuit, control circuit and steering
column monitor circuit.
• Main Circuit
The engine and accessory operation related circuit.
• Monitor Circuit
The electrical circuit group consists of the monitors,
sensors and switches, and displays the machine
operation status.
• Control Circuit (Refer to the SYSTEM / Control Sys-

tem group.)
The control circuit is categorized into the engine,
pump and valve control circuits. Each circuit con-
sists of the actuators such as solenoid valves, MC
(main controller), ECM (engine control module),
switch panels, sensors and pressure switches.
• Steering Column Monitor Circuit

This circuit is used when the machine travels and
consists of head light, turn signal light, stop light and
steering column monitor.
T2-5-1
MAIN CIRCUIT
The major functions and circuits in the main circuit are
as follows.
• Electric Power Circuit: Supplies all electric power

to all electrical systems on this machine. [Key
Switch, Batteries, Fuses (Fuse Boxes, Fusible
Links), Battery Relay]
• Accessory Circuit
Becomes operative when the key switch is turned
to the ACC position.
• Starting Circuit
Starts the engine. [ Key Switch, Starter, Starter
Relay]
• Charging Circuit
Charges the batteries. [Alternator, (Regulator)]
• Serge Voltage Prevention Circuit

Prevents the occurrence of serge voltage devel-
oped when stopping the engine. [ Load Damp
Relay]
• Pilot Shut-Off Circuit (Key Switch: ON)

Supplies pressure oil to the pilot valve from the
pilot pump by the pilot shut-off solenoid valve.
• Security Lock Circuit

Cut electrical current for starting from the key
switch according to the signals from external
alarm system or monitor unit. Turns the pilot
shut-off solenoid valve OFF and blocks the pilot
circuit.
• Engine Stop Circuit (Key Switch: OFF)

Stops the engine by using ECM. (MC, ECM)
• Security Horn Circuit

Operate the security horn according to the signals
from external alarm system or monitor unit.
• Working Light Circuit

Turn on the work light and cab light.
• Wiper Circuit
Operate the intermittent operation of wiper and
the washer.
T2-5-2
(Blank)
T2-5-3
ELECTRIC POWER CIRCUIT (KEY
SWITCH: OFF)
The battery ground terminal is connected to the vehi-
cle frame. Current from the battery plus terminal flows
as shown below when the key switch is turned OFF.
Battery
↓ →Fuel Pump (Power)
Fusible Link →Terminal #8: ECM Main Relay (Power)
→Glow Plug Relay (Power)
→Terminal #9: Radio (Backup Power)
→Key Switch Terminal B
Security Horn (Power)
→Load Damp Relay (Power)
Security Horn Relay (Power)
→Fuse Box
→Terminal #10: MC (Power), ICF (Power)
→Terminal #11: Horn Relay (Power)
→Terminal #19: Monitor Unit (Backup Power)
Buzzer (Power)
→Terminal #20: Optional
→Terminal #24: Hazard Flasher
Turn Signal Light Relay (Left)
Turn Signal Light Relay (Right)
Hazard Switch
→Terminal #39: Option Controller (Power)
T2-5-4
Key Switch
Fuel Pump
Fuse Box
Fusible Link
Battery
Load
Damp
Relay
Glow Plug Relay
ECM Main Relay

Radio, Security Horn,
Security Horn Relay
MC, ICF
Optional Option
Monitor Unit, Buzzer Controller
Hazard Flasher,
Horn Relay Turn Signal Light Relay (Left),
Turn Signal Light Relay (Right),
Hazard Switch
TCJB-02-05-001
T2-5-5
ACCESSORY CIRCUIT
1. When the key switch is turned to the ACC posi-
tion, terminal B is connected to terminal ACC in
the key switch.
2. Current from key switch terminal ACC flows to ra-
dio (#12), cab light (#12), lighter (#13) and auxil-
iary (#15) through the fuse box and makes each
accessory operable.
T2-5-6
Key Switch
Fuse Box
Battery
15 12
13
Radio, Cab Light
Cigar Lighter
Auxiliary
TCJB-02-05-002
T2-5-7
STARTING CIRCUIT (KEY SWITCH:
START)
1. When the key switch is turned to the START posi- NOTE: As no current flows to terminal S with
tion, terminal B is connected to terminals M and starter cut relay ON, the engine does not
ST in the key switch. start.
2. As current from terminal M excites the battery re-
lay, battery current is routed to starter terminal B
and starter relay terminal B through the battery
relay.
3. When the following conditions exist, current from
terminal ST flows to starter relay terminal S
through the starter cut relay.
4. Current flows to the starter relay coil and starter
relay is turned ON.
5. Current flows to starter terminal C from starter
relay terminal C.
6. Consequently, the relay in starter is turned ON so
that the starter begins rotating.
7. On the other hand, current from key switch ter-
minal M flows to MC, ECM, ICF, monitor unit and
option controller through fuse #18 as a signal in-
dicating that the key switch is in the ON or START
position.
8. As soon as ECM receives this signal, ECM turns
the ECM main relay ON.
9. Current from the battery flows to ECM through
fuse #8, the ECM main relay and fuse #14 and
the main power is turned ON.
10. ECM makes the engine starting condition.
Engine Starting Conditions:

• Pilot Shut-Off Lever: LOCK position
• Engine Stop Switch: OFF
T2-5-8
Key Switch
Fusible Ｂ ST
Link (45A) M
Battery
Battery 8 18
Relay Starter Cut
Relay
Starter
Starter
Relay
Engine
Stop
Switch
ECM
Main
Relay
Brake
P (Parking Switch
Brake) Position
Option
ECM MC Monitor Unit ICF Controller
TCJB-02-05-004
T2-5-9
Starter Relay Operation
1. When the key switch is turned to the START posi-
tion, key switch terminal B is connected to termi-
nal ST.
2. Current from the battery is routed to the base in
transistor (Q2) through resistance R4 in starter
relay. Then, transistor (Q2) is turned ON and cur-
rent flows to coil (L) in starter relay.
3. Therefore, starter terminal B is connected to ter-
minal C and the starter is operated.
4. After the engine starts, the alternator starts gen-
erating electricity and voltage at starter relay ter-
minal R increases.
5. When this voltage increases up to 21 to 22 V,
zener diode (Z) is turned ON.
6. Consequently, transistor (Q1) is turned ON. Then,
current to the base of transistor (Q2) does not
flow and transistor (Q2) is turned OFF.
7. At this moment, starter terminal B is disconnected
from terminal C and the starter is turned OFF.
NOTE: Condenser C1 is used to stabilize the op-

erating voltage. Diode D4 protects the cir-
cuit in case the battery terminals are re-
versely connected.
Starter Relay
S B
D3
(1)
R4 L
C
R3 (2)
(1) C
R2 Z D2
From Alternator R Q2 M B
Terminal L Q1
(2)
C1 C Starter
E D4
B 12V
ST
Key Switch 12V
Battery
T107-04-04-003
T2-5-10
(Blank)
T2-5-11
Brake Switch: OFF, Auto Axle Lock or Axle Lock
Position
• Starting Safety Circuit
tion, current from key switch terminal ST flows to
the starter cut relay.
2. At this time, if the brake switch is in the OFF, auto
axle lock or axle lock position, current from ter-
minal ST excites the starter cut relay and is
grounded from the brake switch.
3. When the starter cut relay is turned ON, the cir-
cuit between key switch terminal ST and starter
relay terminal S is blocked. Therefore, although
the key switch is turned to the START position,
the engine does not start.
T2-5-12
Key Switch
Ｂ ST
Battery
Starter Cut
Relay
Starter
Relay
Brake Switch
OFF
Position
ECM MC Monitor Unit ICF Option

Controller
TCJB-02-05-005
T2-5-13
CHARGING CIRCUIT (KEY SWITCH: ON)
1. After the engine starts and the key switch is Monitor Unit
released, the key switch moves to the ON
position.
2. Key switch terminal B is connected to terminals
ACC and M in the key switch with the key switch
ON.
3. The alternator starts generating electricity with the
engine running. Current from alternator terminal B
flows to the batteries through the battery relay
and charges the batteries.
4. Current from alternator terminal L flows to the
monitor unit, turns the alternator alarm OFF and
flows to ICF.
TCJB-05-02-050
NOTE: Monitor unit detects the alternator charging Alternator
according to power from the alternator and Alarm
turns the Alternator Alarm OFF.
T2-5-14
Key Switch
Battery
Battery
Relay
Alternator
Monitor Unit ICF
TCJB-02-05-006
T2-5-15
Alternator Operation
• The alternator consists of field coil FC, stator coil • At the beginning, no current is flowing through
SC and diode D. The regulator consists of tran- field coil FC. When the rotor starts rotating, alter-
sistors T1 and T2, Zener diode ZD and resis- nate current is generated in stator coil SC by the
tances R1 and R2. rotor remanent magnetism.
• Alternator terminal B is connected to base B of • When current flows through field coil FC, the rotor
transistor T1 through the circuit [B → R → RF is further magnetized so that the generating volt-
→ (R) → (R1)]. age increases. Thereby, current flowing through
• When the battery relay is ON, the battery voltage field coil FC increases. Therefore, generating
is applied to base B of transistor T1 so that col- voltage increases further and the batteries start
lector C is connected to emitter E. Therefore, field charging.
coil FC is grounded through transistor T1.
Alternator
B R L Regulator
RF (R) R5
R3 R4
Battery Relay
R6
D
ZD
R2
Battery SC B
E
R1 C
T2
FC B
D1 C E
T1
(F)
(E)
E
T157-04-02-008
T2-5-16
Regulator Operation
• When generating voltage increases more than • When generating voltage decreases lower than
the set-voltage of Zener diode ZD, current flows the set-voltage of Zener diode ZD, transistor T2 is
to base B of transistor T2 and collector C is con- turned OFF and transistor T1 is turned ON again.
nected to emitter E. • Current flows through field coil FC and generating
• Current which was routed to base B of transistor voltage at stator coil SC increases. The above
T1 disappears due to transistor T2 operation so operation is repeated so that the alternator gen-
that transistor T1 is turned OFF. erating voltage is kept constant.
• No current flows through filed coil FC and gener-
ating voltage at stator coil SC decreases.
RF R3 R4 R5
Battery Relay
R6
ZD
R2
Battery B
SC
A E
C
FC T2
B
R1 C E
T1
(F) D1
(E)
E
T157-04-02-009
T2-5-17
SERGE VOLTAGE PREVENTION CIRCUIT
1. When the engine is stopped (key switch: OFF),
current from key switch terminal M is discon-
nected and the battery relay is turned OFF.
2. The engine continues to rotate due to inertia force
just after the key switch is turned OFF so that the
alternator continues to generate electricity.
3. As the generating current cannot flow to the bat-
tery, surge voltage arises in the circuit and fail-
ures of the electronic components, such as the
controller, possibly cause. In order to prevent the
occurrence of surge voltage, the surge voltage
prevention circuit is provided.
4. When the alternator is generating electricity, gen-
erating current from alternator terminal L flows to
monitor unit terminal #C7. The monitor unit con-
nects terminal #A12 to ground.
5. Current flows through the load damp relay excit-
ing circuit and the load damp relay is turned ON.
6. Accordingly, even if the key switch is turned OFF
while the engine is rotating, battery current con-
tinues to excite the battery relay through the load
damp relay.
7. When the alternator stops generating, the battery
relay is turned OFF.
T2-5-18
Key Switch
OFF Position
M
Battery
Load
Battery Damp
Relay Relay
Alternator
C7 A12
Monitor Unit
TCJB-02-05-007
T2-5-19
PILOT SHUT-OFF CIRCUIT (KEY SWITCH:
ON)
1. When the pilot shut-off lever is turned to the
UNLOCK position, the pilot shut-off switch is
turned ON.
2. Electrical current from fuse #4 flows to the ground
through the pilot shut-off relay and pilot shut-off
switch so that the pilot shut-off relay is excited.
3. At the same time, the starter cut relay is con-
nected to the ground circuit.
4. When the pilot shut-off relay is excited, the
ground in pilot shut-off solenoid valve is con-
nected to the ground through the pilot shut-off re-
lay and security relay.
5. Therefore, the pilot shut-off solenoid valve is
turned ON, pressure oil from the pilot pump is
routed to the pilot valve.
tion, the starter cut relay is excited.
7. When the starter cut relay is excited, the circuit
between terminal ST in the key switch and termi-
nal S in starter relay is blocked.
8. Therefore, when the pilot shut-off lever is in the
UNLOCK position the key switch is turned to the
START position, the engine does not start.
NOTE: The signal; Pilot shut-off switch: ON (Pilot

shut-off lever: UNLOCK position) is recog-
nized by the option controller. The option
controller sends the signal; Pilot shut-off
switch: ON to MC by using CAN commu-
nication.
T2-5-20
Key Switch
ST
B
M
Pilot
Battery Shut-Off
Switch
Battery 4
Relay Starter Cut
Relay
Starter
Relay
Pilot
Shut-Off
Solenoid
Valve
Security
Relay Pilot
Shut-Off
Relay
Option
CAN Communication TCJB-02-05-008
T2-5-21
SECURITY LOCK CIRCUIT
1. When the external alarm signal or password input
error signal from ICF is input to the monitor unit,
terminal #A4 is connected to the ground inside
the monitor unit.
2. Therefore, the security relay and starter cut relay
are excited.
3. When the security relay is excited, the ground
circuit in pilot shut-off solenoid valve is blocked
and the pilot shut-off solenoid valve is turned
OFF.
4. Therefore, pressure oil which flows to the pilot
valve from the pilot pump is blocked by the pilot
shut-off solenoid valve.
5. When the starter cut relay is excited, the circuit
between terminal ST in the key switch and termi-
nal S in starter relay is blocked.
6. Therefore, when the key switch is turned to the
START position, the engine does not start.
T2-5-22
Key Switch
ST
B
M
Pilot
Shut-Off
Battery
Switch
Battery 4
Relay Starter Cut
Relay
Pilot
Shut-Off
Solenoid
Valve
Security Pilot
Relay Shut-Off
Relay
CAN Communication
Option
TCJB-02-05-009
T2-5-23
ENGINE STOP CIRCUIT (KEY SWITCH:
OFF)
1. When the key switch is turned from the ON posi-
tion to the OFF position, the signal current indi-
cating that the key switch is ON stops flowing
from fuse #18 to ECM terminal #24.
2. ECM stops injection of injector and the engine
stops.
3. When the engine stops, ECM turns the ECM
main relay OFF.
T2-5-24
Key Switch
Battery
18
ECM Main Relay
24
ECM
TCJB-02-05-010
T2-5-25
SECURITY HORN CIRCUIT
From Battery
1. When the external alarm signal or password input
error signal from ICF is input to the monitor unit, Fuse #9
terminal #A3 is connected to the ground inside
the monitor unit.
2. Therefore, the security horn relay is excited.
3. When the security horn relay is excited, electrical
current from fuse #9 operates the security horn. Signal from ICF
A3
Monitor Unit
Security Horn
Security Horn
Relay
T1V1-02-05-006
T2-5-26
(Blank)
T2-5-27
WIPER / WASHER CIRCUIT
Wiper Circuit
1. The wiper / washer switch sends the electrical
signal on position the INT. in response to the set Fast
intervals to the monitor unit. Speed
2. The monitor unit connects terminal #A2 to the
ground according to the input intervals.
3. Therefore, the wiper relay repeats to turn ON and
OFF. Middle
Speed
4. When the wiper relay is turned ON, current from
fuse #2 flows to the wiper motor and the wiper Slow
Speed
moves.
Washer Circuit M178-01-016
1. While pushing the wiper/washer switch, the

monitor unit receives the electrical signal from the Position INT. Set Time
wiper/washer switch. Slow 8 seconds
2. The monitor unit connects terminal #A10 to the Middle 6 seconds
ground and the washer relay is excited. Fast 3 seconds
3. Current from fuse #2 flows to the washer motor
and washer liquid jets.
T2-5-28
From
Battery
Wiper / Washer Switch Wiper
Fuse #2
Monitor Unit
Washer
Washer Relay
Wiper Motor
Washer Motor
Wiper Relay
T1V1-02-05-005
T2-5-29
LIGHT CIRCUIT
Clearance Light Circuit (Light Switch: 1)
1. When the light switch is turned to position 1, ter-
minal #1 is connected to terminal #2 in the light
switch.
2. Current from fuses #21 and #31 flows to the
ground through the light switch.
3. Therefore, clearance light relays (right) and (left)
are excited.
4. Current from the battery relay flows to the clear-
ance light and tail light and they are turned on.
T2-5-30
From Battery Relay
21 31
Clearance
Light Relay
(Right)
Clearance
Light Relay
(Left)
Clearance Light
Tail light
Light
Switch TCJB-02-05-012
T2-5-31
Head Light Circuit
NOTE: The operation with the dimmer switch in the

LOW position is explained here.

switch.
2. When the dimmer switch is turned to the LOW
position, terminal #5 is connected to terminal #6 in
the dimmer switch.
3. Current from fuses #22 and #32 flows to the
ground through the dimmer switch and light
switch.
4. Therefore, head light relays (right) and (left) are
excited.
5. Current from fuses #22 and #32 flows to the head
light and the head light is turned on.
NOTE: When the light switch is in position 2, ter-

minals #1 and #2 are connected in the light
switch. Therefore, head light, clearance
lights (right), (left) and tail light are turned
on.
T2-5-32
From Battery
Relay
32
22
Clearance
Light Relay
(Right)
Head Light
Relay (Right)
Clearance
Light Relay
Head Light (Left)
Relay (Left)
Head Light
Clearance Clearance
Light Light
Tail Light
Light
Switch Dimmer TCJB-02-05-013
Switch
T2-5-33
High Beam Circuit
NOTE: The operation with the light switch in posi-

tion 2 is explained here.
1. When the dimmer switch is shifted downward,

terminal #5 is connected to terminal #7 in the
dimmer switch.
switch.
3. Current from fuses #23 flows to the ground
through the dimmer switch and light switch.
4. Therefore, the high beam relay is excited.
5. Current from fuses #23 flows to the high beam
and the high beam is turned on.
NOTE: When the light switch is in position 2, ter-

minals #1 and #2 are connected in the light
switch. Therefore, high beam, clearance
lights (right), (left) and tail light are turned
on.
T2-5-34
From Battery
Relay
23
Clearance
Light Relay
(Right)
Clearance
Light Relay
High (Left)
Beam
Relay
High Beam
Clearance Clearance
Light Light
Tail Light
Light
Switch Dimmer TCJB-02-05-014
Switch
T2-5-35
Passing Circuit
1. When the dimmer switch is shifted upward, ter-
minal #7 is connected to terminal #8 in the dimmer
switch.
through the dimmer switch.
3. Therefore, the high beam relay is excited.
4. Consequently, current from fuse #23 flows to the
high beam. Although the light switch is turned to
the OFF position, the high beam is turned on.
T2-5-36
From Battery
Relay
23
High
Beam
Relay
High Beam
Dimmer TCJB-02-05-015
Switch
T2-5-37
Turn Signal Circuit
1. Current from fuse #24 is divided into two direc-
tions.
2. One flows to flasher terminal B and another flows
to turn signal light relays (right) and (left).
3. When the turn signal switch is turned to left or
right, terminal #9 is connected to terminal #10 (or
terminal #10 is connected to terminal #11) in the
turn signal switch.
through the turn signal switch.
5. Therefore, the turn signal light relay (left) or (right)
is excited.
6. Current from fuse #24 is output by flasher terminal
L intermittently.
7. Current from flasher terminal L flows to the turn
signal light (left) or (right) and the turn signal light
blinks.
NOTE: Although the key switch is turned OFF, the

turn signal light blinks.
T2-5-38
From Battery
24
Flasher
High
Beam
Relay
Turn Signal
Light Relay
Turn (Left)
Turn Signal Light Signal
Light
Relay
(Right)
Turn Signal Light
Turn Signal
T2-5-39
Hazard Circuit
1. Current from fuse #24 is divided into two direc-
tions.
2. One flows to flasher terminal B and another flows
to turn signal light relays (right) and (left).
3. When the hazard switch is turned ON, current
from fuses #24 flows to the ground through the
hazard switch.
4. Therefore, the turn signal light relay (left) or (right)
is excited.
5. Current from the battery is output by flasher ter-
minal L intermittently.
6. Current from flasher terminal L flows to the turn
signal light (left) or (right) and the turn signal light
blinks.
NOTE: Although the key switch is turned OFF, the

turn signal light blinks.
T2-5-40
From Battery
24
Flasher
Turn Signal
Light Relay
Turn (Left)
Hazard Light Signal
Light
Relay
(Right)
Hazard
Switch
Hazard Light
TCJB-02-05-017
T2-5-41
Stop Light Circuit
1. When the brake pedal is depressed, the stop light
switch is turned ON.
through the stop light switch.
3. Therefore, the stop light relay is excited.
4. Current from fuses #25 flows to the stop light and
the stop light is turned on.
T2-5-42
From Battery Relay
25
Stop
Light
Relay
Hazard
Switch
Stop
Light
Stop
Light
Switch
TCJB-02-05-018
T2-5-43
(Blank)
T2-5-44
MEMO
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SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 7 Axle
Outline..................................................................................... T3-1-1 Front Axle................................................................................ T3-7-1
Main Pump............................................................................. T3-1-2 Differential Gear................................................................... T3-7-2
Regulator................................................................................ T3-1-6 Reduction Gear
Solenoid Valve.....................................................................T3-1-22 (ZX140W-3: Up to serial No 005000,
Pilot Pump, Steering Pump............................................T3-1-24 ZX140W-3-AMS: Up to serial No 050000).............. T3-7-8
Pump Delivery Pressure Sensor....................................T3-1-24 Reduction Gear
Pump Control Pressure Sensor.....................................T3-1-24 (ZX140W-3: Serial No 005001 and up,
ZX140W-3-AMS: Serial No 050001 and up).........T3-7-10
Group 2 Swing Device Steering Cylinder...............................................................T3-7-12
Outline..................................................................................... T3-2-1 Rear Axle...............................................................................T3-7-13
Swing Reduction Gear....................................................... T3-2-2
Swing Motor.......................................................................... T3-2-3 Group 8 Travel Motor
Swing Parking Brake........................................................... T3-2-4 Outline..................................................................................... T3-8-1
Valve Unit................................................................................ T3-2-6 Rotor Section......................................................................... T3-8-3
Combination Valve.............................................................. T3-2-9 Regulator................................................................................ T3-8-4
Overload Relief Valve........................................................T3-8-14
Group 3 Control Valve Travel Brake Valve..............................................................T3-8-15
Outline..................................................................................... T3-3-1
Hydraulic Circuit.................................................................T3-3-16 Group 9 Signal Control Valve
Main Relief Valve................................................................T3-3-24 Outline..................................................................................... T3-9-1
Overload Relief Valve Pilot Port.................................................................................. T3-9-2
(with Make-Up Function)...........................................T3-3-26 Shuttle Valve.......................................................................... T3-9-6
Anti-Drift Valve....................................................................T3-3-30 Shockless Valve...................................................................T3-9-10
Regenerative Valve............................................................T3-3-32 Pump 1 and Pump 2 Flow Rate
Flow Rate Control Valve...................................................T3-3-34 Control Valves................................................................T3-9-14
Bypass Shut-Out Valve.....................................................T3-3-36 Bucket Flow Rate Control Valve
Auxiliary Flow Combiner Valve.....................................T3-3-38 Control Spool, Swing Parking Brake
Release Spool.................................................................T3-9-16
Group 4 Pilot Valve
Outline..................................................................................... T3-4-1 Group 10 Steering Valve
Operation................................................................................ T3-4-4 Outline...................................................................................T3-10-1
Steering Valve......................................................................T3-10-4
Group 5 Electric Lever Operation..............................................................................T3-10-5
Outline..................................................................................... T3-5-1 Overload Relief Valve........................................................T3-10-8
Operation................................................................................ T3-5-2 Make-Up Valve....................................................................T3-10-8
Group 6 Transmission Priority Valve........................................................................T3-10-9
Outline..................................................................................... T3-6-1 Operation........................................................................... T3-10-10
Transmission.......................................................................... T3-6-2 Relief Valve........................................................................ T3-10-14
Shift Interlock Control......................................................T3-6-10
Shock Reducing Function...............................................T3-6-12
Disconnect Device.............................................................T3-6-14
CEBT-3-1
Outline...................................................................................T3-11-1
Operation..............................................................................T3-11-2
Pilot Shut-Off Solenoid Valve.........................................T3-12-1
Transmission Changeover
Solenoid Valve...............................................................T3-12-4
Solenoid Valve.....................................................................T3-12-8
Travel Shockless Valve................................................... T3-12-12
Accumulator Charging Valve...................................... T3-12-13
Hose Rupture Valve........................................................ T3-12-18
Accumulator..................................................................... T3-12-24
Pilot Relief Valve.............................................................. T3-12-25
Group 13 Others (Undercarriage)
Swing Bearing.....................................................................T3-13-1
Center Joint..........................................................................T3-13-2
Slip Ring................................................................................T3-13-4
Cylinder.................................................................................T3-13-5
CEBT-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of transmission (9), main The main pump is a bent-axis type variable displace-
pump (pump 1 (1), pump 2 (2)), pilot pump (5) and ment axial plunger pump. Pump 1 (1) and pump 2 (2)
steering pump (6). are integrated as two units in one housing.
The engine output is transmitted to transmission (9) Pilot pump (5) and steering pump (6) are gear pumps.
via coupling (13). After being distributed by the gear, Pump delivery pressure sensors (3, 4) and pump con-
the engine power drives pump 1 (1), 2 (2), pilot pump trol pressure sensors (7, 8) are installed in order to
(5) and steering pump (6). The reduction gear ratios of control the pump and valve.
the main pump, pilot pump (5) and steering pump (6) (Refer to the SYSTEM / Control System group.)
are 1:1. Transmission (9) is lubricated with engine oil.
5 6
12
11
8
10
2 1 9
13
4 3
TCEB-03-01-004
1- Pump 1 5- Pilot Pump 8- Pump 1 Control Pressure 11 - Torque Control Solenoid

Sensor Valve
2- Pump 2 6- Steering Pump 9 - Transmission 12 - Maximum Pump 2 Flow
Rate Control Solenoid Valve
3- Pump 1 Delivery Pres- 7- Pump 2 Control Pressure 10 - Maximum Pump 1 Flow 13 - Coupling
sure Sensor Sensor Rate Control Solenoid Valve
4 - Pump 2 Delivery Pres-
sure Sensor
T3-1-1
MAIN PUMP
The main pump supplies pressure oil to actuate the
hydraulic components such as motors or cylinders.
The main pump consists of pump 1 and pump 2. Shaft
(3) is connected to each pump cylinder block (6) via
seven plungers (4). When shaft (3) is rotated with cyl-
inder block (6) together, plunger (4) oscillates in cylin-
der block (6) and hydraulic oil is drawn and delivered.
Each main pump is equipped with regulator (1) which
controls the flow rate.
6 3
4
T1V1-03-01-007
1 - Regulator 3 - Shaft 5 - Valve Plate 6 - Cylinder Block

2 - Housing 4 - Plunger
T3-1-2
Operational Principle
Engine torque is transferred to the shaft and the seven

plungers, causes the cylinder block to rotate while
sliding along the valve plate surface. The plunger os-
cillates in the cylinder block bores and alternately hy-
draulic oil is drawn and delivered.
Plunger
Valve Plate
Shaft
Cylinder Block
T105-02-03-002
T3-1-3
Increasing and Decreasing Flow Rate
Changing inclination of cylinder block (3) causes the
plunger (2) stroke to increase or decrease depending
on the slant angle in order to control the main pump
flow rate. Up-down movement of servo piston (6)
changes inclination of cylinder block (3). Servo piston
(6) is interlocked with valve plate (4) via pin (5). The
one end of cylinder block (3) is kept in contact with
the surface of valve plate (4) and slides along it.
Maximum Displacement Angle:
3
α
T105-02-03-021
Minimum Displacement Angle (Operable Limit Angle): 5
6 4 2 T1V1-03-01-008
T105-02-03-022
2 - Plunger 4 - Valve Plate 5 - Pin 6 - Servo Piston

3 - Cylinder Block
T3-1-4
(Blank)
T3-1-5
REGULATOR
The regulator controls the main pump flow rate in re-
1 3 2 4
sponse to the various command signal pressures so
that the pump driving power does not exceed the en- Dr
gine power. Pump 1 and pump 2 are provided with one 5
regulator for each. The major parts of regulator are
spring (1), sleeve A (2), sleeve B (8), spool A (3), spool Pi
B (7), piston (4), load piston 1 (5), load piston 2 (6),
Pd1 Air
inner spring (9) and outer spring (10). According to the Bleeding
various command signal pressures, the regulator Circuit
Pps
opens or closes the circuit to servo piston (11), the Dr
inclination of cylinder block (12) is changed and the Pd2
pump flow rate is controlled.
Dr
9, 10
NOTE: Pilot oil pressure is constantly supplied in 6 8 7
the smaller chamber side of servo piston Pg
(11). 11 13 T1V1-03-01-005
Increase Decrease
Cylinder Block Inclination
Pd1 -Pump 1 Delivery Pres- Pi - Pump Control Pressure

sure
Pd2 -Pump 2 Delivery Pres- Pps -Torque Control Pressure
sure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)
1- Spring 8- Sleeve B
2- Sleeve A 9- Inner Spring
3- Spool A 10 - Outer Spring
4- Piston 11 - Servo Piston
5- Load Piston 1 12 - Cylinder Block
6- Load Piston 2 13 - Link
7- Spool B
T3-1-6
1 2 3 4
5 6 7 8 9 10 T1V1-03-01-009
13
12
11
T1V1-03-01-007
1- Spring 5- Load Piston 1 8 - Sleeve B 11 - Servo Piston

2- Sleeve A 6- Load Piston 2 9 - Inner Spring 12 - Cylinder Block
3- Spool A 7- Spool B 10 - Outer Spring 13 - Link
4- Piston
T3-1-7
Regulator Control Function
The regulator has the following four control functions.
• Control by Pump Control Pressure

When a control lever is operated, the pump flow
rate control valve in signal control valve regulates Flow
Rate (Q)
pump control pressure Pi in response to the lever
stroke. When the regulator receives pump control
pressure Pi, the regulator controls the pump delivery
flow rate in proportion to pump control pressure Pi.
When a control lever is operated, pump control
pressure Pi increases and the regulator increases
the pump delivery flow rate. When the control lever
is returned to neutral, pump control pressure Pi de-
creases and the regulator decreases the pump de- 0 Pump Control Pressure (Pi)
livery flow rate.
• Control by Own or Opponent Pump Delivery Pres-

sure
The regulator receives own pump delivery pressure
Pd1 and opponent pump delivery pressure Pd2 as
control signal pressures. If the two average pres-
Flow
sures increase over the set P-Q line, the regulator Rate (Q)
Pressure Increase
reduces both pump delivery flow rates and the total Flow Rate Decrease
pump output is returned to the set P-Q line. Thereby,
the engine is protected from being overloaded. As
the P-Q line has been designated in order to jointly
regulate both pump operations, both pump delivery
flow rates are regulated almost equally to each other.
Accordingly, although the higher-pressure side
pump is loaded more than the lower-pressure side
pump, the total pump output matches with the en- 0 Pressure (P)
gine output. (Total Output Control)
• Control by Pilot Pressure from Torque Control So-

lenoid Valve
The main controller (MC) operates based on both Flow
Rate (Q)
the engine target speed input data and actual speed
information signals and outputs the signals to the
torque control solenoid valve. In response to the
signals from MC, the torque control solenoid valve
delivers torque control pilot pressure Pps to the
regulator. When receiving pilot pressure Pps, the
regulator reduces the pump delivery flow rate.
(Speed Sensing Power Decrease Control: Slow
Speed Torque Increase Control) 0 Pressure (P)
T3-1-8
• Control by Pilot Pressure from Maximum Pump

Flow Rate Limit Control Solenoid Valve Flow Rate
(Q)
When the main controller (MC) receives the signals
from the work mode (attachment mode) and pres-
sure sensor [auxiliary], MC sends the signals to the
maximum pump flow rate limit control solenoid valve.
In response to the signals from MC, the maximum
pump flow rate limit control solenoid valve reduces
pump control pressure Pi. Therefore, the upper limit
pump delivery flow rate is limited. (Pump Flow Rate
Limit Control) 0 Pressure (P)
Maximum Flow Rate
Flow Rate Upper Limit

(Q) Flow Rate
0 Pressure (P)
Dr
Pi
Pd2 Air
Bleeding
Circuit
Pps
Dr
Pd1
Pg
Increase Decrease T1V1-03-01-005


sure
Pd2 - Pump 2 Delivery Pres- Pps -Torque Control Pressure
sure
T3-1-9
Control by Pump Control Pressure
• Increasing Flow Rate

1. When a control lever is operated, the flow rate
Flow
control valve in signal control valve is shifted and Rate (Q)
pump control pressure Pi increases.
2. Piston (4) pushes spool A (3) and spring (1) so
that spool A (3) is moved toward direction of the
arrow.
3. By this movement, the circuit from the large
chamber of servo piston (11) is opened to the hy-
draulic oil tank.
4. As pilot pressure is always routed into the small
chamber of servo piston (11), servo piston (11) is 0 Pump Control Pressure (Pi)
moved toward direction of the arrow. Then, the
cylinder block is rotated in the maximum inclina-
tion direction and the pump delivery flow rate in-
creases. 1 3 2 4
5. The movement of cylinder block is transmitted to
sleeve A (2) via link (13). Sleeve A (2) is moved in Dr
the same direction as spool A (3).
6. When sleeve A (2) is moved by the same stroke
as spool A (3), the open part between spool A (3) Pi
and sleeve A (2) is closed and the circuit from Air
large chamber of servo piston (11) to the hydrau- Pd1 Bleeding
lic oil tank is closed. Therefore, servo piston (11) Circuit
Pps
is stopped and the flow rate increasing operation Dr
is completed. Pd2
Dr
Pg
11 13 T1V1-03-01-005
Increase Decrease
1 - Spring 4 - Piston
2 - Sleeve A 11 - Servo Piston
3 - Spool A 13 - Link

sure
sure
T3-1-10
To Hydraulic Primary Pilot

1 Oil Tank Pressure 2 3 4 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-010

1 Oil Tank Pressure 2 3 4
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-011
1- Spring 3 - Spool A 11 - Servo Piston 13 - Link
2- Sleeve A 4 - Piston
T3-1-11
• Decreasing Flow Rate
1. When a control lever is returned, the flow rate
control valve in signal control valve is returned Flow
and pump control pressure Pi decreases. Rate (Q)
2. Piston (4) and spool A (3) are pushed by spring
(1) so that spool A (3) is moved toward direction
of the arrow.
3. Pilot pressure is also routed to the large chamber
of servo piston (11).
4. Due to the difference in diameter between the
large and small chambers, servo piston (11) is
moved toward direction of the arrow. Therefore, 0 Pump Control Pressure (Pi)
the cylinder block is rotated in the minimum incli-
nation direction and the pump delivery flow rate 1 3 2 4
decreases.
5. The movement of cylinder block is transmitted to Dr
sleeve A (2) via link (13). Sleeve A (2) is moved in
6. When sleeve A (2) is moved by the same stroke Pi
as spool A (3), the open part between sleeve A (2)
Air
and spool A (3) is closed and pilot pressure to Pd2
Bleeding
servo piston (11) is blocked. Therefore, servo Circuit
Pps
piston (11) is stopped and the flow rate decreas- Dr
ing operation is completed. Pd1
Pg
11 13 T1V1-03-01-005
Increase Decrease

sure
sure
T3-1-12

1 Oil Tank Pressure 2 3 4
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-012
Oil Tank Pressure
1 2 3 4 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-013
1- Spring 3- Spool A 11 - Servo Piston 13 - Link

2- Sleeve A 4- Piston
T3-1-13
Control by Own or Opponent Pump Delivery
Pressure

1. When the pump is loaded by operating any of the
control levers, either pump 1 delivery pressure Flow
Rate (Q)
Pd1 or pump 2 delivery pressure Pd2 increases.
(During operation, pump control pressure Pi is
kept increased.)
2. Load piston 2 (6) pushes spool B (7), inner spring
(9) and outer spring (10). Spool B (7) moves to-
ward direction of the arrow.
3. Due to the movement of spool B (7), pilot pres-
sure is routed to the large chamber of servo pis-
ton (11). 0 Pressure (P)
large and small chambers, servo piston (11)
moves toward direction of the arrow. The cylinder Dr
block is rotated in the minimum inclination direc-
tion and the pump delivery flow rate decreases.
Pi
sleeve B (8) via link (13). Sleeve B (8) is moved in
the same direction as spool B (7). Pd1 Air
6. When sleeve B (8) is moved by the same stroke Bleeding
Pps Circuit
as spool B (7), the open part between sleeve B Dr
(8) and Spool B (7) is close and pilot pressure to
servo piston (11) is blocked. Therefore, servo Pd2
piston (11) is stopped and the flow rate decreas- Dr
9, 10
ing operation is completed.
6 8 7
Pg
11 13 T1V1-03-01-005
Increase Decrease
6- Load Piston 2 10 - Outer Spring

7- Spool B 11 - Servo Piston
8- Sleeve B 13 - Link
9- Inner Spring
Pd1 - Pump 1 Delivery Pres- Pi - Pump Control Pressure

sure
sure
T3-1-14
Oil Tank Pressure
6 7 8 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery 9 10
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-014

Oil Tank Pressure
6 7 8 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
9 10
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-015
6- Load Piston 2 8- Sleeve B 10 - Outer Spring 13 - Link

7- Spool B 9- Inner Spring 11 - Servo Piston
T3-1-15
• Increasing Flow Rate
1. When the pump load is reduced, either pump 1
delivery pressure Pd1 or pump 2 delivery pres-
sure Pd2 decreases. (During operation, pump
control pressure Pi is kept increased.)
Flow
2. Load piston 1 (5), load piston 2 (6) and spool B Rate (Q)
(7) are pushed by inner spring (9) and outer
spring (10). Spool B (7) moves toward direction of
the arrow.
3. Due to the movement of spool B (7), the circuit
from the large chamber of servo piston (11) is
opened to the hydraulic oil tank.
4. As pilot pressure is constantly routed in the small
chamber of servo piston (11), servo piston (11) is
moved toward direction of the arrow. The cylinder 0 Pressure (P)
block is rotated in the maximum inclination direc-
tion and the pump delivery flow rate increases.
5. The movement of cylinder block is transmitted to 3 Dr 2
5
6. When sleeve A (2) is moved by the same stroke
Pi
as spool A (3), the open part between spool A (3)
and sleeve A (2) is closed and pilot pressure to Pd1 Air
servo piston (11) is blocked. Therefore, servo Bleeding
Pps Circuit
piston (11) is stopped and the flow rate increasing Dr
operation is completed.
Pd2
Dr
9, 10
6 7
Pg
11 13 T1V1-03-01-005
Increase Decrease
2- Sleeve A 9- Inner Spring

3- Spool A 10 - Outer Spring
5- Load Piston 1 11 - Servo Piston
6- Load Piston 2 13 - Link
7- Spool B

sure
sure
T3-1-16

Oil Tank Pressure
5 6 2 3 7 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-016
5 6 Oil Tank Pressure 2 3 7 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-017
2- Sleeve A 6- Load Piston 2 9 - Inner Spring 11 - Servo Piston

3- Spool A 7- Spool B 10 - Outer Spring 13 - Link
5- Load Piston 1
T3-1-17
Control by Pilot Pressure from Torque Control
Solenoid Valve

1. When the torque control solenoid valve is acti-
vated by the signals from the main controller Flow
(MC), torque control pressure Pps increases. Rate (Q)
2. Torque control pressure Pps and either pump 1
delivery pressure Pd1 or pump 2 delivery pres-
sure Pd2 are combined and applied to load piston
1 (5).
3. Load piston 1 (5) pushes load piston 2 (6), spool
B (7) and inner spring (9) and outer spring (10).
Spool B (7) moves toward direction of the arrow.
4. Due to the movement of spool B (7), pilot pres- 0 Pressure (P)
sure is routed into the large chamber of servo
piston (11).
large and small chambers, servo piston (11) is
Dr
moved toward direction of the arrow. Therefore,
the cylinder block is rotated in the minimum incli- 5
nation direction and the pump delivery flow rate
decreases. Pi
6. The movement of cylinder block is transmitted to Air
Pd1 Bleeding
sleeve B (8) via link (13). Sleeve B (8) is moved in
Circuit
the same direction as spool B (7). Pps
7. When sleeve B (8) is moved by the same stroke Dr
as spool B (7), the open part between sleeve B Pd2
(8) and spool B (7) is closed and pilot pressure to
Dr
the large chamber of servo piston (11) is blocked. 9, 10
Therefore, servo piston (11) is stopped and the 6 8 7
flow rate decreasing operation is completed. Pg
11 13 T1V1-03-01-005
Increase Decrease
5- Load Piston 1 10 - Outer Spring

6- Load Piston 2 11 - Servo Piston
7- Spool B 13 - Link
8- Sleeve B
9- Inner Spring

sure
sure
T3-1-18

5 6 Oil Tank Pressure 7 8 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-018
5 6 Oil Tank Pressure 7 8
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-019
5- Load Piston 1 7- Spool B 9 - Inner Spring 11 - Servo Piston

6- Load Piston 2 8- Sleeve B 10 - Outer Spring 13 - Link
T3-1-19
Control by Pilot Pressure from Flow Rate Control
Solenoid Valve
Flow Rate (Q)
• Upper Limit Flow Rate Control
1. The maximum pump flow rate control solenoid
valve in pump control pressure Pi circuit is acti-
vated by the signals from the main controller
(MC).
2. The maximum pump flow rate control solenoid
valve functions as a pressure reducing valve and
pump control pressure Pi decreases.
3. Piston (4) is moved toward direction of the arrow 0 Pump Control Pressure (Pi)
by reduced pump control pressure Pi.
4. Piston (4) pushes spool A (3) and spring (1), until
Maximum Flow Rate
the force acting on piston (4) by pump control
pressure Pi becomes balanced with the spring (1) Flow Rate (Q) Upper Limit Flow Rate
force, spool A (3) moves toward direction of the
arrow.
5. As pump control pressure Pi has been reduced,
spool A (3) is moved in a shorter distance than
usual.
6. Due to the movement of spool A (3), the circuit
from the large chamber of servo piston (10) is
opened to the hydraulic oil tank.
7. As pilot pressure is constantly routed the small 0 Pressure (P)
chamber of servo piston (11), servo piston (11) is
moved toward direction of the arrow. Therefore,
the cylinder block is rotated in the maximum in-
clination direction and the pump delivery flow rate 1 3 2 4
increases.
Dr
9. When sleeve A (2) is moved by the same stroke Pi
as spool A (3), the open part between spool A (3) Air
Pd1
and sleeve A (2) is closed and pilot pressure to Bleeding
the large chamber of servo piston (11) is blocked. Pps Circuit
Dr
10. Therefore, servo piston (11) is stopped and the
flow rate increasing operation is completed. Pd2
11. Accordingly, pump control pressure Pi increases
Dr
in proportion to the stroke of control lever and the
pump delivery flow rate increases. However, as
Pg
pump control pressure Pi is regulated, the strokes
of spool A (3) and servo piston (11) are reduced 11 13 T1V1-03-01-005
so that the maximum flow rate becomes less than Increase Decrease
usual. Cylinder Block Inclination
Pd1 - Pump 1 Delivery Pres- Pi - Pump Control Pressure

sure
sure
T3-1-20

Pump Control
Oil Tank Pressure
1 2 3 4 Pressure Pi Regu-
lated by Maximum
Pump Flow Rate
Control Solenoid
Valve
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-020
Oil Tank Pressure Pump Control
1 2 3 4 Pressure Pi Regu-
lated by Maximum
Pump Flow Rate
Control Solenoid
Valve
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2 13
11
T1V1-03-01-021
1 - Spring 3 - Spool A 11 - Servo Piston 13 - Link

2 - Sleeve A 4 - Piston
T3-1-21
SOLENOID VALVE
The torque control solenoid valve and maximum pump
2 flow rate limit control solenoid valve are provided on
the pump 2 regulator. The torque control solenoid
valve supplies torque control pressure Pps to both the
pump 1 and pump 2 regulators and the pump delivery
flow rate decreases. The maximum pump 2 flow rate
limit control solenoid valve reduces the pump control
pressure to the pump 2 regulator so that the upper
limit pump delivery flow rate is limited.
The maximum pump 1 flow rate limit control solenoid
valve is provided on the pump 1 regulator.
The maximum pump 1 flow rate limit control solenoid
valve reduces the pump control pressure to the pump
1 regulator so that the upper limit pump flow rate is
limited.
Operation
1. When in neutral, port P is connected to the output
port through the notch on spool.
2. When the current flows to the solenoid from the
main controller (MC), the solenoid is magnetized
and pushes the piston.
3. Spring 1 pushes the spool so that the output port
is connected to port T through the notch on spool.
4. Thereby, pressure at the output port begins to
decrease.
5. As for the notch, spool right diameter (B) is larger
than spool left diameter (A).
6. Accordingly, when pressure at the output port be-
gins to decrease, the spool is move toward the
right side because of the force as P1 × B + S1 >
P1 × A + S2.
7. When pressure at the output port disappears and
when P1 × B + S1 becomes equal to P1 × A + S2,
the spool stops moving.
P1 : Pressure at the output port

A and B: Pressure receiving area on the spool
S1 : Spring 1 force
(pushing the spool toward the right side)
S2 : Spring 2 force
(pushing the spool toward the left side)
T3-1-22
Neutral state:
Solenoid Spring 1 Spring 2 Sleeve Spool
T176-03-01-030
A Port P Port T B
Output Port
Operating state:
Solenoid Spring 1 Spring 2 Sleeve Spool
T176-03-01-031
A Port P Port T B
Output Port
T3-1-23
PILOT PUMP, STEERING PUMP
Inlet Port
1
Drive gear (1) is driven by the engine via the transmis-
sion which in turn rotates driven gear (2) as they are 2
meshed together.
1 - Drive Gear 2 - Driven Gear
Outlet Port
T137-02-03-005
PUMP DELIVERY PRESSURE SENSOR

This sensor detects the pump delivery pressures,
which are used in order to control various operations.
When oil pressure is applied to diaphragm (6), dia-
phragm (6) is deformed. The deformation of dia-
phragm (6) is detected as electrical signals. T157-02-03-010
3 4 5 6
3- Ground 5- Power Source (5V)
4- Output 6- Pressure Receiving Area
(Diaphragm)
PUMP CONTROL PRESSURE SENSOR

This sensor detects the pump control pressures,
which are used in order to control various operations.
When oil pressure is applied to diaphragm (7), dia-
phragm (7) is deformed. The deformation of dia-
phragm (7) is detected as electrical signals.
7- Pressure Receiving Area 9- Output

7 8 9 10
(Diaphragm)
T176-03-01-023
8 - Ground 10 - Power Source (5V)
T3-1-24
OUTLINE
The swing device consists of the valve unit, the swing The combination valve is provided for the main circuit
motor and the swing reduction gear. in swing motor.
The valve unit prevents the cavitation and overloads in The combination valve reduces shock when the swing
the swing circuit. brake is applied and also prevents aftershock.
The swing motor is a swash-plate type axial plunger
motor (with built-in swing parking brake), which is
driven by pressure oil from the pump, and the rotation
is transmitted to the swing reduction gear.
The swing reduction gear turns the swing motor with
large torque at the slow speed and swings the
upperstructure.
Valve Unit
Swing Motor
Swing Reduction Gear
TCEB-03-02-001
T3-2-1
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary Shaft (5) is engaged with the internal gear of swing
reduction gear. bearing fixed to the undercarriage in order to swing the
Ring gear (3) is monolithically built with the housing upperstructure.
bolted to the upperstructure and does not allow to
rotate.
Shaft (1) of the swing motor turns first stage sun gear
(10), whose turning torque is transmitted to second
stage sun gear (8) through first stage planetary gear
(2) and first stage carrier (9).
Second stage sun gear (8) turns shaft (5) through
second stage planetary gear (4) and second stage
carrier (7).
Swing Motor
10 2
9 3
4
8
5
TCGB-03-02-001
1 - Shaft (Swing Motor) 4- Second Stage Planetary 7- Second Stage Carrier 9- First Stage Carrier
Gear
2 - First Stage Planetary Gear 5 - Shaft 8- Second Stage Sun Gear 10 - First Stage Sun Gear
3 - Ring Gear 6 - Housing
T3-2-2
SWING MOTOR
The swing motor consists of swash plate (9), rotor (12), When pressure oil is supplied from the pump, plunger
valve plate (13), housing (11) and swing parking brake (6) is pushed. Shoe (10) at the top of plunger (6) slides
(springs (1), brake pistons (2), plate (3), friction plate over swash plate (9) so that rotor (12) rotates.
(5) and swing parking brake selection valve (4)). The top of shaft (8) is splined to the first stage sun
Shaft (8) is splined to rotor (12) into which plunger (6) gear of swing reduction gear. Therefore, the rotation of
is inserted. shaft (8) is transmitted to the swing reduction gear.
1
13
2
12 3
4
11
5
10
6
9 7
T1V1-03-02-008
1- Spring 5 - Friction Plate 8 - Shaft 11 - Housing

2- Brake Piston 6 - Plunger 9 - Swash Plate 12 - Rotor
3- Plate 7 - Retainer 10 - Shoe 13 - Valve Plate
4- Swing Parking Brake Selection
Valve
T3-2-3
SWING PARKING BRAKE
The swing parking brake is a wet type multi-plate disc
brake and a negative mechanism that releases the
brake when brake release pressure acts on the brake
piston chamber.
The brake release pressure is supplied from the pilot
pump only when either swing, front attachment,
positioning or assist (optional) is operated.
In other cases (including engine stopping), the brake
release pressure returns to the hydraulic oil tank, so
that the brake is applied automatically by the spring.
When Brake is Released When Brake is Applied

1. The swing or front attachment is operated, the 1. When the swing or front attachment control lever
swing parking brake release spool in signal is returned to neutral, the swing parking brake
control valve is shifted. In addition, the positioning release spool in signal control valve is returned to
or assist (optional) is operated, the swing parking neutral. In addition, the positioning pedal or assist
brake release solenoid valve is shifted. switch (optional) is returned to neutral, the swing
2. Then, pilot pressure from the pilot pump is parking brake release solenoid valve is OFF.
supplied to port SH. 2. Then, pilot pressure to port SH disappears.
3. Pilot pressure to port SH pushes to open check 3. Check valve (4) is closed and the brake release
valve (4) and acts on brake piston chamber (5). pressure through orifice (3) is released to the
4. As a result, as brake piston (2) is pushed upward, swing motor housing.
plate (7) and friction plate (6) are freed and the 4. As a result, the force of spring (1) acts on friction
brake is released. plate (6), which is engaged with the external
circumference of rotor (8), and on plate (7), which
is engaged with the inside of motor housing
through brake piston (2). Thus, the external
circumference of rotor (8) is secured with friction
force.
When the engine stops, the brake is applied
automatically as pressure is not supplied to port
SH.
T3-2-4
8
3
7 4
Port SH
(Brake: Released)
6
5
T178-03-02-003
1- Spring 3 - Orifice 5- Brake Piston Chamber 7 - Plate

2- Brake Piston 4 - Check Valve 6- Friction Plate 8 - Rotor
T3-2-5
VALVE UNIT
The valve unit consists of make-up valve and relief
valve.
The make-up valve prevents cavitation in the circuit,
and the relief valve prevents surge pressure and Relief valve
overloads in the circuit.
Make-Up Valve
Make-Up Valve
During swing stopping operation, the swing motor is
driven by the inertial force of swing frame. The swing
motor is turned forcibly in excess of oil pressure from
the pump, so that cavitation may be generated in the
motor. Port M
In order to avoid this cavitation, when pressure in the
swing circuit becomes lower than that in the return
Control Valve
circuit (port M), the poppet opens to draw hydraulic oil
and compensates the lack of oil feed.
T107-02-04-013
Control Valve
Poppet
Make-Up Valve Make-Up Valve
Port M
T1V1-03-02-011
Relief Valve
T3-2-6
Relief Valve
During starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the set-pressure.
• Low Pressure Relief Operation (Shockless • High Pressure Relief Operation (Overload
Function): Prevention):
1. Pressure at port HP (swing circuit) is routed to oil 1. After the piston is moved to full stroke, the spring
chamber C through the poppet orifice. is compressed so that the circuit pressure
2. Pressure oil in oil chamber C is further routed to becomes the set-pressure.
oil chambers A and B via passages A and B 2. If pressure at port HP increases more than the
respectively. spring set-pressure, the poppet is unseated and
3. The pressure receiving area in oil chamber B is pressure oil flows to port LP.
larger than oil chamber A so that the piston moves 3. When pressure at port HP is reduced to the
to the left. specified level, the poppet is seated by the spring
4. As long as the piston keeps moving, a pressure force.
difference is developed between the front and the
rear of poppet by the orifice. When this pressure
difference is increased more than spring force,
the poppet is unseated, pressure oil flows to port
LP.
5. When the piston is moved to full stroke, the
pressure difference between the front and the
rear of poppet disappears and the poppet is
seated.
Poppet Orifice Spring Passage A Passage B Piston
HP
LP
Oil Chamber C Oil Chamber B T178-03-02-005
Oil Chamber A
T3-2-7
(Blank)
T3-2-8
COMBINATION VALVE
The combination valve is provided for the main circuit
in swing motor.
As the combination valve relieves swing brake pres-
sure (aftershock pressure) with the control lever re-
leased to the circuit in opposite side (low-pressure
side), the dampener valve reduces the shock when
applying the swing brake and prevents the aftershock.
Combination Valve
TCEB-03-02-003
T3-2-9
Operation
• Output Curve: Between A and B (When relieving)

1. When releasing the control lever, the spool in
control valve moves to the neutral position. As the Pressure at Port AM
swing motor rotates due to the inertia force of
machine, pressure in the circuit at port BM (return Pressure (P)
side) increases momentarily and operates the
swing relief valve.
2. Pressure oil from port BM acts on combination
valves (A, B) respectively. A B CD E
• Operation of Combination Valve (A): Time (T)

3. Pressure oil acting on combination valve (A)
T1V1-03-02-001
opens ball (2) and flows to chamber N through
poppet (1).
4. When pressure in chamber N is larger than
spring (4) force and spring (7) force (pressure in Pressure at Port BM
chamber N > spring (4) force + spring (7) force),
piston (5) tries to move to the left. However, pis- Pressure (P) With Combina-
A B tion Valve
ton (5) is blocked by the plug and cannot move. C
5. Plunger (3) and poppet (1) pushes springs (4, 7) D
and move to the right in union. E
This state continues until pressure at port BM be-
gins to decrease (output curve: between B and
C). Time (T)
Without Combi-
• Operation of Combination Valve (B): nation Valve
T1V1-03-02-002
6. Pressure oil acting on combination valve (B) flows

to the spring (4) chamber through the inner pas-
sage.
7. When pressure in spring (4) chamber is larger
than spring (4) force and spring (7) force (pres-
sure in spring (4) chamber > spring (4) force +
spring (7) force), plunger (3), piston (5) and pop-
pet (1) compress springs (4, 7) and move to the
left in union.
This state continues until pressure at port BM de-
creases (output curve: between C and D).
T3-2-10
Swing Motor
AM BM
6 7
Plug Chamber N
Combination Valve (A)

5 4 3 2 Chamber M 1
Chamber M
1 2 3 4 5
Combination Valve (B)
Chamber N
7 6
Control Valve
T1V1-03-02-013
1 - Poppet 3 - Plunger 5 - Piston 7 - Spring

2 - Ball 4 - Spring 6 - Orifice
T3-2-11
• Output Curve: Between B and C (Pressure begins
to decrease)
When the swing motor rotation due to the inertia force
of machine is reduced, pressure at port BM decreases.
At this time, combination valve (A) functions as the
following.
• Operation of Combination Valve (A): Pressure at Port AM

1. When pressure at port BM decreases, pressure
Pressure (P)
acting to chamber N also decreases.
2. When pressure in chamber N becomes smaller
than the spring (4) force, the spring (4) force
moves plunger (3) to the left.
3. At the same time, poppet (1) is pushed to the left A B CD E
by the spring (7) force.
4. As the pressure difference due to orifice (6) ap- Time (T)
pears, pressure in chamber M increases. T1V1-03-02-001
5. Therefore, poppet (1) moves to the left more
slowly.
6. Consequently, the clearance between poppet (1)
and plunger (3) appears. Pressure oil from port Pressure at Port BM
BM flows to port AM through the clearance be- Pressure (P) With Combina-
tween poppet (1) and plunger (3). A B tion Valve
7. As combination valve (A) makes pressure oil in C
port BM (high-pressure) flow to port AM D
E
(low-pressure), pressure increase at the
high-pressure side is controlled and aftershock
pressure is reduced.
This state continues until aftershock pressure at Time (T)
port AM appears (output curve: between D and Without Combi- T1V1-03-02-002
E). nation Valve
T3-2-12
Swing Motor
AM BM
6 7
Chamber N

5 4 3 2 Chamber M 1
1 Chamber M 2 3 4 5
Chamber N
7 6
Control Valve
T1V1-03-02-014
1- Poppet 3- Plunger 5- Piston 7- Spring

2- Ball 4- Spring 6- Orifice
T3-2-13
• Output Curve: Between C and D (Pressure at port
BM decreases)
When the swing motor rotation is reduced more,
pressure at port BM decreases more. At this time,
combination valve (B) functions as the following.
• Operation of Combination Valve (B):

1. When pressure at port BM decreases more, Pressure at Port AM
pressure acting on the spring (4) chamber in
Pressure (P)
combination valve (B) also decreases.
2. When pressure in the spring (4) chamber be-
comes smaller than the spring (4) force, the
spring (4) force moves plunger (3) to the right.
3. At the same time, poppet (1) is pushed to the A B CD E
right by the spring (7) force.
4. As the pressure difference due to orifice (6) ap- Time (T)
pears, pressure in chamber M increases. T1V1-03-02-001
5. Therefore, poppet (1) moves to the right more
slowly.
6. Consequently, the clearance between poppet (1)
and plunger (3) appears. Pressure oil from port Pressure at Port BM
BM acts on poppet (1) and ball (2).
Pressure (P) With
7. Therefore, ball (2) is pushed by poppet (1). Pop- A B Combination
pet (1) and ball (2) compress spring (7) and move C Valve
to the left in union. D
E
8. As combination valve (B) functions like this, and
when aftershock pressure appears pressure is re-
lieved promptly.
This state continues until aftershock pressure at Time (T)
port AM appears (output curve: between D and Without T1V1-03-02-002
E). Combination
Valve
T3-2-14
Swing Motor
AM BM
6 7
Chamber N

5 4 3 2 Chamber M 1
1 Chamber M 2 3 4 5
Chamber N
7 6
Control Valve
T1V1-03-02-015
1- Poppet 3 - Plunger 5 - Piston 7 - Spring

2- Ball 4 - Spring 6 - Orifice
T3-2-15
• Output Curve: Between D and E (During aftershock)
When the swing motor stops rotating, aftershock
pressure appears at port AM and pressure at port AM
increases. (Port AM: High Pressure, Port BM: Low
Pressure) Pressure at Port AM
At this time, combination valves (A, B) function as the
following. Pressure (P)
• Operation of Combination Valve (A):

1. Pressure oil from port AM acts on ball (2) and
poppet (1) through the inner passage. A B CD E
2. Therefore, ball (2) and poppet (1) move to the
right. Time (T)
3. As combination valve (A) functions like this, and
T1V1-03-02-001
when aftershock pressure appears, pressure is
relieved promptly.
• Operation of Combination Valve (B): Pressure at Port BM

4. Pressure oil from port AM opens ball (2) and With
Pressure (P)
flows to port BM through poppet (1). A B Combination
5. As combination valve (B) makes pressure oil from C Valve
port AM (high-pressure) flow to port BM D
(low-pressure), pressure increase at E
high-pressure side is controlled and aftershock
pressure is reduced.
Time (T)
6. Combination valves (A, B) repeat these proce- Without T1V1-03-02-002
dures and prevent aftershock of the machine. Combination
When pressures at ports AM and BM decrease Valve
completely, the combination valve stops function-
ing.
T3-2-16
Swing Motor
AM BM
Combination Valve （A）
1 2
Control Valve
T1V1-03-02-016
1- Poppet 2- Ball
T3-2-17
(Blank)
T3-2-18
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls pressure oil, flow rate, and The spool arrangements are as follows.
oil flow direction in the hydraulic circuit. 4-Spool Side: Travel, Bucket, Boom 1, Arm 2
The major parts of the control valve are the main relief 5-Spool Side: Blade/Outrigger, Auxiliary, Boom 2, Arm
valve, overload relief valve, anti-drift valve, flow rate 1, Swing
control valve, regenerative valve, auxiliary flow
combiner valve, bypass shut-out valve and spools.
The spools are operated by pilot pressure oil.
Control Valve
Travel
Bucket
Boom 1
Arm 2
Blade/Outrigger
4-Spool Side
Auxiliary
Boom 2
Arm 1
Swing
Front
5-Spool Side T16W-03-03-029
Positioning Control Valve
T1F3-03-03-018
T3-3-1
Component Layout
1 2 3 4 5 6 7 8 9 10
41
11
40
12
39
38 13
14
37
36 15
35
34 16
17
33
32
18
31 19
30
29
20
28
21
27 26 25 24 23 22
T16W-03-03-018
T3-3-2
11
4 14
41
18
35, 36
Front
38 31
T16W-03-03-030
1- Load Check Valve 12 - Make-Up Valve 22 - Load Check Valve 32 - Arm Anti-Drift Valve (Check
(Blade/Outrigger (Travel Forward Side) (Arm 2 Tandem Circuit) Valve)
Tandem Circuit)
2 - Load Check Valve 13 - Bucket Regenerative Circuit 23 - Bypass Shut-Out Valve 33 - Arm Anti-Drift Valve
(Blade/Outrigger Parallel (Selector Valve)
Circuit)
3 - Check Valve 14 - Overload Relief Valve (Bucket 24 - Check Valve (Orifice) 34 - Load Check Valve
(Main Relief Circuit) Rod Side) (Arm 2 Parallel Circuit) (Boom 2 Parallel Circuit)
4 - Main Relief Valve 15 - Overload Relief Valve (Bucket 25 - Load Check Valve (Arm 1 35 - Aux. Flow Rate Control
Bottom Side) Parallel Circuit) Valve (Poppet Valve)
5- Auxiliary Flow Combiner 16 - Load Check Valve 26 - Load Check Valve 36 - Aux. Flow Rate Control
Valve (Boom 1 Parallel Circuit) (Arm 1 Tandem Circuit) Valve (Selector Valve)
6- Check Valve 17 - Boom Regenerative Circuit 27 - Load Check Valve 37 - Overload Relief Valve
(Auxiliary Flow (Swing Circuit) (Auxiliary)
Combiner Circuit)
7- Check Valve 18 - Overload Relief Valve 28 - Arm Regenerative Valve 38 - Overload Relief Valve
(Main Relief Circuit) (Boom Bottom Side) (Selector Valve) (Auxiliary)
8- Check Valve (Flow 19 - Overload Relief Valve 29 - Arm Regenerative Circuit 39 - Load Check Valve
Combiner Circuit) (Boom Rod Side) (Bucket Parallel Circuit)
9- Bucket Flow Rate 20 - Boom Anti-Drift Valve 30 - Overload Relief Valve 40 - Overload Relief Valve
Control Valve (Selector (Check Valve) (Arm Bottom Side) (Blade/Outrigger Rod Side)
Valve)
10 - Bucket Flow Rate 21 - Boom Anti-Drift Valve 31 - Overload Relief Valve 41 - Overload Relief Valve
Control Valve (Poppet (Selector Valve) (Arm Rod Side) (Blade/Outrigger Bottom
Valve) Side)
11 - Make-Up Valve
(Travel Reverse Side)
T3-3-3
1 2 3 4 5 6 7 8 9 10
41
11
40
12
39
38 13
14
37
36 15
35
34 16
17
33
32
18
31 19
30
29
20
28
21
27 26 25 24 23 22
T16W-03-03-018
T3-3-4
19 15 9, 10 12 39
23
30 37 40 5
Front T16W-03-03-031
1- Load Check Valve 12 - Make-Up Valve 22 - Load Check Valve 32 - Arm Anti-Drift Valve
(Blade/Outrigger (Travel Forward Side) (Arm 2 Tandem Circuit) (Check Valve)
Tandem Circuit)
Circuit)
3 - Check Valve 14 - Overload Relief Valve 24 - Check Valve (Orifice) 34 - Load Check Valve
(Main Relief Circuit) (Bucket Rod Side) (Arm 2 Parallel Circuit) (Boom 2 Parallel Circuit)
4 - Main Relief Valve 15 - Overload Relief Valve 25 - Load Check Valve (Arm 1 35 - Aux. Flow Rate Control
(Bucket Bottom Side) Parallel Circuit) Valve (Poppet Valve)
Combiner Circuit)
Valve)
Valve) Side)
11 - Make-Up Valve
T3-3-5
1 2 3 4 5 6 7 8 9 10
41
11
40
12
39
38 13
14
37
36 15
35
34 16
17
33
32
18
31 19
30
29
20
28
21
27 26 25 24 23 22
T16W-03-03-018
T3-3-6
A B
C
C
D
D
E E
F F
G G
H
H
A B T16W-03-03-002
Cross Section A-A 8 Cross Section B-B

13
Travel
Blade/
Outrigger Bucket
Auxiliary
Boom 2 Boom 1
Arm 2
Arm 1
Swing
28 17
TCHB-03-03-001
29 T16W-03-03-008
Tandem Circuit)
Circuit)
Combiner Circuit)
Valve)
Valve) Side)
11 - Make-Up Valve
T3-3-7
1 2 3 4 5 6 7 8 9 10
41
11
40
12
39
38 13
14
37
36 15
35
34 16
17
33
32
18
31 19
30
29
20
28
21
27 26 25 24 23 22
T16W-03-03-018
T3-3-8
Cross Section C-C Cross Section D-D
Blade/ Travel
Outrigger
41 11
4 7
5
8 6 39
40 12 T16W-03-03-013
T16W-03-03-014
Tandem Circuit)
Circuit)
Combiner Circuit)
Valve)
Valve) Side)
11 - Make-Up Valve
T3-3-9
1 2 3 4 5 6 7 8 9 10
41
11
40
12
39
38 13
14
37
36 15
35
34 16
17
33
32
18
31 19
30
29
20
28
21
27 26 25 24 23 22
T16W-03-03-018
T3-3-10
Cross Section E-E Cross Section F-F
Boom 2 Boom 1
Auxiliary Bucket
38 14
31 21
20
35 10 34
16
36 9
17
T16W-03-03-012
T16W-03-03-011
37 15 19
Tandem Circuit)
Circuit)
Combiner Circuit)
Valve)
Valve) Side)
11 - Make-Up Valve
T3-3-11
1 2 3 4 5 6 7 8 9 10
41
11
40
12
39
38 13
14
37
36 15
35
34 16
17
33
32
18
31 19
30
29
20
28
21
27 26 25 24 23 22
T16W-03-03-018
T3-3-12
Cross Section G-G Cross Section H-H
Arm 1 Arm 2 Swing
33 18
28
32
22
27
25
26
24
29 23
T16W-03-03-009
T16W-03-03-010
30
Tandem Circuit)
Circuit)
Combiner Circuit)
Valve)
Valve) Side)
11 - Make-Up Valve
T3-3-13
Layout of Positioning Control Valve (2-Piece Boom)
2
3
Positioning TCEB-03-03-001
Control Valve
T3-3-14
Cross Section X-X

X
4
T178-03-03-070
T198-03-03-003
X
1- Load Check Valve 2- Load Check Valve 3- Overload Relief Valve 4- Overload Relief Valve
(Positioning Parallel Circuit) (Positioning Tandem Circuit) (Positioning: Bottom Side) (Positioning: Rod Side)
T3-3-15
HYDRAULIC CIRCUIT
Main Circuit
Pressure oils from pump 1 and pump 2 flow to the
4-spool section and 5-spool section of the control
valve respectively.
The parallel circuit is provided in both right and left
main circuits and makes the combined operation
possible. The flow combiner circuit is provided in both
boom and arm circuits so that pressure oils from
pump 1 and pump 2 are combined during a single
operation.
The main relief valve is provided in the main circuit

(between pump and actuator). The main relief valve
works so that the pressure in main circuit does not
exceed the set pressure when the spool is in operation
(or when the control lever is in operation).
The overload relief valve is provided in the actuator
circuits (between control valve and actuator) of boom,
arm and bucket. The overload relief valve prevents
surge pressure caused by external force in the
actuator circuit does not exceed the set pressure
when the spool is in neutral (with the control lever in
neutral).
The make-up valve is provided in the actuator circuit
(between control valve and actuator) of travel.
When pressure in the actuator circuit decreases, the
make-up valve refills oil from the hydraulic oil tank and
prevents cavitation.
T3-3-16
Blade/Outrigger
Cylinder Main Relief 4-Spool Section Travel Motor
Valve Parallel Circuit
5-Spool Section 4-Spool Section
Make-Up
Valve
Overload
Relief Valve Bucket
Cylinder
Optional
Attachment
Arm Cylinder
Overload Relief
Valve
Overload
Relief Valve
Swing Motor
Boom
Cylinder
Flow Combiner
5-Spool Section Circuit
Parallel Circuit
Pump 2 Pump 1
T16W-03-03-027
T3-3-17
Positioning Circuit (2-Piece Boom)
When operating boom lower and positioning, pressure

oil from each pilot valve flows to the bypass shut-out
valve through the shuttle valve. Therefore, the bypass
shut-out valve is switched.
• During Single Operation:
As the bypass shut-out valve is switched, the
neutral circuit in 4-spool section of control valve is
blocked and pressure oil from pump 1 is supplied
to the positioning control valve.
• During Combined Operation:
When operating combined operation of boom,
arm or bucket and positioning, the neutral circuit
in 4-spool section is blocked by each spool.
Pressure oil from pump1 is supplied to the
positioning control valve through the 4-spool
section parallel circuit.
The overload relief valve is provided in the actuator
circuit (between positioning control valve and actuator)
of positioning. The overload relief valve prevents surge
pressure caused by external force in the actuator
circuit does not exceed the set pressure when the
spool is in neutral (with the control lever in neutral).
T3-3-18
4-Spool Section
Parallel Circuit
4-Spool Section
Neutral Circuit
Pilot Pressure
from Attachment
or Positioning
Bypass
Shut-Out Valve
Positioning
Cylinder
Hydraulic
Oil Tank
Pump 1
Overload Relief Positioning TCEB-03-03-002

Valve Control Valve
T3-3-19
Pilot Control Circuit External Pilot Pressure Circuit
Pressure oil (indicated with numbers) from the pilot • The arm regenerative valve is shifted by pilot
valve acts to the spool in control valve in order to pressure from solenoid valve unit (SC).
move the spool. • The bucket flow rate control valve is shifted by
In the following operations, pressure oil moves the pressure oil from the bucket flow rate control
spool and acts to the switch valves as follows. valve spool in signal control valve.
• During arm roll-in (4) operation, pressure oil • The auxiliary flow combiner valve and bypass
moves the arm spool and shifts the spool in shut-out valve are shifted by pressure oil from the
switch valve of arm anti-drift valve. auxiliary flow combiner control solenoid valve.
• During boom lower (2) operation, pressure oil (Only the machine equipped with the optional
moves the boom spool and shifts the spool in parts)
switch valve of boom anti-drift valve. • The auxiliary flow rate control valve is shifted by
pilot pressure from the auxiliary flow rate control
The air bleed circuit is located on the upper section of solenoid valve (optional). (Only the machine
control valve and bleeds any air trapped inside equipped with the optional parts)
automatically.
NOTE: In general, the auxiliary flow combiner
valve and auxiliary flow rate control valve
are routed to the drain circuit.
The auxiliary flow rate control solenoid
valve is equipped for only the machine
equipped with the optional parts.
T3-3-20
Pilot Pressure from Auxiliary Flow
Pilot Pressure from
Combiner Control Solenoid Valve
Front Attachment,
(Only machine equipped
Travel Pilot Pressure from
with optional parts)
Auxiliary Flow Bucket Flow Rate
Combiner Valve Control Valve Spool in
Air Bleed Circuit
11
9 12
Auxiliary Flow 10
Rate Control Bucket Flow Rate
Valve Control Valve
7
Pilot Pressure 8
13
from Auxiliary 14
Flow Rate
Control Solenoid
Valve
(Only machine
equipped with
optional parts) 2
1 1
Arm Anti-Drift Boom Anti-Drift
Valve Valve
4
Pilot Pressure 3
from Solenoid 3
Valve Unit
(SC)
Pilot Pressure
from Auxiliary
Flow
Combiner
Control
Arm Solenoid
Regenerative Valve
Valve 5 6
Bypass
Shut-Out Valve
T16W-03-03-022
1- Boom Raise 5- Left Swing 9- Blade/Outrigger Raise 13 - Auxiliary
2- Boom Lower 6- Right Swing 10 - Blade/Outrigger Lower 14 - Auxiliary
3- Arm Roll-Out 7- Bucket Roll-In 11 - Travel Reverse
4- Arm Roll-In 8- Bucket Roll-Out 12 - Travel Forward
T3-3-21
Pilot Control Circuit (2-Piece Boom) External Pilot Pressure Circuit (2-Piece Boom)
Pressure oil (indicated with numbers) from the pilot • The arm regenerative valve is shifted by pilot
valve acts to the spool in control valve in order to pressure from solenoid valve unit (SC).
move the spool. • The bucket flow rate control valve is shifted by
In the following operations, pressure oil moves the pilot pressure from the bucket flow rate control
spool and acts to the switch valves as follows. valve spool in signal control valve.
• During arm roll-in (4) operation, pressure oil • The auxiliary flow combiner valve and bypass
moves the arm spool and shifts the switch valve shut-out valve are shifted by pressure oil from the
in arm anti-drift valve and the spool in hose auxiliary flow combiner control solenoid valve.
rupture valve (arm). (Only the machine equipped with the optional
• During boom lower (2) operation, pressure oil parts)
moves the boom spool and shifts the switch valve • The auxiliary flow rate control valve is shifted by
in boom anti-drift valve and the spool in hose pilot pressure from the auxiliary flow rate control
rupture valve (boom). solenoid valve (optional). (Only the machine
• During positioning raise (31) or lower (32) equipped with the optional parts)
operation, pressure oil moves the positioning
spool and shifts the bypass shut-out valve. NOTE: In general, the auxiliary flow combiner
• During positioning lower (32) operation, pressure valve and auxiliary flow rate control valve
oil moves the spool in hose rupture valve are routed to the drain circuit.
(positioning). The auxiliary flow rate control solenoid
valve is installed to only the machine
The air bleed circuit is located on the upper section of equipped with the optional parts.
control valve and bleeds any air trapped inside
automatically.
T3-3-22
Pilot Pressure from Pilot Pressure from Auxiliary Flow
Front Attachment, Combiner Control Solenoid Valve
Travel (Only machine equipped
with optional parts) Pilot Pressure from Bucket
Auxiliary Flow Flow Rate Control Valve
Combiner Valve Spool in Signal Control
Valve
Air Bleed Circuit
12
11
9
Auxiliary Flow 10
Rate Control
Valve Bucket Flow Rate
Control Valve
7
Pilot Pressure 8
from Auxiliary 13
14
Flow Rate
Control Solenoid
Valve
(Only machine
equipped with
optional parts) 2
1 1
Boom Anti-Drift
Pilot Pressure Valve
from Hose
Rupture Valve
(Arm)
Pilot
Arm Anti-Drift 4 Pressure to
Valve Hose Rupture
3 Valve (Boom)
Pilot Pressure 3
from Solenoid
Valve Unit
(SC)
Pilot Pressure
from
Positioning
Solenoid
Arm
Valve
Regenerative
Valve 6
5
Bypass
Shut-Out Valve
31
32
Pilot Pressure to
Hose Rupture Valve
(Positioning)
TCEB-03-03-003
1- Boom Raise 5- Left Swing 9- Blade/Outrigger Raise 13 - Auxiliary
2- Boom Lower 6- Right Swing 10 - Blade/Outrigger Lower 14 - Auxiliary
3- Arm Roll-Out 7- Bucket Roll-In 11 - Travel Reverse 31 - Positioning Raise
4- Arm Roll-In 8- Bucket Roll-Out 12 - Travel Forward 32 - Positioning Lower
T3-3-23
MAIN RELIEF VALVE
The main relief valve prevents pressure in the main
circuit from increasing more than the set-pressure
during operations of actuators such as the motors and
the cylinders.
Thereby, oil leakage from hoses and pipe joints and
damage to the actuators are prevented.
Operation
1. The oil pressure in port HP (main circuit) acts on
the pilot poppet through orifice A in the main
poppet and orifice B in the seat.
2. When the oil pressure in port HP increases more
than the spring B set-force, the pilot poppet is
unseated, allowing the pressure oil to flow to port
LP (hydraulic oil tank) through passage A and
around the outer diameter of sleeve.
3. At this time, a pressure difference arises between
port HP and the spring chamber due to orifice A.
4. When this pressure difference increases more
than the spring A set-force, the main poppet is
unseated, causing the pressure oil in port HP to
flow to port LP.
5. Thereby, the main circuit pressure decreases.
6. When the main circuit pressure decreases more
than the specified pressure, the main poppet is
seated by spring A.
T3-3-24
When Normal:
Main Poppet Orifice A Orifice B Seat Passage A Spring B
HP
LP T176-03-03-010
Sleeve Spring Spring A Pilot Poppet
Chamber
When Relieving:
Main Poppet Orifice A Orifice B Seat Passage A Spring B
HP
LP T176-03-03-011
Sleeve Spring Spring A Pilot Poppet
Chamber
T3-3-25
OVERLOAD RELIEF VALVE (with Make-Up
Function)
The overload relief valves are provided in the boom, Make-Up Operation
arm, bucket, auxiliary, blade/outrigger and positioning 1. When pressure at port HP (actuator circuit) is
control valve circuits. The overload relief valve reduced more than port LP (hydraulic oil tank),
prevents each actuator circuit pressure from rising the sleeve is moved to the right.
excessively when the actuators are moved by external 2. Then, the hydraulic oil flows in port HP from port
loads. LP to prevent the cavitation.
In addition, when the actuator circuit pressure is 3. When pressure in port HP increases more than
reduced, draws the hydraulic oil from the hydraulic oil the specified pressure, the sleeve is closed by
tank to prevent the occurrence of cavitation (make-up spring C.
function).
NOTE: The operations of overload relief valves in

boom, arm, bucket, auxiliary,
blade/outrigger bottom side and positioning For Positioning Control Valve
control valve are same.
Accordingly, operation of the overload relief
Seat Spring C Sleeve Spring A Main Poppet
valve for the boom, the arm, and the
bucket is explained on this page. Orifice A
HP
Relief Operation
1. The oil pressure in port HP (main circuit) acts on
the pilot poppet through orifice A in the main
poppet and orifice B in the seat.
2. When the oil pressure in port HP increases more
than the spring B set-force, the pilot poppet is Passage A
Pilot Poppet Valve
unseated, allowing the pressure oil to flow to port Spring B Spring
LP (hydraulic oil tank) through passage A and Chamber LP
T198-03-03-006
around the outer diameter of sleeve.
3. At this time, a pressure difference arises between
port HP and the spring chamber due to orifice A.
4. When this pressure difference increases more
than the spring A set-force, the main poppet is
unseated, causing the pressure oil in port HP to
flow to port LP.
5. Thereby, the actuator circuit pressure is reduced.
6. When the actuator circuit pressure is reduced to
the specified pressure, the main poppet is closed
by spring A.
T3-3-26
When Normal: Passage
Main Orifice Orifice
Sleeve Make-Up Valve Seat A Spring B
Poppet A B
HP
LP T176-03-03-012
Spring
Spring C Chamber Spring A Pilot Poppet
When Relieving:
Sleeve Main Poppet Orifice A Orifice B Seat Passage A Spring B
HP
LP T176-03-03-013
Spring Spring A Pilot Poppet
Chamber
When Operating Make-Up:
Make-Up Valve
HP
LP T1F3-03-03-021
Spring C
T3-3-27
Overload Relief Valve (Blade/Outrigger Rod Side)
(with Make-Up Function)
Relief Operation Make-Up Operation

1. Pressure in port HP (actuator circuit) acts on the 1. When pressure in port HP (actuator circuit)
pilot poppet through an orifice in the piston. decreases lower than port LP (hydraulic oil tank),
2. When pressure in port HP increases more than the sleeve moves to the right.
set-force of spring B, the pilot poppet is unseated 2. Hydraulic oil flows in port HP from port LP and
and pressure oil flows to port LP (hydraulic oil cavitation is prevented.
tank) through passage A and clearance around 3. When pressure in port HP increases more than
the sleeve. the specified pressure, the sleeve is closed by the
3. At this time, a pressure difference arises between force of spring C.
port HP and the spring chamber due to the
orifice.
4. If this pressure difference increases more than
set-force of spring A, the main poppet is unseated
so that pressure oil in port HP flows to port LP.
5. Thereby, the actuator circuit pressure decreases.
6. When the actuator circuit pressure decreases to
the specified level, the piston and main poppet
are seated by the force of spring A.
T3-3-28
During Normal Operation:
Make-Up Valve Main Poppet Sleeve Spring A Passage A Spring B
HP
LP
Orifice Piston Spring Pilot Spring C T107-02-05-019
Chamber Poppet
During Relief Operation:
Main Poppet Sleeve Spring A Passage A Spring B
HP
LP
Orifice Piston Spring Pilot T178-03-03-049
Chamber Poppet
During Make-Up Operation:
Sleeve
HP
LP
Spring C T178-03-03-050
T3-3-29
ANTI-DRIFT VALVE
The anti-drift valves are located in the boom cylinder
bottom and arm cylinder rod side circuits to reduce the
cylinder drift.
NOTE: The boom and arm anti-drift valves are

identical in construction.
Boom Cylinder
Blocking Operation
1. When the control lever (the spool) is in neutral,
the anti-drift valve (selector valve) is not shifted.
2. Therefore, the pressure oil in the boom cylinder
bottom (arm cylinder rod side) is applied to the
anti-drift valve check valve via the selector valve.
3. Consequently, the check valve is seated, blocking
the return oil circuit from the cylinder so that the
cylinder drift is reduced.
Releasing Operation
1. When rolling the arm in or lowering the boom, the
T176-03-03-028
pressure oil from the pilot valve shifts the anti-drift Anti-Drift Valve Anti-Drift Valve
valve (selector valve). (Selector Valve) (Check Valve)
2. The hydraulic oil in the check valve spring To
Pressure Oil Hydraulic
chamber is returned to the hydraulic oil tank via from Pump 1 Oil Tank Boom Cylinder
the orifice in the Selector valve.
3. Accordingly, the check valve is unseated, allowing
the return oil from the boom cylinder bottom side
(arm cylinder rod side) to flow to the spool.
From Pilot
Valve
To
Hydraulic
Oil Tank
T176-03-03-029
Anti-Drift Valve Anti-Drift Valve

(Selector Valve) (Check Valve)
T3-3-30
When Blocking:
Hydraulic
Oil Tank
Boom
Cylinder
To Pilot Valve
Selector Valve
Sleeve
Spring B
Seat
Spring A
Check Valve
To Spool
TCGB-03-03-008
When Releasing:
Hydraulic
Oil Tank
Boom
Cylinder
From Pilot Valve
Selector valve
Sleeve
Spring B Pressure Oil

from Pump
Seat
Spring A
Check Valve
To Spool
TCGB-03-03-009
T3-3-31
REGENERATIVE VALVE
The regenerative valves are located in the boom lower, 3. Then, the return oil from the cylinder bottom side
arm roll-in and bucket roll-in accelerating the cylinder flows into the rod side so that the return pressure
operating speeds, preventing the cylinders from oil is regenerated, increasing the cylinder
making a pose in movement, and improving machine operating speed.
controllability. 4. When the cylinder is fully stroked or digging loads
increase, the oil pressure in the cylinder bottom
NOTE: Operational principles of each regenerative circuit decreases more than the rod side, causing
valve are almost identical. Therefore, the the check valve to seat so that regeneration is
boom regenerative valve is used as an stopped.
example.
NOTE: Arm Regenerative Valve (Selector Valve)
Operation Operation
1. When the boom is lowered, the return oil from the The arm regenerative valve (selector
cylinder bottom side (the rod side in case of the Valve) is shifted by the pilot pressure oil
arm cylinder) is routed the check valve via from solenoid valve unit (SC) so that the
anti-drift valve and hole A on the spool. (Refer to return oil circuit from the cylinder rod side
T3-3-30 as for the operation of the anti-drift to the hydraulic oil tank is blocked. (Refer
valve.) to the SYSTEM / Control system group.)
2. At this moment, when the pressure oil in the
cylinder rod side (the bottom side in case of the
arm cylinder) is lower than the bottom side, the
check valve is unseated.
Pressure Oil Regenerative Boom 1

from Pump 1 Valve Spool Boom Cylinder
Hole A
From Boom 2 Spool

(Pressure Oil from Pump 2)
Anti-Drift Valve Check Anti-Drift Valve

(Selector Valve) Valve (Check Valve)
T1F3-03-03-022
T3-3-32
When Operating:
Boom 2 Boom 1
Spool Spool
Boom
Cylinder
Anti-Drift Valve
(Check Valve)
Hole A
Check
Valve
T16W-03-03-023
T3-3-33
FLOW RATE CONTROL VALVE
The flow rate control valve is located in the bucket and NOTE: The bucket flow rate control valve restricts
auxiliary circuits. When a combined operation is made, the bucket circuit oil flow when the bucket,
the flow rate control valve restricts the oil flow so that boom raise and arm roll-in operations are
the other actuators are given priority to operate. made simultaneously. The auxiliary flow
rate control valve restricts the auxiliary
circuit oil flow when a combined operation
When bucket (auxiliary) single operation is made: with the auxiliary and other front
1. The pressure oil from pump 1 acts on the check attachment is made. The bucket flow rate
valve in the poppet via port P1. control valve is used here as an example.
2. Normally, the selector valve is kept open so that
the pressure oil from pump 1 unseats the check
valve and flows into the main spool through the
selector valve.
3. Thereby, the poppet valve is opened, allowing the
pressure oil to flow to the bucket spool. Pressure Oil
Poppet Valve from Pump 1 To Hydraulic
Oil Tank
When the combined operation of the bucket
(auxiliary), boom raise, and arm roll-in is made:
1. When the boom raise and arm roll-in functions
are operated simultaneously, the selector valve is
shifted so that the bucket flow rate control valve in
Selector
the signal control valve is shifted by the boom Bucket
Valve
Cylinder
raise pilot pressure.
2. Then, the oil pressure behind the poppet valve
increases, and the force to close the poppet valve
appears.
3. Consequently, the opening clearance of the
poppet valve is reduced so that oil flow to the
bucket spool is restricted, allowing the pressure
oil to be routed to the high-pressure side of the T176-03-03-030
boom raise circuit. Boom Raise Pilot Pressure Oil
To Hydraulic
Pressure from Pump 1
Oil Tank
Poppet Valve
Selector
Valve Bucket
Cylinder
T176-03-03-031
T3-3-34
When Normal Operation:
Poppet Check Valve Spring A

Spring B
To Main Spool
To Hydraulic Oil
Tank
Pressure Oil P1 Selector

from Main Valve
Pump 1
Boom Raise
Pilot Pressure
To Main Spool
T176-03-03-019
Plug 2
When Oil Flow is Restricted:
Poppet Check Valve Spring A

Spring B
To Main Spool
To Hydraulic
Oil Tank
Selector
Pressure Oil
Valve
from Main
Pump 1 P1
Boom Raise
Pilot Pressure
To Main Spool
T176-03-03-020
Plug 2
T3-3-35
BYPASS SHUT-OUT VALVE
The bypass shut-out valve is located after the 4-spool
side circuit. When the blade/stabilizer is operated, the When Neutral:
bypass shut-out valve is shifted, blocking the neutral Spring Spool 4-Spool Side
passage in the 4-spool side circuit. Neutral Circuit
Operation
1. When the control levers are in neutral, the bypass
shut-out valve is not shifted. The pressure oil
from pump 1 returns back to the hydraulic oil tank
through the neutral passage in the 4-spool side
circuit.
2. When the blade/stabilizer is operated, the pilot
pressure from the pilot valve is routed to port SJ Return to
so that the bypass shut-out valve is shifted. Hydraulic
Oil Tank
3. Consequently, the neutral passage in the 4-spool
side circuit is blocked, allowing the pressure oil
from pump 1 to flow to the auxiliary control valve.
Port SJ T176-03-03-022
When Operating:
Spring Spool 4-Spool Side
Neutral Circuit
Return to
Hydraulic
Oil Tank
Port SJ T176-03-03-024
T3-3-36
Pilot Pressure from

Auxiliary and
Positioning
Bypass Shut-Out
SJ
Valve
Pump 1
Control Valve
T3-3-37
AUXILIARY FLOW COMBINER VALVE
Auxiliary Flow Combiner Valve
The auxiliary flow combiner valve is located before the When Neutral:
4-spool side circuit. The auxiliary flow combiner valve Port SN
operates differently depending on whether a single or
combined operation is made. Spring B
To Auxiliary
Spool
NOTE: The auxiliary flow combiner valve operates Check Valve
only on the machines equipped with the
optional parts. Normally, port SN and port Pressure Oil
from Pump 1
SM are connected to the hydraulic oil tank.
Signal Operation
When the single front attachment operation is made,
the aux. flow combiner valve allows the pressure oil Spool
from pump 1 to flow to the aux. spool together with the
pressure oil from pump 2, increasing the attachment
operating speed.
1. When the front attachment is operated, the pilot Spring A

pressure oil is routed to port SM and port SJ so
that both the aux. flow combiner valve and
Port SM
bypass shut-out valve are shifted.
2. When the bypass shut-out valve is shifted, the
neutral circuit in the 4-spool side is blocked.
3. At this moment, the aux. flow combiner valve is
also shifted, allowing the pressure oil from the T176-03-03-021
4-spool side (pump 1) to flow to the aux. spool via
the aux. flow combiner valve. When Operating:
4. Therefore, pressure oil from both pumps 1 and 2 Port SN
is supplied to the attachment, increasing
Spring B
attachment operation speed.
To Auxiliary
Spool Check Valve
Pressure Oil
from Pump 1
Spool
Spring A
Port SM
T176-03-03-023
T3-3-38
Signal Control Pilot Pressure Oil from

Pressure Valve Positioning/Auxiliary
Reducing Valve
Auxiliary Flow
Combiner Control
Solenoid Valve
Auxiliary Flow
Combiner Valve
5-Spool Side SN SM 4-Spool Side
Auxiliary Spool
Neutral Circuit
Bypass Shut-Out
Valve
SJ
Pump 2 Pump 1
TCEB-03-03-005
NOTE: The pressure reducing valve and the

auxiliary flow combiner control solenoid
valve are installed only on the machines
T3-3-39
Combined Operation
Auxiliary Flow Combiner Valve
When the attachment and the boom, arm, bucket, or
travel functions are operated simultaneously, the Port SN
auxiliary flow combiner valve is not shifted. Thereby,
the specified operating speed of the boom, arm, Spring B
To Auxiliary
bucket, or travel function is ensured. Spool
However, the combined oil flow is supplied to the Check Valve
auxiliary circuit when the pilot pressure to port SN is
reduced by the pressure reducing valve. Pressure Oil
from Pump 1
1. When the front attachment is operated, the pilot
pressure oil is routed to port SM on the auxiliary
flow combiner valve.
2. When the boom, arm, bucket, or travel is
Spool
operated at the same time, the pilot pressure oil
from the signal control valve is routed to port SN.
3. The pressure oil from port SM acts on the
auxiliary flow combiner valve spool toward
opening direction. The pressure oil from port SN
Spring A
and spring A act toward the closing direction.
4. Since the force to close the spool is larger than
that to open the spool, the spool is kept closed. Port SM
5. When the pilot pressure to port SN is reduced by
the pressure reducing valve, the pilot pressure in
port SM overcomes the pilot pressure in port SN
and spring (A) force. Then, the auxiliary flow
T176-03-03-037
combiner valve is opened. Therefore, the
pressure oil from pump 1 and pump 2 are
combined and supplied together to the auxiliary
spool.
T3-3-40
Pilot Pressure Oil

from Signal Pilot Pressure Oil from
Control Valve Positioning/Auxiliary
Pressure
reducing valve
Auxiliary Flow
Combiner Control
Solenoid Valve
Auxiliary Flow
Combiner Valve
5-Spool Side SN SM 4-Spool Side
Neutral Circuit
Auxiliary Spool
Bypass Shut-Out
Valve
SJ
Pump 2 Pump 1
TCEB-03-03-006
NOTE: The pressure reducing valve and the

auxiliary flow combiner control solenoid
valve are installed only on the machines
T3-3-41
(Blank)
T3-3-42
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls pilot pressure oil in order to
move the spool in control valve. The pilot valve outputs
pressure according to the control lever stroke by PPC
(Pressure Proportional Control Valve) function and
moves the spool in control valve.
The 4-port pilot valves for front attachment/swing is
standard.
The 2-port pilot valve is for travel.
• Front and Swing Pilot Valve

Port No. HITACHI ISO Standard
Standard
1 Boom Lower ←
2 Bucket Roll-Out ←
Right 3 Boom Raise ←
4 Bucket Roll-In ←
1 Right Swing Arm Roll-Out
2 Arm Roll-In Right Swing
Left
3 Left Swing Arm Roll-In
4 Arm Roll-Out Left Swing
Hydraulic Symbol
3 2
T
P
2 PT 4 1 3 1 PT 3 2 4
T566-03-05-002
4 1
T1F3-03-04-001
T3-4-1
• Travel Pilot Valve
Port No.
1 Travel
2 Plug
Hydraulic Symbol
P T T
T
P
P
1 2
T554-02-07-009
1 2
T1LA-03-04-001
1 2
T3-4-2
(Blank)
T3-4-3
OPERATION
• Front Attachment and Swing Pilot Valves Full Stroke Operation

(Pusher Stroke: E to F on the Diagram)
In Neutral (Pusher Stroke: A to B on the Diagram) 1. When the control lever is moved full stroke,
1. When the control lever is in neutral, spool (6) pusher (2) is moved downward until spring guide
completely blocks pressure oil from port P. The (3) comes in contact with the stepped section of
output port is open to port T via the notch on the casing.
spool (6) so that the output port pressure is equal 2. Then, spool (6) is directly pushed by the bottom
to pressure in the hydraulic oil tank. of pusher (2) at this moment. Accordingly, even if
2. When the control lever is moved slightly, cam (1) pressure in the output port increases, spool (6)
is tilted to push pusher (2). Pusher (2) is moved cannot move upward. Then, the output port is
downward together with spring guide (3) while kept connected to port P via the notch on spool
compressing return spring (5). (6).
3. Spool (6) is pushed by balance spring (4) and is 3. Therefore, pressure in the output port is
moved downward until clearance (A) becomes maintained at the same pressure in port P. The
zero. total lever stroke is decided by stroke C of the
4. While moving downward, the output port is kept pusher.
connected to port T so that pressure oil is not
routed to the output port.
E F
NOTE: The lever stroke moved until clearance (A)
Pilot
becomes zero, corresponds to the lever Pressure
play in the neutral position.
D
Operation Corresponding to Control Lever Stroke

(Pusher Stroke: C to D on the Diagram)
1. As the control lever is moved further, port P is
C
connected to the output port via spool (6),
increasing pressure in the output port.
2. The increase pressure in the output port acts on
surface B of spool (6), causing spool (6) to move A B Pusher Stroke
upward. T505-02-07-006
3. As long as this upward pressure force is lower
than balance spring (4) force, balance spring (4)
is not compressed. Therefore, port P is kept
connected to the output port so that output port
pressure continues to increase.
4. Then, the output port pressure increases further,
force to push spool (6) upward increases. When
this pushing force increases more than set-force
of balance spring (4), spool (6) is moved upward
while compressing balance spring (4).
5. As spool (6) is moved upward, the output port is
disconnected from port P. Thereby, pressure oil is
not supplied to the output port from port P,
stopping the pressure increase in the output port.
6. As described, balance spring (4) is compressed
by the same stroke as spool (6) is moved
downward. The output port pressure at this time
is equivalent to the pressure balancing with spring
force applied to spool (6).
T3-4-4
Pusher Stroke: A to B
3
4
5
Notch
Port T
（A） (Clearance A:0)
Port P
T577-03-04-002 T577-03-04-003
Output Port
Pusher Stroke: C to D Pusher Stroke: E to F
4 （C）
3
Port T
Notch
6
Port P
Port P
6
Surface B
T577-03-04-005
T577-03-04-004 Output Port
Output Port
1 - Cam 3 - Spring Guide 5 - Return Spring 6 - Spool

2 - Pusher 4 - Balance Spring
T3-4-5
• Travel Pilot Valve
Control Pedal-In Neutral (Pusher Stroke: A to B) Control Pedal-Full Stroke (Pusher Stroke: E to F)
1. When the control pedal is in neutral, spool (7) 1. When the control pedal is moved to full stroke,
blocks the pressure oil in port P completely. The pusher (2) is moved down until it comes into
output port is connected to port T through the contact with the top of plate (3).
passage in spool (7), so the pressure at output 2. Thereby, spool (7) is pressed directly by the
port becomes equal to the hydraulic oil tank bottom of pusher (2). As a result, notch (B) of
pressure. spool (7) does not close even if the pressure at
2. When the control pedal is moved slightly, cam (1) output port rises.
moves and pusher (2) and spring guide (4) move 3. As a result, the pressure at output port becomes
downward together, compressing return spring equal to the pressure at port P.
(6).
3. At this time, balance spring (5) pushes spool (7)
and spool (7) moves downward until clearance
(A) becomes ZERO.
4. While spool (7) moves downward, the output port
is connected to port T and the pressure oil does
not flow into the output port.
NOTE: The pedal stroke moved until clearance (A)

becomes zero, corresponds to the pedal Pilot Pressure D
play in the neutral position.
Control Pedal-Operated (Pusher Stroke: C to D

Metering) C
1. When the control pedal is moved further, the hole
on spool (7) is connected to notch (B).
A B Pusher Stroke
2. The pressure oil in port P flows into the output
port via the hole in spool (7) from notch (B), so T1F3-03-09-004
the pressure at output port increases.
3. The pressure at output port acts on the bottom of
spool (7), to push spool (7) upward.
4. If the acting force on spool (7) is smaller than the
spring force of balance spring (5), balance spring
(5) will not be pressed. As a result, as port P is
connected to the output port, the pressure at
output port increases continuously.
5. If the pressure at output port increases further,
the force to push up spool (7) increases. When
this force becomes larger than the spring force of
balance spring (5), spool (7) pushes balance
spring (5), and moves upward.
6. When spool (7) moves upward, notch (B) closes,
so the pressure oil does not flow into the output
port from port P. Thereby, the pressure at port P
stops raising.
7. Accordingly, the amount balance spring (5) is
compressed is equal to the amount spool (7) is
pressed down, so the balanced pressure between
the spring force and the force acting on spool (7)
becomes the pressure at output port.
T3-4-6
Pusher Stroke: A to B
3
4
5
Port T
6
(A)
Clearance (A): 0
Port P
Hole
7
Passage
T1LA-03-04-002
T1LA-03-04-003
Output Port
Pusher Stroke: C to D Pusher Stroke: E to F
2
3
Port T Port T
Notch (B) Notch (B)
Port P Port P
Hole
7 7
Output Port T1LA-03-04-004

Output Port T1LA-03-04-005
1 - Cam 3 - Plate 5 - Balance Spring 7 - Spool

2 - Pusher 4 - Spring Guide 6 - Return Spring
T3-4-7
(Blank)
T3-4-8
COMPONENT OPERATION / Electric Lever
OUTLINE
The electric lever outputs the signal according to the
electric lever operation to the option controller. The
option controller activates the solenoid valves for each
operation according to the electric lever operation.
Consequently, pressure oil from the pilot pump flows
to the spool ends in control valve and moves the
spools.
The electric levers are for auxiliary, positioning and
blade/outrigger.
1 2
• Auxiliary Electric Lever
Port No.
1 Auxiliary (Open)
2 Auxiliary (Close)
• Positioning Electric Lever

Port No.
1 Positioning Raise
2 Positioning Lower
T1MG-03-09-018
• Blade/Outrigger Electric Lever
Port No.
1 Outrigger Raise
2 Outrigger Lower
T1MG-03-09-012
T3-5-1
OPERATION
1. When the electric lever is operated, cam (5) and
arm (4) are tilted.
2. The arm (4) movement is transmitted to V
potentiometer (1) through pin (3) in arm (4) and
support (2) in potentiometer (1). Output
Output (Main)
3. Potentiometer (1) outputs the signal according to
Voltage
the support (2) tilt to the option controller.
NOTE: Potentiometer (1) outputs the main and sub
signals. Output
If one signal is faulty, the machine can (Sub)
operate due to the other.
Control Lever deg
Stroke
Operating Torque:
1. When the electric lever is operated, cam (5) is
tilted and pusher (6) is pushed down.
2. Pusher (6) compresses spring (7).
N⋅m
3. Therefore, torque when operating the electric
lever is obtained.
Operating
Torque
Control Lever deg T1MG-03-09-017

Stroke
T3-5-2
6
3
TCJB-03-05-001
1 - Potentiometer 3 - Pin 5 - Cam 7 - Spring

2 - Support 4 - Arm 6 - Pusher
T3-5-3
(Blank)
T3-5-4
Outline
The travel device consists of the travel motor (6), the
transmission (5), the front propeller shaft (3), the rear
propeller shaft (2), the front axle (4) and the rear axle
(1). The travel motor (6) is a variable displacement bent
axis type axial plunger motor. The motor is driven by the
pressure oil from the pump and rotates the transmission
(5). A regulator is provided on the travel motor (6) in
order to regulate the torque, which is transferred to the
transmission (5). The travel modes (fast and slow) are
selected at the transmission (5) by the pressure oil from
the pilot pump. Travel motor (6) rotation is transferred to
the propeller shafts and axles.
1
ZX140W-3: Up to serial No 005000 2
ZX140W-3: Serial No 005001 and up 1

2
5
6
4
TCEB-03-06-100
1- Rear Axle 3- Front Propeller Shaft 5- Transmission

2- Rear Propeller Shaft 4- Front Axle 6- Travel Motor
T3-6-1
COMPONENT OPERATION / Transmission
TRANSMISSION
The transmission consists of the shift interlock con- The travel speed reduction gear is controlled by
troller and the travel speed reduction gear. The shift pressure oil supplied from port B (fast speed) or port K
interlock controller prevents the travel speed mode (slow speed) so that either disc brake (15) or disc
switch from moving from the fast position to the slow clutch (13) is released and each gear is driven. The
position during travel operation. (Refer to the shift in- major components of the travel speed reduction gear
terlock control group.) The major components of the are final gears (6), carrier (5), planetary gears (14),
shift interlock controller are gearshift piston (1), relief ring gear (7), disc brake (15), disc clutch (13), shaft
valve (3) and rotary pump (4). (12), clutch piston (10), disc springs (9, 11), brake
piston (8) and accumulator (16). In addition, the travel
N sensor (2) is provided for travel speed check.
Travel Speed
Reduction Gear Shift Interlock Controller
Slow Fast
Speed Speed 1
K B
16
15 2
14
13
3
12
4
Travel Motor
11 5
10
6
9
Propeller Shaft
7
T21W-03-05-001
T3-6-2
9 11 12 15 13 14 5 4
10 8 7
TCEB-03-05-001
1- Gearshift Piston 5- Carrier 9- Disc Spring 13 - Disc Clutch

2- Travel N Sensor 6- Final Gear 10 - Clutch Piston 14 - Planetary Gear
3- Relief Valve 7- Ring Gear 11 - Disc Spring 15 - Disc Brake
4- Rotary Pump 8- Brake Piston 12 - Shaft 16 - Accumulator
T3-6-3
Slow Speed Selection
• Releasing Disc Clutch

1. When the travel speed mode switch is moved to 5. As disc brake (15) is kept applied, ring gear (7)
the slow position, the transmission changeover cannot rotate.
solenoid valve allows pressure oil to flow from the 6. Thereby, the rotation of the travel motor is trans-
pilot pump to port K. (Refer to the COMPONENT mitted to the propeller shaft via shaft (12), plane-
OPERATION / Others (Upperstructure) group.) tary gears (14), carrier (5) and final gears (6).
2. Pressure oil from port K is routed into the clutch 7. At this time, the input shaft speed (Travel motor
piston (10) chamber via gearshift piston (1). side) is reduced at the stages of planetary gears
3. Pressure oil pushes clutch piston (10) to the left (14) and final gears (6). Then, the output shaft
and disc clutch (13) is released. speed (propeller shaft side) is slower than the
4. When the slow mode is selected, no pressure oil input shaft speed (travel motor side).
is routed into brake piston (8). As brake piston (8) 8. Consequently, the output shaft rotates at the slow
is kept pushed to the right by disc spring (9), disc speed.
brake (15) remains applied.
Slow Speed
K
1
16
15
14
13
12
Travel Motor
5
11
10
Propeller Shaft
T21W-03-05-004
9 8 7
T3-6-4
Pilot Pressure
12 15 13 14 5
1
From Travel
Motor
9 11 10 8 7
TCEB-03-05-001
12 7
14
From Travel Motor
4
6
13
15
To Propeller Shaft
TCDB-03-05-001
1- Gearshift Piston 7- Ring Gear 10 - Clutch Piston 13 - Disc Clutch
5- Carrier 8- Brake Piston 11 - Disc Spring 14 - Planetary Gear
6- Final Gear 9- Disc Spring 12 - Shaft 15 - Disc Brake
T3-6-5
Fast Speed Selection
• Releasing Disc Brake

1. When the travel speed mode switch is moved to 5. Thereby, the travel motor, ring gear (7), planetary
the fast position, the transmission changeover gears (14) and carrier (5) rotate as one unit.
solenoid valve allows pressure oil to flow from the 6. Consequently, the input shaft speed (travel motor
pilot pump to port B. (Refer to the COMPONENT side) is reduced only at final gears (6) so that the
OPERATION / Others (Upperstructure) group.) output shaft (propeller shaft side) rotates at a fast
2. Pressure oil from port B is routed into the brake speed.
piston (8) chamber via gearshift piston (1) and the
check valve of accumulator (16).
3. Pressure oil pushes brake piston (8) to the left
and disc brake (15) is released.
4. When the fast mode is selected, no pressure oil is
routed into clutch piston (10). As clutch piston (10)
is kept pushed to the right by disc spring (11), disc
clutch (13) remains engaged.
Fast Speed
B 1
16
15
14
13
12
Travel Motor
5
11
10
6
9
Propeller Shaft
T21W-03-05-005
8 7
T3-6-6
Pilot Pressure 12 15 13 14 5
From Travel
Motor
9 11 10 8 7
TCEB-03-05-001
14
5
From Travel Motor
6
13
15
To Propeller Shaft
TCDB-03-05-002
1- Gearshift Piston 8 - Brake Piston 11 - Disc Spring 14 - Planetary Gear
5- Carrier 9 - Disc Spring 12 - Shaft 15 - Disc Brake
6- Final Gear 10 - Clutch Piston 13 - Disc Clutch 16 - Accumulator
7- Ring Gear
T3-6-7
Parking Brake
1. When the brake switch is turned to the P (parking

brake) position, the transmission changeover so-
lenoid valve blocks pressure oil from the pilot
pump. (Refer to the COMPONENT OPERATION /
Others (Upperstructure) group.)
2. Pressure oil acting on the clutch piston (10) and
brake piston (8) is routed to the hydraulic oil tank.
3. Therefore, clutch piston (10) and brake piston (8)
are moved by disc springs (11, 9) force to the right
so that disc clutch (13) is engaged and disc brake
(15) is applied.
4. Consequently, all gears are locked and shaft (12)
stops rotating.
15
13
12
11
10
T21W-03-05-001
T3-6-8
9 11 12 15 13
From Travel
Motor
10 8
TCEB-03-05-001
13
15
TCDB-03-05-003
8- Brake Piston 10 - Clutch Piston 12 - Shaft 15 - Disc Brake

9- Disc Spring 11 - Disc Spring 13 - Disc Clutch
T3-6-9
SHIFT INTERLOCK CONTROL
The shift interlock controller prevents the travel speed
mode switch from moving from the fast position to the
slow position during travel operation, and protects the
travel motor from being damaged. Although the travel
speed mode switch is moved from the fast position to
the slow position while traveling in the fast travel mode,
the machine continues to travel in the fast travel mode.
Then, after the travel speed is reduced to the gearshift
speed range (about 75 % of the maximum speed), the
transmission is automatically shifted to the slow travel
mode.
NOTE: The shift interlock controller does not pre-

vent the machine from running away while
traveling on a down slope. The travel motor
brake valve makes travel speed control on
a down slope.
1. As the travel speed is accelerated with the travel

speed mode switch in the fast position, the travel
motor rotation speed increases so that delivery
pressure from rotary pump (4) increases due to
pressure oil from port B.
2. When the delivery pressure of rotary pump (4)
overcomes the spring force of gearshift piston (1),
gearshift piston (1) is shifted.
3. Thereby, although the travel speed mode switch
is moved to the slow position in the fast travel
mode, as the travel motor continues to rotate at a
fast speed, the delivery pressure from rotary
pump (4) is kept at a high pressure.
4. Then, gearshift piston (1) remains in the shifted
position.
5. Consequently, although the travel speed mode
switch is in the slow position, brake piston (8) is
kept pushed to the left by pressure oil from port K.
The travel speed remains unchanged in the fast
speed mode.
6. After the machine travel speed decreases to the
gearshift speed range, gearshift piston (1) is re-
turned to the original position by the spring force
so that the machine travel speed mode is auto-
matically shifted.
7. Consequently, the travel motor is prevented from
running at an excessive speed.
T3-6-10
Spring Slow Fast

Speed Speed
K B
1
Travel Motor
8
T21W-03-05-006
1 - Gearshift Piston 4- Rotary Pump 8- Brake Piston
T3-6-11
SHOCK REDUCING FUNCTION
Accumulator (16) is provided for the fast speed side in
transmission. Accumulator (16) keeps pressure oil in
the fast speed side, makes time-lag for disc clutch (13)
and disc brake (15) operation and reduces shock to
the machine when shifting travel mode.
• Slow Speed → Fast Speed

1. When the travel speed mode switch is turned to
the slow mode, pressure oil from port K is routed
to the clutch piston (10) chamber.
2. At the same time, returning oil of the brake piston
(8) is routed to accumulator (16).
3. As the check valve in accumulator (16) blocks
returning oil, returning oil is routed to the orifice
side and reduced.
4. As returning oil pressure in brake piston (8) in-
creases, the force pushing brake piston (8) to the
left and that pushing clutch piston (10) to the right
occur.
5. Therefore, brake piston (8) and clutch piston (10)
are controlled not to operated suddenly.
6. When pressure in brake piston (8) decreases
slowly, brake piston (8) moves to the right due to
disc spring (9) and applies disc brake (15).
7. In addition, clutch piston (10) moves to the left
and releases disc clutch (13).
8. Consequently, when travel speed is shifted into
the fast mode, pressure to the travel motor is
prevented from increasing rapidly and the ma-
chine is protected from shock.
T3-6-12
Slow
Orifice Check Valve Speed
K
16
15
13
10
T21W-03-05-004
9 8
8- Brake Piston 10 - Clutch Piston 15 - Disc Brake 16 - Accumulator

9- Disc Spring 13 - Disc Spring
T3-6-13
DISCONNECT DEVICE
The disconnect device is activated when towing the

machine. When grease is filled into the disconnect
device from the grease fitting, the parking brake is
released.
Operation
1. When grease is filled from the grease fitting, the
piston moves to the left and pushes the pin.
2. The piston and pin push brake piston (8) and
clutch piston (10) to the left respectively.
3. Therefore, as disc brake (15) and disc clutch be-
come free, the parking brake is released.
4. Consequently, the transmission is neutral and the
machine can be towed regardless of travel speed.
Grease Fitting
WCEB-03-04-006
11 10 13 Grease 11 10 13
Fitting
9 8 Pin Piston 15 Grease 9 8 Pin Piston 15

T21W-03-05-015 T21W-03-05-016
8- Brake Piston 10 - Clutch Piston 13 - Disc Clutch 15 - Disc Brake

9- Disc Spring 11 - Disc Spring
T3-6-14
Group 7 Axle
Front Axle
The front axle consists of body (1), differential gear (2),
reduction gears (3) and steering cylinder (4). The front
axle functions to change the machine travel direction,
to support the machine weight, and to transfer the front
propeller shaft power to the wheels. The front axle is
controlled by the axle lock cylinders. When the axle lock
cylinders are released, the front axle is allowed to oscillate
so that the machine vibration is reduced during traveling
(auto-axle lock control). (Refer to the SYSTEM / Control
System group.)
Front Axle
Axle Lock Cylinder
TCEB-01-02-001
View A
2
1
3 4
T1GL-03-05-020
T3-7-1
Group 7 Axle
Differential Gear
The differential gear allows the right and left drive
wheels to rotate at different speeds each other when
the machine changes the travel direction, or when the
machine travels on uneven road surfaces.

1 2 3 4 5
TCEB-03-06-004
4 8
1- Axle Shaft 3- Half Gear 5- Spider 7- Axle Shaft

2- Side Gear 4- Idle Gear 6- Half Case 8- Ring Gear
T3-7-2
Group 7 Axle

1 2 3 4 5 2 6
4
9
T21W-03-05-018
1- Axle Shaft 4- Idle Gear 7- Axle Shaft

2- Side Gear 5- Spider 8- Ring Gear
3- Half Gear 6- Half Case 9- Pinion Shaft
T3-7-3
Group 7 Axle
Function
 Purpose of Differential Gear
1. When the machine is steered, the rear wheels
move along the circular having its center point on
the extension line of the rear wheel drive shaft.
Therefore, the outer wheel must rotate faster than
the inner wheel.
2. Let study the case when the rear wheels are driven
by a propeller shaft via an axle having no differential
gear.
3. In this case, both outer and inner wheels rotate
at the same speed. If the machine is steered, the
outer wheel must move faster than the inner wheel,
in sliding and/or premature wearing of the tire
occurs. In addition, the axle will be twisted and
the constant transmission of driving force is not
allowed.
4. When a differential gear is installed, the outer wheel
can rotate at different speed from that of the inner
wheel so that the problem as mentioned above
does not occur.
Extension Line of Rear

Wheel Drive Shaft
When the Machine is Steered: When the Machine Travels on an

Uneven Road Surface:
T202-03-05-005
T3-7-4
Group 7 Axle
 Basic Operational Principle of Differential Gear

The operational principle of differential gear is
explained by using a pair of racks and a pinion gear.
1. When handle (C) is moved upward by distance (H) W W W

while applying equal loads (W) onto both racks (A
and B) respectively, both racks (A and B) move by
distance (H) together with the pinion gear. C
C
2. When handle (C) is moved upward without applying
load (W) onto rack (B), the pinion gear is moved
upward while rotating along rack (A) to which load
(W) is kept applied.
3. Rack (B) to which no load is applied is moved H H
upward as the pinion gear rotates.
4. At this time, the moving distance of rack (B) is
longer than the moving distance of the pinion gear 2H
that rotates along rack (A).
5. The moving distance of rack (B) can be obtained as
Rack (A) Rack (B) Pinion
H + H = 2H. This is equal to the operational principle
of the differential gear. Pinion
T202-03-05-006
T3-7-5
Group 7 Axle
 Operation of Differential Gear

1. Axle shafts (1, 7) are coupled to side gears (2)
through the spline joints. When equal loads are
applied to axle shafts (1, 7) on both side, or when
the machine is traveling straight on a flat surface,
idle gears (4) do not rotate.
Pinion
2. Half case (6) and half gear (3) are connected to ring 8 Shaft
gear (8). As idle gears (4) mesh with side gears (2)
and mutual movement is kept stationary, half case
(6) and half gear (3) rotate together with ring gear 4
(8).
7
3. As mentioned above, as long as all parts are rotating
as one unit, differential gear function does not work.
Therefore, side gears (2), idle gears (4) and spider (5)
work as a joint connecting axle shafts (1, 7).
2 2 1
4. When the machine is steered, uneven resistance
forces are applied to the driving wheels. Depending
on the difference in resistance force applied to the 6 5 3
inner and outer wheels, idle gears (4) start revolving
along side gears (2) while rotating around spider (5). T202-03-05-007
5. In case the resistance force applied to axle shaft (1)

is larger than that applied to axle shaft (7), idle gears
(4) revolve along side gears (2) in the same direction
as ring gear (8) rotates while rotating around spider
(5). Then, the rotation speed on axle shaft (1) is
reduced. To the contrary, the rotation speed on axle
shaft (7) is increased so that the differential gear
8 Pinion Shaft
function operates.
6. Supposing that ring gear (8) is driven by the pinion
shaft at the speed of 100, the both side driving 4
wheels rotate at the same speed as long as the
7
machine travel straight.
7. When the machine is steered and the travel speed
on the right side driving wheel is reduced to 90, the
left side travel speed is increased by 10 (100-90) so
that the machine is steered with the left side driving 2 2 1
wheel rotating at the speed of 110.
8. Consequently, when ring gear (8) rotates at the 6 5 3
speed of 100, the total rotation speed of both side
wheels is kept constantly at 200 irrespective of T202-03-05-008
difference in speed between both side wheels.
T3-7-6
Group 7 Axle
(Blank)
T3-7-7
Group 7 Axle
Reduction Gear
(ZX140W-3: Up to serial No 005000, ZX140W-
3-AMS: Up to serial No 050000)
The reduction gear is a planetary gear type one-stage Ring gear (5) is connected to ring gear support (4)
reduction gear that transfers the driving force from the through the spline joints. The ring gear (5) assembly are
differential gear to the wheels. The brake is a wet type secured to knuckle (1) with nut (9). Plate (11) and friction
multi disc brake. The major components are knuckle (1), plate (10) are connected to hub (3) and ring gear (5)
piston (2), hub (3), ring gear support (4), ring gear (5), through the spline joints respectively.
planetary carrier (6), shaft (7), planetary gear (8), friction
plate (10) and plate (11).
1 2 3
4 5
11 10 9
TCEB-03-06-002
1- Knuckle 4- Ring Gear Support 7- Shaft 10- Friction Plate

2- Piston 5- Ring Gear 8- Planetary Gear 11- Plate
3- Hub 6- Planetary Carrier 9- Nut
T3-7-8
Group 7 Axle
Brake Operation
1. When the brake pedal is depressed, pressure 4. Planetary gear (8) meshes with shaft (7) and ring
oil from the brake valve is routed into piston (2) gear (5). Thereby, as both ring gear (5) stop rotating,
through the inner passage in knuckle (1). planetary gear (8) stops rotating.
2. Pressure oil moves piston (2) to the right so that 5. Consequently, shaft (7) and planetary carrier (6)
friction plate (10) and plate (11) are pushed. stop so that the brake is applied.
3. Therefore, hub (3) ring gear (5) stop rotating. fNOTE: When the machine travels normally, the disc
brake is free as pressure oil to piston (2) flows to the
hydraulic oil tank.
1 2 3
4 5
11 10 9
TCEB-03-06-002

T3-7-9
Group 7 Axle
Reduction Gear
(ZX140W-3: Serial No 005001 and up,
ZX140W-3-AMS: Serial No 050001 and up)
The reduction gear is a planetary gear type one-stage Shaft (7) is connected to disc carrier (4) through the spline
reduction gear that transfers the driving force from the joints. Plate (10) and friction plate (9) are connected
differential gear to the wheels. The brake is a wet type to hub (2) and ring gear (5) through the spline joints
multi disc brake. The major components are knuckle (1), respectively.
hub (2), piston (3), disc carrier (4), ring gear (5), planetary
carrier (6), shaft (7), planetary gear (8), friction plate (9)
and plate (10).
1 2
3 4 5
10 9 8
T21W-03-05-019
1- Knuckle 4- Disc Carrier 7- Shaft 10- Plate

2- Hub 5- Ring Gear 8- Planetary Gear
3- Piston 6- Planetary Carrier 9- Friction Plate
T3-7-10
Group 7 Axle
Brake Operation
1. When the brake pedal is depressed, pressure 4. Planetary gear (8) meshes with shaft (7) and ring
oil from the brake valve is routed into piston (3) gear (5). Thereby, as both ring gear (5) stop rotating,
through the inner passage in knuckle (1). planetary gear (8) stops rotating.
2. Pressure oil moves piston (3) to the left so that 5. Consequently, shaft (7) and planetary carrier (6)
friction plate (9) and plate (10) are pushed. stop so that the brake is applied.
3. Therefore, hub (2) ring gear (5) stop rotating. fNOTE: When the machine travels normally, the disc
brake is free as pressure oil to piston (3) flows to the
hydraulic oil tank.
1 2
3 4 5
10 9 8
T21W-03-05-019
1- Knuckle 4- Disc Carrier 7- Shaft 10- Plate

T3-7-11
Group 7 Axle
Steering Cylinder
The steering valve operates the steering cylinder. When
the steering wheel is turned to either the right or left,
pressure oil from the steering valve is routed into the
steering cylinder. Then, the rod in steering cylinder is
moved so that the front wheels are steered to either the
right or left.
Tie Rod
Cylinder
Piston Rod
TCEB-03-06-007
T3-7-12
Group 7 Axle
Rear Axle
The rear axle consists of body (3), differential gear (1) and
a pair of reduction gears (2). The rear axle transfers the
fNOTE: The rear axle operational principle is identical
to that of the front axle. In addition, the rear axle
driving force from the rear propeller shaft to the wheels construction is common to differential gear (1).
while supporting the machine weight. Therefore, only the construction of reduction gears (2)
are illustrated.

T1F3-03-05-016
2

T21W-03-05-021
T3-7-13
Group 7 Axle
Reduction Gear
(ZX140W-3: Up to serial No 005000, ZX140W-3-
AMS: Up to serial No 050000)
1 2 3 4 5
9
11 10
TCEB-03-06-009

T3-7-14
Group 7 Axle
Reduction Gear
(ZX140W-3: Serial No 005001 and up, ZX140W-3-
AMS: Serial No 050001 and up)
2
1
3 4 5
9 8
10
T21W-03-05-022
1- Knuckle 4- Disc Carrier 7- Sun Gear 10- Plate

T3-7-15
Group 7 Axle
(Blank)
T3-7-16
COMPONENT OPERATION / Travel Motor
OUTLINE
The travel motor consists of the motor section and The brake valve consists of the counterbalance valve,
brake valve. The motor section is rotated by pressure load check valves, check valves and shuttle valve and
oil from the main pump and transfers the motor rota- prevents the machine from running away.
tion to the transmission. The motor section consists of
the regulator, overload relief valve, pilot piston and NOTE: The make-up valve in control valve pre-
travel motor displacement control solenoid valve. The vents occurrence of cavitation in the motor
pilot piston and travel motor displacement control so- circuit. (Make-up function)
lenoid valve control the regulator by the signals from
motor driving oil pressure and MC.
The regulator controls the motor displacement angle
so that the motor is rotated at the displacement angle
in proportion to the pilot pressure oil.
The overload relief valves prevent surge pressure due
to overloads from occurring in the motor circuit.
Brake Valve Motor
Travel Motor Displacement

Pilot Piston
Counterbalance
Valve
Load Check Valve/

Check Valve
Overload
Relief Valve
TCJB-03-07-001
Regulator
T3-8-1
Component Layout
1 2 3 4
12 5
11
TCJB-03-08-006
10 9 8 7 6
1 - Pilot Piston 4 - Check Valve 7 - Orifice 10 - Load Check Valve

(Travel Forward Side)
2 - Travel Motor Displacement 5 - Travel Motor 8 - Overload Relief Valve 11 - Shuttle Valve
3 - Check Valve 6 - Servo Piston 9 - Check Valve 12 - Counterbalance Valve
T3-8-2
ROTOR SECTION
FV F
The rotor section consists of valve plate (1), rotor (2),
drive shaft (3) and plungers (4). When pressure oil is FR
4
routed to port AM on valve plate (1), pressure oil flows
into the half side of rotor (2) so that plungers (4) are
pushed. The component force (FV) of plunger pushing AM
force (F) rotates drive shaft (3). As drive shaft (3) ro-
tates, rotor (2) is also rotated. Then, when plunger (4)
1 3
is rotated up to port BM in sequence, pressure oil in
rotor (2) is returned to the hydraulic oil tank. Supplying
pressure oil to either port AM or BM can achieve for- 2
ward and reverse travel direction change.
BM
T216-03-05-015
1 2 3
TCJB-03-07-005
1- Valve Plate 2- Rotor 3- Drive Shaft 4- Plunger
T3-8-3
REGULATOR
The major components of regulator are travel motor NOTE: The motor circuit pressure is constantly
displacement control solenoid valve (1), spool (2), routed into the small chamber of servo
sleeve (3), piston (4), spring (5), bushing (6), collar (7), piston (11).
return spring (8), balance spring (9), pin (10), servo
piston (11), orifice (12) and pilot piston (13). Corre-
sponding to various signal pressures delivered to the
regulator, the regulator opens or closes the circuit to
servo piston (11) so that the tilt angle of rotor is ad-
justed and the travel motor rotation is controlled.
13 1 2 3
14
9
TCJB-03-08-001
12 11
Port A: Travel Reverse Side Port B: Travel Forward Side
T3-8-4
View A
A
13 14
5
Pilot Piston
6
10
11
12
TCJB-03-07-010
1 - Travel Motor Displacement 5 - Spring 9 - Balance Spring 12 - Orifice

2 - Spool 6 - Bushing 10 - Pin 13 - Pilot Piston
3 - Sleeve 7 - Collar 11 - Servo Piston 14 - Spring
4 - Piston 8 - Return Spring
T3-8-5
(Blank)
T3-8-6
Control Function of Regulator
Pressure oil routed to travel motor displacement con-

trol solenoid valve (1) and pilot piston (13) controls the
displacement angle of travel motor. Travel motor dis-
placement control solenoid valve (1) and pilot piston
(13) control pressure oil routed into the large chamber
of servo piston (11) in order to control the motor dis-
placement angle.
NOTE: Travel motor displacement control solenoid

valve (1) is the proportional solenoid valve
and controlled by the signal from MC (Main
Controller).
The regulator is controlled by the following two meth-

ods.
• Control by travel motor displacement control sole-
noid valve (1) Motor Dis-
When travel motor displacement control solenoid placement
Angle
valve (1) is shifted by the signal from MC, the motor
circuit pressure is routed to the regulator so that the
motor displacement angle is increased or decreased.
Then, the machine travels at the slow speed or fast
speed. (Travel motor displacement angle control)
(Superfine travel speed control) (Travel motor ex-
cessive speed rotation preventive control) (Refer to
the SYSTEM / Control System group.)
• Control by motor driving oil pressure Driving Oil
Pressure
When the motor driving oil pressure increases to
more than the set-pressure, the regulator increases
the motor displacement angle in order to increase
the power torque. Therefore, the maximum traction
power in improved. When the motor driving oil
pressure decreases to lower than the set-pressure,
the regulator decreases the motor displacement
angle in order to increase the motor rotation speed
so that the machine travels at the fast speed.
T3-8-7
Slow Speed (Large Displacement Angle) Selec-
tion
1. One pressure oil from port B or port A flows to the NOTE: Orifice (12) is equipped between the large
plunger through the valve plate. chamber of servo piston (11) and pilot pis-
The other pressure oil pushes to open the check ton (13).
valve and flows to spool (2) and the small cham- Therefore, pressure oil in the large cham-
ber of servo piston (11). ber of servo piston (11) is reduced and
2. When travel motor displacement control solenoid flows to the hydraulic oil tank gradually.
valve (1) moves upward due to the signal from Consequently, the displacement angle is
MC, pressure oil in the large chamber of servo smoothly changed and shock during travel
piston (11) flows to the hydraulic oil tank through speed change is reduced.
pilot piston (13) and spool (2).
3. Therefore, servo piston (11) moves downward
and the motor displacement angle increases.
4. Consequently, the motor rotates at slow speed.
(Superfine travel speed control, Travel motor ex-
cessive speed rotation preventive control)
13 From MC 1 2
Check Valve
B
Motor Circuit
Pressure
TCJB-03-08-002
12 11
T3-8-8
13
Hydraulic
Oil Tank
11
Motor Circuit
Pressure
12 TCJB-03-07-012
1 - Travel Motor Displacement 11 - Servo Piston 12 - Orifice 13 - Pilot Piston

2 - Spool
T3-8-9
Fast Speed (Small Displacement Angle) Selection
1. One pressure oil from port B or port A flows to the NOTE: Orifice (12) is equipped between the large
plunger through the valve plate. chamber of servo piston (11) and pilot pis-
The other pressure oil pushes to open the check ton (13).
valve and flows to spool (2) and the small cham- Therefore, pressure oil from pilot piston
ber of servo piston (11). (13) is reduced and flows to the large
2. When travel motor displacement control solenoid chamber of servo piston (11) gradually.
valve (1) moves downward due to the signal from Consequently, the displacement angle is
MC, pressure oil from port B or port A flows to the smoothly changed and shock during travel
large chamber of servo piston (11) through pilot speed change is reduced.
piston (13) and spool (2).
3. As for the pressure receiving area in servo piston
(11), as that in the large chamber is larger than
that in the small chamber, servo piston (11)
moves upward to the position where servo piston
(11) balances with balance spring (9) so that
travel motor displacement angle decreases.
4. Consequently, the motor rotates at fast speed.
(Travel motor displacement angle control)
13 From MC 1 2
Check Valve
B
Motor Circuit
Pressure
12 11 TCJB-03-08-003
T3-8-10
13
11
Motor Circuit
Pressure
12 TCJB-03-07-013
1 - Travel Motor Displacement 9- Balance Spring 13 - Orifice 14 - Pilot Piston

2 - Spool 11 - Servo Piston
T3-8-11
Slow Speed Selection (at Large Overload)
1. Pressure oil from port B or port A flows to pilot NOTE: Orifice (12) is equipped between the large
piston (13) through the shuttle valve. chamber of servo piston (11) and pilot pis-
2. When pressure at port B or port A increases at ton (13).
large overload, pressure acting on pilot piston Therefore, pressure oil in the large cham-
(13) also increases. ber of servo piston (11) is reduced and
3. When this pressure exceeds the spring (14) force, flows to the hydraulic oil tank gradually.
pilot piston (13) moves downward. Consequently, the displacement angle is
4. Pressure oil in the large chamber if servo piston smoothly changed and shock during travel
(11) flows to the hydraulic oil tank through pilot speed change is reduced.
piston (13).
5. Therefore, servo piston (11) moves downward
and the motor displacement angle increases.
6. Consequently, the motor rotates at slow speed.
7. When the motor load is large, the motor rotates at
slow speed so that the motor overload is pre-
vented.
Motor Driving
Oil Pressure 13
14
Motor Circuit B
Pressure
Shuttle Valve
TCJB-03-08-004
12 11
T3-8-12
13 14
Motor Driving
Hydraulic Oil Pressure
Oil tank
11
Motor Circuit
Pressure
12 TCJB-03-07-014
11 - Servo Piston 12 - Orifice 13 - Pilot Piston 14 - Spring
T3-8-13
OVERLOAD RELIEF VALVE
The motor is equipped with the overload relief valves
that prevents surge pressure from occurring in the
motor circuit.
Circuit Protection
1. When the circuit oil pressure increases to higher
than the set-pressure of overload relief valve, the
overload relief valve opens, surge pressure is re-
lieved to the lower pressure side so that the travel Overload Re-
lief Valve
motor is protected from being overloaded.
NOTE: When the motor runs faster than the oil

volume supplied from the pump, the coun-
terbalance valve is closed, and pressure in
the returning oil pressure from the motor
increases.
Counter-
balance
Valve
B A
TCJB-03-08-005
When Relieving:
To Housing
1 2 3 4 5 (Hydraulic Oil Tank)
Ａ B T1F3-03-05-035
1 - Spring 3 - Spring 4- Check Valve 5- Piston

2 - Poppet
T3-8-14
TRAVEL BRAKE VALVE
The travel brake valve is located on the head of travel
motor and consists of the counterbalance valve, check
valves and shuttle valve.
A
Counterbalance Valve:
Ensures smooth start and stop travel operation and
prevents the machine from running away when trav-
eling on a down slope.
Check Valve:
Blocks the return circuit from travel motor.
Shuttle Valve: A
Routes the travel motor driving high-pressure oil into
the pilot piston in regulator. TCJB-03-07-001
Cross Counterbalance Valve

Section A-A
B B
Check Valve Check Valve
Load Check Valve

Load Check Valve
Cross
Section B-B
A B TCJB-03-07-008
Shuttle Valve
T3-8-15
When Traveling: When Traveling on a Down Slope:
1. When pressure oil from the control valve is sup- 1. While traveling on a down slope, the machine
plied to port A, pressure oil diverges into two di- weight causes the travel to forcibly rotate so that
rections. the travel motor works as if it is a hydraulic pump.
2. The one oil flow opens check valve (6) and is 2. Therefore, when travel motor draws the hydraulic
routed to motor port AM and to counterbalance oil, oil pressures at port A and motor port AM de-
valve spool (1). crease. Then, spool (1) is moved to the left and
3. The other oil flow is routed onto the end of spool the returning oil flow from the travel motor is re-
(1) after passing through passage (7) and the in- duced.
side of spool (1). 3. Therefore, oil pressure at port BM increases and
4. The returning oil from the travel motor is routed to the brake force to the travel motor is developed.
spool (1) and check valve (3) via motor port BM. 4. As the returning oil flow is reduced and oil pres-
5. As both check valve (3) and spool (1) block the sure at port A increases again, spool (1) is moved
returning oil flow from the travel motor, pressure back to the right. Repetition of this operation (hy-
at port A increases. draulic brake) prevents the machine from running
6. When pressure at port A increases higher than away.
the spring (2) force, spool (1) is moved to the
right.
7. The returning oil from the travel motor flows to
passage (8) through the notch on spool (1).
8. The returning oil pushes to open load check valve
(4) and flows to port B. As pressure oil starts
flowing at this stage, the travel motor starts rotat-
ing.
9. When the accelerator pedal is returned to neutral,
spool (1) is returned to the original position by the
spring (2) force the circuit is closed so that the
travel motor stops rotating.
T3-8-16
When Traveling:
8 Notch 1 2
AM BM
TCJB-03-07-006
6 5 A B 4 3
When Traveling on a Down Slope:
AM BM
TCJB-03-07-006
1 - Spool (Counterbalance 3 - Check Valve 5 - Check Valve 7 - Passage

Valve)
2 - Spring 4 - Load Check Valve 6 - Load Check Valve 8 - Passage
T3-8-17
(Blank)
T3-8-18
COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit
between the pilot valve and control valve, and controls
pilot signal pressure to regulate the pumps and valves.
The major components of signal control valve are
shuttle valve, shockless valve, pump 1 flow rate
control valve, pump 2 flow rate control valve, bucket
flow rate control valve control spool and swing parking
brake release spool.
Pilot Valve Side
T178-03-06-016
Cross Section A-A
Shockless Valve
Bucket Flow Rate Control Valve

Control Spool
Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve
Swing Parking Brake

Release Spool
T178-03-06-002
T3-9-1
PILOT PORT
Pilot Valve Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve Side
K N
I
SH
J
DF
SA L
T178-03-06-016
Pilot Valve Side

Port Name Connecting to Remark
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Swing Shockless Valve (Left Pilot Valve) Arm Roll-Out Pilot Pressure
Port D Swing Shockless Valve (Left Pilot Valve) Arm Roll-In Pilot Pressure
Port E Swing Shockless Valve (Left Pilot Valve) Left Swing Pilot Pressure
Port F Swing Shockless Valve (Left Pilot Valve) Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I - Plug
Port J - Plug
Port K Travel Shockless Valve (Travel Pilot Valve) Travel Reverse Pilot Pressure
Port L Travel Shockless Valve (Travel Pilot Valve) Travel Forward Pilot Pressure
Port M Blade/Outrigger Solenoid Valve Blade/Outrigger Pilot Pressure
Port N Auxiliary Solenoid Valve Auxiliary Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Shut-Off Solenoid Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Solenoid Valve Primary Pilot Pressure (Heat Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T3-9-2
Control Valve Side
3
1
Pressure Sensor 5
(Auxiliary)
13
2 4
SK SE
Pressure Sensor 8
(Swing)
14
Control 7
Valve Side
9
10 6
SN
SL
11
T1F3-03-06-003
12 SP
Control Valve Side
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10 - Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 - Plug
Port 14 - Plug
Port SE - Plug
Port SN - Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL - Plug
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
2-Piece Boom Specification Machine

Port SP Positioning Solenoid Valve Pump 1 Control Pressure
T3-9-3
NOTE: Machine with front attachment (pulverizer 1

to 5 and crusher 1 to 5) attached.
Control Valve Side
14
Control
Valve Side
SN
T1F3-03-06-003
Control Valve Side

Port Name Connecting to Note
Port 14 Auxiliary Flow Combiner Contorl Solenoid Auxiliary Flow Combiner Valve Control
Valve Pressure
Port SN Pressure Reducing Valve Auxiliary Flow Combiner Valve Control
Pressure
NOTE: The auxiliary flow combiner control

solenoid valve and pressure reducing valve
are installed only on the machines
T3-9-4
(Blank)
T3-9-5
SHUTTLE VALVE
The shuttle valve selects pilot pressure to perform
each operation and routes pilot pressure to the
corresponding flow rate control valves and/or control
valve spools. The flow rate control valves and/or
control valve spools corresponding to each operation
are as follows:
Pump 1 Flow Pump 2 Flow Bucket Flow Swing

Rate Control Rate Control Rate Control Parking
Valve Valve Valve Control Brake
Spool Release
Spool
Boom Raise { { - {
Boom Lower { - - {
Arm Roll- Out { { - {
Arm Roll- In { { { {
Bucket Roll-In { - - {
Bucket Roll-Out { - - {
Right Swing - { - {
Left Swing - { - {
Travel { - - -
Blade/Outrigger - { - {
Auxiliary *{ { - {
Positioning
(2-Piece Boom { - - -
Only)
NOTE: *As for the machine with the front

attachment (pulverizer 1 to 5 and crusher 1
to 5) attached, the pump 1 flow rate control
valve is operated by pressure from the
auxiliary solenoid valve.
T3-9-6
Monoblock Boom / STD Specification
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Travel Arm Swing Boom Bucket
15
Blade/ 16
Outrigger
17
Pump 1 Flow Pump 2 Flow Bucket Flow Swing Parking T21W-03-06-003

Rate Control Rate Control Rate Control Brake Release
Valve Valve Valve Spool Spool
1- Unused 6- Boom / Arm / Bucket / 11 - Boom / Arm / Bucket 16 - Swing / Blade /

Travel / Auxiliary / Outrigger / Auxiliary
Positioning
2- Travel 7 - Boom / Arm 12 - Boom / Arm / Bucket / Swing 17 - Blade / Outrigger /
/ Auxiliary Auxiliary
3- Travel 8- Boom 13 - Arm / Boom Raise / Swing /
Blade / Outrigger / Auxiliary
4- Boom / Arm / Bucket / 9- Arm / Boom Raise 14 - Bucket
Travel
5 - Arm 10 - Boom Raise / Arm / Travel / 15 - Swing
Swing / Blade / Outrigger /
Auxiliary
T3-9-7
Machine with Monoblock Boom and Optional Parts
6 10 12 13 16 17
Auxiliary
Auxiliary
Flow
Combiner
Control
Solenoid
Valve
Pump 1 Flow Rate Pump 1 Flow Rate Shuttle

Control Valve Control Valve Valve
Swing Parking Brake

Release Spool
T21W-03-06-002
Machine with 2-Piece Boom and Optional Parts

6
Positioning
Shuttle
Valve
Pump 1 Flow Rate Shuttle

Control Valve Valve
T21W-03-06-001
T3-9-8
Pilot Valve Side
T178-03-06-016
Cross Section B-B
9
5
8
7
16
17
15
13
11
14
6 10
12
3
1
4
2
T178-03-06-009
1- Unused 6- Boom / Arm / Bucket / 11 - Boom / Arm / Bucket 16 - Swing / Blade /

Travel / Auxiliary / Outrigger / Auxiliary
Positioning
2- Travel 7 - Boom / Arm 12 - Boom / Arm / Bucket / 17 - Blade / Outrigger /
Swing / Auxiliary Auxiliary
3- Travel 8- Boom 13 - Arm / Boom Raise / Swing /
4- Boom / Arm / Bucket / 9- Arm / Boom Raise 14 - Bucket
Travel
5 - Arm 10 - Boom Raise / Arm / Swing / 15 - Swing
T3-9-9
SHOCKLESS VALVE
The shockless valve is provided in the boom raise
Port A
circuit and functions during boom lowering operation. Spool Spring B
During Boom Raising Operation:

1. Boom raise pilot pressure is routed from port A
and acts on the spool.
2. Immediately after operation is started, low pilot
pressure flows into the spring B chamber through
clearance C between spool and housing. At the
same time, pilot pressure flows to port 1 through
inner passage 2.
3. When pilot pressure increases and pressure in Port 1 T1V1-03-06-003
the spring B chamber increases, the spool
pushes spring A and moves to the left.
4. As the spool is moved, port A is connected to port
1 and pressure in port 1 increase so that the
spool in control valve moves. Port A
Spring A Spool Spring B
Port 1 T1V1-03-06-002
T3-9-10
During Boom Raising Operation
Spring A Spool Port A
Inner Passage 2
Spring B
Port 1 T183-03-06-003
Spool Port A
Port 1 T183-03-06-004
Detail of Housing
Clearance C
Spool T1V1-03-06-008
T3-9-11
During Boom Lowering Operation (Shock
Reducing Operation)
1. When the boom is lowered, the return oil from the
Port A
boom raise spool in control valve is routed to port Spring A Spool Spring B
1.
2. As the spool blocks the oil passage between port
1 and port A, returning oil cannot flow directly to
port A.
3. Port 1 is connected to the spring A side in spool
via inner passage 1 and to the oil chamber via
inner passage 2.
4. Pressure oil in the oil chamber flows from
clearance C between spool and housing and
pressure in the oil chamber decreases. The spool Port 1 T1V1-03-06-004
is moved to the right by pressure acting on the
spring A side. Thereby, clearance C between
spool and housing is closed and pressure oil is
blocked.
5. When clearance C is closed, pressure in the oil Port A
Spring A Spool Spring B
chamber increases and the spool moves to the
left. Therefore, clearance C is opened again and
pressure oil flows to port A.
6. As operations in steps (4 and 5) are repeated,
pressure oil is gradually returned to port A so that
the spool in control valve returns slowly.
Port 1 T1V1-03-06-002
T3-9-12
During Boom Lowering Operation (Shockless
Operation)
Spring A Inner Passage 1 Spool

Port A
C
Inner Passage 2 Oil Chamber

Port 1 TCJB-03-09-004
Spool
Port A
Inner Passage 2 Oil Chamber

Port 1 TCJB-03-09-005
Detail of Clearance C
Housing
Spool T1V1-03-06-008
T3-9-13
PUMP 1 AND PUMP 2 FLOW RATE
CONTROL VALVES
The pump flow rate control valve delivers pump
control pressure Pi to the pump regulator in response
to pilot pressure from the pilot valve.
1. Pilot oil pressure from the pilot valve is routed into

the chamber A side in either the pump 1 or pump
2 flow rate control valve after being selected by
the shuttle valves in signal control valve.
2. The spool is moved to the left and primary pilot
pressure flows in either port SA or SB.
3. Therefore, pressure in port SA or SB increases.
4. Pressure oil in port SA or SB acts on the spring
chamber. Thus, the spool is moved back until
pressure force balances with pilot pressure force
in the chamber A side so that pressure in port SA
or SB stops increasing.
NOTE: The pump 1 flow rate control valve

operates when the boom (raise or lower),
arm (roll-in or out), bucket (roll-in or out),
travel, auxiliary (machine with front
attachment (pulverizer 1 to 5, crusher 1 to
5) attached) and positioning functions are
operated.
The pump 2 flow rate control valve
operates when the boom (raise), arm
(roll-in or out), swing (right or left), blade /
outrigger and auxiliary functions are
operated.
T3-9-14
Ports SA, SB
Spool
Spring
To Hydraulic
Oil Tank
Chamber A
Shuttle Valve
Primary Pilot
Pressure
Pilot Pressure
From Pilot Valve
T1V1-03-06-005
T3-9-15
BUCKET FLOW RATE CONTROL VALVE
CONTROL SPOOL, SWING PARKING
BRAKE RELEASE SPOOL
Bucket Flow Rate Control Valve Control Spool:
NOTE: The spools above are identical in To Hydraulic Boom Raise Control
operational principle. Oil Tank Pilot Pressure
Spool Spring
1. The bucket flow rate control valve control spool is
shifted by arm roll-in control pilot pressure and
supplies boom raise control pilot pressure to the
bucket flow rate control valve in control valve.
T178-03-06-014
Arm Roll-In To Bucket Flow Rate
Control Pilot Control Valve
Pressure
2. The swing parking brake release spool is shifted Swing Parking Brake Release Spool:
by the boom, arm, bucket, swing or auxiliary To Hydraulic Primary Pilot
control pilot pressure and supplies primary pilot Oil Tank Pressure
pressure to the swing motor. Spool Spring
T178-03-06-014
Boom, Arm, To Swing
Bucket or Motor
Auxiliary Pilot
Pressure
T3-9-16
COMPONENT OPERATION / Steering Valve
OUTLINE
The steering valve is located between steering pump The overload relief valve is provided in the steering
and steering cylinders. The steering valve delivers valve. When the steering valve is in neutral (when no
pressure oil from the steering pump to the steering steering operation is performed), the overload relief
cylinders in proportion to the steering wheel operation. valve prevents the circuit pressure between steering
(Refer to the SYSTEM / Hydraulic System group.) cylinders and steering valve from being increased
The steering valve consists of the steering valve (orbit more than the set pressure by external force.
motor) and priority valve.
The steering valve delivers pressure oil from the
steering pump to the steering valve and accumulator
charging valve in proportion to the steering valve op-
eration. (Refer to the SYSTEM / Hydraulic System
group.)
Priority Valve
Steering Valve
Steering Wheel (Orbit Motor)
TCJB-03-10-002
T3-10-1
Component Layout
18 3
17
4
16
5
15 6
TCJB-03-10-012
14
13 12 11 10 9 8 7
1 - Make-Up Valve 6- Orifice 11 - Orifice 15 - Relief Valve

2 - Overload Relief Valve 7- Port EF 12 - Port T 16 - Orifice (Check Valve)
(To Accumulator Charging Valve) (To Hydraulic Oil Tank)
3 - Gerotor 8 - Spool 13 - Port L 17 - Spool
(To Steering Cylinder)
4 - Check Valve 9- Port P 14 - Port R 18 - Sleeve
(From Steering Pump) (To Steering Cylinder)
5 - Check Valve 10 - Spring
13 14 9
A A
12
TCJB-03-10-001
T3-10-2
Cross
Section A-A View C
16 5
B C
D D
17 18 3 D
TCJB-03-10-005 D
TCJB-03-10-004
Cross
Section E-E
11
E E
10 15
TCJB-03-10-006
Cross
Section D-D 1
F F
TCJB-03-10-008
F
F Cross
Section F-F 2
TCJB-03-10-003
TCJB-03-10-007
T3-10-3
STEERING VALVE
Construction
The steering valve consists of gerotor (1), drive (2), 1

sleeve (3), spool (4), pin (5), housing (6) and centering
springs (7).
When the steering wheel is rotated, spool (4) is rotated
4
and the oil passage is opened between spool (4) and
sleeve (3). Pressure oil from the steering pump is
routed into the steering cylinders via spool (4) and
sleeve (3). Centering springs (7) are provided in both
spool (4) and sleeve (3) so that sleeve (3) is returned
to neutral when the steering wheel is released. TCJB-03-10-013
8 3
Steering Wheel
T1F3-03-07-002
6 5 4 3 2 1
1 - Gerotor 3- Sleeve 5- Pin 7- Centering Spring

2 - Drive 4- Spool 6- Housing 8- Check Valve
T3-10-4
7 8
OPERATION
Sleeve (3), spool (4) are connected to drive (7) with pin
(5). The pin hole in spool (4) is the hole. When the
steering wheel (spool (4)) is rotated, a displacement
angle between spool (4) and sleeve (3) appears. The
steering wheel exact rotation is transferred only to
spool (4). Port P (from the steering pump) is connected
to port R or L (to the steering cylinders) via sleeve (3)
and spool (4).
T1F3-03-07-002
2 5 4 3
2 4
1 3
Port L
Port R
Hole
Port P
10
6
T1F3-03-07-004
1 - Housing 4 - Spool 7 - Drive 9 - Spacer
2 - Centering Spring 5 - Pin 8 - Gerotor 10 - Cap
3 - Sleeve 6 - Plate
T3-10-5
Left Steering:
1. When the steering wheel is turned counterclock- 4. When pressure oil from the steering pump is
wise, spool (4) is rotated. Then, pressure oil from routed through gerotor (8), gerotor (8) is rotated
the steering pump is routed as follow: counterclockwise. The rotation of gerotor (8) is
Port P → Sleeve (3) → Spool (4) → Sleeve (3) → transferred to sleeve (3) via drive (7) and sleeve
Housing (1) → Gerotor (8) (3) rotates counterclockwise.
2. Pressure oil from gerotor (8) is routed further as 5. When sleeve (3) is rotated by the same angle as
follow: spool (4) is rotated, the oil passage between
Housing (1) → Sleeve (3) → Spool (4) → Sleeve sleeve (3) and spool (4) is closed so that the
(3) → Port L → Steering Cylinders steering cylinder operation is stopped.
Then, the steering cylinders are operated so that 6. Accordingly, gerotor (8) is rotated in proportion to
the machine is turned to the left. rotation of the steering wheel. Therefore the
3. The returning oil from the steering cylinders flows steering cylinders are operated in proportion to
back to the hydraulic oil tank as follow: Housing rotation of the steering wheel.
(1) → Sleeve (3)→ Spool (4) → Sleeve (3) → Port
T
Port L Port R
Overload 章
Relief Valve
Make-Up
Valve
Port T
1 8
Hydraulic Port P
Oil Tank
Steering
Pump
4 2 3 TCJB-03-10-009
T3-10-6
Right Steering:
1. When the steering wheel is turned clockwise, T L R P
pressure oil from the steering pump as follows:
Port P → Port R → Steering Cylinders
The steering cylinders are operated so that the
front wheel is turned to the right.
2. The returning oil from the steering cylinder flows
back to the hydraulic oil tank via port L and port T.
T487-03-02-010
In Neutral:
T P
1. When the steering wheel is in neutral, pressure oil
from the steering pump is routed to port P on the 4
steering valve. As port P is blocked by spool (4),
pressure oil do not flow to the steering cylinders.
2. Then, the steering cylinders are inoperative.
When Steering Pump Stops (When Engine Stops): T487-03-02-011
1. When the steering wheel is turned to a certain

angle, spool (4) touches pin (5) so that drive (7) Check Valve
T
rotates.
2. Drive (7) rotates gerotor (8) and functions as the
hand pump to send oil to the steering cylinder.
3. Oil is inhaled up from the tank port via the check
valve. 4
4. As results, the steering operation is performed
even if the steering pump is completely stopped.
T1F3-03-07-002
5 7 8
T3-10-7
OVERLOAD RELIEF VALVE MAKE-UP VALVE
The overload relief valves are located in the steering The make-up valves are located in the steering valve.
valve and prevents the circuit oil pressure between If the circuit oil pressure between steering cylinders
steering cylinders and steering valve from increasing and steering valve decreases below pressure in the
more than the set pressure. hydraulic oil tank, the make-up valve draws the hy-
draulic oil through port T in order to prevent cavitation.
Operation:
1. In case an external force is applied in the left Operation:
steering direction, surge oil pressure is developed 1. If the circuit oil pressure between steering cylin-
in the circuit. ders and steering valve decreases below pres-
2. If the circuit pressure increases more than the set sure in the hydraulic oil tank, pressure oil from
pressure in the overload relief valve, the ball and port T moves the ball in the make-up valve up-
holder in the overload relief valve are moved upward and flows into the circuit between steering
ward so that pressure oil is routed to the hydraulic cylinders and steering valve.
oil tank via the oil passage around the holder. 2. When the circuit oil pressure between steering
3. When the circuit oil pressure decreases, the ball cylinders and steering valve increases, the ball is
and holder are moved downward by the spring moved downward by pressure oil and the
force and the overload relief valve is closed again. make-up valve is closed again.
Steering Cylinder Overload Relief

Valve
Spring
Holder
Ball
Orifice
Steering
Make-Up Valve
Valve
Ball
Port T
Hydraulic
Oil Tank
Steering Pump
TCJB-03-10-010
T3-10-8
PRIORITY VALVE
Construction:
The priority valve consists of relief valve (15), spool (9), Port P is connected to the steering pump. Chamber A
spring (12), orifice (8) and orifice (13). and the spring (12) chamber are connected to the
steering valve. In addition, the spring (12) chamber is
The illustration shows the spool (9) position when the connected to relief valve (15). Port EF is connected to
engine stops. Spool (9) is pushed to the right by spring the accumulator charging valve. Port T is connected to
(12). the hydraulic oil tank.
To Accumulator
Charging Valve
Spring Chamber EF Chamber A
12 13
P
Hydraulic Steering
15 Pump
Oil Tank
Steering Valve
TCJB-03-10-011
T3-10-9
OPERATION
When steering is in neutral:

1. Pressure oil from the steering pump flows to the
steering valve through chamber A, port P and the
outer circumference in spool (9).
2. When the steering valve is in neutral (the steering
wheel is not operated), pressure oil which flows to
the steering valve from chamber A is blocked by
the steering valve so that pressure in chamber A
increases.
3. Pressure oil from port P is divided into two direc-
tion through the inner passage in spool (9).
4. One pressure oil flows to chamber B through ori-
fice (8).
5. The other pressure oil flows to the steering valve
through orifice (13) and spring (12).
6. As pressure oil in spring (12) flows to the hydrau-
lic oil tank through the steering valve, the pres-
sure difference occurs due to orifice (13).
7. Therefore, pressure in spring (12) is lower than
that in chamber B.
8. When the pressure difference increases beyond
the force of spring (12), spool (9) moves to the left
by compressing spring (12)
9. Consequently, when the steering valve is in neu-
tral, pressure oil from the steering pump always
flows to the accumulator charging valve through
port EF.
T3-10-10
Steering Valve
Hydraulic
Oil Tank
Chamber A
13
12
Chamber B
9 P
Steering Pump TCJB-03-10-015
To Accumulator
Charging Valve
EF
12
Chamber B
13
9
P
8- Orifice 9- Spool 12 - Spring 13 - Orifice
T3-10-11
When steering is operated:
NOTE: Orifice D in the steering valve is a variable

orifice so that the open area becomes large
in proportion to the steering wheel rotation
speed.
1. The steering valve spool moves at the moment

when the steering wheel is turned, orifice S opens,
and pressure oil in the circuit between chambers
B and A in the priority valve and orifice C in the
steering valve flows to the gerotor.
2. As pressure oil flows to the gerotor, pressure in
the circuit between chambers B and A in the pri-
ority valve and orifice C in the steering valve de-
creases so that spool (9) moves to the right due to
the spring (12) force.
3. Spool (9) becomes stable at the position where
pressure oil in proportion to the orifice C open
area flows to the steering valve.
4. At this time, pressure oil from the steering pump
flows to the steering valve through spool (9) and
the accumulator charging valve through port EF
respectively.
gerotor through spool and sleeve in the steering
valve.
6. The gerotor delivers pressure oil while rotating as
a hydraulic motor. Pressure oil flows to the steer-
ing cylinder and the machine turns.
T3-10-12
Steering Cylinder
Gerotor
Spool Steering Valve
Orifice C
Sleeve
To Accumulator
Charging Valve
EF
Chamber A
12
Chamber B
Priority Valve
9- Spool 12 - Spring
T3-10-13
RELIEF VALVE
The relief valve prevents the circuit pressure between
priority valve and steering valve from increasing more
than the set pressure when the steering cylinder is at
the stroke end.
When steering cylinder is at stroke end:

1. Pressure oil to the steering valve is divided inside
the spool. One pressure oil flows to the gerotor.
2. The other pressure oil flows to the spring (12)
chamber through the inner passage.
3. When the steering cylinder reaches the stroke
end, pressure in port P increases. At the same
time, pressure in chamber B and the spring (12)
chamber increases.
4. When pressure in the spring (12) chamber
reaches the set pressure of relief valve (15), relief
valve (15) operates and pressure oil acting on the
spring (12) chamber flows to the hydraulic oil tank
from relief valve (15).
5. When relief valve (15) operates, pressure oil in
the spring (12) chamber flows to the hydraulic oil
tank. Therefore, the pressure difference between
the spring (12) chamber and chamber B occurs
due to orifice (13).
6. When the pressure difference overcomes the
spring (2) force, spool (9) moves to the left.
accumulator charging valve through port EF and
spool (9).
8. Therefore, when the steering cylinder is at the
stroke end, the relief valve makes pressure oil
flow to the accumulator charging valve.
T3-10-14
Gerotor
Spool
Inner
Passage To Accumulator
Charging Valve
EF
9
13
12
Chamber B
8
15
Hydraulic Steering TCJB-03-10-018

Oil Tank Pump
8- Orifice 12 - Spring 13 - Orifice 15 - Relief Valve

9- Spool
T3-10-15
(Blank)
T3-10-16
COMPONENT OPERATION / Brake Valve
OUTLINE
The brake valve is operated by the brake pedal and
MC (work brake control). (Refer to the SYSTEM /
Control System group.)
The brake valve delivers pilot oil pressure in proportion
to the brake pedal stroke and both the front and rear
wheel brakes are applied.
In addition, when the work brake control is enabled,
pilot pressure from solenoid valve unit (SF) shifts the
brake valve so that the brake is constantly applied.
Brake Pedal
Brake Valve
TCJB-03-11-001
T3-11-1
OPERATION
• When the brake pedal is operated:
Output Diagram: Range A to B (Neutral)

1. When brake pedal (1) is not stepped on, spool
(10) is pushed to the left by spring (12) via re-
tainer (11).
2. Therefore, piston (13) is moved to the left by
spool (10).
3. Spool (7) is pushed to the left by spring (9) via
retainer (8) together with the reaction force of D
spring (14). Pilot
4. Thereby, balance spring (6) is pushed to the left. Pressure
5. Push rod (2) and pilot piston (3) are pushed to the
left by return spring (5) and balance spring (6) via C
retainers (4, 15).
6. Accordingly, when in neutral, spools (7, 10) com-
A B Pedal Stroke
pletely block pressure oil flow from ports PA and
PB. Ports BA and BB are connected to port T T1F3-03-09-004
through the outer circumference around spools (7,
10). Thereby, oil pressure at ports BA and BB
becomes equal to that at port T.
7. When brake pedal (1) is slightly stepped on, push
rod (2) and pilot piston (3) are moved in so that
push rod (2), pilot piston (3) and retainers (4, 15)
move as one assembly and push return spring (5)
and balance spring (6).
8. As pressure at ports BA and BB is equal to that at
port T and the resultant spring force [springs (9,
12 and 14)] pushing spools (7, 10) to the left is
less than the balance spring (6) force, spools (7,
10) are moved to the right.
9. This condition is kept maintained until the notches
on spool (7, 10) are connected to ports BA and
BB.
T3-11-2
1 2 3 Port PP 4 5 6 Port BA 7 8 9 Port BB 10 11 12
T1F3-03-09-002
15 Port T 14 Port PA 13 Port PB
1 2 3 4 5 6 Notch 7 9 Notch 10 12
15 14
T1F3-03-09-002
Port PP Port BA Port BB

1 (to the rear wheel brakes) (to the front wheel brakes)
12
T1F3-03-09-003
2 6 7 Port PA 14 10 Port PB Port T
1- Brake pedal 5- Return Spring 9- Spring 13 - Plunger

2- Push Rod 6- Balance Spring 10 - Spool 14 - Spring
3- Pilot Piston 7- Spool 11 - Retainer 15 - Retainer
4- Retainer 8- Retainer 12 - Spring
T3-11-3
Output Diagram: Range C to D
1. When brake pedal (1) is further stepped on and

push rod (2) and pilot piston (3) are pushed, the
notches on spools (7, 10) are connected to ports
BA and BB respectively and pressure oil from
ports PA and PB flow to port BA and BB.
2. Oil pressure in ports BA and BB is routed into the D
inside of spools (7, 10) through each spool hole Pilot
so that spools (7, 10) are pushed to the left. Pressure
3. When the force pushing spools (7, 10) to the left
is smaller than the balance spring (6) force, bal- C
ance spring (6) is not compressed. Therefore,
spools (7, 10) do not move so that oil pressure in
A B Pedal Stroke
port BA and BB continues to increase.
4. When oil pressure in ports BA and BB increases T1F3-03-09-004
further, the force pushing spools (7, 10) to the left
increases. When this force overcomes the bal-
ance spring (6) force, spools (7, 10) compresses
balance spring (6) and move to the left.
5. When spools (7, 10) move to the left, the notches
are closed, no pressure oil flows to ports BA and
BB from ports PA and PB. Thereby, oil pressure in
ports BA and BB stops increasing.
6. As described above, balance spring (6) is com-
pressed by the stroke of spools (7, 10). During
this operation, spring force increases in propor-
tion to force to push spools (7, 10). Oil pressure
creating this force is equal to the oil pressure in
ports BA and BB.
T3-11-4
Port BA Port BB
1 2 3 Port PP 6 7 10
T1F3-03-09-002
Port T Port PA Port PB
Port BB Notch Port BB Notch

10 10
From Port PB Hole
T1F3-03-09-006 T1F3-03-09-005
1 - Brake Pedal 3- Pilot Piston 7 - Spool 10 - Spool

2 - Push Rod 6- Balance Spring
T3-11-5
• When the work brake is applied:
NOTE: The brake operates by using the same

mechanism as brake pedal (1) is stepped
on except that pilot oil pressure is routed
from port PP.
1. Pilot oil pressure from port PP is routed into the

pilot chamber in push rod (2) through the hole in
push rod (2).
2. Pressure oil to the pilot chamber acts on the head
of pilot piston (3).
3. When oil pressure overcomes the balance spring
(6) force, pilot piston (3) is moved to the right.
4. While compressing balance spring (6) via retainer
(15), pilot piston (3) moves pistons (7, 10) to the
right.
5. When spools (7, 10) are moved until the notch on
each spool is connected to ports PA and PB, oil
pressure from ports PA and PB flows into port BA
and BB.
6. Consequently, the brake is applied.
T3-11-6
1 2 3 Port PP 6 Port BA 7 Port BB 10
T1F3-03-09-002
15 Port T Port PA Port PB
2 Pilot Chamber Port PP 7 Notch 10 Notch
T1F3-03-09-002
Hole 3 15 6 Port PA Port PB
1 - Brake Pedal 3- Pilot Piston 7 - Spool 15 - Retainer

2 - Push Rod 6- Balance Spring 10 - Spool
T3-11-7
(Blank)
T3-11-8
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF SOLENOID VALVE
Cross Section Z-Z
The pilot shut-off solenoid valve is the ON/OFF sole- Pilot Shut-Off
Solenoid Valve
noid valve.
The spool in pilot shut-off solenoid valve is shifted by
the pilot shut-off lever and turns on or off pilot pres- To Ports
T1 to T4
sure oil to the pilot valve and signal control valve.
To Ports A1
to A4
Port P
Spool
T1J1-03-07-011
Port HT
A1
P T1
T2
A2
A3
Z
T3
T4
A4
T1V1-03-07-011
A1 - Left Pilot Valve A4 - Plug T1 - Left Pilot Valve T3 - Blade / Outrigger / Auxiliary /
Positioning / Assist / Swing
Parking Brake Release So-
lenoid Valve
A2 - Right Pilot Valve HT - Signal Control Valve T2 - Right Pilot Valve T4 - Hydraulic Oil Tank
(Port PH) / Swing
Shockless Valve (Port
HT)
A3 - Blade / Outrigger / Auxiliary / P - Primary Pilot Pressure
Positioning / Assist / Swing
Parking Brake Release So-
lenoid Valve
T3-12-1
• Pilot Shut-Off Lever: LOCK Position Pilot Shut-Off Lever: LOCK Position
1. When the pilot shut-off lever is in the LOCK posi-
tion, the pilot shut-off relay is turned OFF and the Pilot Shut-Off
pilot shut-off solenoid valve is turned OFF. (Refer Solenoid Valve
to the SYSTEM / Electrical System group.)
To Hydrau-
2. As pressure oil from the pilot pump is blocked by lic Oil Tank
the spool in pilot shut-off solenoid valve, pressure
oil does not flow to ports A1 to A4.
3. Pressure oil from ports A1 to A4 flows to the hy-
From Pilot
draulic oil tank. Pump
4. Therefore, although the control lever is operated,
the pilot valve is not operated. From Port
A1 to A4
Spool
To Signal T1J1-03-07-011
Control Valve
Pilot Shut-Off Lever: UNLOCK Position

• Pilot Shut-Off Lever: UNLOCK Position
Pilot Shut-Off
1. When the pilot shut-off lever is in the UNLOCK Solenoid Valve
position, the pilot shut-off relay is turned ON and
To Hydrau-
the pilot shut-off solenoid valve is activated. (Re- lic Oil Tank
fer to the SYSTEM / Electrical System group.)
2. Therefore, the circuit to hydraulic oil tank is
blocked by the spool in pilot shut-off solenoid
valve. From Pilot
Pump
3. Pressure oil from the pilot pump flows to the ports
A1 to A4. To Port A1
4. Consequently, when the control lever is operated, to A4
the pilot valve is operated.
Spool
To Signal T1J1-03-07-001
Control Valve
T3-12-2
(Blank)
T3-12-3
TRANSMISSION CHANGEOVER SOLE-
NOID VALVE
The transmission changeover solenoid valve consists
of travel mode selector solenoid valve and pressure
reducing valve.
• Travel mode selector solenoid valve • Pressure Reducing Valve

When the travel speed mode switch is turned to the When pressure in the transmission increases, the
slow position, current from the slow speed selection pressure reducing valve restricts pressure and re-
relay shifts the solenoid valve. lease pressure in order to keep pressure in the cir-
Consequently, pressure oil from the pilot pump re- cuit to specification.
leases the disc clutch in transmission and applies
the disc brake so that travel speed is selected into
the slow speed.
When the travel speed mode switch is turned to the
fast position, current from the fast speed selection
relay shifts the solenoid valve.
Consequently, pressure oil from the pilot pump re-
leases the disc brake in transmission and activates
the disc clutch so that travel speed is selected into
the fast speed.
T3-12-4
Operation
Pressure reducing state:
• Pressure Reducing Valve Passage Spool Spring
1. Pressure oil from the pilot pump acts on the spool
end through the spool.
2. When pressure in the transmission (port K or B),
pressure acting on the spool end also increases.
3. As pressure acting on the spool end is larger than Pilot Pump
the spring force, the spool compresses the spring
and moves to the right.
4. Therefore, as port K or B is connected to the hy- Hydraulic
draulic oil tank, pressure in port K or B de- Oil Tank
creases.
5. At the same time, as the passage to spool end is
also connected to the hydraulic oil tank, pressure
decreases. K B T21W-03-09-008
6. As the spring force is larger than pressure acting

on the spool end, the spool moves to the left.
7. Pressure acting on the spool end increases again Transmission
and the spool moves to the right until pressure
balances with the spring force. Pressure increasing state:
8. These steps above are repeated so that pressure Passage Spool Spring
in the transmission is kept constant.
Pilot Pump
K B
T21W-03-09-009
Transmission
T3-12-5
Pressure Re-
• Slow speed selection ducing Valve
1. Pressure oil from port P flows to the travel mode
P
selector solenoid valve spool through the pres-
sure reducing valve.
the slow position, current from the slow speed
selection relay activates the solenoid valve and
shifts the spool.
3. Therefore, port P is connected to port K so that
pressure oil from port P flows to the slow side in
transmission through port K.
From Slow
4. Consequently, travel speed is selected into the Speed Selection
slow speed. Relay K B
Travel Mode Spool
Selector So-
lenoid Valve
Transmission T21W-03-09-004
• Fast speed selection

selector solenoid valve spool through the pres- Pressure Re-
sure reducing valve. ducing Valve
2. When the travel speed mode switch is turned to P
the fast position, current from the fast speed se-
lection relay activates the solenoid valve and
shifts the spool.
3. Therefore, port P is connected to port B so that
pressure oil from port P flows to the fast side in
transmission through port B.
4. Consequently, travel speed is selected into the From Fast
fast speed. Speed
Selection
Relay
K B
Travel Mode Spool
Selector So-
lenoid Valve
Transmission T21W-03-09-006
T3-12-6
• Parking Brake
Pressure Re-
selector solenoid valve spool through the pres- ducing Valve Spring B
Spring A
sure reducing valve.
P
the N (neutral) position or the brake switch is
turned to the P (parking brake) position, MC turns
the fast speed selection relay or slow speed se-
lection relay OFF so that the travel mode selector
solenoid valve is not shifted.
(Refer to the SYSTEM / Control System group.) Hydraulic
3. Therefore, the solenoid valve spool moves to the Oil Tank
position (neutral position) where spring A bal-
ances with spring B.
4. Pressure oil from port P is blocked by the sole-
noid valve spool. K B
Travel Mode Spool
5. Pressure oil from port K or B flows to the hydrau- Selector Sole-
lic oil tank through the solenoid valve spool. noid Valve
6. Consequently, as the disc clutch and disc brake Transmission T21W-03-09-005
are operated, the transmission stop rotating and

the parking brake is applied.
(Refer to the COMPONENT OPERATION /
Transmission group.)
T3-12-7
SOLENOID VALVE
The solenoid valve consists of the 3-spool solenoid
valve unit for pump and valve control, the auxiliary so-
lenoid valve unit (optional) for auxiliary flow rate con-
trol, and 2-spool solenoid valve for operate check
valve control on the blade / outrigger cylinder.
3-Spool Solenoid Valve Unit

Controls the control valve, brake valve and operate SC SF SI
check valve on the axle lock cylinder by the signal
from MC (main controller). (Refer to the SYSTEM /
Control System group.) The 3-spool solenoid valve
unit consists of proportional solenoid valves (SC, SF
and SI).
• SC: Control the arm regenerative valve and arm

2 flow rate control valve (switch valve) in
control valve
• SF: Control the brake valve
• SI: Control the operate check valve on the axle
lock cylinder TCGB-03-12-001
T3-12-8
Auxiliary Solenoid Valve Unit (for Auxiliary Flow
Rate Control) (Optional) Auxiliary Flow Auxiliary Flow Pressure Re-
The auxiliary solenoid valve unit consists of the auxil- Combiner Control Rate Control ducing Valve
iary flow combiner control valve, auxiliary flow rate Solenoid Valve Solenoid Valve
control solenoid valve and pressure reducing valve.
The auxiliary flow combiner control solenoid valve is
the ON/OFF solenoid valve. The auxiliary flow com-
biner valve in control valve is shifted by shifting the
option switch.
The auxiliary flow rate control solenoid valve is the
proportional solenoid valve. The auxiliary flow rate
control valve in control valve is shifted by the signal
from MC.
The pressure reducing valve reduces pressure of front
attachment/travel and supplies pressure to the auxil- TCJB-03-12-001
iary flow combiner valve. Therefore, during combined

operation of auxiliary and front attachment /travel, flow
rate to the auxiliary circuit is adjusted.
2-Spool Solenoid Valve for Blade/Outrigger Cylinder

2-Spool Solenoid Valve (for Blade/Outrigger Cyl-
inder) (Optional)
The 2-spool solenoid valve for blade/outrigger cylinder
is the ON/OFF solenoid valve. The 2-spool solenoid
valve opens the operate check valve for
blade/outrigger cylinder when the signal arrives from
the control switch.
T1F3-03-08-001
T3-12-9
Proportional Solenoid Valve
Controls by an electric current signal from MC and

outputs pressure in proportional to degree of the
electric current.
• When not energized (In neutral): • When energized:

1. Spring (2) pushes spool (1) to the right and output 1. Solenoid (3) pushes spool (1) to the left due to
port S is connected to tank port T. force in proportional to the electric current flowing
through solenoid (3).
2. Pilot pressure oil from port P flows into output
port S and pressure at output port S increases.
3. Pressure at output port S acts on step part a on
spool (1).
Because of difference in the pressure receiving
area between step part a, spool (1) is pushed to
the right.
4. When pressure at output port S increases and
the force to push spool (1) to the right overcomes
the force to push spool (1) to the left by solenoid
(3), spool (1) moves back to the right side and the
passage between output port S and port P is
closed. As a result, pressure at output port S
stops increasing.
1 2 3
T S P
a
T107-02-07-005
1- Spool 2- Spring 3- Solenoid
T3-12-10
ON/OFF Solenoid Valve
The ON/OFF solenoid valve shifts the brake switch

and each control switch in order to shift pilot pressure.
• In Neutral State
Spool (1) is pushed to the right by spring (2).
Output port (S) is connected to tank port (T).
• In Operation
As solenoid (3) is activated, spool (1) moves to the left.
Pilot port (P) is connected to output port (S) and tank
port (T) is blocked.
P S T
1 2 T105-02-11-010
1 - Spool 2 - Spring 3 - Solenoid
T3-12-11
TRAVEL SHOCKLESS VALVE
The travel shockless valve is located between the
travel pilot valve and the signal control valve. The
travel shockless valve prevents the travel spool from
quickly returning so that the occurrence of cavitation in
travel motor is reduced. In addition, the travel shock-
less valve is provided with two solenoid valves, one
each in the forward and the reverse circuits in order to
restrict travel operation. (Refer to the SYSTEM / Con-
trol System group.)
Travel Pilot Valve

NOTE: The procedures for travel forward opera-
tion are explained here.
• Shockless Function
Travel Shockless
1. Returning oil from the control valve flows to port Valve
B2 in the travel shockless valve through the sig-
nal control valve.
2. Returning flows to port T (hydraulic oil tank) Spool
through the orifice and outer circumference of
solenoid valve spool.
3. At this time, pressure difference occurs due to the Check
Valve
orifice.
4. Consequently, as the travel spool in control valve
is operated by the orifice slowly, the travel spool is
prevented from quick operation.
• Travel Operation Limit Function Hydraulic

1. When the solenoid valve is activated, the spool Oil Tank
moves to the right.
Orifice
2. The spool blocks pressure oil from port A2 com-
pletely. TCJB-03-12-003
3. Consequently, the machine cannot travel al-

though the travel reverse operation is done during
travel forward operation.
T3-12-12
ACCUMULATOR CHARGING VALVE Brake Valve
1
The accumulator charging valve is located between
the steering valve and the brake valve circuit. The ac- 2
cumulator charging valve functions to give the pres- 3
sure oil priority to flow to the brake circuit and simul-
taneously charges the accumulator in the brake circuit
with the pressure oil. (Refer to the SYSTEM / Hydrau- 13
lic System group.)
From Steering P
4
Valve
5
12
11
T N
6
10
9 8 7
TCJB-03-12-008
A B C
Cross Section A-A
9
10
8
7
T
11
12
A B C
Cross Section B-B Cross Section C-C
1 5
P From Steering
Valve
4
2
TCJB-03-12-012
1- Check Valve 5- Passage 9 - Passage 12 - Piston
2- Check Valve 6- Chamber A 10 - Spring 13 - Accumulator
3- Accumulator 7- Spool 11 - Pilot Piston 14 - Accumulator
4- Check Valve 8- Spring
T3-12-13
• Between pressure charging start and pressure
charging finish 14 Brake Valve
1. When pressure in the brake circuit (accumulator) 1
decreases, pressure in passage (5) also de-
creases. Pilot piston (11) and piston (12) move 2
downward due to the spring (10) force (upward as
illustrated in the circuit diagram.) 3
2. Therefore, as passage (9) is disconnected to port
13
T by pilot piston (11), pressure in passage (9) in-
creases gradually.
3. When pressure in passage (9) + spring (8) force 4
is lager than pressure in chamber A (6), spool (7) P 5
From Steering
moves downward (to the right as illustrated in the Valve
circuit diagram) and the circuit between port P
and port N is blocked.
12 6
4. Pressure oil from port P pushes to open check
valves (4, 1, 2) and flows to accumulators (14, 13, 11 7
T N
3) and the brake circuit.
10
5. Therefore, when pressure in the brake circuit de- 87
creases, pressure oil flows to the brake circuit by
priority. At the same time, the accumulator starts 9 TCJB-03-12-010
charging pressure.
6. These procedures are continued until accumula-
tors (14, 13, 3) become saturated (cut-out pres- 1- Check Valve 8- Spring
sure). 2- Check Valve 9- Passage
3- Accumulator 10 - Spring
4- Check Valve 11 - Pilot Piston
5- Passage 12 - Piston
6- Chamber A 13 - Accumulator
7- Spool 14 - Accumulator
T3-12-14
A B C
Cross Section A-A 9

10
8
7
T
N
11
12
A B C
5
1
P From Steering
Valve
4 TCJB-03-12-013

T3-12-15
• After pressure charging finish 14
1. Pressure in passage (5) acts on piston (12). Brake Valve
2. Pressure in accumulators (3, 13, 14) is blocked 1
and kept by check valves (2, 1, 4) respectively.
3. When the accumulator becomes saturated 2
(cut-out pressure), piston (12) moves upward due 3
to pressure in passage (5) (downward as illus-
trated in the circuit diagram). 13
4. As passage (9) is connected to port T (hydraulic
oil tank), pressure in passage (9) decreases.
5. Therefore, as pressure in chamber A (6) is larger
than pressure in passage (9) + spring (8) force, From Steering P 4
spool (7) moves upward (to the left as illustrated Valve
in the circuit diagram). 5
6. Consequently, pressure oil in port P flows to port 12
N (hydraulic oil tank). 6
11
7. These procedures are continued until the service T N
7
brake is applied (pressure in the brake circuit de- 10
creases). 8
9 TCJB-03-12-011

2- Check Valve 9- Passage
3- Accumulator 10 - Spring
4- Check Valve 11 - Pilot Piston
5- Passage 12 - Piston
6- Chamber A 13 - Accumulator
7- Spool 14 - Accumulator
T3-12-16
A B C
Cross Section A-A 9

10
8
7
T
N
11
12
A B C
5
1
P From Steering
Valve
4 TCJB-03-12-014

T3-12-17
HOSE RUPTURE VALVE
The hose rupture valve is installed to boom cylinder
(bottom side circuit), arm cylinder (bottom side circuit)
and positioning cylinder (2-piece boom) (bottom side
circuit).
When the hose of front attachment is damaged, the
hose rupture valve holds the front attachment and
prevents the front attachment from falling.
NOTE: The hose rupture valve in boom cylinder is

explained here.
• Control Lever: In Neutral

1. As pilot pressure Pi does not act on spool (2), 4. Therefore, poppet (6) is pushed downward by
spool (2) is pushed to the right by the spring (10) force (pressure of the spring (5) chamber +
force. spring (5) force).
2. One holding pressure of cylinder at port B acts on 5. Consequently, as holding pressure at port B is
poppet (6) and the other acts on spool (2) through blocked completely, the front attachment is held
passage C (9). and prevented from falling when the hose of front
3. Holding pressure through passage C (9) is attachment is damaged.
blocked by spool (2).
Although pressure oil in the spring (5) chamber
also acts on spool (2) through passage A (4),
pressure oil is blocked by spool (2) and does not
flow to passage B (8).
5 9 4
External Pressure Pi
Force
B
10 8 2
To Spool in Control T21W-03-10-004

Valve (To Hose of
Front Attachment)
2- Spool 5- Spring 8- Passage B 10 - Spring

4- Passage A 6- Poppet 9- Passage C
T3-12-18
10 11 1 2 3
Port Pi
9 5
8 Port B
Port A
T1V1-03-07-017
1- Relief Valve 4- Passage A 7- Orifice 10 - Spring

2- Spool 5- Spring 8- Passage B 11 - Orifice
3- Piston 6- Poppet 9- Passage C
T3-12-19
• During Boom Lowering Operation (Control Lever
Stroke: Less than Half-Stroke)
1. When the boom is lowered, pilot pressure Pi acts
on piston (3).
2. When the boom lower control lever is less than
half-stroke, piston (3) pushes spool (2) to the po-
sition where orifice (7) is opened.
3. Pressure oil in the spring (5) chamber is blocked
by spool (2) and poppet (6) is pushed downward.
4. Pressure oil from port B flows to the spool in con-
trol valve through passage C (9), orifice (7) and
passage B (8) and lowers the boom.
5. As oil flow rate through the spool in control valve
is reduced by orifice (7), the boom is lowered
slowly.
5 9 4
Pressure Pi
B
7 10 8 2 3
To Spool in Control Valve T21W-03-10-005

(To Hose of Front Attachment)
2- Spool 5- Spring 7 - Orifice 9 - Passage C

3- Piston 6- Poppet 8 - Passage B 10 - Spring
4- Passage A
T3-12-20
10 11 1 2 3
Pressure Pi
9 5
8 Port B
Port A
T1V1-03-07-015

T3-12-21
• During Boom Lowering Operation (Control Lever
Stroke: More than Half-Stroke)
1. When the boom lower control lever is more than
half-stroke, piston (3) pushes spool (2) to the po-
sition where passage (4) is connected to the hole
on spool (2).
2. Therefore, pressure oil in the spring (5) chamber
flows to passage B (8) through spool (2) from the
hole on spool (2).
3. At this time, a pressure difference between port B
and the spring (5) chamber occurs due to orifice
(7) and poppet (6) moves upward.
4. Consequently, returning oil from port B flows to
the spool in control valve through poppet (6) from
port A and lowers the boom.
5. As pressure oil in port B flows to port A directly, oil
flow rate through the spool in control valve in-
creases and boom lowering speed becomes fast.
5 4
Pressure Pi
B
7
A
10 8 2 3
To Spool in Control Valve T21W-03-10-006

(To Hose of Front Attachment)
2- Spool 4- Passage A 6- Poppet 8 - Passage B

3- Piston 5- Spring 7- Orifice 10 - Spring
T3-12-22
10 11 1 2 3
Pressure Pi
9 5
8 Port B
Port A
T1V1-03-07-016

T3-12-23
ACCUMULATOR
The accumulators are provided in the pilot circuits for
the brake valve. The accumulator is charged with
high-pressure nitrogen gas. Pressure oil from the pilot
pump compresses the nitrogen gas via the film. The
compressed nitrogen gas maintains oil pressure for
each operation circuit constant.
Nitrogen Gas
Film
T1F3-03-08-007
From Pilot Pump
T3-12-24
PILOT RELIEF VALVE
Pilot Relief
Valve
The pilot relief valve has a pilot filter incorporated.
Port P
The pilot relief valve functions to regulate pilot pump
pressure routed to port P to a set constant pressure.
Pilot Filter
T178-03-07-001
T3-12-25
(Blank)
T3-12-26
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing sustains self weight of the upper- The internal gear of inner race (3) engages with the
structure and makes smooth swing. This bearing is a output shaft of swing reduction gear.
single-row shear ball-type bearing and consists of
outer race (1), inner race (3), balls (6), supports (5)
and seals (2, 4). Outer race (1) is bolted to the
upperstructure and inner race (3) is bolted to the
undercarriage.
T135-03-02-001
1 - Outer Race 3 - Inner Race 5 - Support 6 - Ball

2 - Seal 4 - Seal
T3-13-1
CENTER JOINT
The center joint is a 360° rotating joint. When the up- Pressure oil flows to each port on the body through the
perstructure is rotated, the center joint avoids twisting spindle. Then, pressure oil is routed to the travel mo-
of hoses and allows hydraulic oil to flow smoothly to or tors, transmission, front and rear wheel brakes, oper-
from the travel motors. The spindle is attached to the ate check valve (blade/outrigger), steering cylinders,
upperstructure and the body is bolted to the swing 2-spool solenoid valve (blade/outrigger), outrigger cyl-
center of undercarriage. inders and blade cylinders. The seal prevents oil leak-
age between spindle and body.
9 10 Spindle 1 2 3
11 4
15
8
5
14
7
12
13 Body 5
6
9
3
Seal
14
8
4
1
6
2
10
7
12 Seal
11
13
T1F3-03-10-001
1 - Port 7: Plug (To Hydraulic Oil Tank) 6- Port 8: To Steering Cylinder 11 - Port 14: Transmission Changeover
(Right Steering Side) Solenoid Valve (To Hydraulic Oil
Tank)
2 - Port 9: To Steering Cylinder (Left 7- Port 11: Plug (To Hydraulic Oil Tank) 12 - Port 12 To Rear Wheel Brake
Steering Side)
3 - Port 3: To Blade/Outrigger Cylinder 8- Port 5: To Travel Reverse Side 13 - Port 13: To Front Wheel Brake
Rod Side (Raise Side)
4 - Port 6: To Axle Lock Cylinder / 9- Port 2: To Travel Forward Side 14 - Port 4: Pilot Pressure to Operate
Make-Up Valve for Travel Motor Check Valve for Blade/Outrigger
Cylinder / To Transmission Change-
over Solenoid Valve
5 - Port 1: To Blade/Outrigger Cylinder 10 - Port 10: Pilot Pressure to Operate Check 15 - Port D: To Hydraulic Oil Tank
Bottom Side (Lower Side) Valve for Axle Lock Cylinder
T3-13-2
SLIP RING
The slip ring is installed on the spindle upper part of
center joint.
The slip ring is a joint which rotates 360°. When the
upperstructure rotates, it transmits the current to the
undercarriage while preventing the wiring from twist-
ing.
Also, it transmits the detected figures from sensors
installed on the undercarriage to the upperstructure.
Center Joint Slip Ring
Spindle
T1F3-03-10-015
T1F3-03-10-014
T3-13-3
(Blank)
T3-13-4
CYLINDER
The axle lock cylinders, outrigger cylinders and blade
cylinders are mounted on the chassis. Each cylinder
consists of the cylinder section and operate check
valve section.
Operate Check Valve Blade Cylinder
Operate Check Valve
Outrigger Cylinder
Operate Check Valve
Axle Lock Cylinder

TCEB-01-02-001
Operate Check Valve Operate Check Valve

(For Axle Lock Cylinder) (For Blade/Outrigger Cylinder)
TCJB-03-13-002
TCJB-03-13-003
T3-13-5
Operate Check Valve (Axle Lock Cylinder)
• When releasing the axle lock:

(Brake Switch: OFF)
1. When solenoid valve unit (SI) is shifted, pressure

oil from the pilot pump is routed into port P of the
operate check valve. Pressure oil acts on the pis-
ton and the piston is pushed to the right.
2. The piston pushes the poppet and check valve to
the right so that port A (axle lock cylinder) is con-
nected to port T (hydraulic oil tank).
3. Consequently, pressure oil in both right and left
axle lock cylinders can move freely between them
and to the hydraulic oil tank so that the axle lock
cylinders can oscillate.
NOTE: The reaction loads from the travel road

surface are absorbed by oscillation of both
right and left axle lock cylinders. (Refer to
T3-13-6
Front Axle
Axle Lock Cylinder
A A
Operate
Check Valve
T P P T
SI Solenoid Valve Unit
Hydraulic Oil Tank Pilot

From MC
Pump TCJB-03-13-007
Piston Check Valve Poppet
Operate
Check Valve
P
T A
Pilot Pump Axle Lock

Cylinder
Hydraulic
Oil Tank TCJB-03-13-005
T3-13-7
• When operating the axle lock:

(Brake Switch: P (Parking Brake), Axle Lock or
Auto Axle Lock position)
NOTE: When traveling at the brake switch in the

auto axle lock position, axle lock is re-
leased. (Auto Axle Lock Control) (Refer to
1. Pressure oil from the pilot pump is blocked by the

solenoid valve unit (SI) spool.
2. As long as the check valve is kept opened, oil
pressure in port A is equal to that in port T.
Thereby, the poppet and check valve in the oper-
ate check valve are moved to the left by spring
force.
3. Therefore, port A (axle lock cylinder) in the oper-
ate check valve is disconnected from port T (hy-
draulic oil tank).
4. Consequently, pressure oil is enclosed in the axle
lock cylinder so that the axle is locked.
T3-13-8
Front Axle
Axle Lock Cylinder
A A
Operate
Check Valve
T T
SI Solenoid Valve Unit
Hydraulic Pilot TCJB-03-13-008

Oil Tank Pump
Piston Check Valve Poppet Spring
Operate
Check Valve
T A
Axle Lock
Cylinder
Hydraulic
TCJB-03-13-004
Oil Tank
T3-13-9
Operate Check Valve (Blade/Outrigger Cylinder)
• When operating the blade/outrigger:
NOTE: When the blade/outrigger control switch is

operated, the 2-spool solenoid valve
(blade/outrigger) is shifted. (Refer to the
SYSTEM / Control System group.)
1. When the 2-spool solenoid valve for

blade/outrigger is shifted, pressure oil from the
pilot pump is routed to port P on the operate
check valve. As pressure oil acts on the piston,
the piston is moved to the left.
2. The piston pushes the poppet and check valve to
the left so that port V is connected to port C.
3. Then, pressure oil from pump 2 flows to either the
rod or bottom side of blade/outrigger cylinder via
port V and port C on the operate check valve so
that cylinder is extended or retracted.
T3-13-10
Blade/Outrigger
2-Spool Solenoid Valve Cylinder
C C
Operate
Check Valve
V V
P
Pilot Hydraulic
Pump Oil Tank
Pump 2 TCJB-03-13-009
Check Valve Poppet Piston
Hydraulic Oil Tank

C V
Blade/Outrigger
Cylinder
Pilot
Pump
Operate
Check Valve
C V
Check Valve Poppet Piston
Pump 2 TCJB-03-13-006
T3-13-11
(Blank)
T3-13-12
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

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

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

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

INTRODUCTION
TO THE READER
age.):
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
• This manual contains the revision information
to the 13, July 2009.
• Please refer to the other materials (operator’s

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

Example : T 1-3-5

Group Number
Section Number
IN-01
INTRODUCTION
NOTATIONS

death.
• NOTE:
know-how.
heavy parts.
UNITS USED
this manual.
From From
mm ft 0.003281 MPa psi 145.0
L US qt 1.057 kW HP 1.341
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION

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

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

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

of information.
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
• Learn how to operate the machine and its controls correctly
and safely.
• Allow only trained, qualified, authorized personnel to oper- SA-003
ate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, func-
tion, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or equip-
ment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are intended to
illustrate basic safety procedures of machines. However it is
impossible for these safety messages to cover every hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES

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

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

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

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

• Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or
uncomfortably loud noises.
006-E01A-0434
SA-434
SA-3
SAFETY
INSPECT MACHINE
• Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435 SA-435
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal ac-
cident.
• Do not leave parts and/or tools lying around the operator’
s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly start-
ing a fire.
• Refrain from listening to the radio, or using music head-
phones or mobile telephones in the cab while operating
the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the tem-
perature in the cab increases, the lighter may explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS

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

• A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the op-
erator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear
SA-378
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR LEAV-

ING OPERATOR’S SEAT
• Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
• Before leaving the machine, be sure to first lower the
front attachment to the ground and then move the pilot
control shut-off lever to the LOCK position. Turn the key
switch OFF to stop the engine.
• Before leaving the machine, close all windows, doors, and
access covers and lock them up.
SA-5
SAFETY
FASTEN YOUR SEAT BELT

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

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

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine. SA-083
• Use appropriate illumination. Check that all lights are op-
erable before operating the machine. If any faulty illumi-
nation is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressur-
ized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
SA-293
036-E01A-0293-3
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• NEVER start the engine while standing on the track or on
ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-084
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow the
instructions shown in the “OPERATING THE ENGINE” chap-
ter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
S013-E01A-0032
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
014-E01B-0427
SA-091
SA-7
SAFETY
PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equip-
ment appropriate for the job, such as a hard hat, etc.
when operating the machine.
• Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
• When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M202-05-014
SA-8
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from fall-
ing and to prevent the ground, stockpiles, or banks from
collapsing.
• Make a work plan. Use machines appropriate to the work
and job site.
• Reinforce ground, edges, and road shoulders as necessary.
Keep the machine well back from the edges of excava-
tions and road shoulders.
• When working on an incline or on a road shoulder, em- SA-085
ploy a signal person as required.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
• Make sure the worksite has sufficient strength to firmly sup-
port the machine.
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicu-
lar to the cliff face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
• Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on a soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm M202-05-015
enough to easily support the machine.
• Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with ma-
chine movements.
SA-9
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS, FOPS

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

FOPS: Falling Object Protective Structure
SA-686
PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

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

• Incorrect steering wheel/forward/reverse pedal operation
may result in serious injury death.
• Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when steering wheel is operated to
the front.
SA-092
017-E01A-0491
SA-10
SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the steer-
ing wheel/forward/reverse switch direction corresponds to
the direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.
• Driving on a slope may cause the machine to slip or over-

SA-090
turn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 35 degrees or steep-
er slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket fac-
ing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, imme-
diately lower the bucket to the ground and stop.
SA-288
AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the ground.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 5 min-
utes to cool down the engine.
• Stop the engine and remove the key from the key switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
SA-278
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND SWING

ACCIDENTS
• If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
• Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW SA-383
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
• Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
• Keep windows, mirrors, and lights clean and in good con-
dition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility SA-384
decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the
021-E01A-0494
SA-12
SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
• A person may be hit severely by the swinging front attach-
ment or counterweight and/or may be crushed against an
other object, resulting in serious injury or death.
• Keep all persons clear from the area of operation and
machine movement.
• Before operating the machine, set up barriers to the sides
and rear area of the bucket swing radius to prevent any-
one from entering the work area.
022-E01A-0386
M202-05-014
NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
023-E01A-0487 SA-682
AVOID UNDERCUTTING
• Always confirm that ground conditions are strong enough
to support the machine weight when operating near a cliff.
Operate the machine with the chassis frame positioned
perpendicular to the cliff face so that the machine can more
easily evacuate if the cliff face collapses.
• If the footing starts to collapse and if retreat is not pos-
sible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.
024-E01A-0488 SA-683
SA-13
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-
CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL
RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
• The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to the ma-
SA-088
chine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging loads.
• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become
soft and make ground travel unstable.
025-E03B-0463
SA-684
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing
026-E01A-0519
SA-685
SA-14
SAFETY
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
• Before digging check the location of cables, gas lines, and
water lines.
• Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
• If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
• Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities. SA-086
027-E01A-0382
OPERATE WITH CAUTION

• If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
• Take care to avoid hitting overhead obstacles with the
boom or arm.
028-E01A-0389 SA-087
SA-15
SAFETY
AVOID POWER LINES

• Serious injury or death can result if the machine or front at-
tachments are not kept a safe distance from electric lines.
• When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
• Check and comply with any local regulations that may ap-
ply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-089
029-E01A-0381
PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop op-
eration, and lower the bucket to the ground. Evacuate to
a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed safety
devices are found, operate the machine only after repair-
ing them.
SA-1241
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be struck
by the falling load or may be crushed underneath it, result-
ing in serious injury or death.
• When using the machine for craning operations, be sure
to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the travel
motors at the rear.
• Move the load slowly and carefully. Never move it sud-
denly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
032-E01A-0132
SA-014
SA-16
SAFETY
PROTECT AGAINST FLYING DEBRIS

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

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position. SA-093
• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.
HANDLE FLUIDS SAFELY−AVOID FIRES

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

SA-018
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontane-
ously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-17
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading or un-
loading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe trans-
portation.
• Select an appropriate truck or trailer for the machine to
be transported.
• Be sure to use a signal person.
• Always follow the following precautions for loading or
unloading:
Less than 15°
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the SA-094
machine weight.
3. Turn auto-idle switch OFF.
4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck or
trailer using the front attachment functions when driving
up or down the ramp.
6. Never steer the machine while on the ramp. If the travel-
ing direction must be changed while the ramp, unload
the machine from the ramp, reposition the machine on
the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a Less than 15°
sudden bump. Take care when traveling over it.
SA-095
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the TRANS-

PORTING section.
035-E07A-0454
SA-18
SAFETY
PRACTICE SAFE MAINTENANCE

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

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5 min-
utes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving SA-028
the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
• If a maintenance procedure must be performed with the

engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 100˚ angle
between the boom and arm. Securely support any ma-
chine elements that must be raised for service work.
• Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the SA-527
“MAINTENANCE” chapter in the operator’s manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable detergent
oil. Never use highly flammable oil such as fuel oil and
gasoline to clean parts or surfaces.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02C-0520
SA-19
SAFETY
• Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
• Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.
• Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
SS3076175 SS2045102
SUPPORT MACHINE PROPERLY

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

• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
503-E01B-0344
SA-344
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
• Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
504-E01A-0034 SA-034
SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can cause seri-
ous injury or death.
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
• When inflating tires, use a chip-on chuck and exten-sion
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
it available.
• Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
• Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and SA-249
may result in tire explosion.
521-E02A-0249
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO NOT
remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all pres-
sure to be released before removing the cap.
SA-039
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
• Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
505-E01B-0498
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
• Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
• Avoid this hazard by relieving pressure before disconnect-
ing hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this type
of injury immediately. Any fluid injected into the skin
SA-031
must be surgically removed within a few hours or gan-
grene may result.
507-E03A-0499
SA-292
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or hoses.
SA-019
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight(8) to ten(10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine
daily and by removing spilled or accumulated flammables
immediately.
Check Key Switch:

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

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393
SA-24
SAFETY
EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the following
way:
• Stop the engine by turning the key switch to the OFF
position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with the
emergency evacuation hammer to escape from the cab. SA-393
Refer the explanation pages on the Emergency Evacuation
Method.
18-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES

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

• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and pre-
pared area. Store flammable objects in a safe place before
starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
• After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
523-E01A-0818
SA-25
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near pres-
surized fluid lines, resulting in severe burns to yourself and
bystanders.
• Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
• Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary fire-
resistant guards to protect hoses or other materials before
engaging in welding, soldering, etc..
AVOID APPLYING HEAT TO LINES CONTAINING SA-030
FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flam-
mable fluids.
• Clean them thoroughly with nonflammable solvent be-
fore welding or flame cutting them.
510-E01B-0030
REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area. Dis-
pose of paint and solvent properly.
• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with
SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
SA-26
SAFETY
BEWARE OF ASBESTOS DUST

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

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

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

• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the instructions described on the container for
proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
SA-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

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

• Improperly disposing of waste can threaten the environ-
ment and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source.
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
516-E01A-0226
SA-28
SAFETY
BEFORE RETURNING THE MACHINE TO THE CUS-

TOMER
• After maintenance or repair work is complete, confirm that:
• The machine is functioning properly, especially the safety
systems.
• Worn or damaged parts have been repaired or replaced
S517-E01A-0435
SA-435
SA-29
SAFETY
(Blank)
SA-30
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
SECTION 5 TROUBLESHOOTING
(Troubleshooting)
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Electric Lever
Group 2 Control System Group 6 Transmission
Group 3 ECM System Group 7 Axle
All information, illustrations and speci- Group 4 Hydraulic System Group 8 Travel Motor
fications in this manual are based on Group 5 Electrical System Group 9 Signal Control Valve
the latest product information available Group 10 Steering Valve
at the time of publication. The right is Group 11 Brake Valve
reserved to make changes at any time Group 12 Others (Upperstructure)
without notice. Group 13 Others (Undercarriage)
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
←これ以下
記載しない
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Motor
Group 2 Tightening Torque Group 3 Center Joint
Group 3 Painting Group 4 Transmission
Group 4 Bleeding Air from Hydrau- Group 5 Axle
lic Oil Tank Group 6 Axle Lock Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Operate Check Valve
Group 1 Cab (Axle Lock Cylinder)
Group 2 Counterweight SECTION 4 FRONT ATTACHMENT
Group 3 Main Frame Group 1 Front Attachment
Group 4 Pump Device Group 2 Cylinder
Group 5 Control Valve Group 3 Hose Rupture Valve
Group 6 Swing Device Group 4 Operate Check Valve
Group 7 Pilot Valve (Blade/Outrigger)
Group 11 Travel Shockless Valve
Group 12 Swing Shockless Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Tests ................... T4-1-1 Primary Pilot Pressure..................................T4-5-1
Preparation for Performance Tests .............. T4-1-2 Secondary Pilot Pressure.............................T4-5-3
Solenoid Valve Set Pressure ........................T4-5-4
Group 2 Standard
Main Pump Delivery Pressure......................T4-5-6
Performance Standard ................................. T4-2-1
Main Relief Set Pressure..............................T4-5-8
Main Pump P-Q Diagram............................. T4-2-6
Relief Pressure (When relieving Swing).... T4-5-10
Sensor Activating Range.............................. T4-2-8
Overload Relief Valve Set Pressure .......... T4-5-12
Group 3 Engine Test Main Pump Flow Rate Measurement ........ T4-5-14
Engine Speed............................................... T4-3-1 Swing Motor Drainage ............................... T4-5-24
Engine Compression Pressure .................... T4-3-4 Steering Valve Relief Pressure.................. T4-5-26
Valve Clearance ........................................... T4-3-6 Brake Pressure (Front and Rear) .............. T4-5-28
Lubricant Consumption ................................ T4-3-9 Brake Accumulated Pressure .................... T4-5-30
Brake Warning Set Pressure (Decrease) .. T4-5-32
Group 4 Excavator Test
Brake Warning Set Pressure (Increase).... T4-5-34
Travel Speed ................................................ T4-4-1
Service Brake Function................................ T4-4-3
Parking Brake Control Function................... T4-4-4
Swing Speed ................................................ T4-4-5
Swing Function Drift Check.......................... T4-4-6
Swing Motor Leakage .................................. T4-4-8
Maximum Swingable Slant Angle ................ T4-4-9
Swing Bearing Play.................................... T4-4-10
Hydraulic Cylinder Cycle Time ................... T4-4-12
Dig Function Drift Check ............................ T4-4-14
Control Lever Operating Force .................. T4-4-15
Control Lever Stroke .................................. T4-4-16
Combined Operation of Boom Raise/Swing
Function Check ........................................ T4-4-17
CEBT-4-1
(Blank)
CEBT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deteriorate
titatively check all system and functions on the ma- as the working hours increase. However, the machine
chine. performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
Purpose of Performance Tests ingly, restoring the machine performance by repair,
1. To comprehensively evaluate each operational adjustment, or replacement shall consider the number
function by comparing the performance test data of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 300 m (984 ft 3 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork- T105-06-01-003
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance T212-07-01-003
to obtain correct data.

2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
Performance Standard
The performance standard values are listed in the table * The standard measurement conditions are as follows.
below.  Engine Control Dial: Fast Idle
For details including measuring method, refer to T4-3  Power Mode Switch: P mode
onward.  Auto-Idle Switch: OFF
The value indicated in parentheses is only a reference.  Work Mode: Digging mode
 Engine Speed Control Mode Selection Switch: Dial
mode
 Hydraulic Oil Temperature: 50±5 ˚C (122±9 ˚F)
Performance Reference
Descriptions Remarks
Standard Page
ENGINE SPEED min-1 T4-3-1
Slow Idle Speed 900±100 Value indicated on Dr. ZX.
Fast Idle Speed 1700±50 
Fast Idle Speed (with ECO deactivated) 1800±50 
Fast Idle Speed (Relief operation) Arm roll-in relief control. Value
1800±50
indicated on Dr. ZX.
Fast Idle Speed (E mode) 1600±50 Value indicated on Dr. ZX.
Fast Idle Speed (HP mode, Relief operation) Arm roll-in relief control. Value
2000±50
indicated on Dr. ZX.
Slow Idle Speed (Pedal mode) Travel speed mode switch: Fast
speed
1100±50 Brake switch: OFF or Axle lock
Jack up and measure.
Value indicated on Dr. ZX.
Fast Idle Speed (Pedal mode, Working accelerator) FNR switch: N
Brake switch: OFF, Auto axle
2000±50
lock or Axle lock
Value indicated on Dr. ZX.
Fast Idle Speed (Pedal mode, Relief operation) Travel speed mode switch: Fast
speed
Brake switch: OFF, Auto axle
lock or Axle lock
2200±50
Depress the brake pedal,
perform travel relief or jack up
and measure.
Values indicated on Dr. ZX.
Auto-Idle Speed 1100±100 Value indicated on Dr. ZX.
Warming-Up Speed 1400±100 
ENGINE COMPRESSION PRESSURE 3.04±0.2 Engine speed: at 200 min-1 T4-3-4
MPa (kgf/cm2, psi) (31±2, 440)
VALVE CLEARANCE (IN, EX) mm 0.15 With engine cold T4-3-6
LUBRICANT CONSUMPTION Hour meter: 2000 hours or less T4-3-9
mL/h 30 or less
(Rated Output)
T4-2-1
Group 2 Standard
Descriptions Reference
Standard Page
TRAVEL SPEED km/h (100 m) T4-4-1
Fast Engine speed control mode
35.0+1.0-3.0 selection switch: Pedal mode,
Travel speed mode switch: Fast
Slow Engine speed control mode
selection switch: Pedal mode,
8.6±0.5
Travel speed mode switch:
Slow
Creeper ZX140W-3: Up to serial No
005000, ZX140W-3-AMS: Up to
2.2±0.3 serial No 050000
Engine speed control mode
selection switch: Creeper mode
ZX140W-3: Serial No 005001
and up, ZX140W-3-AMS: Serial
1.8±0.3 No 050001 and up
Engine speed control mode
selection switch: Creeper mode
SERVICE BRAKE FUNCTION N (kgf ) T4-4-3
Service Brake Tire
lock
Parking Brake Tire
lock
PARKING BRAKE FUNCTION mm/5 min (0) T4-4-4
SWING SPEED sec/3 rev 13.1±1.5 Bucket: empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/90 ˚ 720 or less Bucket: empty T4-4-6
SWING MOTOR LEAKAGE mm/5 min 0 Bucket: loaded T4-4-8
MAXIMUM SWINGABEL SLANT ANGLE deg. 18 or more Bucket: loaded T4-4-9
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-10
HYDRAULIC C YLINDER CYCLE TIME 2.52 m arm T4-4-12
sec 0.3 m3 (PCSA heaped) bucket,
Bucket: empty, Without HRV
Boom Raise (Monoblock Boom) 4.1±0.3 Without bucket: 3.9±0.3
Boom Lower (Monoblock Boom) 4.5±0.3 Without bucket: 4.3±0.3
Boom Raise (2-Piece Boom) 2.8±0.3 Without bucket: 3.1±0.3
Boom Lower (2-Piece Boom) 3.0±0.3 Without bucket: 3.3±0.3
Arm Roll-In 3.7±0.3 Without bucket: 3.9±0.3
Arm Roll-Out 3.1±0.3 Without bucket: 3.1±0.3
Bucket Roll-In 3.5±0.3 Without bucket: 3.9±0.3
Bucket Roll-Out 2.8±0.3 Without bucket: 2.9±0.3
Positioning Extend 7.6±0.5 Without bucket: 7.6±0.5
Positioning Retract 5.1±0.4 Without bucket: 5.1±0.4
Blade Raise 2.0±0.3
Blade Lower 2.5±0.3
Outrigger Raise 1.9±0.3
Outrigger Lower 1.9±0.3
fNOTE: HRV: Hose Rupture Valve
T4-2-2
Group 2 Standard
Standard Page
HYDRAULIC CYLINDER CYCLE TIME 2.52 m arm T4-4-12
sec 0.3 m3 (PCSA heaped) bucket,
Bucket: empty, With HRV
Boom Raise (Monoblock Boom) 4.1±0.3 Without bucket: 3.9±0.3
Boom Lower (Monoblock Boom) 3.0±0.3 Without bucket: 3.3±0.3
Boom Raise (2-Piece Boom) 4.5±0.3 Without bucket: 4.3±0.3
Boom Lower (2-Piece Boom) 3.2±0.3 Without bucket: 4.1±0.3
Arm Roll-In 3.9±0.3 Without bucket: 4.1±0.3
Arm Roll-Out 3.1±0.3 Without bucket: 3.1±0.3
Bucket Roll-In 3.5±0.3 Without bucket: 3.9±0.3
Bucket Roll-Out 2.8±0.3 Without bucket: 2.9±0.3
Positioning Extend 7.6±0.5 Without bucket: 7.6±0.5
Positioning Retract 5.3±0.4 Without bucket: 5.3±0.4
Blade Raise 2.0±0.3
Blade Lower 2.5±0.3
Outrigger Raise 1.9±0.3
Outrigger Lower 1.9±0.3
DIG FUNCTION DRIFT CHECK 2.52 m arm T4-4-14
(Maximum Reach Position) mm/5 min 0.3 m3 (PCSA heaped) bucket,
bucket loaded
Boom Cylinder 5 or less
Arm Cylinder 10 or less
Bucket Cylinder 15 or less
Positioning Cylinder 15 or less
Front Drift Amount (Bucket Bottom) 100 or less
CONTROL LEVER OPERATING FORCE N (kgf ) T4-4-15
Right Lever: Forward/Backward 15 (1.5) or less
Right Lever: Right/Left 15 (1.5) or less
Left Lever: Forward/Backward 15 (1.5) or less
Left Lever: Right/Left 15 (1.5) or less
Steering Wheel Turns (lock-to-lock) 20 (2.0) or less
CONTROL LEVER STROKE mm T4-4-16
Right Lever: Forward/Backward 62±10
Right Lever: Right/Left 62±10
Left Lever: Forward/Backward 74±10
Left Lever: Right/Left 74±10
Steering Wheel Turns (lock-to-lock) 7.0±0.5
2.52 m arm T4-4-17
COMBINED OPERATION OF BOOM
sec 3.6±0.3 0.3 m3 (PCSA heaped) bucket,
RAISE/SWING FUNCTION CHECK
Bucket: empty
Bucket Teeth Height: H mm 5500 or more
fNOTE: HRV: Hose Rupture Valve
T4-2-3
Group 2 Standard
Standard Page
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE T4-5-1
MPa (kgf/cm2, psi)
4.0+1.0-0.5
Fast Idle
(41 -5, 581+145-73)
+10
SECONDARY PILOT PRESSURE 3.3 to 3.9 Value indicated on Dr. ZX. T4-5-3
(For Fast Idle, Slow Idle) (34 to 40, (Control lever: Full stroke)
MPa (kgf/cm2, psi) 480 to 567)
STEERING PUMP PRESSURE 2.5±1.0
MPa (kgf/cm2, psi) (26±10, 363±145)
SOLENOID VALVE SET PRESSURE T4-5-4
MPa (kgf/cm2, psi)
Solenoid Valve Unit Set Pressure (Value of Dr. ZX) ±0.2 Value indicated on Dr. ZX.
(2, 29)
MAIN PUMP DELIVERY PRESSURE 1.0+1.0-0.5 In neutral, Value indicated T4-5-6
MPa (kgf/cm2, psi) (10+10 , 145+145 ) on Dr. ZX
-5.0 -73
MAIN RELIEF VALVE RELIEF PRESSURE T4-5-8

MPa (kgf/cm2, psi)
Boom, Arm, Bucket (Relief operation for each) 34.3+1.2-0.8 Value indicated on Dr. ZX.
(350+12-8, 4980+175-115)
RELIEF PRESSURE
MPa (kgf/cm2, psi)
Relief operation of swing 33.4+2.3-0.5 Value indicated on Dr. ZX. T4-5-10
(340+23-5, 4860+335-73)
Relief operation of travel 35.3+2.0-1.0 Value indicated on Dr. ZX.
(360 -10, 5130 -145)
+20 +290
Relief operation of blade/outrigger raise 28.0+2.0-0 Value indicated on Dr. ZX.

(285+20-0, 4070+290-0)
Relief operation of blade/outrigger 28.0+2.0-1.0 Value indicated on Dr. ZX.
lower (285 -10, 4070 -145)
+20 +290
OVERLOAD RELIEF VALVE RELIEF PRESSURE T4-5-12

MPa (kgf/cm2, psi)
Boom (lower), Arm (roll-in), Bucket (roll-in), (Reference values at 50 L/
37.2 (379, 5410)
Blade/Outrigger (raise/lower) min)
Boom (raise), Arm (roll-out), Bucket (roll-out) (Reference values at 50 L/
39.2 (400, 5700)
min)
(Reference values at 135
Auxiliary 28.0 (285, 4070)
L/min)
T4-2-4
Group 2 Standard
Standard Page
MAIN PUMP FLOW RATE L/min - Refer to T4-2-6. T4-5-14
SWING MOTOR DRAINAGE L/min
With constant speed 0.2 to 0.3 T4-5-24
With motor relieved (2 to 5)
STEERING VALVE RELIEF PRESSURE 17.5±1.0 T4-5-28
MPa (kgf/cm2, psi) (179±10,
2540±145)
BRAKE PRESSURE (FRONT/REAR) 7.0±1.0 T4-5-30
(including work brake operating pressure) (70±10,
MPa (kgf/cm2, psi) 1020±145)
BRAKE ACCUMULATOR PRESSURE 17.7±1.0 T4-5-32
MPa (kgf/cm2, psi) (181±10,
2570±145)
BRAKE ALARM PRESSURE
MPa (kgf/cm2, psi)
Decrease 8.3±0.3 T4-5-34
(85±3, 1210±44)
9.0±0.3 T4-5-36
Increase
(92±3, 1310±44)
T4-2-5
Group 2 Standard
Main Pump P-Q Diagram

 Hydraulic P-Q Control (Torque Control)
(NOTE: Measured at Test Stand)
 Rated Pump Speed: 2200 min-1 (rpm)

 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
fNOTE: Refer to T4-5-14.
P-Q Point
Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm)
Pump 1: 220±3
A 3.9 (40, 570)
(58.0±0.8)
Pump 2: 165±3
A’ 3.9 (40, 570)
(43.5±0.8)
B 11.8 (120, 1720) Pump 1: [218 (57.5)]
B’ 16.7 (170, 2430) Pump 2: [163 (43.0)]
C 18.6 (190, 2700) 147±6 (38.8±1.6)
D 20.6 (210, 2990) [125 (33.0)]
E 22.5 (230, 3270) 110±6 (29.0±1.6)
F 34.3 (350, 4990) 53±10 (14.0±2.6)
The value indicated in parentheses is only a reference.
L/min A
B
A’ B’
D
Flow Rate
E
Delivery Pressure MPa (kgf/cm2) TCEB-04-02-001
T4-2-6
Group 2 Standard
 P-Q Control by Pump Control Pilot Pressure Signal

(NOTE: Measured at Test Stand)
 Rated Pump Speed: 2200 min-1 (rpm)

fNOTE: Refer to T4-5-16.
P-Q Point
Pump Control Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm)
1.9±0.05 (19±0.5, Pump 1: 91±2 (24.0±0.5)
A
276±7.3) Pump 2: 70±2 (18.5±0.5)
3.4±0.05 (35±0.5,
B 129±8 (34.0±2.1)
494±7.3)
Pump 1: 220±3
2.9+0.05-0.29 (58.0±0.8)
C
(30 -3, 422+7.3-42.2)
+0.5
Pump 2: 165±3
(43.5±0.8)
fNOTE: B: With flow rate limit control

C: Without flow rate limit control
L/min
Flow Rate
Pump Control Pressure MPa (kgf/cm2, psi) T1T1-04-02-001
T4-2-7
Group 2 Standard
Sensor Activating Range

1. Measuring Method
 Unless specified:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Fast Idle Digging
P OFF
Speed mode
 Monitor each sensor by using Dr. ZX.
2. Sensor Activating Range
Item Operation Standard

Slow Idle 0.3 to 1.0 V
Engine Control Dial
Fast Idle 4.0 to 4.7 V
Control lever: Neutral position 0 to 0.1 MPa
Pressure Sensor Pilot shut-off lever: LOCK position (0 to 1.0 kgf/cm2, 0 to 14.5 psi)
(Boom Raise, Arm Roll-In, Swing) Control lever: Full stroke 3.3 to 3.9 MPa
Pilot shut-off lever: UNLOCK position (34 to 40 kgf/cm2, 480 to 570 psi)
Control Lever: Neutral position 0 to 0.1 MPa
Pilot shut-off lever: LOCK position (0 to 1.0 kgf/cm2, 0 to 14.5 psi)
Pressure Sensor (Travel)
Control lever: Full stroke 2.7 to 3.3 MPa
Pilot shut-off lever: UNLOCK position (28 to 34 kgf/cm2, 390 to 480 psi)
0.7 to 1.3 MPa
Control lever: Neutral position
(7 to 13 kgf/cm2, 100 to 190 psi)
Pump Control Pressure Sensor
2.9 to 3.9 MPa
Control lever: Full stroke
(30 to 40 kgf/cm2, 420 to 570 psi)
Travel N Sensor 20 °C (GND to SIGNAL) 810±240 Ω
T4-2-8
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure the engine speed by using the monitor
unit or Dr. ZX.
2. Measure the engine speeds in each mode.
NOTE: If the engine speed is not adjusted correctly,

all other performance data will be unreliable.
Consequently, measure the engine speed
before performing all other tests in order to
check that the engine speed meets
specification.
Preparations:
1. Select the service menu of monitor (In case of Dr.
ZX, install Dr. ZX first).
2. Warm up the machine until coolant temperature
reaches 50 °C (122 °F) or more, and hydraulic oil
temperature is 50±5 °C (122±9 °F).
T4-3-1
Measurement: Remedy:
1. Measure the engine speeds in the "dial mode" and Refer to Troubleshooting B in Group T5-7.
"pedal mode" positions for the engine speed
control mode selection switch.
NOTE: ECO stands for the auto engine speed
2. When measuring, set the switch and test condition -1
reduction system by 100 min .
as shown in the table below in response to the
engine speed to be measured.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
• Engine Speed Control Mode Selection Switch: Dial mode

Engine Power Auto-
Item Control Mode Idle Work Mode Test Conditions
Dial Switch Switch
Slow Idle Digging Lever in neutral.
Slow Idle P OFF
mode
Fast Idle Check in the Dr. ZX special
(with ECO Digging functions with ECO deactivated.
Fast Idle P OFF
deactivated) mode Measure engine speed with the
lever in neutral.
Fast Idle Move the pilot shut-off lever to the
Digging
(Heater control Fast Idle P OFF UNLOCK position. Measure engine
mode
OFF) speed with the lever in neutral.
Fast Idle Digging Measure engine speed while
Fast Idle P OFF
(Relief operation) mode relieving the boom raise circuit.
Fast Idle Digging Lever in neutral.
Fast Idle E mode OFF
(E mode) mode
Fast Idle Digging Measure engine speed while
Fast Idle HP mode OFF
(HP mode) mode relieving the boom raise circuit.
Auto-Idle Measure engine speed 4 seconds
Digging
Fast Idle P ON after returning all control levers to
mode
neutral.
Warming-Up Engine speed can be measured
Digging
Slow Idle P OFF only when hydraulic oil
mode
temperature is 0 °C (32 °F) or less.
T4-3-2
• Engine Speed Control Mode Selection Switch: Pedal mode

Accelerator Power Mode Auto-Idle Work
Test Conditions
Pedal Switch Switch Mode
• FNR switch: (F or R)
Not Digging • Brake switch:
Slow Idle P OFF
depressed mode OFF or Axle lock
• Engine control dial: Slow
Max. Digging • FNR switch: N
Fast Idle P OFF
depressing mode • Work brake: Operable
• Travel speed mode switch: Fast
• Brake switch:
Fast Idle
Max. Digging OFF or Axle lock
(Relief P OFF
depressing mode • Raising Machine
operation)
• Travel operation with brake
depressed
Method Raising Machine:

As for a machine attached with an outrigger or a blade
in front and rear of the chassis, raise the machine off
the ground by using the outrigger or blade.
CAUTION: Securely support the raised

machine by using the blocks.
As for a machine attached with an outrigger or a blade

only in rear of the chassis, raise the machine by using
a front attachment as illustrated in the right.
Switch Panel: T1F3-04-02-002
Engine Control Monitor Unit:

Dial
Digging Mode
Travel Speed
Mode Switch
Engine Speed
Control Mode
Selection Switch
Power Mode
Switch
Auto-Idle
TCJB-05-02-064
T4-3-3
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
and check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system,
including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Remove the negative terminal of the battery.
Remove all the glow plugs from each cylinder.
： 20 N⋅m (2.0 kgf⋅m, 14.8 lbf⋅ft)
IMPORTANT: If disconnecting the connector of Injector

injector, fuel cannot be jetted.
Therefore, ECM judges that the fuel
system is faulty and the fault code is
displayed. After measurement,
delete the displayed fault code.
5. Disconnect the connector of injector.

6. Install the negative terminal of the battery.
7. Turn the starter. Exhaust foreign subjects from the
cylinder.
8. Install a pressure gauge and an adaptor (Isuzu
5-8840-2815-0) to the glow plug mounting part.
(Sufficiently install them in order to prevent air
leakage.) T1T1-04-03-001
Glow Plug
Measurement:
1. Turn the starter and measure compression
pressure of each cylinder.
2. Repeat the measurement three times and
calculate the mean values.
Evaluation:
Refer to OERATIONAL PERFORMANCE TEST /
Remedy:
Refer to the engine shop manual.
T1T1-04-03-002
T4-3-4
(Blank)
T4-3-5
VALVE CLEARANCE
Injector
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparation:
1. Disconnect the connector of inject.
2. Remove the leak off hose.
3. Remove the head cover.
4. Rotate the crank pulley. Align the top dead center
(TDC) mark on crank pulley with the top mark
located on timing gear case. Leak Off Hose T1T1-04-03-001
NOTE: When rotating the crank pulley, remove the

fan guard. Then, rotate the fan while
holding the fan belt. If it is difficult to rotate,
remove all glow plugs and release
compression pressure. Crank Pulley
5. Check if cylinder No.1 (or cylinder No.4) is now

positioned at the TDC in the compression stroke.
NOTE: When both intake and exhaust valve are
closed, this cylinder is positioned at TDC in
the compression stroke.
6. Start measurement from the cylinder No.1 (or Top Mark

cylinder No.4) positioned at TDC in the
compression stroke. T1T1-04-03-003
TDC Mark
T4-3-6
Measurement:
1. Insert a thickness gauge into the clearance
between rocker arm roller and cam shaft and A
measure the valve clearance.
A
NOTE: The cylinders are aligned from No.1 to A

No.4 in that order, as viewed from the fan A
side. Injection Order: 1-3-4-2 A
2. When measurement is started from No.1 cylinder, A

perform the same measurement to all valves A
○
indicated with the mark “ ” in the table below.
(When measurement is started from No.4 cylinder, A
T1T1-04-03-006
perform the measurement in the valves shown
with mark “×”.)
Cylinder No. No.1 No.2 No.3 No.4

Valve locations I E I E I E I E
When the measurement is
started from No.1 cylinder
○ ○ ○ ○
When the measurement is
× × × ×
started from No.4 cylinder
3. Rotate the crankshaft 360°. Align the TDC mark

with the pointer. Continue measurement of other Section A
valves in the same way.
Valve Clearance Caam Shaft Valve Clearance
Evaluation:
Refer to OERATIONAL PERFORMANCE TEST /
T1T1-04-03-005
Rocker Arm Roller
T4-3-7
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
Cam Shaft
1. Loosen the lock nuts (16 used) and adjusting
screws (16 used), which secure the rocker arm by
using adjust nut wrench (Isuzu 5-8840-2822-0).
2. Insert a thickness gauge into the clearance
between rocker arm roller and cam shaft.
3. Tighten the adjusting screw of rocker arm until Thickness
Gauge
condition for the thickness gauge is proper.
4. Tighten the lock nut of rocker arm.
: 18 N⋅m (1.8 kgf⋅m, 13.2 lbf⋅ft)
5. Check the valve clearance after the lock nuts are
tightened. T1T1-04-03-004
Adjust Nut Wrench Rocker Arm
Valve Clearance Cam Shaft Valve Clearance
T1T1-04-03-005
Rocker Arm Roller
T4-3-8
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or
until the oil level lowers to the low-level gauge.
IMPORTANT: Keep the machine-leaving time in

Step 1 above.
5. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level gauge
while measuring the oil-replenishing volume C.
NOTE: When measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the

following equation:
Oil replenishing volume (C) [mL] / Operating hours
(B-A) [hr]
Evaluation:
T4-3-9
(Blank)
T4-3-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
1. Measure the time required for the excavator to
travel a 100 m (328 ft) test track and check the
performance of travel device systems (from main
pump to travel motor).
Preparation:
CAUTION: Set the swing lock lever to the
LOCK position while traveling.
1. Adjust pressure of all tires equally.

2 End
Pressure: 650 kPa (6.5 kgf/cm , 94 psi)
2. Prepare a flat and solid test track 100 m (328 ft) 100 m
long, with an extra length of 400 m (1310 ft) on
both ends of the test track for machine Start
acceleration and deceleration. Acceleration Zone
400 m T1F3-04-04-003
NOTE: If it is difficult to prepare a test track 400 m

(1310 ft) long, set the travel speed mode
switch to slow idle before measurement.
NOTE: When measuring travel speed at slow idle

or creeper speed, prepare a test track 200
m (656 ft) long.
3. Position the front attachment as illustrated in the

4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-1
Measurement:
CAUTION: Do not measure travel speed
when traveling in reverse. (FNR Switch: F)
1. Measure at fast, slow and creeper speed.

2. Select the following switch positions:
Engine Travel Speed Engine Speed Control Accelerator Power Mode Auto-Idle
Work Mode
Control Dial Mode Switch Mode Selection Switch Pedal Switch Switch
Max.
Fast Slow idle Fast Pedal mode P Digging mode OFF
depressing
Max.
Slow Slow idle Slow Pedal mode P Digging mode OFF
depressing
Max.
Creeper Slow idle Slow Creeper mode P Digging mode OFF
depressing
3. Turn the FNR switch to the F (forward) position.

Depress the accelerator pedal to full stroke and
travel the machine from the acceleration zone.
4. Measure travel speed (second) in each mode.
5. Repeat the measurement three times. Calculate
the average values.
6. Convert the measured values to km/h.
Measured value (second) = S (sec)

Converted value (km per hour) = A (km/h)
A= 100 × 3600
S ×1000
Evaluation:
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-2
SERVICE BRAKE FUNCTION
Summary: Evaluation:
1. Check the performance of hydraulic brake circuit Refer to OPERATIONAL PERFORMANCE TEST /
and brake. Standard in Group T4-2.
2. Brake control function is the safety item. Carry out
the performance test of brake certainly. Remedy:
Preparation: in Group T5-7.
CAUTION: Set the swing lock lever to the
LOCK position while traveling.
1. Adjust pressure of all tires equally.
Pressure: 650 kPa (6.5 kgf/cm2, 94 psi)
2. Prepare a dry and paved test track 200 m (656 ft)
long (acceleration zone 100 m (328 ft) and test
track 100 m (328 ft)). Determine the brake start
position.
(122±9 °F).
Measurement:
Stop Position
CAUTION: Do not measure travel speed Stop Distance
when traveling in reverse. (FNR Switch: F)
Brake
1. Measure travel speed in fast idle. Start Position (100 m Position)
T1F3-04-04-004
Travel Speed Engine Speed Control Accelerator Power Mode Auto-Idle

Work Mode
Mode Switch Mode Selection Switch Pedal Switch Switch
Max. Digging
Fast Pedal P OFF
depressing mode
3. Turn the FNR switch to the F (forward) position.
Depress the accelerator pedal to full stroke and
travel the machine at fast.
4. Depress the brake pedal at the brake start
position and stop the machine completely.
5. Measure the distance from the brake start position
to the tread of a front tire.
the average values.
T4-4-3
PARKING BRAKE FUNCTION
Summary:
1. Measure the parking brake function on a specified
slope.
2. Brake control function is the safety item. Carry out
the performance test of brake certainly.
Preparation:
1. The surface of test slope shall be even paved
road with a gradient (11.31°).
(122±9 °F).
Measurement:
1. Climb a slope and set the brake switch to the P
(parking brake) position.
2. Stop the engine.
3. After the machine stops, put the mark (white line)
on the tire and slope.
4. After 5 minutes, measure the distance between
marks (white line) on the tire and slope.
T1F3-04-04-005
Evaluation:
T4-4-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns and check the performance of swing device
systems (from main pump to swing motor).
Preparation:
1. Check lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this test
on a slope.
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the boom foot pin is the same as Height of the boom
foot pin is the
the arm tip pin. (The bucket must be empty.) same as the
4. Maintain hydraulic oil temperature at 50±5 °C arm tip pin
(122±9 °F).
T1F3-04-04-006
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Measurement:
Engine Power Mode Work Auto-Idle
Brake Switch Work Brake
Control Dial Switch Mode Switch
Digging Axle lock or
Fast idle P OFF Operable
mode Auto axle lock
2. Operate the swing control lever fully.
3. Measure the time required to swing three turns in
one direction.
4. Measure for the right and left swing.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-4-5
SWING FUNCTION DRIFT CHECK
Summary:
1. Measure the swing drift on swing bearing outer
circumference when stopping after a 90°
full-speed swing and check the performance of
swing brake valve.
2. The mechanical brake for swing parking brake is
equipped for the swing motor.
Preparation:
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this test
on a slope.
that the height of the boom foot pin is the same as
the arm tip pin. (The bucket must be empty.) Put the matching marks on swing
4. Put the matching marks on the swing bearing bearing outer circumference and
T202-07-03-005
outer circumference (upperstructure side) and the chassis.

chassis.
5. Set the marks on swing bearing and chassis with Before starting the measurement,
swing the upperstructure 90°
an angle of 90°.
(122±9 °F).

T1F3-04-04-007
T4-4-6
Measurement:
mode Auto axle lock
2. Operate the swing control lever fully. Return the
swing control lever to the neutral position when
the mark on upperstructure aligns with that on
chassis after swinging 90°.
3. After the upperstructure stops, measure the Measure the distance between the marks.
distance between the marks along swing bearing
outer circumference and chassis.
4. Measure for the right and left swing.
the average values.
Evaluation: Mark on Chassis

Standard in Group T4-2. Mark on Swing Bearing
T105-06-03-010
Remedy:
in Group T5-7.
T4-4-7
SWING MOTOR LEAKAGE

Summary: Evaluation:
1. Measure the upperstructure drift while keeping the Refer to OPERATIONAL PERFORMANCE TEST /
upperstructure with an angle of 90° relative to the Standard in Group T4-2.
slope on a 15±1° slope and check the
performance of swing parking brake. Remedy:
(The mechanical brake for swing parking brake is Refer to TROUBLESHOOTING / Troubleshooting B
equipped for the swing device.) in Group T5-7.
Preparation:
bearing.
2. Load a specified weight 750 kg (1660 lb) into the
bucket.
the arm tip pin.
4. The test slope angle shall be flat with a gradient
(15±1°).
5. Climb a slope and swing the upperstructure to
position it 90° relative to the slope. Put the
matching marks on the outer circumference of
swing bearing (upperstructure side) and chassis
by using the tape.
(122±9 °F).
T212-07-03-001
Measurement:
Slow idle P OFF Operable
mode Auto axle lock
2. Maintain the engine at slow idle. After five minutes,
measure the distance between the marks along
swing bearing outer circumference and chassis. Measure the distance between the marks.
3. Measure on the right and left swing.
4. Repeat the measurements three times. Calculate
the average values.
Mark on Chassis
Mark on Swing Bearing
T105-06-03-010
T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE
CAUTION: As the machine may turn over

during swing operation, turn the brake switch
to the Axle Lock or Auto Axle Lock position.
Summary:
1. With the upperstructure swing 90° relative to the
slope, check the maximum slant angle on which
the upperstructure can swing to the uphill side.
Preparation:
bearing.
bucket.
the arm end pin.
4. Climb a slope and swing the upperstructure 90°
relative to the slope.
T212-07-03-001
(122±9 °F).
Measurement:
mode Auto axle lock
2. Operate the swing control lever to full stroke and
swing the upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle. Measure for the right
and left swing.
5. Repeat the measurement three times.
Evaluation:
Remedy:
in Group T5-7.
T4-4-9
SWING BEARING PLAY
Summary:
1. Measure the swing bearing play between inner
Dial Gauge
race and outer race and check the wear of swing
bearing races and balls.
Preparation:
1. Check the swing bearing mounting bolts for
looseness.
2. Check lubrication of the swing bearing. Check that
the swing bearing rotation is smooth and without
noise.
3. Secure a dial gauge on the round trunk of chassis
by using a magnetic base.
4. Position the upperstructure in the same direction
as traveling the chassis.
5. Position the dial gauge so that its needle point
comes into contact with the bottom surface of
swing bearing outer race. Magnetic T202-07-03-008
6. The bucket must be empty. Base
NOTE: The measured value will vary depending on Dial Gauge

where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the swing
bearing as possible.
Measurement: Round Trunk

bucket cylinder fully extended, hold the bucket Magnetic
Base
100 mm above the ground. Record dial gauge
reading (h1). T105-06-03-015
2. Lower the bucket to the ground and raise the front Measurement [h 1]
idler 0.5 m (20 in) by using the front attachment.
Record dial gauge reading (h2).
3. Calculate swing bearing play (H) from these data
(h1 and h2) as follows:
[H]=[h2]ー[h1]
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST / 100 mm
T212-07-05-003
Measurement [h 2]
T1F3-04-04-008
T4-4-10
(Blank)
T4-4-11
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Measure the cycle time of boom, arm, bucket,
blade (optional) and outrigger (optional) cylinders
and check the performance of front attachment
systems (from main pump to each cylinder).
2. The bucket must be empty.
Preparation:
1. Measure at the position as follows.
1-1. Measurement of the cycle time of boom
cylinders:
With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
Boom Cylinder:
on to the ground.
1-2. Measurement of the cycle time of arm cylinder:
Retract or extend the bucket cylinder so that the
arm and bucket teeth are vertical to the ground.
Set the arm so that the center of arm operation
is vertical.
1-3. Measurement of the cycle time of bucket
cylinder: T202-07-03-012
Adjust each cylinder of boom and arm so that
Arm Cylinder:
the center of bucket full stroke is vertical.
1-4. Measurement of the cycle time of blade
cylinders:
Raise the machine by using the front
attachment in order to be able to move the
blade cylinder to fully stroke.
1-5. Measurement of the cycle time of outrigger
cylinders:
Raise the machine by using the front
attachment in order to be able to move the
outrigger cylinder to fully stroke.
0.5 m

(122±9 °F). T1V1-04-05-005
Bucket Cylinder:
T105-06-03-018
T4-4-12
Measurement:
Engine Power Mode Auto-Idle
Work Mode Work Brake
Control Dial Switch Switch
Digging
mode
2. Measure the cylinder cycle times as follows.
(Cylinder full stroke includes cylinder cushioning
Blade Cylinder:
zone.)
2-1. Boom cylinder:
Operate the boom control lever to full stroke.
Measure the time to raise and lower the boom.
2-2. Arm cylinder:
Operate the arm control lever to full stroke.
Measure the time to roll in and roll out the arm.
2-3. Bucket cylinder:
Operate the bucket control lever to full stroke.
Measure the time to roll in and roll out the
bucket.
2-4. Blade cylinder:
Operate the blade control lever to full stroke.
Measure the time to raise and lower the blade.
2-5. Outrigger cylinder:
Operate the outrigger control lever to full stroke. TCJB-04-04-001
Measure the time to raise and lower the NOTE: The illustration shows the rear blade.
outrigger. Measure the time for the cylinders
one by one. Outrigger Cylinder:

the average values.
Evaluation:
Remedy: TCJB-04-04-002
NOTE: The illustration shows the rear outrigger.
in Group T5-7.
T4-4-13
DIG FUNCTION DRIFT CHECK
• Maximum Reach Position

Summary:
1. Load a specified weight into the bucket. Measure
the cylinder rod drift and judge oil leakage in the
boom, arm and bucket cylinders, and the control
valve.
2. When measuring the drift just after cylinder
replacement, slowly operate the cylinder for ten
minutes and bleed air from the cylinder.
Preparations:
bucket.
Extended Distance
that the height of the boom foot pin is the same as Retracted Distance
the arm tip pin. Retracted
3. Position the arm and buckets cylinders with the Distance
rod 50 mm (2 in) retracted from the fully extended
position. Height of the
boom foot pin is
4. Maintain hydraulic oil temperature at 50±5 °C the same as the arm tip pin.
(122±9 °F).
Drift Amount
Measurement: T1F3-04-04-011
1. Stop the engine.

2. Five minutes after the engine has been stopped, Boom and Bucket Cylinder Retraction
measure the change in position of bottom of the
bucket, as well as the boom, arm and bucket Mark Mark
cylinders.
the average values.
Evaluation:
T110-06-03-002
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B Arm Cylinder Extension
in Group T5-7.
Mark
T110-06-03-001
T4-4-14
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure a play and operating condition of each
control lever.
2. Measure the maximum operating force of front
attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
(122±9 °F).
CAUTION: Prevent personal injury. Always T107-06-03-003

starting the measurement. Knob
Measurement:
1. Measure for each control lever.
2. Select the following switch positions: TCJB-04-04-003

Digging
mode
3. In case of boom (raise), arm and bucket control
lever, measure the maximum operating force for
each with each actuator relieved.
4. In case of boom (lower) control lever, measure the
maximum operating force with the boom (lower)
relieved by raising the machine in a safe area.
5. In case of swing control lever, measure the
maximum operating force with swing relieved after
securing the front attachment to prevent swinging.
6. In case of handle, measure the maximum
operating force by using a spring balance
attached to knob.
the average values.
Evaluation:
T4-4-15
CONTROL LEVER STROKE
Summary:
1. Check a play and operating condition of each
control lever and measure the stroke.
2. Measure the control lever stroke at the grip center Stroke Stroke
of each control lever.
3. In case control lever stroke play is present in the
neutral position, add half (1/2) the play present to
both side control lever strokes.
Neutral
Preparations:
1. Maintain hydraulic oil temperature at 50±5 °C T1F3-04-04-012
(122±9 °F).
Measurement:
1. Stop the engine.
2. Measure each control lever stroke from neutral to
the stroke end of each control lever of boom, arm,
bucket, swing and travel.
3. Measure the number of rotation of handle from
right to left stroke end and from left to right stroke
end.
4. Measure the straight dimension.
the average values.
Evaluation:
T4-4-16
COMBINED OPERATION OF BOOM RAISE
/ SWING FUNCTION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions
simultaneously.
2. Check that the cylinders do not hesitate while
operating the cylinder with the engine running at
fast.
Preparation:
bucket cylinder fully extended, lower the bucket
onto the ground. (The bucket must be empty.)
2. Maintain hydraulic oil temperature at 50±5 °C T212-07-03-005
(122±9 °F).

Measurement: T212-07-03-006

Digging
mode
2. Raise the boom and roll the swing in full stroke at
the same time. When the upperstructure rotates
90°, release the control levers to stop both
functions. Measure the time required to swing 90°
and height (H) of the bucket teeth. (The bucket
must be empty.)
the average values.
H
Evaluation:
Remedy: 90° T212-07-03-007

in Group T5-7.
T4-4-17
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure.
3. Remove the plug from the pilot filter. Install
adapter (ST 6069) and pressure gauge (ST 6942)
to the pressure check port.
: 14 mm
4. Start the engine. Check for any oil leaks at the
pressure gauge connection. Plug
(122±9 °F).
Measurement: T178-03-07-001
1. Select the following switch positions.
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
Digging
Slow idle P OFF
mode
2. Measure pilot pressure in each specified setting
above without load by using a pressure gauge.
the average values.
Evaluation:
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set pressure if necessary.
Relief Valve
1. Remove plug (1) from the relief valve.
: 22 mm
2. Install the estimated number of shims (2).
3. After adjustment, tighten plug (1).
+2 +0.2 +1.5
: 25 N⋅m (2.5 kgf⋅m, 18.4 lbf·ft) T178-03-07-001
4. After adjustment, check the set pressure.
1
NOTE: Standard Change in Pressure (Reference) 2
Shim Change in Pressure
Thickness
kPa (kgf/cm2) (psi)
(mm)
0.25 78 (0.8) (11)
0.5 157 (1.6) (23)
1.0 304 (3.1) (44)
T111-06-04-004
T4-5-2
SECONDARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and Pilot Valve Signal Control Valve
3. Measure pressure at the location between pilot Hose
valve and signal control valve. Remove the pilot
hose from the circuit to be measured. Install the Fitting
hose (9/16-18UNF, Length: approx. 400 mm (16
in)) to the signal control valve side. Install tee
(4351843), adapter (ST 6460), fitting (ST 6069),
coupling (ST 6332) and pressure gauge (ST 6315)
between the hoses. Pressure
Gauge
: 17 mm, 19 mm
Tee
Adapter
NOTE: When removing the lines from signal con-
trol valve, use tool (SNAP-ON
GAN850812B: size 19.05 mm) in order to
easily remove the lines.

pressure gauge connection.
(122±9 °F). T1F3-04-05-008
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
Digging
Slow idle P OFF
mode
2. Measure pilot pressure by using a pressure gauge
with the corresponding control lever operated to
full stroke.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-3
SOLENOID VALVE SET PRESSURE
Use both Dr. ZX and a pressure gauge.
Preparation:
1. Stop the engine.
Solenoid Valve Unit
3. Remove the line from the solenoid valve to be Pressure Gauge
measured. Install tee (ST 6451), hose (Parts
Number: 4216453), adapter (ST 6461) and pres-
sure gauge (ST 6942).
: 17 mm, 19 mm, 22 mm
4. Connect Dr. ZX and select the monitoring function.
6. Maintain hydraulic oil temperature at 50±5 °C Hose Tee Adapter
(122±9 °F). T157-05-04-002
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
Digging
Slow idle P OFF
mode
2. Operate as instructed below for each measuring
solenoid valve:
• Solenoid Valve SI: SC SF SI
Set the brake switch to the Axle lock position.
• Solenoid Valve SF:
When setting the brake switch to the Axle lock or
Auto axle lock position and stopping the machine,
depress the brake pedal.
• Solenoid Valve SC:
Combined operation of swing and arm roll-in.
3. Read the values on both Dr. ZX and the pressure
gauge.
the average values. TCGB-03-12-001
Evaluation:
T4-5-4
Solenoid Valve Adjustment Procedure
7 O-Ring
IMPORTANT: As O-ring is damaged and oil leak-

8
age may cause, do not loosen ad-
justing screw (8) excessively.
Do not loosen adjusting screw (8)
more than 2 turns.
1. Loosen lock nut (7). Turn adjusting screw (8) and

adjust the set pressure.
2. After adjustment, tighten lock nut (7).
: 10 mm T1V1-04-05-004
: 5 N⋅m (0.5 kgf⋅m, 3.7 lbf·ft) 2.0 mm (0.079 in) or less

: 3 mm from end of Lock Nut
NOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
kPa 69 137 206 275 7
Change
(kgf/cm2) (0.7) (1.4) (2.1) (2.8)
in Pressure
(psi) (10) (20) (30) (40)
T1V1-04-05-003
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-5
MAIN PUMP DELIVERY PRESSURE
This pressure can also be measured by using Dr. ZX.
Preparation:
1. Stop the engine.
3. Remove the plug of pressure check port from the
main pump delivery port. Install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
4. Connect Dr. ZX and select the monitoring func-
tion.
(122±9 °F).
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch T157-05-04-005
Digging
Fast idle P OFF
mode
2. Measure pressure with the control levers in neu-
tral without load.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-6
(Blank)
T4-5-7
MAIN RELIEF SET PRESSURE
Summary:
Measure the main relief valve set pressure at the de-
livery port in main pump. (This pressure can also be
measured by using Dr. ZX.)
Preparation:
1. Stop the engine.
3. Remove the plug of pressure check port from
: 6 mm
4. Connect Dr. ZX and select the monitoring func-
tion.
(122±9 °F).
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch T157-05-04-005
Switch
Digging
Fast idle P OFF
mode
2. First, slowly operate the bucket, arm and boom
control levers to the stroke end and relieve each
function.
3. As for the swing control function, secure the up-
perstructure so it is immovable. Slowly operate
the swing control lever and relieve the swing
function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel control levers and relieve the travel function.
Evaluation:
T4-5-8
NOTE: If the measure pressures for all functions

are lower than the specified range, the
probable cause is a decrease of the main Main Relief
relief valve setting pressure. Valve
If the relief pressure of a particular function
is lower, the probable cause is other than
main relief valve.
Main Relief Pressure Setting Adjustment Proce-

dure
Adjustment:
1. Loosen lock nut (1).
: 17 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
2. Turn adjusting screw (2) to adjust the main relief

set pressure referring to the table below.
3. Retighten lock nut (1). T16W-03-03-032
4. Recheck the set pressures.

1 2

Plug Turns 1/4 1/2 3/4 1
Change in MPa 2.79 5.59 8.36 11.2
2
Relief (kgf/cm ) (28.5) (57) (85.2) (114)
Pressure (psi) (405) (811) (1212) (1620)
T176-03-03-010
Adjusting
Screw
Pressure Pressure
Increase Decrease
T105-06-05-002
T4-5-9
RELIEF PRESSURE (WHEN RELIEVING Swing Relief
SWING) Valve

: 24 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Turn adjustiing screw (2) to adjust the swing relief

pressure setting referring to the table below.
: 8 mm
3. Retighten lock nut (1).
4. Recheck the set pressures.

Screw Turns 1/4 1/2 3/4 1
Change in MPa 0.9 2.0 2.9 3.9
2
Relief (kgf/cm ) (10) (20) (30) (40)
Pressure (psi) (142) (284) (427) (570)
T176-01-02-002
1 2
T176-04-04-004
Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-10
(Blank)
T4-5-11
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 5. Maintain hydraulic oil temperature at 50±5 °C
ing an external force while blocking the return cir- (122±9 °F).
cuit from the control valve. This measuring
method is hazardous and the results obtained with Measurement:
this method are unreliable. 1. Select the following switch positions.
2. The oil flow rate used to set the overload relief Engine Power Mode Auto-Idle
Work Mode
pressure is far less than that used to set the main Control Dial Switch Switch
relief pressure. Therefore, measuring the overload Digging
pressure in the main circuit by increasing the main Fast idle P OFF
mode
relief set pressure more than the overload valve
set-pressure is not a proper method. In addition, in 2. Slowly operate the bucket, arm or boom control
case a main relief valve designed to leak a small levers to the stroke ends and relieve each func-
quantity of oil before reliving is used, its tion.
pre-leaking start pressure must be increased 3. Read pressures on the pressure gauge at this
more than the overload relief valve set pressure. time.
However, the pre-leaking start pressure is not al- 4. Perform the measurement for the bucket, arm and
ways increased more than the overload relief boom in that order.
valve set-pressure as the adjustable upper limit of 5. Repeat the measurement three times. Calculate
the main relief valve set pressure is provided. the average value for each.
Accordingly, the overload relief valve assembly
should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil
passage. When this type of overload relief valve is
checked, the control valve body must be precisely
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload re-
lief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
by using Dr. ZX as follows.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the oil supply
cap and release any remaining pressure.
3. Remove the plug from pressure check port of
T157-05-04-005
: 6 mm
4. Connect Dr. ZX and select the monitoring function.

Start the engine. Check for any oil leaks at the
T4-5-12
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.

Overload Relief Valve Pressure Adjustment Pro-

cedure
NOTE: In principle, adjust the overload relief valve
pressure on a test stand.
Loosen lock nut (1) and adjust pressure with adjust-

ing screw (2).

: 17 mm
2. Turn adjusting screw (2) in order to adjust pres- 1
sure.
: 6 mm
3. Tighten lock nut (1).
: 17 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf·ft)
2
NOTE: Standard Change in Pressure (Reference) W107-02-05-128
Adjusting Screw (2)

1/4 1/2 3/4 1
Turns
MPa 5.2 10.6 15.9 21.1
Change 2
(kgf/cm ) (54) (108) (162) (216)
in Pressure 2
(psi) (770) (1540) (2300) (3070)
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-13
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control)

Summary:
Main pump performance is checked by measuring 5. Install a pressure gauge to the main pump to be
the pump flow rate by using a hydraulic tester in- measured. (Refer to “Main Relief Set Pressure”.)
stalled at the main pump delivery port (one side) to : 6 mm
be measured. Use Dr. ZX and a pressure gauge at 6. Remove pipe (13) from the regulator. Install plug
the same time. (G 1/4) to pipe (13) in the regulator.
: 17 mm
IMPORTANT: This measurement procedure is a 7. Remove the vacuum pump. Loosen plug (12) on
simple method. The measured data top of the pump casing. Bleed air from the casing
will be lower by approx. 5 % than the until oil only comes out.
accurately measured value. In order 8. Fully open the loading valve of hydraulic tester.
to measure accurately, disconnect 9. Start the engine. Check for any oil leaks at the
the return circuit from the control pressure gauge connection. Install Dr. ZX and
valve and connect it to the hydraulic select the monitoring function.
oil tank.
Measurement:
Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C
1. Stop the engine. Push the air bleed valve and (122±9 °F).
bleed air. Install a vacuum pump to the oil filler 2. Measure the maximum flow rate.
port. 3. Select each switch position as follows.
NOTE: Operate the vacuum pump with the pump Engine Power Mode Auto-Idle
Work Mode
flow rate test line connected. Control Dial Switch Switch
2. Remove the delivery hose from main pump (one Digging
Fast idle P OFF
side) to be measured. Install pipe (1 or 2) by using mode
the split flanges and bolts which were used for the
removed delivery hose. 4. Adjust the relief set pressure of main relief valve in
: 41 mm control valve to each pressure point specified
: 10 mm along the main pump P-Q curve. (Refer to
3. Install pipe (1 or 2) to hydraulic tester (5) by using T4-2-13.) Slowly restrict the loading valve of hy-
test hose (3) and adapter (4). Install adapter (6), draulic tester while relieving pressure in the arm
joint (7), test hose (8) and flange (9) to hydraulic roll-in circuit. Measure the flow rates and engine
tester (5). speeds at each pressure point specified in the
: 41 mm P-Q curve.
: 10 mm 5. Repeat each measurement three times. Calculate
4. Install the delivery hose to flange (9) with split the average values.
flanges (10) and bolt (11).
: 10 mm
T4-5-14
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed by using the following for- Refer to OPERATIONAL PERFORMANCE TEST /
mulas: Standard in Group T4-2.
Qc = Ns×Q/Ne NOTE: When actually measuring, install pipe (1 or

2) only to the pump to be measured.
Qc : Converted Flow Rate
Q : Measured Flow Rate
-1
Ns : Specified Engine Speed: 2200 min
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
13
12
TCEB-03-01-001
1 - Pipe E (ST 6144) 5- Hydraulic Tester (ST 6299) 8- Test Hose (ST 6320) 11 - Bolt (ST 6409) (4 Used)
2 - Pipe B (ST 6143) 6- Adapter PF1 × UNF1-7/8 9- Flange (ST 6118) 12 - Plug
(ST 6146)
3 - Test Hose (ST 6145) 7 - Joint (ST 6330) 10 - Split Flange (ST 6130) 13 - Pipe
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-15
• Pilot Pressure Characteristics
Summary:
Main pump performance is checked by measuring 5. Install hose (19) and adapter (20) to port T of
the pump flow rate by using a hydraulic tester in- pressure reducing valve (16). Remove plug L
stalled at the main pump delivery port (one side) to from the return pipe. Install hose (19).
be measured. Use Dr. ZX and a pressure gauge at : 19 mm, 22 mm
the same time. 6. Remove pipe (21) from the regulator. Install plug
(G 1/4) to the mounting hole for pipe (21) in the
IMPORTANT: This measurement procedure is a regulator.
simple method. The measured data : 17 mm
will be lower by approx. 5 % than the 7. Remove the vacuum pump. Loosen the plug from
accurately measured value. In order top of the pump casing. Bleed air from the pump
to measure accurately, disconnect casing until oil only comes out.
the return circuit from the control 8. Fully open the loading valve of hydraulic tester.
valve and connect it to the hydraulic 9. Start the engine. Check the connections for any
oil tank. oil leaks.
Preparation:
1. While referring to steps 1 to 4 on page T4-5-18.
Install a hydraulic tester to the main pump to be
measured.
2. Remove the hose from regulator port Pi of the
pump to be measured. Install plug (ST 6213) to
the removed hose.
: 6 mm, 19 mm
3. Install adapters (15) (3 used) to pressure reducing
valve (16). Remove plug M from the pilot filter.
Install adapter (13) and hose (14) to the pilot filter.
Install hose (14) to regulator port P1 on pressure
reducing valve (16).
: 19 mm
4. Install tee (17) to port P2 of pressure reducing
valve (16). Install pressure gauge (18) and hose
(14) to tee (17). Install hose (14) to the regulator.
: 19 mm
T4-5-16
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
21
12
Plug M
Port Pi
T178-03-07-001
TCEB-03-01-001
Pressure Reducing Valve Port Position

Pressure Reducing Return Pipe
Valve
T L
20
18
P1 P2 19
15
To Regulator To Pilot Filter

Port Pi
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
2 - Pipe B (ST 6143) 8 - Test Hose (ST 6320) 13 - Adaptor UNF7/16 18 - Pressure Gauge (ST
×PF1/4 (ST 6069) 6931)
3 - Test Hose (ST 6145) 9 - Flange (ST 6118) 14 - Hose UNF7/16× 19 - Hose UNF7/16×
UNF7/16(4334309) UNF7/16 (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange 15 - Adapter PF3/8×UNF7/16 20 - Adapter PF3/8×UNF7/16
(ST 6146) (ST 6130) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 Uded) 16 - Pressure Reducing Valve 21 - Pipe
(4325439)
(ST 6146)
T4-5-17
Measurement:
(122±9 °F).
2. Measure pump flow rate in response to the ex-
ternal command pilot pressure.
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
4. Adjust the pressure reducing valve set pressure
to each pressure point specified along the main
pump P-Q curve. (Pilot Characteristics) (Refer to
T4-2-14.)
Measure the flow rates and engine speeds at the
pressure points specified in the P-Q curve.
the average values.
Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following
formulas:
Qc = Ns×Q/Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
-1
Ns : Specified Engine Speed: 2200 min
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
2. Standard Flow Rate

Refer to OPERATIONAL PERFORMANCE TEST
/ Standard in Group T4-2.
NOTE: When actually measuring, install pipe (1)

(ST 6144) or (2) (ST 6143) only to the
pump to be measured.
T4-5-18
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control Valve)
T173-04-04-002
21
12
Plug M
Port Pi
T178-03-07-001
TCEB-03-01-001
Pressure Reducing Valve Port Position

Pressure Reducing Valve
Return Pipe
T L
20
18
P1 P2 19
15
To Regulator Port Pi To Pilot Filter
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7- Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
2 - Pipe B (ST 6143) 8- Test Hose (ST 6320) 13 - Adaptor UNF7/16 18 - Pressure Gauge (ST
×PF1/4 (ST 6069) 6931)
3 - Test Hose (ST 6145) 9- Flange (ST 6118) 14 - Hose UNF7/16× 19 - Hose UNF7/16×
UNF7/16 (4334309) UNF7/16 (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange 15 - Adapter PF3/8×UNF7/16 20 - Adapter PF3/8×UNF7/16
(ST 6146) (ST 6130) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 Used) 16 - Pressure Reducing Valve 21 - Pipe
(4325439)
(ST 6146)
T4-5-19
Regulator Adjustment
6 5 1
2
10
4 3
7 8
T1V1-03-01-009
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut (For P-Q 9 - Lock Nut (For P-Q
Flow Rate) Maximum Flow Rate) Control) Control)
2 - Adjusting Screw (For 5 - Lock Nut (For Pilot 8 - Adjusting Screw (For P-Q 10 - Adjusting Screw (For P-Q
Minimum Flow Rate) Pressure Characteristic) Control) Control)
3 - Lock Nut (For Maximum 6 - Adjusting Screw (For Pilot
Flow Rate) Pressure Characteristic)
Adjustment Item Adjustment Procedure Remarks

1. Minimum Flow Rate Loosen lock nut (1) and turn adjusting 1) Do not turn adjusting screw (2)
screw (2). more than two turn.
Rotating adjusting screw (2) 1/4 a 2) Securely tighten lock nut (1) after
turn clockwise increases the mini- adjustment.
mum pump flow rate by 6.56 cm3/rev.
3
(0.4 in /rev).
: 17 mm
: 19.6 N⋅m
(2 kgf⋅m, 14.5 lbf·ft)
2. Maximum Flow Rate Loosen lock nut (3) and turn adjusting 1) Do not turn adjusting screw (4)
screw (4). more than two turn.
Rotating adjusting screw (4) 1/4 a 2) Do not increase the maximum flow
turn clockwise decreases the maxi- rate.
mum pump flow rate by 8.22 cm3/rev. In other words, do not turn adjust-
3
(0.5 in /rev). ing screw (4) counterclockwise.
: 13 mm 3) Securely tighten lock nut (3) after
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf·ft) adjustment.
T4-5-20

3. Pilot Pressure Characteristics Loosen lock nut (5) and turn ad- 1) Do not turn adjusting screw (6) more
justing screw (6). than one turn.
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned
a turn clockwise decreases the clockwise, the maximum flow rate
3
flow rate by 13.2 cm /rev. will also be decreased.
Q 3
(0.71 in /rev). In order to maintain the maximum
: 30 mm flow rate unchanged, turn adjusting
: 29.5 N⋅m screw (4) counterclockwise twice as
(3 kgf⋅m, 21.5 lbf⋅ft) much as adjusting screw (6) is
turned.
This ratio of 2 (adjusting screw (4)
counterclockwise turn) to 1 (adjust-
ing screw (6) clockwise turn) is to
Pi
counterbalance.
3) Securely tighten lock nut (5) after
adjustment.
4. P-Q Control A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws
(Torque Adjustment) adjusting screw (8). more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws watch-
Q 1/4 a turn clockwise increases ing the engine performance.
3
the flow rate by 15.3 cm /rev. 3) Securely tighten lock nut (7) or (9)
3
A (0.93 in /rev.). after adjustment.
B: Loosen lock nut (9) and turn 4) Do not decrease the maximum flow
adjusting screw (10). rate. In other words, do not turn ad-
Rotating adjusting screw (10) justing screws (8, 10) counter-
1/4 a turn clockwise increases clockwise.
3
the flow rate by 3.60 cm /rev.
Pd 3
(0.22 in /rev).
Pd
T4-5-21
Adjustment of Maximum Pump 1 and 2 Flow Rate
Limit Control Solenoid Valve
Maximum Pump 2 Flow Rate Limit

Torque Control
Solenoid Valve

TCEB-03-01-001

1. Flow Rate of Flow Rate Loosen lock nut (1) of the solenoid 1) Adjust only maximum pump 2 flow
Limit valve and turn adjusting screw (2). rate limit control solenoid valve at
(When using boom, arm, Rotating adjusting screw (2) 1/4 a the pump 2 side.
bucket, swing and attach- turn clockwise decreases the pump 2) Do not turn adjusting screw (2)
ment) flow rate by 13.2 cm3/rev. (0.8 more than one turn.
3
in /rev). 3) Securely tighten lock nut (1) after
: 10 mm adjustment.
Q
: 5.0 N⋅m (0.5 kgf⋅m, 3.7 lbf·ft)
Pi
T4-5-22
(Blank)
T4-5-23
SWING MOTOR DRAINAGE
Summary:
1. Measure amount of oil draining from the swing
motor while swinging the upperstructure and
check the swing motor performance.
2. Secure absolute safety for the measuring persons
as well as for the surrounding while measuring.
3. Keep oil temperature constant as the drain
amount from the swing motor is much influenced
by oil temperature.
Preparation:
(122±9 °F). Rotate the swing motor in order to
warm inside of the motor.
2. Stop the engine. Push air bleed valve (1) of the oil
supply cap and release any remaining pressure. 1
3. Remove drain hose (2) of the swing motor at the
hydraulic oil tank end. Install plug (ST 6213) to the
removed end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)

Also, take care not to fall off the machine T157-05-04-014
while the measurement.

2
Conditions for Measurement

Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
T178-04-04-005
T4-5-24
Measurement:

Also, take care not to fall off the machine
while the measurement.
Height of the boom
• Amount of Oil Drained While Swinging the Up- foot pin is the same
perstructure as the arm tip pin
1. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Hold the boom so that the arm tip T212-07-04-001
pin height is the same as the boom foot pin height.

The bucket must be empty.
2. Start the engine. Operate and hold the swing
control lever to full stroke. After the swing speed
reaches a constant maximum speed, start drain-
ing oil measurement when drain oil starts coming
out of the drain hose end.
3. Repeat the measurement three times in both
clockwise and counterclockwise directions. Cal-
culate the average values.
4. The measuring time should be for more than 45
seconds.
T212-07-04-002
• Amount of Oil Drained While Relieving Swing
Motor Circuit
1. Thrust the bucket teeth into the ground so that the
upperstructure does not rotate. Set the swing lock
lever to the LOCK position so that the upper-
structure does not rotate.
2. Start the engine. Operate and hold the swing
control lever to full stroke. Start draining oil
measurement when drain oil starts coming out of
the drain hose end.
3. Repeat the measurement three times in both
clockwise and counterclockwise directions. Cal-
culate the average values.
4. The measuring time should be for more than 45
seconds. Swing Lock Lever M216-05-004
Evaluation:
∗ Conversion of amount of drain oil measured into the

per-minute value
First measure amount of drain oil by using a cali-
brated container. Then, convert the measured drain
oil into the per-minute value by using the formula
below:
∆Q = 60 × q / t
∆Q : Amount of drain oil per minute (L/min)
T107-06-05-008
t : Measured time (seconds)
q : Total amount of drain oil (L)
T4-5-25
STEERING VALVE RELIEF PRESSURE
Use both Dr. ZX and a pressure gauge.

CAUTION: If air is mixed in the brake system,
the brake function is reduced, and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines of steering and brake and replacing hy-
draulic oil.
(Refer to the TROUBLESHOOTING / Trouble-
shooting B group.)
Summary:
The steering circuit is provided with the steering relief
valve. When the steering relief valve is faulty, the
handle will turn heavily.
Preparation:
1. Stop the engine.
2. Push the air bleed valve (1) on top of the hydraulic
oil tank and release any remaining pressure. 1
3. Remove the hoe of steering filter outlet or inlet.
Install tee 3/4-16UNF (ST 6477), fitting (ST 6069)
and pressure gauge assembly (ST 6933) between
steering filter and hose.
: 22 mm, 24 mm
4. Connect Dr. ZX and monitor the pump 3 pressure.
(122±9 °F).
MCBB-07-025
Steering Filter
MCBB-07-027
T4-5-26
Measurement:
Engine Power Work Auto-Idle
Control Mode Mode Switch
Dial Switch
Digging
Fast idle P OFF
mode
2. Measure the steering pressure in the handle from
right to left stroke end and from left to right stroke
end by using a pressure gauge.
3. Repeat the measurements three times. Calculate
the average values.
Evaluation:
Remedy
The steering relief valve cannot be adjusted. If the
steering pressure does not meet standard value, re-
place the steering relief valve as an assembly.
T4-5-27
BRAKE PRESSURE (FRONT AND REAR)

the brake function is reduced and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines and replacing hydraulic oil.
(Refer to TROUBLESHOOTING / Trouble-
shooting B in Group T5-7.)
Summary:
Measure the brake pressure at the brake valve outlet
side. Measure the pressure when depressing the
brake pedal and applying the working brake.
Preparation:
CAUTION: Install the measuring equipment
under a machine. Install it on flat and solid SA-1140
ground after securing the front attachment in
order to prevent running away and an oper-
ating error.
1. Stop the engine.

release any remaining pressure from the hydraulic Front
oil tank. Axle
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Install the measuring equipment to front and rear
wheel brake circuit.
4-1. Front wheel brake circuit pressure: Remove
front wheel brake hose (1). Install tee
9/16-18UNF (ST 6485), fitting (ST 6069) and
pressure gauge assembly (ST 6932) to the re- T1F3-04-05-003
moved hose.
: 19 mm, 22 mm 1
4-2. Rear wheel brake circuit pressure: Remove rear
wheel brake hose (2). Install tee 9/16-18UNF
(ST 6485), fitting (ST 6069) and pressure gauge
assembly (ST 6932) to the removed hose.
: 19 mm, 22 mm Rear
Axle
(122±9 °F).
T1F3-04-05-004
T4-5-28
Engine Power Mode Work Mode Auto-Idle FNR Brake
Control Dial Switch Switch Switch Switch
Fast idle P Digging mode OFF N OFF
Measurement:
1. Measure the pressure when fully depressing the
brake pedal.
2. Measure the pressure when the work brake is
operable.
the average values.
Evaluation:
Remedy
in Group T5-7.
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
T4-5-29
BRAKE ACCUMLATED PRESSURE

the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
Refer to TROUBLESHOOTING / Trouble-
shooting B group.
Summary:
The accumulated brake pressure is measured at
output port of the accumulator. The accumulated
brake pressure varies according to operation of the
brake. Record the maximum value.
Preparation:

under a machine. Install it on flat and solid
ating error.
1. Stop the engine.

2. Push the air bleed valve on the oil supply cap and
release any remaining pressure in the hydraulic oil
tank.
circuit.
4. Remove the cover under the cab.
Remove brake hose (1).
Install tee (9/16-18UNF) (ST 6485), fitting (ST
6069) and pressure gauge assembly (ST 6932)
between the removed hoses.
: 19 mm, 22 mm
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-5-30
Engine Power Mode Work Mode Auto-Idle FNR Brake
Measurement:
1. When depressing the brake pedal slowly several
times, measure the maximum pressure.
the average values.
Evaluation:
Remedy
in Group T5-7.
T4-5-31
BRAKE WARNING SET PRESSURE
(DECREASE)

shooting B group.)
Summary:
When the warning buzzer sounds by reducing the
accumulated brake pressure, measure the pressure
at the output port of accumulator.
Preparation:

ating error.
1. Stop the engine.

tank.
circuit.
： 19 mm, 22 mm
(122±9 °F).
T4-5-32
Conditions for Measurement:
Forward/Reverse Lever Parking Brake Switch
N P (Parking Brake)
Measurement:
1. Stop the engine. Turn the key switch to ON posi-
tion.
2. Measure the pressure when warning buzzer
sounds by slowly depressing the brake pedal
several times.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-33
BRAKE WARNING SET PRESSURE
(INCREASE)

shooting group.)
Summary:
When sounding of the warning buzzer stops by in-
creasing the accumulated brake pressure, measure
the pressure at the output port of accumulator.
Preparation:

ating error.
1. Stop the engine.

tank.
circuit.
： 19 mm, 22 mm
(122±9 °F).
T4-5-34

Engine Power Mode Auto-Idle FNR Brake
Work Mode
Measurement:
1. Stop the engine. Turn the key switch to ON posi-
tion.
2. Set the engine control dial to slow idle.
3. Depress the brake pedal several times and make
the warning buzzer sound.
4. Start the engine. Measure the pressure when
sounding of the warning buzzer stops. Notice that
it is difficult to read the gauge as the pressure in-
creases rapidly.
5. Repeat the measurement three times and calcu-
late the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-35
(Blank)
T4-5-36
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 4 ICF
Introduction........................................................................... T5-1-1 Outline..................................................................................... T5-4-1
Diagnosing Procedure....................................................... T5-1-2 List of Daily Report Data.................................................... T5-4-2
List of Frequency Distribution Data.............................. T5-4-5
Group 2 Monitor Unit
List of Total Operating Hours........................................... T5-4-6
Outline..................................................................................... T5-2-1 How to Download and
How to Use Screens..........................................................T5-2-17 Upload Data of ICF......................................................... T5-4-8
Screen Display When An Alarm Various Setup of ICF and
is Issued............................................................................T5-2-24 Satellite Communication Terminal
Contents of Alarms............................................................T5-2-26 by Using Dr. ZX..................................................................T5-4-11
Time Setting.........................................................................T5-2-29 List of Fault Code................................................................T5-4-23
Attachment Adjustment Satellite Communication System.................................T5-4-24
(Pump 2 Flow Rate Adjustment).............................T5-2-30
Displaying Operating Conditions................................T5-2-32 Group 5 Component Layout
Maintenance Settings......................................................T5-2-34 Main Component Layout.................................................. T5-5-1
Work Mode (Attachment Selection)...........................T5-2-40 Electrical Component Layout
Mail (Optional)....................................................................T5-2-44 (Overview)......................................................................... T5-5-6
Meter Display Selection...................................................T5-2-46 Electrical Component Layout
Password Change (Optional).........................................T5-2-48 (Monitors and Switches).............................................. T5-5-8
Back Monitor Settings......................................................T5-2-52 Electrical Component Layout
Language Settings............................................................T5-2-56 (Controllers and Relays).............................................T5-5-11
Meter Combination Settings.........................................T5-2-58 Engine....................................................................................T5-5-13
Unit Settings........................................................................T5-2-60 Pump Device.......................................................................T5-5-14
Service Menu (Built-In Diagnosing System) Swing Device.......................................................................T5-5-14
Operation........................................................................T5-2-63 Signal Control Valve..........................................................T5-5-14
Troubleshooting.................................................................T5-2-64 Control Valve.......................................................................T5-5-15
Monitoring...........................................................................T5-2-66 Brake Valve...........................................................................T5-5-15
Controller Version..............................................................T5-2-70 3-Spool Solenoid Valve Unit...........................................T5-5-15
Blade/Outrigger Settings................................................T5-2-72 Solenoid Valve Unit (for Electric Lever)......................T5-5-15
Keyless Hour Meter...........................................................T5-2-74 Travel Shockless Valve......................................................T5-5-16
List of Monitor Unit Sitting Function..........................T5-2-75 Transmission Changeover
Solenoid Valve...............................................................T5-5-16
Group 3 Dr. ZX
Travel Device.......................................................................T5-5-16
Outline..................................................................................... T5-3-1 Filter........................................................................................T5-5-16
MC Monitoring List.............................................................. T5-3-2 Components in Control Valve........................................T5-5-18
ECM Monitoring List........................................................... T5-3-5 Pilot Port................................................................................T5-5-32
Monitor Unit Monitoring List........................................... T5-3-6
Steering Column Monitor Group 6 Troubleshooting A
Monitoring List................................................................ T5-3-7 Troubleshooting A Procedure......................................... T5-6-1
Option Controller Monitoring List................................. T5-3-8 MC Fault Code List............................................................... T5-6-2
MC Adjustment List...........................................................T5-3-10 ECM Fault Code List...........................................................T5-6-24
MC Attachment Adjustment List..................................T5-3-12 ICF Fault Code List.............................................................T5-6-48
ICF Adjustment Item List.................................................T5-3-16 Satellite Terminal Fault Code List.................................T5-6-49
Option Controller Adjustment List..............................T5-3-18 Monitor Unit Fault Code List..........................................T5-6-49
Dr. ZX Operation Procedure...........................................T5-3-20 Option Controller Fault Code List................................T5-6-50
CEBT-5-1
Steering Column Monitor Option Controller Fault Code 15516........................ T5-6-152
Fault Code.......................................................................T5-6-68 Option Controller Fault Code 15517........................ T5-6-153
MC Fault Codes 11000 to 11002...................................T5-6-70 Option Controller Fault Code 15518........................ T5-6-154
MC Fault Code 11003.......................................................T5-6-71 Option Controller Fault Code 15519........................ T5-6-155
MC Fault Code 11004.......................................................T5-6-72 Option Controller Fault Code 15570........................ T5-6-156
CAN Harness Check...........................................................T5-6-73 Option Controller Fault Code 15571........................ T5-6-157
MC Fault Code 11100.................................................... T5-6-105 Option Controller Fault Code 15572........................ T5-6-158
MC Fault Code 11200.................................................... T5-6-107 Option Controller Fault Codes
MC Fault Code 11202.................................................... T5-6-108 15574-3 and 15578-3............................................... T5-6-160
MC Fault Code 11306.................................................... T5-6-116 20300 to 20303.......................................................... T5-6-164
MC Fault Codes 11910 to 11920................................ T5-6-128 Option Controller Fault Codes
MC Fault Code 11901.................................................... T5-6-129 15565 to 15577.......................................................... T5-6-176
ECM Fault Codes 100 to 190....................................... T5-6-130 Steering Column Monitor
ECM Fault Codes 628 to 1485..................................... T5-6-131 Fault Code 16000....................................................... T5-6-177
ECM Fault Codes 10001 to 10013.............................. T5-6-132
ICF Fault Codes 14000 to 14003................................ T5-6-133
Information C/U: Intialize............................................. T5-6-134 Troubleshooting B Procedure......................................... T5-7-1
Control Data: Intialize.................................................... T5-6-135 Relationship between Machine Trouble
Enter Model and Serial No........................................... T5-6-136 Symptoms and Related Parts..................................... T5-7-2
ICF Fault Codes 14006, 14008..................................... T5-6-137 Correlation between Trouble
Satellite Terminal Fault Codes Symptoms and Part Failures.....................................T5-7-22
14100 to 14106.......................................................... T5-6-138 Engine System Troubleshooting..................................T5-7-38
Monitor Unit Fault Code 13303................................. T5-6-139 All Actuator System Troubleshooting.........................T5-7-66
Monitor Unit Fault Code 13304................................. T5-6-140 Front Attachment System
Monitor Unit Fault Codes Troubleshooting...........................................................T5-7-74
13306 and 13308....................................................... T5-6-141 Swing System Troubleshooting....................................T5-7-88
Monitor Unit Fault Code 13310................................. T5-6-142 Travel System Troubleshooting....................................T5-7-90
Monitor Unit Fault Code 13311................................. T5-6-143 Brake System Troubleshooting.................................. T5-7-102
Pilot Shut-Off Lever Alarm........................................... T5-6-144 Steering System Troubleshooting............................ T5-7-105
Option Controller Fault Codes Other System Troubleshooting.................................. T5-7-106
15500 to 15504.......................................................... T5-6-145 Exchange Inspection..................................................... T5-7-126
Option Controller Fault Code 15505........................ T5-6-146 Bleeding Air from Transmission................................. T5-7-130
Option Controller Fault Code 15506........................ T5-6-147 Bleeding Air from Brake (Axle)................................... T5-7-131
Option Controller Fault Code 15510........................ T5-6-148 Emergency Boom Lowering Procedure
Option Controller Fault Code 15511........................ T5-6-149 (without Hose Rupture Valve)............................... T5-7-132
Option Controller Fault Code 15514........................ T5-6-150 Attachment Circuit Pressure Release
Option Controller Fault Code 15515........................ T5-6-151 Procedure..................................................................... T5-7-133
CEBT-5-2
Precautions for Inspection and
Maintenance.................................................................... T5-8-1
Instructions for Disconnecting
Connectors....................................................................... T5-8-3
Fuse Inspection..................................................................... T5-8-4
Fusible Link Inspection...................................................... T5-8-6
Battery Voltage Check........................................................ T5-8-7
How to Check Alternator................................................... T5-8-8
Continuity Check................................................................. T5-8-9
Voltage and Current Measurement.............................T5-8-10
Check by False Signal.......................................................T5-8-17
Test Harness.........................................................................T5-8-18
CEBT-5-3
(Blank)
CEBT-5-4
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Refer to the inspection and troubleshooting proce-

dures after any machine trouble has occurred. The
inspection and troubleshooting procedures are pre-
sented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution.
The troubleshooting section in this manual consists of

8 groups; Diagnosing Procedure, Monitor Unit, Dr. ZX,
ICF, Component Layout, Troubleshooting A (base
machine diagnosis by using fault codes), Trouble-
shooting B (base machine diagnosis starting with in-
spection of abnormal operational status) and Electrical
System Inspection.
• Diagnosing Procedure • Troubleshooting A (base machine diagnosis by

using fault codes)
• Monitor Unit Refer to these procedures if any fault codes are
Refer to this group as for the display screen and displayed when each controller (MC, ECM, ICF
operating procedures of monitor unit. and monitor unit) is diagnosed by using Dr. ZX (or
the service menu of monitor unit).
• Dr. ZX
This group contains the operating procedures for
Dr. ZX. IMPORTANT: ICF receives and retains a record of
the electrical signal system mal-
• ICF function of each controller in the
This group contains as follows. form of fault codes by using CAN
Download data from ICF and Upload communication. In addition, ICF
Procedures when starting satellite communication, self-diagnosing function records the
when installing the satellite communication con- electrical signal system malfunction
troller and when replacing ICF in the form of fault codes
Explanation for the satellite communication sys- Ex.) Fault Code 11004-2: Failure of CAN Com-
tem munication
• Component Layout • Troubleshooting B (base machine diagnosis start-

ing with inspection of abnormal operational
status)
Refer to these procedures when no fault codes
are displayed after diagnosing the machine with
Dr. ZX (or the service menu of monitor unit).
Ex.) Although the engine control dial is turned,
engine speed does not change.
• Electrical System Inspection

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

troubleshooting:
1. Study the System

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

Before inspecting, get the full story of
malfunctions from the operator below.
T107-07-01-001
(a) How is the machine being used? (Find out if

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

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

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

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

Before starting the troubleshooting procedure, T107-07-01-002
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.
T107-07-01-003
T5-1-2
4. Operate the machine yourself

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses correponding to the trouble.
T5-1-3
5. Perform troubleshooting
CAUTION: Do not disconnect harnesses or

hydraulic lines while the engine is running.
The machine may malfunction or pressurized
oil may spout, possibly resulting in personal
injury. Stop the engine before disconnecting
harnesses or hydraulic lines.
Perform diagnosis by connecting Palm to the

machine or by using the service menu of monitor
unit. In case any fault code has been displayed by
diagnosis by using Dr. ZX (the service menu of T107-07-01-005
monitor unit), check the cause of the trouble by

referring to Troubleshooting A in this section. In
case any fault code has been displayed by diag-
nosis by using Dr. ZX (the service menu of moni-
tor unit), write the fault code. Delete the fault code
once and retry self-diagnosis again. If the fault
code is displayed again, check the cause of the
trouble by referring to Troubleshooting A in this
section. After the machine trouble has been cor-
rected, the fault code (displayed by the service
menu of monitor unit) will be deleted. Therefore,
in case the problems which are not easily
re-predicable are encountered, check the fault
code by using Dr. ZX.
In case the fault code is not displayed, check T107-07-01-006
operating condition of each component by refer-

ring to Troubleshooting B in this section and by
using Dr. ZX (the service menu of monitor unit).
NOTE: Note that the fault codes displayed do not

necessarily indicate machine trouble. The
controller stores even temporary electrical
malfunctions, such as a drop in battery
output voltage or disconnections of the
switches, sensors, etc., for inspections.
For this reason, the “RETRIAL” is required
to erase the accumulated fault codes from
the controller memory and to confirm if any T107-07-01-007
fault codes are indicated after the
“RETRIAL”.
T5-1-4
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T5-1-5
(Blank)
T5-1-6
TROUBLESHOOTING / Monitor Unit
OUTLINE
Primary Screen
7
1 2 3 4 5 6 8
9
10
11
12
13
14
15
16
17
18
35 34
20 20 19
TCJB-05-02-043
33 32 31 30 29 28 27 26 25 24 23 22
1 - Work Mode Display 10 - Parking Brake Display 19 - Trip Meter Display 28 - Work Mode Display
2 - Auto-Idle Display 11 - Work Brake Display 20 - Odometer Display 29 - Auxiliary Selection
3 - Overload Alarm Display 12 - Axle Lock Display 21 - Hour Meter Display 30 - Coolant Temperature
(Optional) Gauge
4 - Auto Axle Lock Display 13 - Work Light Display 22 - Back Monitor Selection 31 - Work Mode Selection
5 - Auxiliary 14 - Auxiliary 2 (Positioning) 23 - Menu 32 - Return to Primary Screen
Selection Display
6 - Glow Signal Display 15 - Auxiliary 1 (Attachment) 24 - Meter Display Selection 33 - Brake Oil Pressure Gauge
Selection Display
7 - Trip Meter 16 - Blade/Outrigger Settings 25 - Fuel Gauge 34 - Speedometer
and Brake Mode Display
8 - Odometer 17 - Mail Display (Optional) 26 - Auxiliary 35 - Tachometer
9 - Hour Meter 18 - Clock 27 - Mail Selection (Optional)
T5-2-1
7
• Display of Meters
Data to be displayed on each meter are displayed on
the monitor unit according to the input signal from
sensor, the signal received from ICF by using CAN
and the internal data of monitor unit.
Items to be displayed 18
7. Trip Meter (Signal received from MC by using CAN)

8. Odometer (Signal received from MC by using CAN)
9. Hour Meter (Internal data of the monitor unit)
18. Clock (Signal received from ICF by using CAN)
25. Fuel Gauge (Input signal from the fuel sensor)
30. Coolant Temperature Gauge (Input signal from the
coolant temperature sensor) 8 TCJB-05-02-057
34 33 30 25
33. Brake Oil Pressure Gauge (Signal received from
MC by using CAN)
34. Speedometer (Signal received from MC by using
CAN)
35. Tachometer (Signal received through MC from
ECM by using CAN)
TCJB-05-02-056
9
TCJB-05-02-042
35 TCJB-05-02-041
T5-2-2
• Work Mode Display (1) 1 7
The attachments being used are displayed accord-
ing to the signals received from MC by using CAN.
Digging Mode
18
T1V1-05-01-108
Attachment Mode
Breaker
T1V1-05-01-104
Pulverizer
TCJB-05-02-057
34 33 30 25
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibrating Hammer
T1V1-05-01-107
Others
T1V1-05-02-003

pattern are same.
T5-2-3
• Auto-Idle Display (2)
2 3 4 6
When the auto-idle switch on switch panel is turned
ON, the data is displayed.
When the key switch is turned ON with the auto-idle
switch ON, the data blinks for 10 seconds.
• Overload Alarm (3)
TCJB-05-02-061
The system measures the load of suspended load

from the boom cylinder bottom pressure sensor.
When overload is detected, an alarm is displayed.
(Refer to T5-2-15.)
• Auto Axle Lock Display (4)

The data is displayed when the brake switch in the TCJB-05-02-042
auto axle lock position.
• Glow Signal Display (5)

While ECM is supplying current to the glow plug, the
data is displayed according to the signal from ECM.
T5-2-4
• Fuel Gauge (25) 30 25
The data of fuel level is displayed.
• Coolant Temperature Gauge (30)

Temperature of engine coolant is displayed.
TCJB-05-02-064
• Brake Oil Pressure Gauge (33) 34 33

Pressure in the brake circuit is displayed.
• Speedometer (34)
Travel speed is displayed.
NOTE: When the machine travels forward and al-

though other setting on the monitor unit is
done, the primary screen is displayed.
(Screen Forcible Transition Control)
(Refer to the SYSTEM / Control System
group.)
TCJB-05-02-064
35
• Tachometer (35)
Engine speed is displayed.
NOTE: Speedometer (34) or tachometer (35) is

displayed on the monitor screen due to the
setting.
TCJB-05-02-065
T5-2-5
• Parking Brake Display (10)
When the parking brake is applied, the red indicator 4 10 11 12
lights.
(Brake Switch: P (Parking Brake) Position
• Work Brake Display (11)

When the work brake is applied (under the work
brake control), the red indicator lights.
• Axle Lock Display (12)

When the axle lock is operated, the red indicator
lights. (Brake Switch: Axle Lock or Auto Axle Lock
position)
NOTE: When the brake switch is in the auto axle

TCJB-05-02-042
lock position and the lever is in neural, auto
axle lock display (4) or axle lock display
(12) lights.
At this time, the accelerator pedal is de-
pressed, the axle lock is released by the
axle lock control and axle lock display (12)
goes off.
As the brake switch is in the auto axle lock
position, auto axle lock display (4) is kept to
light.
(Refer to the SYSTEM/Control System
group.)
T5-2-6
• Work Light Display (13)
The work light switch is turned ON, the green indi- 15 14
cator lights.
• Auxiliary 2 (Positioning) Selection Display (14) 13

When the auxiliary/positioning selection switch is in 16
the Positioning position, the green indicator lights.
• Auxiliary 1 (Attachment) Selection Display (15)

When the auxiliary/positioning selection switch is in
the Auxiliary (Attachment) position, the green indi-
cator lights.
• Blade/Outrigger Setup and Brake Mode Display (16)

The combination data of blade/outrigger is displayed.
When the parking brake, work brake or TCJB-05-02-042
blade/outrigger is operated, the green indicator re-
lated to the operated function lights.
When applying parking brake
NOTE: The illustration shows the screen on the
front outrigger and rear blade specification.
Green indicator
lights.
TCJB-05-02-074
When applying work brake

lights. lights.
TCJB-05-02-075
When operating blade/outrigger

lights. lights.
TCJB-05-02-102
T5-2-7
• Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
Sensor Error Display Display
TCJB-05-02-104
When the fuel sensor is faulty or if the harness be-

tween fuel sensor and monitor unit is open circuit,
the data is displayed on the fuel gauge.
• Coolant Temperature Sensor Error Display
TCJB-05-02-103
When the coolant temperature sensor is faulty, the

data is displayed on the coolant temperature gauge.
TCJB-05-02-045
• Alarm and Remedy Displays against Alarm

Alarm marks are displayed on bottom of the screen
according to the alarm signals from pilot shut-off
lever, overheat switch, fuel sensor, hydraulic oil filter,
alarm switch (optional), air cleaner restriction switch,
alternator, battery system and ECM and the alarm
signals received from MC by using CAN. The rem-
edy for each alarm is displayed by key operation.
Alarm Display TCJB-05-02-049
Remedy Display against T1V5-05-01-013
Alarm
T5-2-8
Main Menu
• Time Setting
Time is set. (Refer to T5-2-29.)
Time Set Screen T1V5-05-01-021
• Operating Conditions
This screen displays machine operating hour, fuel
usage and fuel consumption rate registered by the
monitor unit.
(Refer to T5-2-32.)
Operating Conditions Screen T1V5-05-01-025
• Attachment Selection (Work Mode)

Selects digging mode and attachment mode set by
Dr. ZX on this screen.
(Refer to T5-2-40.)
NOTE: In attachment mode, the following four

modes are set by default.
1 - Digging
2 - Breaker 1
3 - Breaker 2
4 - Pulverizer 1
5 - Crusher 1
1 2 3 4 5 T1V5-05-01-109

pattern are same. Attachment Selection Screen
T5-2-9
• Pump 2 Flow Rate Adjustment (Attachment Adjust- Figure 1
ment)
When using the attachments, fine adjust flow rate of
pump 2 by keys 1 and 2 operation.
(Refer to T5-2-30.)
The signals from monitor unit are sent to MC by us-
ing CAN.
When breaker 1 or 2 is used, MC adjusts maximum
flow rate of pump 2 while controlling maximum pump
2 flow rate limit control solenoid valve. (Figure 1) Key 1
(Pump 2 Flow Rate Limit Control)
When pulverizer 1 or crusher 1 is used, MC adjusts Key 2
flow rate of pressure oil that flows from pump 2 to
pulverizer or crusher while controlling the auxiliary When using Breaker 1 T1V5-05-01-111
flow rate control solenoid valve. (Figure 2) (Pulver- Figure 2

izer / Crusher Control)
NOTE: When the 2-speed selector circuit is OFF,

maximum flow rate of pump 2 can be ad-
justed while controlling the maximum pump
2 flow rate limit control solenoid valve.
(Figure 1)
When the 2-speed selector circuit is ON, Key 1
flow rate of pressure oil that flows from
pump 2 to the attachments can be adjusted Key 2
while controlling the auxiliary flow rate con- T1V5-05-01-024
trol solenoid valve. (Figure 2) When using Pulverizer 1
The table blow shows the default.
Type of 2-Speed Valve Selector Accumulator Secondary

Attachments Display Selector Circuit Circuit Circuit Hydraulic
Relief Selector
Circuit
Breaker 1 Figure 1 OFF O/T OFF ON
Breaker 2 Figure 1 OFF O/T OFF OFF
Pulverizer 1 Figure 2 ON C/V OFF OFF
Crusher 1 Figure 2 ON C/V OFF OFF
NOTE: O/T: Hydraulic Oil Tank
C/V: Control Valve

pattern are same.
Pulverizer 1 Secondary Crusher 1
Crusher 1 Primary Crusher 1
T5-2-10
• Maintenance Settings
The data; date of the last replacement, hour meter,
the remaining hours until the next replacement and
the replacement interval are displayed.
As the items to be replaced are displayed in a list,
record performed replacement by selecting an item
from the list.
(Refer to T5-2-34.)
• Interval ON/OFF Settings

Set change interval for each item to be replaced.
• Items included in Maintenance Settings Maintenance Setup Screen T1V5-05-01-049

Engine Oil
Engine Oil Filter
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Filter
Pump Transmission Oil
Swing Reduction Gear Oil
Swing Bearing Grease
Hydraulic Oil Brake Steering Filter
Travel Device Transmission Oil
Axle Gear Oil (Front, Rear, each Hub)
Drive Shaft Greasing
Front Axle King Pin Greasing
Front Axle Center Pin Greasing Interval ON/OFF Setup Screen T1V5-05-01-052
Wheel Nut Torque Check
Air Filter
Engine/Air Conditioner V-belt
Fuel Filter
Air Conditioner Filter
User Setting (TRIP 1)
T5-2-11
• Mail (Optional Function)
Sends requests such as general, fuel replenishment,
service maintenance and forwarding requests in the
mail switch screen.
Contents of mails are registered in ICF, and are sent
to the central server by a satellite terminal.
(Refer to T5-2-44.)
Mail Switch Screen T1V5-05-01-037
• Meter Display Selection (HOUR↔ODO↔TRIP)

The meter display; hour meter, odometer and trip
meter on primary screen is switched.
The selected item is displayed on the primary
screen.
When the key switch is turned OFF, the item is reset
into the meter combination setting.
(Refer to T5-2-46.)
Meter Display Selection Screen TCJB-05-02-072
• Back Monitor Settings

By key operation, image display ON/OFF of
Auto-Control for switching image of the back monitor
while the machine travels backward.
(Refer to T5-2-52.)
T1V5-05-01-173
T5-2-12
• Language Settings
Select a language to be used in screens from
among preset languages, according to work envi-
ronment. (Refer to T5-2-56.)
Language Setup Screen T1V1-05-01-137
• Meter Combination Settings (km/h↔min-1)

-1
Speedometer (km/h), tachometer (min ), hour meter,
odometer and trip meter on the primary screen are
combined and set respectively.
(Default: Speedometer+Hour Meter)
(Refer to T5-2-58.)
TCJB-05-02-068
Meter Combination Setup Screen
• Unit Setting (km↔mile)

The units; km and mile, in the primary screen are set.
(Refer to T5-2-60.)
TCJB-05-02-016
Unit Setup Screen
T5-2-13
• Service Menu (Built-In Diagnosing System)
• Troubleshooting
This screen displays the fault codes according to
the signals received from each controller by using
CAN.
(Refer to T5-2-64.)
Fault Code Display T1V5-05-01-097
• Monitoring
This screen displays temperature and pressure
data received from each controller by using CAN.
By key operation, the displayed data can be hold.
(Refer to T5-2-66.)
Monitoring Screen T1V5-05-01-087
• Controller Version
This screen displays the version of MC, ICF,
monitor unit, steering column monitor and option
controller.
(Refer to T5-2-70.)
Controller Version Display TCHB-05-02-008
• Blade/Outrigger Settings
Combination of blade and outrigger displayed on
the primary screen is set.
(Refer to T5-2-72.)
T5-2-14
• Overload Alarm
(Only the machines equipped with optional parts) Overload Alarm
IMPORTANT: When using overload alarm, make

overload alarm available by using Dr.
ZX.
1. MC detects load of the suspended load by the

signal from the boom bottom pressure sensor.
2. When the overload alarm switch (optional) is
turned ON and load of the suspended load be-
comes overloaded, the monitor unit displays an
alarm message on the primary screen and rings a
buzzer according to the signal from MC by using
CAN.
3. If overload of the suspended load is dissolved, the Primary Screen TCJB-05-02-042
alarm message disappears and the buzzer stops

ringing. (Optional)
NOTE: Even if the work is done while displaying a

screen except the primary screen, when an
overload condition is reached, the screen
of monitor unit is switched to the primary
screen, an alarm message is displayed and
a buzzer is rung.
Even after the overload alarm is dissolved,
the monitor unit keeps on displaying the
primary screen without returning to the
screen while the work is done.
T1V1-05-02-004
T5-2-15
(Blank)
T5-2-16
HOW TO USE SCREENS
Displaying Primary Screen
IMPORTANT: Start the engine after the primary

screen is displayed.
When the key switch is turned to the ON position, the

starting screen appears for about two seconds and the
primary screen appears.
Key Switch: ON T1V1-05-01-115
Primary Screen TCJB-05-02-064
IMPORTANT: Until the alternator starts generating

power after the engine starts, alter-
nator alarm is displayed on the pri-
mary screen.
TCJB-05-02-050
Alternator Alarm
T5-2-17
Displaying Primary Screen by Password Input
(Optional)
IMPORTANT: Before performing this operation,

make the password function avail-
able by using Dr. ZX.
Starting Screen T1V1-05-01-115
1. When the key switch is turned to the ON position,

the starting screen appears and the primary Password
Icon
screen appears.
NOTE: Only the operations including the engine

start and key 1 on the monitor unit can be
done on this screen.
Key 1
2. When key 1 is pushed or the key switch is turned

to the START position, the password input screen
appears.
TCJB-05-02-054
Primary Screen
T1V5-05-01-093
Password Input Screen
T5-2-18
3. Input a password by using the keys located under
the screen. If pushing the confirm key, the monitor
unit matches the input password to the registered
one. If they match, the primary screen appears.
NOTE: When inputting the password again, the

entered characters can be erased by
pushing the erase key.
Confirm Key Erase Key

T1V5-05-01-002
T5-2-19
In Case of Inputting an Incorrect Password
1. If inputting an incorrect password, the message

“Password is incorrect.” appears by pushing the
confirm key.
Password Input Screen T1V5-05-01-093
T1V5-05-01-002
2. Return to the password input screen by pushing

the back key.
NOTE: When inputting the password again, the

entered characters can be erased by
pushing the erase key.
T1V5-05-01-004
Back Key
T1V5-05-01-093
T5-2-20
3. If inputting an incorrect password three times, a
screen appears informing that the security lock
has been applied, and a buzzer rings. While the
key switch is turned to the ON position, the buzzer
does not stop ringing. When the key switch is
turned to the OFF position, the security lock dis-
play disappears and the buzzer rings for thirty
seconds.
Security Lock Screen T1V5-05-01-005
4. If the key switch is turned to the ON position after

the buzzer stops ringing, the starting screen ap-
pears and the primary screen appears again.
Then a password can be input again. After that,
Password
when key 1 is pushed or the key switch is turned Icon
to the START position, the password input screen
appears and the password can be re-input. If in-
putting an incorrect password even once this time,
the security lock screen appears again and a
buzzer rings. While the key switch is turned to the
Key 1
ON position, the buzzer does not stop ringing.
When the key switch is turned to the OFF position,
the buzzer rings for thirty seconds.
5. After the buzzer stops ringing, a password can be

input. Turn the key switch to the ON position and
input a password after the password input screen
appears. (Refer to T5-2-20).
6. If inputting an incorrect password again, the se-

curity lock screen appears again and a buzzer
rings. While the key switch is turned to the ON
position, the buzzer does not stop ringing. When
the key switch is turned to the OFF position, the
buzzer rings for thirty seconds.
T1V5-05-01-093
Password Input Screen
T5-2-21
Extending Password Duration Time
IMPORTANT: This operation is applicable only to

those machines that display the
primary screen based upon pass-
word input.
By using the password duration screen, password

duration time can be set. When restarting the machine,
a password need not be input within that timeframe.
1. When the key switch is turned to the OFF position,

the monitor unit displays the password duration
screen for ten seconds.
Key 1 Key 2 Key 3 Key 4 Key 5 T1V1-05-01-012
2. While the password duration screen is still dis- Password Duration Screen (Key Switch: OFF)
played, push a relevant key, and password dura-
tion time is set.
Duration time assigned to each key is as follows:
key 1: 0 minute
key 2: 30 minutes
key 3: 60 minutes
key 4: 90 minutes
key 5: 120 minutes
NOTE: If password duration time is not set explic-

itly, 0 minute on duration time is assumed.
3. If the key switch is turning to the ON position

within password duration time, the monitor unit Key Switch: ON T1V1-05-01-115
displays the primary screen after the starting

screen.
T5-2-22
(Blank)
T5-2-23
SCREEN DISPLAY WHEN AN ALARM IS
ISSUED
When an alarm is issued, the alarm marks are dis-

played at the bottom of screen.
• When the number of alarm is three or less
TCJB-05-02-046
• When the number of alarm is four to five
TCJB-05-02-047
• When the number of alarm is six to seven
TCJB-05-02-048
• When the number of alarm is eight or more
TCJB-05-02-049
T5-2-24
When an alarm is issued, if the key under a relevant
alarm mark is pushed, the remedy against the alarm is
displayed.
Push a Relevant Key TCJB-05-02-046
T1V5-05-01-013
T5-2-25
CONTENTS OF ALARMS
Display Buzzer Contents of Alarms Remedy

Overheat Alarm Temperature of engine coolant is going up abnormally
Continuously higher.
sounds Stop the work. Run the engine at low idle in order to
M178-01-036 lower the coolant temperature.
Engine Warning Alarm Failure of the engine or its related parts.
Please contact our authorized distributor or dealer.
-
M183-01-080
Engine Oil Pressure Pressure of engine lubricant oil is decreasing.

Continuously Alarm Stop the engine immediately and inspect the engine oil
sounds system and oil level of the engine.
M178-01-037
Alternator Alarm The electrical system is faulty.

- Inspect the alternator and battery system.
M183-01-071
Fuel Level Alarm Level of remaining oil is becoming less.

Refuel oil earlier.
-
M178-01-034
Hydraulic Oil Filter The hydraulic oil filter is clogged.

- Alarm Clean or replace the hydraulic oil filter.
M1CC-01-039
Air Filter Restriction The air filter is clogged.

Alarm Clean or replace the air filter.
-
M183-01-067
Hydraulic Oil Tem- Hydraulic oil temperature is going up abnormally higher.

perature Alarm Stop operation. Run the engine at low idle in order to
- lower the oil temperature.
T1JB-05-02-001
T5-2-26
Display Buzzer Contents of Alarms Remedy

Brake Pressure Alarm Brake oil pressure is low.
Continuously Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-032
Attachment Operating Attachment pedal operating signal is abnormal.

Intermittently Signal Alarm Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-033
Blade/Outrigger Operat- Blade/outrigger operating signal is abnormal.

Intermittently ing Signal Alarm Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-034
Assist Operating Signal Assist operating signal is abnormal.

Alarm Please contact our authorized distributor or dealer.
-
TCJB-05-02-035
Electric Lever Solenoid Electric lever solenoid valve output is abnormal.

Continuously Valve Output Alarm Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-036
Network Alarm Network system is abnormal.

-
TCJB-05-02-037
Work Mode Alarm Network system is abnormal.

-
T1V1-05-01-102
Pilot Shut-Off Lever Alarm The pilot shut-off lever system is abnormal.
-
T1V1-05-01-103
T5-2-27
(Blank)
T5-2-28
TIME SETTING
1. When the primary screen appears, push the

menu key and display main menu.
Menu Key
TCJB-05-02-064
Primary Screen
2. Select time set from main menu by using keys 1
and 2. Push the confirm key. Then, the time setup
screen appears.
Back Key
T1V5-05-01-019
Key 1 Key 2 Confirm Key
3. On the time setup screen, select the items to be

set (Year, Month, Day and Time) by using keys 1
and 2 and set the figures by using keys 3 and 4. Move the
item to
4. By using key 2, move the item to . Push the this icon
confirm key. Then, system time is updated with
the values specified on the screen.
NOTE: When pushing the back key, return to the

previous screen.
Back Key
5. Push key 6, and return to the primary screen. T1V5-05-01-021
Key 1 Key 2 Key 3 Key 4 Confirm Key
Back Key
Key 6 T1V5-05-01-022
T5-2-29
ATTACHMENT ADJUSTMENT
(PUMP 2 FLOW RATE ADJUSTMENT)
NOTE: Only the machines equipped with optional

parts.
IMPORTANT: This operation is effective when at-

tachments are used.
When using breaker 1 or breaker 2

menu key and display main menu. Menu Key
TCJB-05-02-0064
Primary Screen
2. Select Attachment Adjustment from main menu
by using keys 1 and 2. Push the confirm key.
Then, the attachment adjustment screen appears.
3. Push key 2. Then, the attachment adjustment

screen for currently installed attachments ap-
pears.
T1V5-05-01-019
4. Adjust flow rate of pump 2 by using keys 1 and 2.

When breaker 1 or breaker 2 is used, pushing key
1 will decrease flow rate of pump 2 and pushing
key 2 will increase respectively.
NOTE: When pushing the back key, return to the T1V5-05-01-111

Key 1 Key 2 Back Key
previous screen.
5. Push key 6, and the primary screen appears.
T5-2-30

parts.
IMPORTANT: This operation is effective when at-

tachments are used.
When using pulverizer or crusher

2. Select attachment adjustment from main menu by

using keys 1 and 2. Push the confirm key. Then, Menu Key
the attachment adjustment screen appears. TCJB-05-02-0064
Primary Screen
3. Push key 2. Then, the attachment adjustment
screen for currently installed attachments ap-
pears.
T1V5-05-01-019
4. When the pulverizer or crusher is used, pushing

key 1 will increase flow rate of boom raise, arm
roll-out, swing or travel circuit sides.
Pushing key 2 will increase flow rate of attach-
ment side.

previous screen.
T1V5-05-01-024
Key 1 Key 6 Key 2 Back Key
T5-2-31
DISPLAYING OPERATING CONDITIONS

Menu Key
TCJB-05-02-064
Primary Screen
2. Select operating conditions from main menu by

using keys 1 and 2. Push the confirm key. Then,
the operating conditions screen appears.
T1V5-05-01-019
3. Push the reset key, and a screen appears in order
to confirm if it's OK to reset data.
If it’s OK to reset data, push the confirm key.

previous screen.
IMPORTANT: Total fuel consumption and fuel

consumption rate depend on the
operating environment and the op-
eration method of machine.
The values shown on the screen are
just for reference.
T1V5-05-01-025
There could arise ± 20% of differ- Reset Key Back Key
ences between actual fuel con-
sumption and fuel consumption
which is displayed by the monitor
unit.
Back Key
T1V5-05-01-026
Key 6 Confirm Key
T5-2-32
(Blank)
T5-2-33
MAINTENANCE SETTINGS

Menu Key
2. Select maintenance settings from main menu by

the maintenance settings screen appears.
T1V5-05-01-019
3. Select an item to be set from among the list of

maintenance settings screen by using keys 1 and
2. Push the confirm key. Then, the interval
ON/OFF setup screen appears.
(In the right example, Engine Oil is selected.)
T1V5-05-01-049
T5-2-34
Maintenance Information Display ON/OFF
Example: Maintenance Information Display OFF→ON
ON: When time comes to change, the informa-

tion message is displayed on the screen.
OFF: No information message is displayed.
1. Select maintenance information display by using

Key 1
keys 1 and 2. Confirm
Key
Key 2
2. Push the confirm key and select ON.
Key 6
Interval ON/OFF Setup Screen T1V5-05-01-052

3. In order to complete setting, push key 6. Then,
the primary screen appears.
T5-2-35
Change Interval Settings
IMPORTANT: Change interval can only be set

when maintenance information dis-
play is set to ON.
1. Select change interval by using keys 1 and 2.
2. Set time for change interval by using keys 3 and Key 1

4.
Key 2 Key 3 Key 4 T1V5-05-01-052
Interval ON/OFF Setup Screen
3. Select remaining hours by using keys 1 and 2 and

push the confirm key.
Key 1
T1V5-05-01-138
Key 2 Confirm Key
4. The message “Adjust remaining hours to new

change interval. OK?” appears. Then, push the
confirm key.
Key 6 Confirm Key T1V5-05-01-139
Menu Key
T5-2-36
Resetting Data
If data is reset, push key 5 on the interval ON/OFF

setup screen.
The message “Reset Data. OK?” appears. Then,
The value of remaining hours is reset to that of
change interval. The previous change date/hour is
updated with current date and time.
Key 5
Interval ON/OFF Setup Screen T1V5-05-01-052
Confirm Key T1V5-05-01-140
T5-2-37
Notice
Screen Display when Maintenance Information
Display is ON
• When only one item is displayed

1. If the key switch is turned to the ON position, the
primary screen appears. At this time, if mainte-
nance is required, the primary screen gives notice
of the maintenance item. In three seconds, the
maintenance information display screen is dis-
played automatically.
(In the right example, Hydraulic Oil is displayed.)
NOTE: As for a machine which the primary screen

is displayed according to a password on, Primary Screen TCJB-05-02-055
after the password is input successfully and
the confirm key is pushed. And then the
primary screen appears.
2. If data is reset, push the reset key while the

played.
push the confirm key. Back Key
change interval. The previous change date/hour
is updated with current date and time. Reset Key
NOTE: When pushing the back key while the Maintenance Information Display Screen T1V5-05-01-170
maintenance information display screen is

displayed, return to the primary screen.
NOTE: When pushing the back key while reset

screen is displayed, return to the mainte-
nance information display screen.
3. After the maintenance information display screen Back Key

is displayed for ten seconds, the primary screen is
displayed.
Confirm Key
T1V5-05-01-171
Reset Screen
TCJB-05-02-064
Primary Screen
T5-2-38
Notice
• When more than two items are displayed
1. If the key switch is turned to the ON position, the
primary screen appears. At this time, if mainte-
nance is required, the primary screen gives notice
of the maintenance item. In three seconds, the
played automatically.
(In the right example, Hydraulic Oil is displayed.)
NOTE: As for a machine which the primary screen

is displayed according to a password on,
after the password is input successfully and
the confirm key is pushed. And then the
primary screen appears. Primary Screen TCJB-05-02-055
2. If data is reset, while the scheduled maintenance

screen is displayed, select the required item by
the maintenance information display screen for
the selected item appears.
(In the right example, Hydraulic Oil is selected.)
Key 1 Back Key

NOTE: When pushing the back key while the
scheduled maintenance screen is dis-
played, the primary screen appears. Confirm
Key 2 Key
3. Push the reset key while the maintenance infor-
T1V5-05-01-169
mation display screen is displayed. Scheduled Maintenance Screen
change interval. The previous change date/hour
is updated with current date and time.
NOTE: When pushing the back key while the

maintenance information display screen is Back Key
displayed, return to the scheduled mainte-
nance screen.
Reset Key
NOTE: When pushing the back key while the reset
screen is displayed, return to the mainte-
Maintenance Information Display Screen TCHB-05-02-011
nance information display screen.
4. After the maintenance information display screen

is displayed for ten seconds, the primary screen is
displayed.
Back Key
Reset Screen T1V5-05-01-171
T5-2-39
WORK MODE (ATTACHMENT SELECTION)

parts.
IMPORTANT: Select the attachments from the

work mode screen.
In order to display the work mode
screen, push key F1 after the pri-
mary screen appears, or select from
main menu.
Selecting Attachment by Using Key F1

Key F1 TCJB-05-02-064
Primary Screen
1. When the primary screen appears, push key F1
and display the work mode screen.
2. Push a relevant key under an attachment mark to

be used in order to select the attachment.
(In the right example, Crusher 1 is selected.)
NOTE: When selecting Digging, return to the pri-

mary screen.
Digging
Back Key
Select Crusher Work Mode Screen T1V5-05-01-109

1
3. On the attachment specification screen, confirm if

specification of the installed attachment agrees
with that displayed on the screen.

previous screen.
4. Push the confirm key, and the primary screen

appears. Back Key
Confirm
Key
TCEB-05-02-008
Attachment Specification Screen
T5-2-40
Selecting Attachment from Main Menu

Menu Key
TCJB-05-02-064
Primary Screen
2. Select work mode from main menu by using keys
1 and 2. Push the confirm key. Then, the work
mode screen appears.
Back Key
TCHB-05-02-001
3. Push the relevant key under an attachment mark

to be used in order to select the attachment.
(In the right example, Crusher 1 is selected.)
NOTE: When selecting digging, return to main

menu.
4. On the attachment specification screen, confirm if

specification of the installed attachment agrees
with that displayed on the screen.
Digging
If they do not match, perform the setting of at-
tachment by using Dr. ZX. Back Key
For details of the attachment specification screen, Select T1V5-05-01-109
Crusher 1 Work Mode Screen
refer to T5-2-42 and 43.

previous screen.
5. Push the confirm key, and the primary screen

appears.
Back Key
Confirm
Key
Attachment Specification Screen TCEB-05-02-008
T5-2-41
Attachment Specification Screen
Maximum Pump 2 Flow Rate
Maximum Engine Speed
Accumulator Control Solenoid Valve:

OFF
Secondary Hydraulic Relief Selector

Control Solenoid Valve: ON
Selector Valve Control Solenoid Valve: ON

The selector valve is connected to the
hydraulic oil tank.
Auxiliary Flow Combiner Solenoid

Valve: OFF
TCEB-05-02-005

OFF

Control Solenoid Valve: OFF
Selector Valve Control Solenoid Valve: ON
The selector valve is connected to the
hydraulic oil tank.
Auxiliary Flow Combiner Solenoid Valve:

OFF
TCEB-05-02-006
T5-2-42
Maximum Pumps 1 and 2 Flow Rate

OFF
Selector Valve Control Solenoid Valve: OFF

The selector valve is connected to the control
valve.

ON
TCEB-05-02-007
Maximum Pumps 1 and 2 Flow Rate

OFF
Selector Valve Control Solenoid Valve: OFF

The selector valve is connected to the control
valve.

ON
TCEB-05-02-008
T5-2-43
MAIL (Optional)
IMPORTANT: This function is available only to a

machine equipped with a satellite
terminal.
When using the mail function, make
the mail function available by using
Dr. ZX.
1. When the primary screen appears, push key F3

and display the mail screen.
2. If a relevant request key is pushed, mail informa-

Key F3 Primary Screen
tion is sent to ICF. TCJB-05-02-044
1 - General Request
2 - Fuel Replenishment Request
3 - Service Maintenance Request
4 - Forwarding Request
T1V5-05-01-037
1 2 3 Mail Screen 4
3. While mail information is sent to ICF, the message
“Mail is being delivered.” is displayed on the
screen.
T1V5-05-01-038
4. When ICF completes receives mail information,

the message “Mail delivery successful.” is dis-
played on the screen.
When pushing the back key, return to the mail
screen.
5. Then, a mail is sent from the satellite terminal to

the central server via the satellite.
NOTE: Depending on machine operating envi-

ronment or position of the satellite on its
orbit, the mail may not be sent. Back Key
T1V5-05-01-039
T5-2-44
NOTE: When ICF could not receive the mail, the

message “Mail delivery failed.” is displayed
on the screen.
T1V5-05-01-040
T5-2-45
METER DISPLAY SELECTION
NOTE: The meter display selection screen is dis-

played by pushing key F4 or selecting main
menu after the primary screen is displayed.
Select Meter Display Selection from Key F4
1. After the primary screen is displayed, push key F4.

Then, the meter display selection screen is dis- Key F4
played.
NOTE: If key F4 is pushed for two seconds or more,

the meter display is changed on the primary Primary Screen TCJB-05-02-064
screen as follows.
Hour Meter → Odometer → Trip Meter
2. Select the meter by using keys 1 and 2. Push the Data Reset
confirm key. (In the right example, Trip Meter is Icon
selected.)

Key 1 Back Key
previous screen.
Key 6
Confirm
3. Only when the trip meter is selected, the data re- Key
set icon is displayed. If data is reset, push key 5.
Key 2 Key 5
Meter Display Selection Screen
4. The message “Reset Data. OK?” appears. Push TCJB-05-02-012
the confirm key.
5. Push key 6, and the primary screen is displayed.
NOTE: The contents which are set by the meter

display selection are available until the key
switch is turned OFF. When the key switch
is turned OFF, the contents are reset to
those by the meter combination settings. Back Key
Confirm
Key
Key 6
TCHB-05-02-006
T5-2-46
NOTE: The meter display selection screen is dis-

played by pushing key F4 or selecting main
menu after the primary screen is displayed.
Select Meter Display Selection from Main Menu
1. After the primary screen is displayed, push the

menu key. The main menu is displayed.
Primary Screen
2. Select HOUR ↔ ODO ↔ TRIP from main menu TCJB-05-02-069
by using keys 1 and 2. Push the confirm key. Then,

the meter display selection screen is displayed.
Back Key
Key 1 Key 2 Confirm Key TCHB-05-02-001
3. Select the meter by using keys 1 and 2. Push the

confirm key. (In the right example, Hour Meter is
selected.)

previous screen.
4. Push key 6, and the primary screen is displayed. Key 1

Back Key
NOTE: The contents which are set by the meter Key 2 Confirm
display selection are available until the key Key
switch is turned OFF. When the key switch Key 6
is turned OFF, the contents are reset to Meter Display Selection Screen TCJB-05-02-072
those by the meter combination settings.
T5-2-47
PASSWORD CHANGE (OPTIONAL)

Menu Key
2. Select password change from main menu by us-

ing keys 1 and 2. Push the confirm key. Then, the
password change screen appears.
T1V5-05-01-041
Registered Password
3. Input the registered password and push the con-
firm key.
4. If inputting the password again, the entered

characters can be erased by pushing the erase
key.
Confirm Key Erase Key T1V5-05-01-042
T5-2-48
NOTE: If inputting an incorrect password after

pushing the confirm key, the message
“Password is incorrect.” appears.
Push the back key and go back to the pre-
vious screen. Input the password again.
T1V5-05-01-044
Back Key
5. The message “Enter password to be registered.”

appears. Then, input a new password with three
or four digits and push the confirm key.
6. If inputting the password again, push the erase

key.
T1V5-05-01-130
A New Password
T1V5-05-01-131
T5-2-49
7. The message “Re-enter password.” appears.
Then, input a new password again and push the
confirm key.
8. If inputting the password again, push the erase

key in order to erase the entered characters.
T1V5-05-01-132
Confirm Key Erase Key T1V5-05-01-133
9. The message “New password has been regis-

tered.” appears. This completes the password
change process.
T1V5-05-01-043
Key 6
T5-2-50
(Blank)
T5-2-51
BACK MONITOR SETTINGS
IMPORTANT: Image displayed on the back monitor

is of auxiliary nature at best. When
the machine is operated, pay thor-
ough attention to surrounding situa-
tion.
Auto-Control: ON
When the FNR switch is turned to the R (reverse)

position, image on the monitor unit is automatically
switched to that of the back monitor. Menu Key
TCJB-05-02-064
Primary Screen
1. When the primary screen appears, push the menu
key and display main menu.
2. Select back monitor settings from main menu by

the back monitor settings screen appears.
Back Key
3. Push the confirm key. Then, auto-control is set to

ON.

previous screen.
4. Push key 6, and return to the primary screen.
Back Key
Key 1 Key 2 Confirm Key T1V5-05-01-173
Back Key
Key 6
T1V5-05-01-174
T5-2-52
5. When the FNR switch is turned to the R (reverse)
position, image on the monitor unit is switched to
rear view image.
NOTE: After rear view image is displayed on the

monitor unit screen and although the ac-
celerator pedal returns to the neutral posi-
tion, rear view image is displayed for three
seconds. If step 2 below is done in three
seconds after rear view image is displayed,
rear view image is not displayed on the
monitor unit screen.
1. Return rear view image to the primary
screen.
2. Turn the FNR switch to the R (reverse)
position.
(While the FNR switch is in the R (reverse)
position, rear view image is not displayed.)
If step 1 above is done in three seconds
after rear view image is displayed, rear view
image is displayed on the monitor unit
screen.
T5-2-53
Auto-Control: OFF
When the FNR switch is the R (reverse) position,

automatic switching function of images between
monitor unit and back monitor is set to OFF.

Menu Key
TCJB-05-02-064
Primary Screen
2. Select back monitor settings from main menu by

the back monitor settings screen appears.
Key 1 Key 2 Confirm Key Back Key TCHB-05-02-003
3. Push the confirm key. Then, auto-control is set to

OFF.

previous screen.
4. Push key 6, and return to the primary screen.
Confirm Key Back Key T1V5-05-01-174
Back Key
Key 6
T1V5-05-01-173
T5-2-54
(Blank)
T5-2-55
LANGUAGE SETTINGS

Menu Key
TCJB-05-02-064
Primary Screen
2. Select language from main menu by using keys 1

and 2. Push the confirm key. Then, the language
settings screen appears.
TCHB-05-02-003
Key 1 Key 2 Confirm Key Back Key
3. Select a desired language by using keys 1 and 2.
Push the confirm key.
NOTE: Languages to be displayed on the screen

of monitor unit have been selected from
twelve languages, namely display lan-
guages 1 or 2, as default.
(Refer to the next page.)

previous screen.
Back Key
T1V1-05-01-137
Key 1 Key 6 Key 2 Confirm Key
T5-2-56
Lists of Display Languages
Display Languages 1
Language Screen Display
Japanese
T1V1-05-01-141
English
T1V1-05-01-142
Chinese
T1V1-05-01-143
Taiwanese
T1V1-05-01-144
Korean
T1V1-05-01-145
Indonesian
T1V1-05-01-146
Thai
T1V1-05-01-147
Vietnamese
T1V1-05-01-148
Myanmarese
T1V1-05-01-149
Arabic
T1V1-05-01-150
Persian
T1V1-05-01-151
Turkish
T1V1-05-01-152
Display Languages 2
Language Screen Display
English
T1V1-05-01-142
Spanish
T1V1-05-01-153
Italian
T1V1-05-01-154
French
T1V1-05-01-155
German
T1V1-05-01-156
Netherlandish
T1V1-05-01-157
Russian
T1V1-05-01-158
Portugese
T1V1-05-01-159
Finlandish
T1V1-05-01-160
Swedish
T1V1-05-01-161
Norwegean
T1V1-05-01-162
Danish
T1V1-05-01-163
T5-2-57
METER COMBINATION SETTINGS

Menu Key
TCJB-05-02-064
Primary Screen
-1
2. Select km/h ↔ min from main menu by using
keys 1 and 2. Push the confirm key. Then, the
meter combination setup screen is displayed.
NOTE: If mile is selected by unit settings (km ↔

-1
mile), mph ↔ min is displayed.
TCHB-05-02-003
3. Select the meter combination by using keys 1 and

2. Push the confirm key.

previous screen.
4. Push key 6, and the primary screen is displayed. Key 1 Back Key
Key 2 Confirm
Key
Key 6
Meter Combination Setup Screen TCJB-05-02-015
Key 1 Back Key
Key 2 Confirm
Key
Key 6
Meter Combination Setup Screen TCJB-05-02-068
T5-2-58
NOTE: Examples of combination

Odometer
• When selecting km (speedometer) and odometer
Speedometer
(km)
TCJB-05-02-069
• When selecting min-1 (tachometer) and hour me- Hour Me-

ter
ter
Tachometer
TCJB-05-02-065
Trip
Meter
• When selecting mph (speedometer) and trip me-
ter
(Unit: When selecting mile)
Speedometer
(mile)
TCJB-05-02-070
T5-2-59
UNIT SETTINGS

Menu Key
2. Select km/h ↔ mile from main menu by using

keys 1 and 2. Push the confirm key. Then, the unit
combination setup screen is displayed.
3. Select the unit by using keys 1 and 2. Push the

confirm key.

previous screen.
4. Push key 6, and the primary screen is displayed. Key 1 Back Key
Key 2 Confirm
Key
Key 6
Unit Setup Screen TCJB-05-02-016
T5-2-60
NOTE: Examples
• When selecting km
TCJB-05-02-069
• When selecting mile
TCJB-05-02-070
T5-2-61
(Blank)
T5-2-62
SERVICE MENU (BUILT-IN DIAGNOSING
SYSTEM) OPERATION
IMPORTANT: This system is to be operated by the

HITACHI dealer only. Do not explain
this system function to the cus-
tomer.
Although Dr.ZX id not used, the following items can be

displayed on the monitor unit.
• Troubleshooting:
The fault code is displayed.
• Monitoring: T1V1-05-01-115
A part of monitor items of Dr.ZX is displayed. Turn key switch ON while pushing the key
• Controller Version:
Each controller version is displayed.
• Blade/Outrigger Settings:
The blade/outrigger settings are changed.
1. Turn the key switch to the ON position while

pushing the key at upper right corner of the
monitor unit. Therefore, service menu is added to
main menu.

Menu Key
TCJB-05-02-064
3. Select service menu from main menu by using Primary Screen
service menu screen appears.

previous screen.
Key 1 Key 2 Confirm Back Key TCHB-05-02-005

Key
Back Key TCHB-05-02-007
T5-2-63
TROUBLESHOOTING
1. Displaying Service Menu

Turn the key switch to the ON position while
pushing the key at upper right corner of the
monitor unit. Therefore, service menu is added to
main menu.
T1V1-05-01-115
Turn key switch ON while pushing the key

Menu Key
TCJB-05-02-064
Primary Screen
3. Select service menu from main menu by using


previous screen.

Key
T5-2-64
4. Select troubleshooting by using keys 1 and 2.
Push the confirm key. Then, the troubleshooting
screen appears.
5. Results of trouble analyses for each controller are A figure enclosed in ( ) indicates the number of fault codes.
displayed on the screen.
Displayed Controller:
• Main Controller
• Engine Governor Controller
• Monitor Controller
• ICF Controller
6. Select Abnormal of a faulty controller by using

keys 1 and 2. Push the confirm key. Then, fault
code is displayed. Key 1 Key 2 Confirm Key Back Key T1V5-05-01-085
As for details of trouble analyses, refer to “Trou-

bleshooting A.”
IMPORTANT: Up to twenty fault codes can be dis-

played. But, one screen can contain
only ten fault codes maximum.
If the screen is fully filled with ten
items, push key 1 and check other
fault codes on the next page.
When returning to the previous page,
push key 2.

previous screen. Key 1 Key 6 Key 2 Back Key T1V5-05-01-097
T5-2-65
MONITORING

pushing the key at upper right corner of the moni-
tor unit. Therefore, service menu is added to main
menu.
T1V1-05-01-115
Turn the key switch ON while pushing the key
2. When the primary screen appeared, push the

Menu Key
TCJB-05-02-064
Primary Screen


previous screen.

Key
T5-2-66
4. Select monitoring by using keys 1 and 2. Push the
confirm key. Then, the monitoring screen appears.
As for items to be monitored, refer to the next
page.
TCHB-05-02-007
5. Select an item to be monitored by using keys 1
and 2. Push the confirm key. Then, the selected
item is brought up to the top.
NOTE: When the key switch is turned OFF, the

order of items to be monitored is reset to
the initial state.
6. Push key 3, and the displayed data are put on

hold.
Push key 3 again, and the records are updated
Back Key
with the displayed data.
T1V5-05-01-087
Key 1 Key 2 Key 3 Key 4 Confirm Key
7. The order of items to be monitored is reset to the
initial state by pushing key 4.
When key 4 is pushed and a confirmation mes-
sage appears, push the confirm key.

previous screen.
Back Key
T1V5-05-01-088
Key 6 Confirm Key
T5-2-67
A List of Items to be Monitored
Items Units Remarks

Engine Torque %
Coolant Temperature (E) °C Input signal to the monitor unit from ECM by
using CAN
Fuel Temperature °C
Engine Oil Pressure kPa
Atmospheric Pressure kPa
Intake Air Temperature °C
Boost Pressure kPa
Boost Temperature °C
Coolant Temperature (M) °C Directly Input signal to the monitor unit from
the coolant temperature sensor (coolant
temperature gauge)
Target Engine Speed min−1
Actual Engine Speed min−1
Pump 1 Delivery Pressure MPa
Pump 1 Pump Control Pressure MPa
Target Pump 1 Flow Rate L/min
Pump 2 Delivery Pressure MPa
Pump 2 Pump Control Pressure MPa
Target Pump 2 Flow Rate L/min
Swing/Front Attachment Control Pilot Pressure MPa
Boom Up Pilot Pressure MPa
Arm In Pilot Pressure MPa
Swing Pilot Pressure MPa
Forward Travel Pilot Pressure MPa
Reverse Travel Pilot Pressure MPa
EC Dial Angle V
Hydraulic Oil Temperature (Tank) °C Signal from main hydraulic oil temperature
sensor
Pump Torque Proportional Valve MPa
Arm Regeneration Proportional Valve MPa
Power Digging Control Pressure MPa 0 MPa is displayed.
Power Mode E/P/HP
Power Digging Switch OFF/ON OFF is displayed.
Radio Signal strength ×/○
T5-2-68
Items Units Remarks

Speed km/h Although mile is selected from main menu, travel
speed (km/h) is displayed.
Travel Motor Over Speed (Count)
Brake Pressure MPa
Emergency Stop OFF/ON
Attachment1/Positioning1 Signal V
Attachment2/Positioning2 Signal V
Blade1/Outrigger1 Signal V
Blade2/Outrigger2 Signal V
Assist1 Signal V
Assist2 Signal V
Assist3 Signal V
Assist4 Signal V
Hydraulic Oil Temperature (Pilot) °C Signal from pilot hydraulic oil temperature sensor
Assist1 Proportional Valve MPa
Positioning1 Proportional Valve MPa
Positioning2 Proportional Valve MPa
Blade1/Outrigger1 Proportional Valve MPa
Blade2/Outrigger2 Proportional Valve MPa
Assist3 Proportional Valve MPa “-” is displayed as default.
Assist4 Proportional Valve MPa “-” is displayed as default.
T5-2-69
CONTROLLER VERSION

menu.
T1V1-05-01-115

Menu Key
TCJB-05-02-064
Primary Screen

NOTE: When pushing the back key, return back to

the previous screen.

Key
T5-2-70
4. Select controller version by using keys 1 and 2.
Push the confirm key. Then, the controller version
screen appears.

previous screen.
TCHB-05-02-007
TCHB-05-02-008
Key 6 Back Key
T5-2-71
BLADE/OUTRIGGER SETTINGS

menu.
T1V1-05-01-115

Menu Key
TCJB-05-02-064
Primary Screen

NOTE: When pushing the back key, return back to

the previous screen.

Key
T5-2-72
4. Select blade/outrigger settings by using keys 1
and 2. Push the confirm key. Then, the
blade/outrigger setup screen appears.
5. Select the screen corresponded to the combina-

tion by using keys 1 and 2.

previous screen.
Key 1
Back Key
Key 2
Key 6
Display the
Selected
Screen
Screen Transition TCJB-05-02-067
6. Push key 6, and the primary screen is displayed.

The last screen is displayed as the primary
screen. TCJB-05-02-064
Primary Screen
NOTE: the blade/outrigger during operation is dis-

played in green on the primary screen.
T5-2-73
KEYLESS HOUR METER
When the key switch is turned OFF, the following items

can be displayed on the monitor unit screen.
• Hour Meter
• Odometer
• Fuel Gauge
When the back monitor selection key is

pushed for one second or more, the keyless
hour meter screen is displayed. Back Monitor
Selection Key
NOTE: While the back monitor selection key is
pushed, the keyless hour meter screen is
displayed. T1V1-05-01-010
Hour Meter
Odometer
Fuel Gauge
Back Monitor
Selection Key
Keyless Hour Meter Screen TCJB-05-02-001
2. When the back monitor selection key is released,

the keyless hour meter screen disappears.
T5-2-74
LIST OF MONITOR UNIT SETTING FUNC-
TION
○: with setting function

×: without setting function
Setting Function
Function Item Monitor Default
Dr.ZX
Unit
Alarm Check alarms while trouble occurs ○ ○(Troubleshooting) －
Security Password function Enable/Disable × ○(Security) Disable
Password change ○ × 0000
Permission/no permission of password change on the
× ○(Security) Permission
monitor
Max.
Maximum password digit change × ○(Security)
4 digits
Password check × ○(Security) －
Extending function Enable/Disable × ○(Security) Enable
Selection on extra time ○ × －
Time Setting Time set function Enable/Disable × ○(Monitor Controller) Enable
Time change ○ ○(ICF) －
Operating Operational condition Enable/Disable × ○(Monitor Controller) Enable
Condition Operational condition reset ○ × －
Maintenance Maintenance operation Allow/Not Allow × ○(Monitor Controller) Allow
Setting Maintenance display items ON/OFF × ○(Monitor Controller) ON
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Engine Oil Change interval ○ × 500 hours
Remaining hours data reset ○ × －
Previous change Date/Hour Meter check ○ × －
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Engine Oil
Change interval ○ × 500 hours
Filter
Hydraulic
Change interval × × 5000 hours
Oil
Hydraulic Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Oil Pilot Change interval × × 1000 hours
Filter Remaining hours data reset ○ × －
T5-2-75
Setting Function
Dr.ZX
Unit
Maintenance Maintenance display items ON/OFF × ○(Monitor Controller) ON
Setting Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Hydraulic
Oil Filter
Pump Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Transmission Change interval × × 1000 hours
Oil Remaining hours data reset ○ × －
Swing Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Reduction Change interval × × 1000 hours
Gear Remaining hours data reset ○ × －
Swing Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Bearing Change interval × × 500 hours
Grease Remaining hours data reset ○ × －
Hydraulic
Oil Brake
Steering
Travel Device Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Transmission Change interval × × 500 hours
Oil Remaining hours data reset ○ × －
Axle Gear
Oil
(Front, Rear,
each Hub) Remaining hours data reset ○ × －
T5-2-76
Setting Function
Dr.ZX
Unit
Setting Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Drive Shaft
Greasing
Front Axle Notification function Enable/Disable ○ ○(Monitor Controller) Enable
King Pin Change interval × × 30 days
Greasing Remaining hours data reset ○ × －
Front Axle Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Center Pin Change interval × × 250 hours
Greasing Remaining hours data reset ○ × －
Wheel Nut Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Torque Change interval × × 250 hours
Check Remaining hours data reset ○ × －
Air Filter Change interval × × 1500 hours
Engine / Air Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Conditioner Change interval × × 1000 hours
V-belt Remaining hours data reset ○ × －
Fuel Filter Change interval × × 500 hours
T5-2-77
Setting Function
Dr.ZX
Unit
Setting Air Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Conditioner Change interval × × 3000 hours
Maintenance display items ON/OFF × × ON
Notification function Enable/Disable ○ × Disable
User Setting
Change interval ○ × 5000 hours
(TRIP 1)
Remaining hours data reset × × －
Optional Work mode function Set/Unset × ○(Monitor Controller) Set
Function Mail function Set/Unset × ○(Monitor Controller) Unset
Send the mail ○ × －
Overload
Overload alarm Enable/Disable × ○(Monitor Controller) Disable
Alarm
Back Monitor Back monitor function Enable/Disable × ○(Monitor Controller) Enable
Setting Auto-display/no auto-display of camera image during No auto
○ ×
travel reverse operation (auto-control) display
Back monitor display Normal/Flip Vertical × ○(Monitor Controller) Normal
Selection of NTSC/PAL (image method) × ○(Monitor Controller) NTSC
Meter Setting Meter setup function Enable/Disable × ○(Monitor Controller) Enable
Speedometer
Meter combination setting change ○ × +
Hour Meter
Unit Setting Unit setup function Enable/Disable × ○(Monitor Controller) Enable
Unit Change ○ × km
Language Select language ○ × English
Setting Register/delete language × × －
Registered language check ○ × －
Trouble- Check alarms while trouble occurs ○ ○(Troubleshooting) －
shooting Check alarms which occurred × ○(Troubleshooting) －
Clear fault code (Retry B) × ○(Troubleshooting) －
Monitoring Item order change ○ × －
Reset item order to default ○ × －
Blade / Out-
Blade/Outrigger setting change ○ × 1/12
rigger Setting
T5-2-78
TROUBLESHOOTING / Dr. ZX
OUTLINE
Dr. ZX is a tool used for troubleshooting of the

electronic control system of MC, ECM, ICF, monitor
unit, steering column monitor and option controller.
It displays the fault code of each controller or sensor by
connecting Dr. ZX to ICF. (Display of Troubleshooting
Result)
Dr. ZX also displays input status of sensor and switch

that connected to each controller and output status of
actuators from controllers to solenoid valves in real
time while it's running. (Controller Troubleshooting)
NOTE: For operation detail about Dr. ZX, refer to

separated "Dr. ZX Manual".
T5-3-1
MC MONITORING LIST
Dr. ZX displays the input signals from switches and
sensors to MC and the control signals to the actuators
from MC.
Item
Unit Data
Selecting Monitoring
-1
Requested Engine Speed Req. Eng min Input signal from engine control dial
-1
Actual Engine Speed Actual Speed min Input signal from ECM
-1
Engine Speed Deviation Eng Speed Deviat min A value subtracted required engine speed from actual engine speed
Vehicle Speed Vehicle Speed km/h Input value from travel N sensor
Pump 1 Delivery Pressure P1 Delivery Pres MPa Input signal from pump 1 delivery pressure sensor
Pump 1 Flow Control Pressure PC 1 Pressure MPa Input signal from pump 1 control pressure sensor
Pump 1 Flow Rate Limit P/S/V Out P1 P/S Valve MPa Control instruction signal to maximum pump 1 flow rate limit control solenoid
valve
Pump 1 Upper Limit Displacement P1 Pres Maxq cm3 Calculation from engine speed and pump 1 delivery pressure
(With attachment only)
Pump 1 Target Flow Rate P1 Set Flow Rate L/min Control instruction signal to maximum pump 1 flow rate limit control solenoid
valve
Pump 2 Delivery Pressure P2 Delivery Pres MPa Input signal from pump 2 delivery pressure sensor
Pump 2 Flow Control Pressure PC 2 Pressure MPa Input signal from pump 2 control pressure sensor
Pump 2 Flow Rate Limit P/S/V Out P2 P/S Valve MPa Control instruction signal to maximum pump 2 flow rate limit control solenoid
valve
Pump 2 Upper Limit Displacement P2Maxq cm3 Calculation from engine speed and pump 2 delivery pressure
(With attachment only)
Pump 2 Target Flow Rate P2 Set Flow Rate L/min Control instruction signal to maximum pump 2 flow rate limit control solenoid
valve
Pump Torque P/S Valve Output P Torque P/S/V MPa Control instruction signal to torque control solenoid valve
Pump 3 Delivery Pressure P3 Pressure MPa Input signal from steering pump delivery pressure sensor
Pump 4 Delivery Pressure P4 Pressure MPa Input signal from pump 4 delivery pressure sensor
Front Pilot Pressure Fr Pilot Press MPa Input signal from pressure sensor (front)
Boom Raise Pilot Pressure Boom Raise MPa Input signal from pressure sensor (boom raise)
Arm Roll-In Pilot Pressure Arm Roll-In MPa Input signal from pressure sensor (arm roll-in)
Arm Roll-Out Pilot Pressure Arm Roll-Out MPa Input signal from pressure sensor (arm roll-out)
Swing Pilot Pressure SW Pilot Press MPa Input signal from pressure sensor (swing)
Travel Forward Pilot Pressure Tr F Pilot Press MPa Input signal from pressure sensor (travel forward)
Travel Reverse Pilot Pressure Tr R Pilot Pilot Press MPa Input signal from pressure sensor (travel reverse)
ATT Control Pilot Pressure ATT Pilot Press MPa Input signal from pressure sensor (auxiliary)
EC Dial Angle Dial Angle V Input signal from engine control dial
Boom Bottom Pressure Bm Bottom Press MPa Input signal from boom bottom pressure sensor
Brake Remain Pressure Brake Remain P MPa Input signal from brake remaining pressure sensor
Brake Pressure Brake Pressure MPa Input signal from brake pressure sensor
E/P SW E/P SW E, P Power mode switch selection status
HP Mode SW HP Mode SW ON, OFF Power mode switch selection status
Auto-Idle SW AI SW AI Auto-idle switch selection status
NOTE: BR: Breaker

PU: Pulverizer
CR: Crusher
VI: Vibrating hammer
Un: Other
ATT: Attachment
OPT: Optional
T5-3-2
Item
Unit Data
Power Boost SW Power Boost SW ON, OFF Power digging switch ON/OFF selection status
Key SW Key SW ON, OFF Key switch ON/OFF selection status
Slight Travel SW Slight Travel SW ON, OFF Engine control mode selection switch (creeper) ON/OFF selection
status
Pedal EC SW Pedal EC SW ON, OFF Engine control mode selection switch (pedal) ON/OFF selection
status
Implement Brake Deactive Imp Brk Release ON, OFF Work brake release switch ON/OFF selection status
Parking Brake SW Parking Brake SW ON, OFF Brake switch (parking brake) ON/OFF selection status
Transmission H/L SW T/M H/L SW Lo, Hi Travel speed mode switch ON/OFF selection status
FNR (R) SW FNR (R) SW ON, OFF FNR switch (R) ON/OFF selection status
Arm Regenerative P/S Valve Output Am Regen P/S/V MPa Control instruction signal to solenoid valve unit (SC)
Power Boost Control Pressure PD Ctrl Pressure MPa Control instruction signal to solenoid valve unit (SG)
ATT P/S Valve Output ATT P/S Valve MPa Control instruction signal to auxiliary flow rate control solenoid valve
Pump 1 Flow Rate Limit P/S/V Out FB P1 Flow P/V FB mA Feedback from maximum pump 1 flow rate limit solenoid valve output
Pump 2 Flow Rate Limit P/S/V Out FB P2 Flow P/V FB mA Feedback from maximum pump 2 flow rate limit control solenoid valve
output
Pump Torque P/S/V Output FB P Torque P/V FB mA Feedback from torque control solenoid valve output
ATT P/S Valve Output FB ATT P/S/V FB mA Feedback from auxiliary flow rate control solenoid valve output
Arm Regenerative P/S/V Output FB Am Rege P/V FB mA Feedback from solenoid valve unit (SC) output
Power Boost chg. Over Pressure FB PD Ctrl Puress FB mA Feedback from solenoid valve unit (SG) output
Travel Motor Swash Angle P/V Valve TrM Swash Angle P/V Out MPa Control instruction signal to travel motor displacement angle control
Output solenoid valve
Travel Makeup P/S/V Output Travel Makeup P/S/V Out MPa Control instruction signal to travel make-up solenoid valve
Implement Brake P/S/V Output Implement Brake P/S/V MPa Control instruction signal to solenoid valve unit (SF)
Axle Lock Output Axle Lock Output MPa Control instruction signal to solenoid valve unit (SI)
Travel Motor Swash Angle P/V FB TrM Swash Angle P/V FB mA Feedback from travel motor displacement angle control solenoid
valve output
Travel Makeup P/S/V FB Travel Makeup P/S/V FB mA Feedback from travel make-up solenoid valve output
Axle Lock Output FB Axle Lock Output FB mA Feedback from solenoid valve unit (SI) output
Implement Brake FB Implement Brake FB mA Feedback from solenoid valve unit (SF) output
Travel Alarm Travel Alarm Action/ Action/No Action status of travel alarm
No Action
Swing Alarm Swing Alarm Action/ Action/No Action status of swing alarm
No Action
Hydraulic Oil Temperature (HOT) Hyd Oil Temp. °C Input signal from hydraulic oil temperature sensor
T/M Change (Low Speed) T/M Change (Low Speed) ON, OFF Travel mode selector solenoid valve (slow) ON/OFF selection status
T/M Change (High Speed) T/M Change (High Speed) ON, OFF Travel mode selector solenoid valve (fast) ON/OFF selection status
Axle Lock Control State Axle Lock Control State ON, OFF Brake switch (axle lock) ON/OFF selection status
Implement Brake State Implement Brake State ON, OFF Work brake ON/OFF selection status
Travel Motor Over Rotation Count TrM Over Rotation Count Count Input value from travel N sensor
NOTE: BR: Breaker

PU: Pulverizer
CR: Crusher
Un: Other
ATT: Attachment
OPT: Optional
T5-3-3
Item
Unit Data
Speed Meter Auto Change Flag Speed Meter Auto Change Flag ON, OFF Speed meter auto switch ON/OFF selection status
Current ATT Type Current ATT Type BR, PU, CR, VI, Un Communication from monitor unit
Current ATT No. Current ATT No. 1, 2, 3, 4, 5 Communication from monitor unit
ATT1 Type ATT1 Type BR, PU, CR, VI, Un Communication from monitor unit
ATT1 No. ATT1 No. 1, 2, 3, 4, 5 Communication from monitor unit
Trip Meter Trip Meter km Unit setting status for monitor unit
Odo Meter Odo Meter km Unit setting status for monitor unit
(German) Specifications Change SW (German) Specifications Change ON, OFF German specification selection switch ON/OFF selection status
SW
FNR (F) SW FNR (F) SW ON, OFF FNR switch (Forward) ON/OFF selection status
NOTE: BR: Breaker

PU: Pulverizer
CR: Crusher
Un: Other
ATT: Attachment
OPT: Optional
T5-3-4
ECM MONITORING LIST
Item
Unit Data
Engine Torque Engine Torque ％ Input signal from ECM
Actual Engine Speed
Act. Eng Speed min-1 Input signal from crank speed sensor and cam angle sensor
(Engine Speed)
Target Engine Speed Tar. Eng Speed min-1 Input signal from engine control dial
Glow Signal Glow Signal OFF, ON Glow Plug Relay ON/OFF selection status
Coolant Temperature (Engine) Coolant Temp. °C Input signal from coolant temperature sensor
Fuel Temperature Fuel Temp. °C Input signal from fuel level sensor
Engine Oil Pressure Eng Oil Pressure kPa Input signal from engine oil pressure sensor
Fuel Flow Fuel Flow L/h Input signal from ECM
Barometric Pressure Barome. Press kPa Input signal from atmospheric pressure sensor
Intake Air Temperature Intake Air Temp. °C Input signal from intake air temperature sensor
Boost Pressure Boost Pressure kPa Input signal from boom boost pressure sensor
Boost Temperature Boost Temp. °C Input signal from boom boost temperature sensor
Battery Voltage Battery Volt V Input signal from ECM
Total Used Fuel Total Used Fuel L Input signal from ECM
T5-3-5
MONITOR UNIT MONITORING LIST
Item
Unit Data
Monitor SW Status Check Monitor SW Status Check − Monitor unit switch status
Coolant Temperature Coolant Temp. °C Input signal from coolant temperature sensor
Fuel Level Fuel Level % Input signal from fuel level sensor
Security Signal Security Signal OFF, ON Communication from monitor unit
Mail SW Mail SW OFF Mail Operation Status
Fuel
Forward
Repair
General
T5-3-6
STEERING COLUMN MONITOR MONITORING LIST
Item
Unit Data
Speed Pulse Speed Pulse Hz Communication from MC
Vehicle Speed Pulse Vehicle Speed Pulse Hz Communication from MC
T5-3-7
OPTION CONTROLLER MONITORING LIST
Item
Unit Data
Att SW Operation (Proportional SW) Att SW Ope (Prop) V Input signal from attachment switch
Auxiliary Operation (Proportional SW) Aux Ope (Prop SW) V Input signal from attachment switch
Positioning/Att 1 Operation Posn/Att 1 Ope V Input signal from attachment pedal
Positioning/Att 2 Operation Posn/Att 2 Ope V Input signal from attachment pedal
Outrigger/Blade 1 Operation OR/BL1 Ope V Input signal from blade/outrigger lever
Outrigger/Blade 2 Operation OR/BL2 Ope V Input signal from blade/outrigger lever
Posn/Att SW Pilot Monitor Pressure Posn/Att SW P Press MPa Input signal from pressure sensor (positioning, attachment)
Outrgr/Blade/Att Pilot Montr Pressr OR/BL/Att P Press MPa Input signal from pressure sensor (blade/outrigger, auxiliary)
Hydraulic Oil Temperature (OPT) Hyd Oil Temp. °C Input signal from pilot oil temperature sensor
Boom Bottom Pressure Bm Bottom Press MPa Input signal from boom bottom pressure sensor
Gate Lock Signal Gate Lock Signal Up, Down Pilot shut-off lever up/down status (Pilot shut-off switch
ON/OFF selection status)
Att SW & Aux (Main SW) Att SW & Aux (Main SW) ON, OFF Electric operation main switch ON/OFF selection status
Att Selection SW Att Selection SW Aux, Posn Attachment selection switch ON/OFF selection status
Att SW 1 Operation Att SW 1 Operation ON, OFF Attachment switch ON/OFF selection status
Att SW 2 Operation Att SW 2 Operation ON, OFF Attachment switch ON/OFF selection status
Outrigger Control SW1 Outrigger Control SW1 ON, OFF Outrigger selection switch ON/OFF selection status
Swing Parking Release Swing Parking MPa Control instruction signal to swing parking brake release
solenoid valve
Att 1 P/S/V Att 1 P/S/V MPa Control instruction signal to auxiliary solenoid valve
Att 2 P/S/V Att 2 P/S/V MPa Control instruction signal to auxiliary solenoid valve
Blade 1/Outrigger 1 P/S/V BL1/OR1 P/V MPa Control instruction signal to blade/outrigger solenoid valve
Blade 2/Outrigger 2 P/S/V BL2/OR2 P/V MPa Control instruction signal to blade/outrigger solenoid valve
Positioning 1 P/S/V Posn 1 P/V MPa Control instruction signal to positioning solenoid valve
Positioning 2 P/S/V Posn 2 P/V MPa Control instruction signal to positioning solenoid valve
Att SW 1 P/S/V Att SW 1 P/S/V MPa Control instruction signal to attachment solenoid valve
T5-3-8
Item
Unit Data
Swing Parking Release FB Swing Parking FB mA Feedback from swing parking brake release solenoid valve
output
Att 1 P/S/V FB Att 1 P/S/V FB mA Feedback from auxiliary solenoid valve output
Att 2 P/S/V FB Att 2 P/S/V FB mA Feedback from auxiliary solenoid valve output
Blade 1/Outrigger 1 P/S/V FB BL1/OR1 P/V FB mA Feedback from blade/outrigger solenoid valve output
Blade 2/Outrigger 2 P/S/V FB BL2/OR2 P/V FB mA Feedback from blade/outrigger solenoid valve output
Positioning 1 P/S/V FB Posn 1 P/V FB mA Feedback from positioning solenoid valve output
Positioning 2 P/S/V FB Posn 2 P/V FB mA Feedback from positioning solenoid valve output
Att SW 1 P/S/V FB Att SW 1 P/V FB mA Feedback from attachment solenoid valve output
Outrigger Control Outrigger Control ON, OFF Outrigger main relay 2 ON/OFF selection status
Valve Selector Valve Selector ON, OFF Selector valve control solenoid valve ON/OFF selection status
2nd Relief Selector 2nd Relief Selector ON, OFF Secondary pilot relief pressure control solenoid valve ON/OFF
selection status
Acc Change Acc Change ON, OFF Accumulator control solenoid valve ON/OFF selection status
Electric Lever Pilot Cut Electric Lever Pilot Cut ON, OFF Outrigger selection switch (pilot cut) ON/OFF selection status
Load Alarm On/Off SW Load Alarm On/Off SW ON, OFF Overload alarm switch ON/OFF selection status
T5-3-9
MC ADJUSTMENT LIST
Engine speed, pump delivery flow rate, solenoid valve
output pressure and so on can be adjusted.
Adjustment Item List

Item Unit Data
-1
Li Speed Adjustment min Adjustment of minimum engine speed
-1
Travel Li Speed Adjustment min Adjustment of minimum engine speed when traveling
-1
WU Speed Adjustment min Adjustment of warming up engine speed
-1
AI Speed Adjustment min Adjustment of auto-idle engine speed
E Speed Adjustment min-1 Adjustment of E-mode engine speed
-1
P Speed Adjustment min Adjustment of P-mode engine speed
Travel P Speed Adjustment min-1 Adjustment of pedal mode speed
PQ Torque Control N⋅m Adjustment of pump P-Q curve
Pump 2 P/S Valve Adjustment MPa Adjustment of maximum pump 2 flow rate limit control solenoid valve
Tr Motor Swash Angle P/V Adjust MPa Adjustment of travel motor displacement angle control solenoid valve
Pump 1 P/S Valve Adjustment MPa Adjustment of maximum pump 1 flow rate limit control solenoid valve
Pump Torque P/S/V Adjustment MPa Adjustment of torque control solenoid valve
ATT P/S Valve Adjustment MPa Adjustment of auxiliary flow rate control solenoid valve
Arm Regenerative P/S/V Adjustment MPa Adjustment of solenoid valve unit (SC)
Slight Travel Flow Adjustment cm3 Adjustment of maximum pump 1 flow rate upper level
Front P1 Control Flow Adjustment cm3 Adjustment of pump 1 delivery flow rate
Front P2 Control Flow Adjustment cm3 Adjustment of pump 2 delivery flow rate
Implement Brake Lock Pressure MPa Adjustment of solenoid valve unit (SF)
ATT Torque Reducing On/Off ON, OFF ON/OFF of torque down control, when a front attachment is operated
ECO Mode On/Off ON, OFF ECO control ON/OFF
HP Mode On/Off ON, OFF HP mode control ON/OFF
Coolant Temp. WU_B Mode On/Off ON, OFF Coolant temperature warming-up control ON/OFF
Engine Burglar Proof On/Off ON, OFF Engine Control Theft Prevention Selection ON/OFF
Pump Burglar Proof On/Off ON, OFF Pump Control Theft Prevention Selection ON/OFF
Heater Mode On/Off ON, OFF Heater control ON/OFF
ATT Mode On/Off ON, OFF Attachment Mode ON/OFF
New E-mode Fix Control Change ON, OFF E-mode control ON/OFF
Speed Meter Auto Change On/Off ON, OFF Speed meter auto switch ON/OFF
ATT Speed Increase Down Waiting Time ms Setting of time required for engine speed decrease
Axle Lock Timer s Time setting for axle lock release (auto axle lock)
Travel Motor Over Rotation Count Times Setting for travel motor over rotation counter
T5-3-10
Adjustment List
Item Unit Minimum Adjustment Adjustable Range Initial Value
Li Speed Adjustment min-1 10 0 to 400 0
-1
Travel Li Speed Adjustment min 10 0 to 400 0
-1
WU Speed Adjustment min 10 -600 to 200 0
-1
AI Speed Adjustment min 10 -300 to 400 0
-1
E Speed Adjustment min 10 Temporarily release 0
(valid only when key is ON)
-1
P Speed Adjustment min 10 -200 to 200 0
Travel P Speed Adjustment min-1 10 -200 to 300 0
PQ Torque Control N⋅m 2.45 -60 to 60 0
Pump 2 P/S Valve Adjustment MPa 0.0196 -1 to 1 0
Tr Motor Swash Angle P/V Adjust MPa 0.0196 -1 to 1 0
Pump 1 P/S Valve Adjustment MPa 0.0196 -1 to 1 0
Pump Torque P/S/V Adjustment MPa 0.0196 -1 to 1 0
ATT P/S Valve Adjustment MPa 0.0196 -1 to 1 0
Arm Regenerative P/S/V Adjustment MPa 0.0196 -1 to 1 0
Slight Travel Flow Adjustment cm3 0.5 32.5 to 100.0 65.0
Front P1 Control Flow Adjustment cm3 0.5 32.5 to 100.0 58.5
Front P2 Control Flow Adjustment cm3 0.5 32.5 to 100.0 58.5
Implement Brake Lock Pressure MPa 0.02394 4.7 to 8.0 6.6
ATT Torque Reducing On/Off ON, OFF - ON/OFF ON
ECO Mode On/Off ON, OFF - ON/OFF ON
HP Mode On/Off ON, OFF - ON/OFF ON
Coolant Temp. WU_B Mode On/Off ON, OFF - ON/OFF ON
Engine Burglar Proof On/Off ON, OFF - ON/OFF OFF
Pump Burglar Proof On/Off ON, OFF - ON/OFF OFF
Heater Mode On/Off ON, OFF - - -
ATT Mode On/Off ON, OFF - ON/OFF OFF
New E-mode Fix Control Change ON, OFF - ON/OFF OFF
Speed Meter Auto Change On/Off ON, OFF - ON/OFF ON
ATT Speed Increase Down Waiting Time ms 40 0 to 3000 0
Axle Lock Timer s 0.5 0 to 10 0
Travel Motor Over Rotation Count Times 1 0 to 253 0
T5-3-11
MC ATTACHMENT ADJUSTMENT LIST

Item Unit Data
ATT1
ATT1 ATT Type BR PU CR VI Un Non Attachment selection
ATT1 ATT No. 12345 Attachment setting number selection
ATT1 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate when using attachment
-1
ATT1 Engine Speed Adjustment min Adjustment of engine speed when using attachment
ATT1 2nd Relief Selector (OPT) ON OFF Secondary pilot relief pressure control valve ON/OFF selection
ATT1 Valve Selector (OPT) ON OFF Selector valve ON/OFF selection
ATT1 Accumulator Change (OPT) ON OFF Accumulator control valve ON/OFF selection
ATT1 2-Speed Change (OPT) ON OFF 2-speed selection ON/OFF selection
ATT2
ATT2 Engine Speed Adjustment min-1 Adjustment of engine speed when using attachment
ATT3
NOTE: ATT: Attachment

BR: Breaker
PU: Pulverizer
CR: Crusher
Un: Other attachment
Non: No setting for attachment
T5-3-12
Item Unit Data

ATT4
-1
ATT4 Engine Speed Adjustment min Adjustment of engine speed when using attachment
ATT5
T5-3-13
Adjustment Value List

Adjustment Data Minimum Adjustment Adjustable Range Initial Value Remark
ATT1
ATT1 ATT Type - BR PU CR VI Un Non BR
ATT1 ATT No. - 1 to 5 1
ATT1 P1 Swash Angle Adjustment 0.5 L/min 52.8 to 105.6 L/min 105.6 L/min
-1 -1 -1
ATT1 Engine Speed Adjustment 10 min -500 to 200 min 0 min
ATT1 2nd Relief Selector (OPT) - ON/OFF ON
ATT1 Valve Selector (OPT) - C/V or O/T O/T
ATT1 Accumulator Change (OPT) - ON/OFF OFF
ATT1 2-Speed Change (OPT) - ON/OFF OFF
ATT2
ATT2 ATT Type - BR PU CR VI Un Non BR
ATT2 Engine Speed Adjustment 10 min-1 -500 to 200 min-1 0 min-1
ATT2 2nd Relief Selector (OPT) - ON/OFF OFF
ATT2 Valve Selector (OPT) - C/V or O/T O/T
ATT2 2-Speed Change (OPT) - ON/OFF OFF
ATT3
ATT3 ATT Type - BR PU CR VI Un Non PU
ATT3 Valve Selector (OPT) - C/V or O/T C/V
ATT3 2-Speed Change (OPT) - ON/OFF ON

BR: Breaker
PU: Pulverizer
CR: Crusher
T5-3-14
Adjustment Data Minimum Adjustment Adjustable Range Initial Value Remark

ATT4
ATT4 ATT Type - BR PU CR VI Un Non CR
-1 -1 -1
ATT4 Engine Speed Adjustment 10 min -500 to 200 min 200 min
ATT4 Valve Selector (OPT) - C/V or O/T C/V
ATT4 2-Speed Change (OPT) - ON/OFF ON
ATT5
ATT5 ATT Type - BR PU CR VI Un Non Unregistration
ATT5 ATT No. - 1 to 5 Unregistration
ATT5 2nd Relief Selector (OPT) - ON/OFF Unregistration
ATT5 Valve Selector (OPT) - C/V or O/T Unregistration
ATT5 Accumulator Change (OPT) - ON/OFF Unregistration
ATT5 2-Speed Change (OPT) - ON/OFF Unregistration

BR: Breaker
PU: Pulverizer
CR: Crusher
T5-3-15
ICF ADJUSTMENT ITEM LIST

Item Data Range
Information C/U: Initialization Initialization/End
Model Number Setting Model ASCII (4 characters) 0 to 9, A to Z
Machine Nos. 000000 to 999999
Time Setting Year 2000 to 2100
Date Month 1 to 12
Day 1 to 31
Hour 0 to 23
Time
Minutes 0 to 59
Control Data: Initialization Initialization/End
Satellite Terminal: Initialization Erase/End
Satellite Terminal Serial Number Verification 12 digits from 0 to 9 and A to Z
Check for Communication Status Connection Connected/Not-connected
ICF↔ Satellite Terminal
Communication OK/NG
Power Source ON/OFF
Satellite Terminal Satellite Transmission available/Not available
Communication
Rod Antenna OK/NG
GPS Antenna OK/NG
Wave Signal Status ON/OFF
Number of Unsent Data 0 to 99
Time of Previous Transmission YYYY/MM/DD hh:mm:ss
Satellite Communication, Sent/Stop Setting Start/Stop
T5-3-16
(Blank)
T5-3-17
OPTION CONTROLLER ADJUSTMENT LIST

Item Unit Data
Att Ope 1 P/S/V Adjustment MPa Adjustment of auxiliary solenoid valve
Att Ope 2 P/S/V Adjustment MPa Adjustment of auxiliary solenoid valve
Blade/OR Ope 1 P/S/V Adjustment MPa Adjustment of blade/outrigger solenoid valve
Blade/OR Ope 2 P/S/V Adjustment MPa Adjustment of blade/outrigger solenoid valve
Att SW Ope 1 P/S/V Adjustment MPa Adjustment of attachment solenoid valve
Positioning Ope 1 P/S/V Adjustment MPa Adjustment of positioning solenoid valve
Positioning Ope 2 P/S/V Adjustment MPa Adjustment of positioning solenoid valve
Attachment Function Enable/Disable Auxiliary operation enable/disable
Outrigger/Blade Function Enable/Disable Blade/Outrigger operation enable/disable
Positioning Function Enable/Disable Positioning operation enable/disable
Att SW Function (Proportional SW) Enable/Disable Attachment operation enable/disable
Att SW Function Enable/Disable Attachment operation enable/disable
Aux Assignment (Proportional SW) 0, 1, 2, 3, 4 Left grip assignment
Load Alarm Min Bottom Pressure kgf/cm2 Setting for boom cylinder minimum bottom pressure
Pressure Alarm Dtrmn Empty Load kgf/cm2 Setting for empty bucket judgment pressure
T5-3-18
Adjustment List
Item Unit Minimum Adjustment Adjustable Range Initial Value
Att Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Att Ope 2 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Blade/OR Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Blade/OR Ope 2 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Att SW Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Positioning Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Positioning Ope 2 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Attachment Function Enable/Disable - - Disable
Outrigger/Blade Function Enable/Disable - - Enable
Positioning Function Enable/Disable - - Enable
Att SW Function (Proportional SW) Enable/Disable - - Disable
Att SW Function Enable/Disable - - Disable
Aux Assignment (Proportional SW) 0, 1, 2, 3, 4 - - 0 (Disable)
Load Alarm Min Bottom Pressure kgf/cm2 2 -100 to 170 0
Pressure Alarm Dtrmn Empty Load kgf/cm2 2 0 to 100 80
T5-3-19
Dr. ZX OPERATION PROCEDURE
Some examples are explained here. As for other Dr.

ZX Operation Procedure, refer to the extra volume, Dr.
ZX Manual.
Parameter Change (Option Controller)

As for the machine equipped with each attachment of
auxiliary, blade/outrigger, positioning and attachment,
the operation item should be selected into
Enable/Disable according to the machine specification.
If the operation item is selected into Enable, the
corresponding attachment can be operated.
IMPORTANT: If the operation item is not selected

into Enable, the corresponding
attachment cannot be operated.
In addition, make the item for the
unnecessary attachment disable.
Example:
• Machine equipped with 2-piece boom, 4 outrigger:
• Attachment Function: Disable
• Outrigger/Blade Function: Enable
• Positioning Function: Enable
• Att SW Function (Proportional SW): Disable
• Att SW Function: Disable
• Machine equipped with monoblock boom, auxiliary,

rear blade
• Attachment Function Enable
• Outrigger/Blade Function: Enable
• Positioning Function: Disable
• Att SW Function (Proportional SW): Disable
• Att SW Function: Disable
T5-3-20
Example: Outrigger/Blade Function: Enable
Push Parameter Change of option Push Enable and Push Exec. Push
controller. Push ESC and return to ESC and return to Parameter
Main Menu screen. Push Outrigger/Blade Function. Change Selection screen.
Select item Select item Outrigger/Blade Function
+ Parameter Change + Attachment Function

Status: Disable
To the
+ ML Parameter Change + Outrigger/Blade
lower
Function
+ All Parameter Positioning Enable Disable
+
initialize Function
+ Att SW Function
(Proportional SW)
ESC ESC Exec ESC
Setup Item Selection Screen Parameter Change Selection Setup Selection Screen
Screen
Push Exec. Push ESC and return

to Parameter Change Selection
screen.
*Adjust Data Confirm*
Adjusting Deviation Data Name

Outrigger/Blade Function
Adjustment: Disable
Data has changed
Current: Enable
Exec ESC ESC
Adjust Data Confirm Screen
T5-3-21
Parameter Change
(Aux Assignment (Proportional SW))
The initial setting of the left proportional switch is in

Disable. If one of the listed operations on the screen is
assigned to the left proportional switch by using Dr. ZX,
the operation can be performed with the left
proportional switch. At this time, the originally assigned
operation cannot be performed.
Example: When assigning attachment function:

• Attachment function with left proportional switch is
enable.
• Furthermore, the assigned operation cannot be
performed by the electric lever/pedal.
As for Parameter Change item,

Push Parameter Change of option refer to Adjustment Item List. Items
controller. Push ESC and return to are displayed by pushing a skip Push Aux Assignment
Main Menu screen. mark. (Proportional SW).
Select item Select item Select item
+ Parameter Change + Attachment Function + Positioning

Function
To the
+ ML Parameter Change + Outrigger/Blade Att SW Function
+ lower
Function (Proportional SW)
+ All Parameter + Positioning Att SW Function
+
initialize Function
Aux Assignment
+ Att SW Function + (Proportional SW)
(Proportional SW)
ESC ESC ESC
Setup Item Selection Screen Parameter Change Selection Parameter Change Selection
Screen Screen
Select assigned function and push

Exec. Push ESC and return to Push Exec. Push ESC and return
Parameter Change Selection to Parameter Change Selection
screen. screen.
Aux Assignment (Proportional SW) *Adjust Data Confirm*
Current: 0: Disable Adjusting Deviation Data Name

0: Disable Aux Assignment (Proportional SW)
1: Att Ope
Current: 0: Disable Data has changed
2: OR/BL Ope
Adjustment: 1: Att Ope
3: Positioning Ope
4: Att SW Ope
Exec ESC Exec ESC ESC
Operation Selection Screen Adjust Data Confirm Screen
T5-3-22
TROUBLESHOOTING / ICF
OUTLINE
ICF (Information Controller) saves the input signals

from various sensors and switches of the machine as
data.
Various input signals are recorded as “list of daily re-
port data”, “list of frequency distribution data”, “list of
total operating hours”, “list of alarm,” and “list of fail-
ure” in ICF.
The recorded data is downloaded to the personal

computer and is uploaded to the center server via
LAN, so that the data can be used as “e-Service”.
The machine equipped with the satellite communica-
tion terminal (optional) sends the data to center server
by using satellite communication. (As for the satellite
communication system, refer to T5-4-24.
T5-4-1
LIST OF DAILY REPORT DATA
Data which can be downloaded by Palm

Item Details
Date Date of daily report data
Time when key switch is first turned ON during a day
Start: Time
(Time is recorded by key switch ON signal.)
Time when key switch is last turned OFF during a day
Stop: Time
(Time is recorded by key switch ON signal.)
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount (Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours selecting HP mode during a day
HP Mode Hours
(Hours are recorded by power mode switch information from MC.)
Engine Operating Total engine operating hours selecting P mode during a day
P Mode Hours
Hours (Hours are recorded by power mode switch information from MC.)
Total engine operating hours selecting E mode during a day
E Mode Hours
(Hours are recorded by power mode switch information from MC.)
Hours when auto-idle switch is turned ON during a day
Auto-Idle Switch ON Time
(Hours are recorded by switch from MC.)
Fast Idle (Hi) Trav- Total operating hours of travel mode (Hi) during a day
Travel Operating eling Hours (Hours are recorded by travel mode switch information from MC.)
Hours Slow Idle (Lo) Trav- Total operating hours of travel mode (Lo) during a day
eling Hours (Hours are recorded by travel mode switch information from MC.)
Total swing operating hours during a day
Swing Operating Hours
(Hours are recorded by swing pressure sensor information from MC.)
Total operating hours selecting front attachment during a day
Digging Operating Hours (Hours are recorded by front attachment pressure sensor information
from MC.)
Breaker Operating Total operating hours selecting breaker during a day
Hours (Hours are recorded by attachment information from MC.)
Secondary Crusher Total operating hours selecting secondary crusher during a day
Operating Hours (Hours are recorded by attachment information from MC.)
Attachment Operat- Hydraulic Crusher Total operating hours selecting hydraulic crusher during a day
ing Hours Operating Hours (Hours are recorded by attachment information from MC.)
Vibrating Hammer Total operating hours selecting vibrating hammer during a day
Operating Hours (Hours are recorded by attachment information from MC.)
Bucket Operating Total operating hours selecting bucket during a day
Hours or Others (Hours are recorded by attachment information from MC.)
T5-4-2
Item Details
Total machine’s waiting hours during a day
No Load Time
(Hours are recorded by each pressure sensor information from MC.)
The highest radiator coolant temperature during a day
Radiator Coolant Temperature
(Value is recorded from monitor unit.)
The highest hydraulic oil temperature during a day
Hydraulic Oil Temperature
(Value is recorded from MC.)
The highest intake air temperature during a day
Intake Air Temperature
(Value is recorded from ECM.)
Engine operating hour distribution during a day
Engine Operating Hour Distribution Data (Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Machine operating hour distribution during a day
Loaded Time Distribution Data (Operating hours are recorded only when operating pressure is con-
tinuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-3
Data which can be sent by satellite communication

Item Details
Date Date of daily report data
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount (Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours during daily operation
Engine Operating Hours
(Hours are recorded with alternator signal ON.)
Travel Operating Hours Total travel operating hours during daily operation
Swing Operating Hours Total swing operating hours during daily operation
Front Attachment Operating Hours Total front attachment operating hours during daily operation
Attachment Operating Hours Total attachment operating hours during daily operation
No Load Time Total machine’s waiting hours during daily operation
Radiator Coolant Temperature The highest radiator coolant temperature during a day
Hydraulic Oil Temperature The highest hydraulic oil temperature during a day
Intake Air Temperature The highest intake air temperature during a day
Engine Operating Hour Distribution Data Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Loaded Time Distribution Data Machine operating hour distribution during daily operation
(Operating hours are recorded only when operating pressure is
continuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-4
LIST OF FREQUENCY DISTRIBUTION DATA
Item Details
Fuel Temperature Frequency distribution of fuel temperature
Frequency distribution of average pump delivery pressure of pumps 1
Pump Load
and 2
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Digging Operation digging operation
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Travel Operation travel operation
Radiator Coolant Temperature Frequency information of coolant temperature
Hydraulic Oil Temperature Frequency information of hydraulic oil temperature
Radiator Coolant Temperature － Intake Frequency information on temperature in which intake air temperature is
Air Temperature pulled from coolant temperature
Hydraulic Oil Temperature － Intake Air Frequency information on temperature in which intake air temperature is
Temperature pulled from hydraulic oil temperature
Frequency information of engine speed and average load rate (average
Pump Load Rate
of pump 1 load rate and pump 2 load rate)
Engine Load Rate Frequency information of engine speed and engine torque
Radiator Coolant Temperature/Intake Air
Frequency information of coolant temperature and intake air temperature
Temperature
Hydraulic Oil Temperature/Intake Air Frequency information of hydraulic oil temperature and intake air tem-
Temperature perature
T5-4-5
LIST OF TOTAL OPERATING HOURS
Item Details
Inner Hour Meter Hour meter’s value accumulated inside ICF
Machine Hour Meter Hour meter’s value accumulated in machine’s monitor
HP Mode Hours Total engine operating hours selecting HP mode
Engine Operating
P Mode Hours Total engine operating hours selecting P mode
Hour
E Mode Hours Total engine operating hours selecting E mode
Auto-Idle Switch ON Time Total hours when auto-idle switch is turned ON
Fast Idle (Hi) Travel-
Total operating hours of travel mode (Hi)
Travel Operating ing Hours
Hour Slow Idle (Lo) Trav-
Total operating hours of travel mode (Lo)
eling Hours
Swing Operating Hour Total swing operating hours during
Front Attachment Operating Hour Total front attachment operating hours
Breaker Operating
Total operating hours selecting breaker during daily operation
Hours
Secondary Crusher Total operating hours selecting secondary crusher during daily opera-
Operating Hours tion
Attachment Operat- Hydraulic Crusher Total operating hours selecting hydraulic crusher during daily opera-
ing Hour Operating Hours tion
Vibrating Hammer Total operating hours selecting vibrating hammer during daily opera-
Operating Hours tion
Bucket Operating
Total operating hours selecting bucket during daily operation
Hours or Others
No Load Time Total machine’s waiting hours
T5-4-6
(Blank)
T5-4-7
HOW TO DOWNLOAD AND UPLOAD DATA Satellite
OF ICF Rear Console Terminal
After the data saved in ICF is downloaded to Palm (Dr.

ZX), is uploaded to the personal computer, and is up-
loaded to the center server by using LAN, the data
can be used as “e-Service”.
Dr. ZX
Connector
How to Download Data from Machine to Palm
1. Connect the Dr. ZX connectors in Palm and the
machine by using the Hot Sync cable and the
connecting harness.
2. Turn Palm ON and start downloading the data.
(Refer to the next page.)
ICF
TCJB-05-04-001
Palm
(Dr. ZX)
Hot Sync
Cable
Connecting
Harness
T1V1-05-07-002
T5-4-8
Data Download
After starting Dr. ZX, push Select

Controller. Push ICF Controller. Push OK.
Select Function Select failure-diagnosis control-
ler
+ Self-Diagnostic Result ・ ICF
+ Engine Controller controller Ver.: XXYY To the
+ Select Controller ・ Satellite terminal Controller lower
+ Main Controller Ver.: XXYY
+ Monitor Controller Is it correct?
+ ICF Controller
ESC ESC OK ESC
Function Selection Screen Controller Selection Screen ICF Controller Screen
While downloading data,

Push Start. Push Date Download. Download Screen is displayed.
Select Item Data Download
Password
+ Information C/U: Various Downloading.
Setup Do not turn off the Palm or To the
Dr. ZX SerVice Soft + Data Download disconnect the download ca- lower
(C)Hitachi Construction ble.
Machinery Co., ltd + Save Data Check
27%
+
Op. Manual
Start Back ESC Cancel
Title Screen Main Menu Screen Data Download Screen
When downloading is completed

normally, Normal End Screen is If pushing Cancel on Data
displayed. Download Screen, Alarm Screen
Push OK and return to Main Menu is displayed. Push OK and return Push ESC and return to Title
Screen. to Main Menu Screen. Screen.
Select Item
+ Information C/U: Various

CAUTION Setup
Initialization has been Initialization has been
completed. completed. + Data Download
i The download is com- The download has been inter-
pleted. rupted.
+ Save Data Check
You may disconnect the No data has been trans-
ferred to the Dr. ZX +
download cable.
OK OK ESC
Normal End Screen Alarm Screen Main Menu Screen
T5-4-9
How to Upload Data from Palm to Personal
Computer
1. Set Palm to the cradle. Connect the USB cable to

the personal computer. Palm
2. Push the Hot Sync button.
NOTE: When pushing the Hot Sync button and
uploading the data to the personal com-
puter, the Palm (or CLIE) Desktop software
with Palm attached need to be installed.
Cradle
Hot Sync
Button
T178-05-07-033
T5-4-10
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Before starting satellite communication, installing the

satellite communication terminal and replacing ICF,
perform the following procedures by using Dr. ZX.
ICF Setup Procedures
Start Dr. ZX
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
1.3 Enter Date and Time
1.4 Enter Model and Serial No.
1.5 Information C/U: Initialize
Communication No Communication
1.6 Satellite Terminal: Initialize
1.7 Satellite Terminal Serial No. Check
1.8 Satellite Terminal, Communicating State Check
2. Self-Diagnosing
T5-4-11

Controller. Push ICF Controller. Push OK.
Select Function Select failure-diagnosis control-
ler
+ Self-Diagnostic Result ・ ICF
+ Engine Controller Controller Ver.: XXYY To the
+ Select Controller ・ Satellite Terminal lower
+ Main Controller Controller Ver.: XXYY
+ Monitor Controller Is it correct?
+ ICF Controller
ESC ESC OK ESC

Push Information C/U: Various
Push Start. Setup.
Select Item Select Item
Password
+ Information C/U: Various + Information C/U: Initialize
Setup
Dr. ZX SerVice Soft + Data Download + Enter Model and Serial
(C)Hitachi Construction No.
Machinery Co., ltd + Save Data Check + Enter Date and Time
+ + Control Data: Initialize
Op. Manual
Start Back ESC ESC
Title Screen Main Menu Screen Information C/U: Various Setup

Screen
T5-4-12
1.3 Enter Date and Time
Push Set and the focused item is
YY.
Push Enter Date and Time. Push ESC and return to Information
Push ESC and return to Main C/U: Various Setup Screen.
Menu Screen.
Select Item Enter Date and Time

YY, MM, DD, HH, and MM
+ Information C/U: Initialize YY 2004 MM 01 DD 01 The focused item is displayed reversely.
At first, the focused item is YY.
+ Enter Model and Serial HH 01 MM 01
No.
+ Enter Date and Time
+ Control Data: Initialize
－＋ YY, MM, DD, HH, and MM

Move the focused item.
ESC Set ESC No repeat input.
Information C/U: Various Setup Enter Date and Time Screen
Screen
－＋
YY, MM, DD, HH, and MM
Value of the focused item is increased or de-
creased one by one.
In case value is beyond maximum one: Change
Select Item value into the minimum one
Information C/U: Various In case value is below minimum one: Change
+ value into the maximum one
Setup
No repeat input.
+ Data Download
+ Save Data Check
ESC
Main Menu Screen
T5-4-13
1.4 Enter Model and Serial No.
Push Enter Model and Serial No.
Select Item
+ Information C/U: Initialize

Enter Model and Serial To the
+ lower
No.
ESC
Information C/U: Various Setup

Screen
After inputting model and serial

Push Exec, and model and serial No., push OK and return to Enter
No. can be input. Model and Serial No. Screen.
Push ESC and return to Informa- Push ESC and return to Informa-
tion C/U: Various Setup Screen. tion C/U: Various Setup Screen. Push ESC and return to Main
Menu Screen.
Enter Model and Serial No. Enter Model and Serial No. Select Item
Model 01J1 + Information C/U: Initialize

Model |
Ex. Mach.No.(HCM1J1⋅⋅⋅12 Enter Model and Serial
3456) Model(01J1) +
Exec ESC No.
Serial No. 123456 Serial No.
ESC OK
Ex. Mach.No.(HCM1J1⋅⋅⋅12 + Control Data: Initialize
3456) Serial No.(123456)
Exec ESC OK ESC ESC
Enter Model and Serial No. Information C/U: Various Setup

Screen
T5-4-14
1.5 Information C/U: Initialize
Push Information C/U: Initialize.
Select Item
+ Enter Model and Serial To the

No. lower
ESC

Screen
Push Init and the controller oper-

ating data is initialized.
Push ESC and return to Informa- Push OK and return to Informa-
tion C/U: Various Setup Screen. Push ESC and return to Main
tion C/U: Various Setup Screen. Menu Screen.
Information C/U: Initialize Select Item

Is operation data erased? Initialization has been
completed. + Enter Model and Serial
Init i Initialization has been No.
completed.
ESC
+ Control Data: initialize
Init ESC OK ESC
Information C/U: Initialize Screen Information C/U: Various Setup

Screen
T5-4-15
1.6 Satellite Terminal: Initialize
Push Exec.
Display the next screen of Infor- Push Satellite Terminal: Initialize. Push ESC and return to Informa-
mation C/U: Various Setup Screen. Push ESC and return to Main tion C/U: Various Setup Screen.
Menu Screen.
Select Item Select Item Satellite Terminal: Initialize
+ Information C/U: Initialize + Satellite Terminal: Initialize

Satellite Terminal No.
+ Enter Model and Serial Confirmation To the
+ Is Un-Transmit data erased?
No. Communicating State lower
+ Enter Date and Time + Check
Enter Satellite Comm.
+ Control Data: Initialize + Start/Stop
ESC ESC Exec ESC
Information C/U: Various Setup Next Screen of Information C/U: Satellite Terminal: Initialize Screen
Screen Various Setup Screen
Push OK and return to Information

C/U: Various Setup Screen.
Satellite Terminal: Initialize Select Item Select Item
+ Satellite Terminal: Initialize + Information C/U: Various

Satellite Terminal No. Setup
Un-Transmit data is erased. Confirmation Data Download
+ +
Communicating State
+ Check + Save Data Check
+ Start/Stop +
OK ESC ESC
Information C/U: Various Setup Main Menu Screen

Screen
T5-4-16
1.7 Satellite Terminal Serial No. Check
Push Satellite Terminal No. Confir- Confirm serial No. (12 digits). Push
mation. ESC and return to Information C/U:
Push ESC and return to Main Various Setup Screen.
Menu Screen.
Select Item Satellite Terminal No. Confirma- Select Item

tion
+ Satellite Terminal: Initialize + Satellite Terminal: Initialize
Satellite Terminal No. Satellite Terminal No.
+ Confirmation + Confirmation
Communicating State Serial No. 8GBDA701862 Communicating State
+ Check + Check
Enter Satellite Comm. Enter Satellite Comm.
+ Start/Stop + Start/Stop
ESC ESC ESC
Information C/U: Various Setup Information C/U: Various Setup

Screen Screen
Select Item
+ Information C/U: Various

Setup
+ Data Download
+ Save Data Check
ESC
Main Menu Screen
T5-4-17
1.8 Satellite Terminal, Communicating State
Check
Push Communicating State
Check.
Push ESC and return to Main
Menu Screen. Check communicating state.
Select Item Communicating State Check
Satellite Terminal: Initialize ICF⇔Satellite Terminal Check the enclosed state.
+
Satellite Terminal No. ・ Conn Un- Un-
Confirmation Uncon: Faulty harness
+ ・ Comm. OK NG
Communicating State NG: Faulty harness for Comm.
Check Satellite Terminal
+ OFF: Faulty harness, Faulty controller
Enter Satellite Comm. ・ Power ON OFF
Stop: 1.9 Enter Satellite Comm. Start/Stop
+ Start/Stop ・ Comm. Enable Stop
ESC ESC
Information C/U: Various Setup Communicating State Check

Screen
Rod Aerial OK NG
When electrical wave of the satellite is caught,
GPS Aerial OK NG the items are turned into OK.
Wave State ON OFF IMPORTANT: Check this with the key of the
machine ON in outdoor.
Un Transmit Data Number According to state of electrical
0 wave, it may take a little longer
time.
Last Transmitting Time
2004/07/01 13：50：00
ESC
Select Item Select Item
+ Information C/U: Various + Satellite Terminal: Initialize

Setup Satellite Terminal No.
Data Download Confirmation
+ +
Communicating State
+ Save Data Check + Check
+ + Start/Stop
ESC ESC
Main Menu Screen Information C/U: Various Setup

Screen
T5-4-18
1.9 Enter Satellite Comm. Start/Stop
Push ▼ and display to the next
screen of Information C/U: Various
Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
+ Satellite Terminal: Initialize

Confirmation To the
+ lower
Communicating State
+ Check
+ Start/Stop
ESC

Screen
When starting Satellite Comm.,

push Start and push Exec.
When stopping Satellite Comm.,
push Stop and push Exec.
Push ESC and return to Informa- Push OK and return to Information
C/U: Various Setup Screen. Push ESC and return to Main
tion C/U: Various Setup Screen.
Menu Screen.
Enter Satellite Comm. Start/Stop Satellite Terminal UnTrasmit Select Item

State
+ Satellite Terminal: Initialize
Confirmation
+
Exec Communicating State
Start Stop Setting has been completed + Check
ESC Enter Satellite Comm.
+ Start/Stop
Exec ESC OK ESC

Screen
T5-4-19
1.10 Control Data: Initialize
Push Control Data: Initialize.
Select Item
To the
+ Enter Model and Serial lower
No.
ESC

Screen
Push Init and the controller oper-

ating data is initialized.
Push ESC and return to Informa- Push OK and return to Information
tion C/U: Various Setup Screen. C/U: Various Setup Screen. Push ESC and return to Main
Menu Screen.
Control Data: Initialize Select Item

Is control data initialized? Initialization has been
completed. + Enter Model and Serial
Init i Initialization has been No.
completed. Enter Date and Time
+
ESC
Init ESC OK ESC
Control Data: Initialize Screen Information C/U: Various Setup

Screen
T5-4-20
(Blank)
T5-4-21
2. Self-Diagnosing
Push Fault of ICF Controller. If
After starting Dr. ZX, push there is no trouble, No Problem is
Self-Diagnostic Result. displayed.
Select Function Self-diagnosing of controllers

below hasn completed.
+ Self-Diagnostic Result
Engine Controller No Problem
+ To the
Select Controller
Main Controller Fault lower
Self-Diagnosing
Monitor Controller No Problem
ICF Controller Fault
ESC ESC ESC
Function Selection Screen Controller Self-Diagnosing Screen

Change the page and
the fault code in back
and forth is displayed.
Push Retry B and return to Controller
Push Details, and Details and Self-Diagnosing Screen after controller
Corrective Action are displayed. self-diagnsing.
Push ESC and Retry B Screen is Push ESC and Retry B Screen is Push ESC and return to Controller
displayed. displayed. Self-Diagnosing Screen.
ICF Controller Fault Code 14000-2

Problem was detected.
Details Retry B
14000 14001 Details CAN Communication Error
Do you want to escape?

Corrective Action
1)Retry B
ESC 2)Check Harness ESC
3)
ESC ESC Retry B ESC

Details
Fault Code Screen Retry B Screen
Self-diagnosing of controllers
below hasn completed.
Execute
Engine Controller No Problem
Retry B
Main Controller Fault
ESC Monitor Controller No Problem
ICF Controller Fault
ESC
Controller Self-Diagnosing Screen
T5-4-22
LIST OF FAULT CODE
Fault Code Trouble Remedy
14000-2 Abnormal CAN Communication Execute retry B in self-diagnosing.

If this fault code is displayed after re-try, check the following
item.
Check the CAN communication line (check the harness).
14001-2 ICF: Flash Memory: Read / Write Execute retry B in self-diagnosing and execute the following
Error item.
Execute 1.5 Information C/U: Initialize (T5-4-15).
14002-2 ICF: External RAM: Read / Write
Error
14003-2 ICF: EEPROM: Sum Check Error Execute retry B in self-diagnosing.

If this fault code is displayed after re-try, check the following
item.
1. Execute 1.10 Control Data: Initialize (T5-4-20).
2. Execute 1.4 Enter Model and Serial No. (T5-4-14).
Then, execute self-diagnosing and execute retry B.
14006-2 ICF: Satellite Communication Ter- Execute retry B in self-diagnosing.

minal: Communication Error If this fault code is displayed after re-try, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.
14008-2 ICF: Abnormal Internal RAM Execute retry B in self-diagnosing.

If this fault code is displayed after re-try, replace the control-
14100-2 Satellite Communication Terminal: ler.
Abnormal EEPROM
14101-2 Satellite Communication Terminal:
Abnormal IB/OB Queue
Abnormal Local Loup Back
The satellite is not found.
Fail 1 of Remote Loup Back
Fail 2 of Remote Loup Back
Sending and receiving data are un-
matched.
T5-4-23
SATELLITE COMMUNICATION SYSTEM
The satellite communication system is used for main- GPS Aerial

tenance of the machine, “e-Service” by transmitting
various data of the machine regularly via a low earth Communication
Aerial
orbit satellite.
NOTE: Depending on the circumstances of the

machine (ex. in the constructions, in the
tunnel, affected by the surrounding building
and affected of noise), the data transfer
rate may become slower, or the communi-
cation might not be established.
The satellite communication system using
a low earth orbit satellite transmits digital
data through the radio wave. If there is ex-
cessively noise or use of electrical equip- T1V1-05-07-003
ment which causes noise near the machine, Satellite

Rear Console Terminal
they cause reduces data transfer rate or
communication might not be established at
worst.
The satellite communication system consists of satel-

lite communication terminal, GPS aerial and commu-
nication aerial. The mail function of monitor unit be-
comes effective.
The functions of each equipment are:
• Satellite Communication Terminal

Receives the data from ICF, GPS aerial and
monitor unit, and sends the data to the commu-
nication aerial. ICF
• GPS Aerial TCJB-05-04-001
Receives location information of the machine

from a low earth orbit satellite. Monitor Unit
• Communication Aerial
Communicates the data with a low earth orbit
satellite.
• Monitor Unit
Sends the mail when pushing the key corre-
sponding to requirement.
1. General Requirement
2. Fuel Replenishing Requirement
3. Service Maintenance Requirement
4. Forwarding Requirement
1 2 3 4 T1V5-05-01-037
Mail Screen
T5-4-24
On the machine equipped with the satellite communi-
cation system, the data are sent according to the con-
dition as follows:
Kinds of data sent from the machine by using satellite

communication:
Items Kinds of Data Condition

Periodical Daily Report Data, Latest Location Infor-
The data are sent once a day. In order to
Transmission mation, Fuel Level avoid congested traffic in the communi-
cation line, the data is sent randomly
between 0:00 and 02:00.
Transmitting Data at Latest Location Information The data is sent only when the machine
Engine Start is moved more than 5 km from the place
where it is recorded lastly.
Emergency Alarm and Error Information The transmission starts immediately
Transmission when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information The data is sent when the hour meter
Transmission exceeds every 100 hours.
Transmission by Mail General Requirement, Fuel Replenishing The transmission starts when the key on
Requirement, Service Maintenance Re- monitor unit corresponding to require-
quirement and Forwarding Requirement ment is pushed.
T5-4-25
(Blank)
T5-4-26
Section 5 TROUBLESHOOTING
Main Component Layout

Upperstructure (1)
1 2 3
8
9
10
11
12
13
14
15
24 16
23 17
22 18
21
20 19 TCEB-01-02-002
1- Rear Camera 8- Battery 14- Travel Shockless Valve 20- Steering Valve
2- Radiator 9- Fuel Cooler 15- Pilot Valve (Left) 21- Brake Valve
3- Inter Cooler 10- Washer Tank 16- Pilot Shut-Off Solenoid Valve 22- Travel Pilot Valve
4- Reserve Tank 11- ECM (Engine Controller) 17- Center Joint 23- Pilot Valve (Right)
5- Air Conditioner Condenser 12- Solenoid Valve Unit (For 18- Accumulator Charging Valve 24- Blade / Outrigger Electric
6- Receiver Drier Electric Lever) 19- Auxiliary / Positioning Electric Lever
7- Air Cleaner 13- Oil Cooler Lever
T5-5-1
Upperstructure (2)
42
41
40
38
37
36
35
34
33
32
31
30
29 28 27 26 25 TCEB-01-02-003
25- Positioning Control Valve 30- Automatic Fueling Switch 35- Engine Oil Filter 40- Steering Filter
26- Shuttle Valve 31- Control Valve 36- Pump Device 41- Pilot Filter
27- Signal Control Valve 32- Automatic Fueling Pump 37- Fuel Pre Filter 42- Engine
28- Heat Circuit Cut Solenoid Valve 33- 3-Spool Solenoid Valve Unit 38- Fuel Main Filter
29- Swing Shockless Valve 34- Swing Device 39- Solenoid Pump
T5-5-2
Undercarriage
1 2
3
9
8
7 6
TCEB-01-02-001

T5-5-3
Undercarriage
1
2
3
8
7
6
TCJB-01-02-011

T5-5-4
Front Attachment
 2-Piece Boom  Monoblock Boom
3 1
2
7
5 7
1
6 4
T1F3-01-02-003 6 T1F3-01-02-004
1- Bucket Cylinder 3- Positioning Cylinder 5- Hose Rupture Valve 6- Hose Rupture Valve (Boom)
2- Arm Cylinder 4- Boom Cylinder (Positioning) 7- Hose Rupture Valve (Arm)
T5-5-5
Electrical Component Layout (Overview)
Pump Device (Refer to T5-5-14.)

· Pump 2 Control Pressure Sensor Filter (Refer to T5-5-16.)
· Pump 1 Maximum Flow Rate Limit · Steering Pump Delivery Pressure Sensor
· Pump 2 Maximum Flow Rate Limit
Control Solenoid Valve Engine (Refer to T5-5-13.)
· Torque Control Solenoid Valve
2
3
4
5
6
8 7
9
10
11 TCEB-01-02-002
Travel Shockless Valve
(Refer to T5-5-16.)
Brake Valve (Refer to T5-5-15.) · Pressure Sensor (Travel Forward)
· Brake Pressure Sensor · Pressure Sensor (Travel Reverse)
· Work Brake Release Switch
· Brake Remain Pressure Sensor
1- Fresh Air Temperature Sensor 5- Battery 8- Solenoid Valve Unit (For 11- Pilot Shut-Off Solenoid Valve
2- Starter Relay 6- ECM Electric Lever) 12- Fuel Sensor
3- Battery Relay 7- Intake Air Temperature Sensor 9- Atmosphere Pressure Sensor 13- Hydraulic Oil Temperature
4- Glow Plug Relay 10- Air Cleaner Restriction Switch Sensor (Main)
T5-5-6
Swing Device
(Refer to T5-5-14.)
· Pressure Sensor (Front)
14
15
16
Control Valve (Refer to T5-5-15.) 17
· Pressure Sensor (Boom Raise)
· Pressure Sensor (Arm Roll-In) TCEB-01-02-003
Signal Control Valve (Refer to T5-5-14.)

· Pressure Sensor (Swing)
· Pressure Sensor (Auxiliary)
14- Horn 16- Pressure Sensor (Positioning) 18- 3-Spool Solenoid Valve Unit
15- Slip Ring 17- Heat Circuit Cut Solenoid Valve
T5-5-7
Electrical Component Layout (Monitors and

Switches)
5 6 7
4 2
3 12
TCJB-01-02-006 TCJB-01-02-014
11 10 9 8
14
22
15 23
16 24
34
13
25
26
27
33
28
17
18 32
19 31 30 29 TCJB-01-02-007
20
21
TCJB-01-02-008
1- Monitor Unit (Refer to T5-5-9.) 9- Brake Pedal 17- Hazard Switch 26- Travel Speed Mode Switch
2- Swing Lock Lever 10- Steering Column Monitor 18- Electrical Control Main Switch 27- Engine Speed Control Mode
3- Blade/Outrigger Lever (Refer to T5-5-10.) (Optional) Selection Switch
4- Pilot Shut-Off Lever 11- Auxiliary/Positioning Pedal 19- Blade/Outrigger Front-Rear 28- Power Mode Switch
5- Engine Stop Switch (Optional) Selector Switch 29- Key Switch
6- Combination Switch 12- Horn Switch 20- Outrigger Left-Right Selector 30- Blade/Outrigger Selector
· Turn Signal Switch 13- Left Analog Switch (Auxiliary) Switch Switch
· Light Switch 14- Horn Switch 21- Heater Seat Switch (Optional) 31- Auto-Idle Switch
· Dimmer Switch 15- Positioning Pedal Selection 22- FNR Switch 32- Work Light Switch
· Passing Switch Switch 23- Auxiliary 33- Wiper/Washer Switch
7- Brake Switch 16- Auxiliary Pedal Selection 24- Auxiliary 34- Right Analog Switch (Assist)
8- Accelerator Pedal Switch 25- Engine Control Dial (Optional)
T5-5-8
Monitor Unit
1 2 3 4 5 6 8
9
10
11
12
13
14
15
16
17
18
34
35
21 20 19
TCJB-05-02-043
33 32 31 30 29 28 27 26 25 24 23 22
1- Work Mode Display 10- Parking Brake Display 17- Mail Display (Optional) 27- Mail Selection (Optional)
2- Auto-Idle Display 11- Work Brake Display 18- Clock 28- Work Mode Display
3- Overload Alarm Display 12- Axle Lock Display 19- Trip Meter Display 29- Auxiliary Selection
(Optional) 13- Work Light Display 20- Odometer Display 30- Coolant Temperature Gauge
4- Auto Axle Lock Display 14- Auxiliary 2 (Positioning) 21- Hour Meter Display 31- Work Mode Selection
5- Auxiliary Selection Display 22- Back Monitor Selection 32- Return to Primary Screen
6- Glow Signal Display 15- Auxiliary 1 (Attachment) 23- Menu 33- Brake Oil Pressure Gauge
7- Trip Meter Selection Display 24- Meter Display Selection 34- Speedometer
8- Odometer 16- Blade/Outrigger Settings and 25- Fuel Gauge 35- Tachometer
9- Hour Meter Brake Mode Display 26- Auxiliary
T5-5-9
Steering Column Monitor
1 2
12
3
11 4
10 6
9 7
TCJB-02-01-008
8
1- Travel Forward Indicator 5- Travel Reverse Indicator 8- Travel Slow Speed Indicator 12- Turn Signal Indicator (Left)
2- Turn Signal Indicator (Right) 6- Hazard Light Indicator 9- Auxiliary
3- Neutral Indicator 7- Auto-Cruise Indicator 10- Clearance Light Indicator
4- Pilot Cut Indicator (Optional) 11- High Beam Indicator
T5-5-10
Electrical Component Layout (Controllers

and Relays)
1 2
7 3
TCJB-01-02-015
6 5
1- MC (Main Controller) 3- Fuse Box 5- Option Controller

2- Satellite Communication 4- Dr.ZX Connector (Use as 6- ICF (Information Controller)
Terminal (Optional) Download Connector) 7- Flasher
T5-5-11
Relays Position
TCJB-01-02-009
Option Controller
Dr.ZX Connector Fuse Box TCJB-01-02-010
1- High Beam Relay 19- Pilot Shut-Off Relay 33- Heater Seat Relay (OP) 45- Twin Wiper Relay 3 (OP)
2- Clearance Light Relay (Left) 20- Security Horn Relay 34- Room Lamp Controller Relay 46- Twin Wiper Relay 4 (OP)
3- Clearance Light Relay (Right) 21- Starter Cut Relay (OP) 47- Twin Wiper Relay 5 (OP)
4- Head Light Relay (Left) 22- Security Relay 35- Assist Relay 1 (OP) 48- Twin Wiper Relay 6 (OP)
5- Head Light Relay (Right) 23- Travel Fast Selection Relay 36- Assist Relay 2 (OP) 49- Swing Alarm Relay (OP)
6- Travel Slow Selection Relay 24- Blade/Outrigger Relay (Rear) 37- Assist Flow Rate Control Relay 50- Rear Head Light Relay (OP)
7- Compressor Relay (A/C) 25- Blade/Outrigger Relay (Front) (OP) 51- Additional Front Head Light
8- Heater Relay (A/C) 26- Blade/Outrigger Relay (Rear- 38- Blank (OP)
9- MAX-Hi Relay (A/C) Right) 39- Auxiliary/Positioning Selection 52- Additional Front Head Light
10- ECM Main Relay 27- Blade/Outrigger Relay (Rear- Relay 1 (OP) (OP)
11- Turn Signal Light Relay (Left) Left) 40- Auxiliary/Positioning Selection 53- Revolving Light Relay (OP)
12- Turn Signal Light Relay (Right) 28- Blade/Outrigger Relay (Main 2) Relay 2 (OP) 54- Immobilizer 1 (OP)
13- Wiper Relay 29- Blade/Outrigger Relay (Front- 41- Auxiliary/Positioning Selection 55- Immobilizer 2 (OP)
14- Boom Light Relay Right) Relay 3 (OP) 56- Immobilizer 3 (OP)
15- Stop Light Relay 30- Blade/Outrigger Relay (Front- 42- Auxiliary/Positioning Selection
16- Washer Relay Left) Relay 4 (OP)
17- Horn Relay 31- Blade/Outrigger Relay (Main 1) 43- Twin Wiper Relay 1 (OP)
18- Load Dump Relay 32- Auto-Cruise Relay (OP) 44- Twin Wiper Relay 2 (OP)
fNOTE: OP: Optional
T5-5-12
Engine
1
2
T1T1-01-02-005 5 6
3 4
7
8
13
T1T1-01-02-003 T1T1-01-02-004
12 11 10
1- EGR Valve 5- Overheat Switch 9- Common Rail Pressure Sensor 13- Supply Pump Actuator
2- Glow Plug 6- Injector 10- Crank Speed Sensor
3- Cam Angle Sensor 7- Boost Pressure Sensor 11- Engine Oil Pressure Sensor
4- Coolant Temperature Sensor 8- Boost Temperature Sensor 12- Fuel Temperature Sensor
T5-5-13
Pump Device
5 6
2 1
11
10
9 8
TCEB-03-01-003 TCEB-03-01-001
4 3
Swing Device Signal Control Valve
13
12 19
18
14
15
17 16
TCEB-01-02-005
TCEB-01-02-004
1- Pump 1 6- Steering Pump 10- Torque Control Solenoid Valve 16- Heat Circuit Cut Solenoid Valve
2- Pump 2 7- Pump 2 Control Pressure 11- Pump 2 Maximum Flow Rate 17- Swing Shockless Valve
3- Pump 1 Delivery Pressure Sensor Limit Control Solenoid Valve 18- Pressure Sensor (Swing)
Sensor 8- Pump 1 Control Pressure 12- Pressure Sensor (Front) 19- Pressure Sensor (Auxiliary)
4- Pump 2 Delivery Pressure Sensor 13- Signal Control Valve
Sensor 9- Pump 1 Maximum Flow Rate 14- Pressure Sensor (Positioning)
5- Pilot Pump Limit Control Solenoid Valve 15- Shuttle Valve
T5-5-14
Control Valve Brake Valve
1 2 4
6
TCGB-01-02-003
3 TCJB-01-02-017
3-Spool Solenoid Valve Unit Solenoid Valve Unit (For Electric Lever)
9 10 11
20 12
19 13
18 14
17 15
TCGB-03-12-001
16
TCJB-01-02-018
1- Main Relief Valve 7- Brake Pressure Sensor 13- Auxiliary Solenoid Valve 17- Blade / Outrigger Solenoid
2- Pressure Sensor (Arm Roll-In) 8- Brake Valve 14- Blade / Outrigger Solenoid Valve
3- Pressure Sensor (Boom Raise) 9- Solenoid Valve Unit (SC) Valve 18- Auxiliary Solenoid Valve
4- Accumulator Charging Valve 10- Solenoid Valve Unit (SF) 15- Travel Make-Up Solenoid Valve 19- Positioning / Assist Solenoid
5- Brake Remain Pressure Sensor 11- Solenoid Valve Unit (SI) 16- Hydraulic Oil Temperature Valve
6- Stop Light / Work Brake 12- Positioning / Assist Solenoid Sensor (For Electric Lever) 20- Swing Parking Brake Release
Release Switch Valve Solenoid Valve
T5-5-15
Travel Shockless Valve Transmission Changeover Solenoid Valve
2 5 6
TCJB-01-02-019 TCJB-05-07-002
4
Travel Device Filter

11 12 13
7 8
10 9 TCJB-01-02-020 15 14
TCEB-01-02-006
1- Pressure Sensor (Travel 4- Pressure Sensor (Travel 8- Transmission 12- Steering Filter
Forward) Reverse) 9- Travel N Sensor 13- Pilot Filter
2- Travel Forward Pi Cut Solenoid 5- Travel Mode Selector Solenoid 10- Travel Motor Displacement 14- Fuel Pre Filter
Valve Valve Control Solenoid Valve 15- Fuel Main Filter
3- Travel Reverse Pi Cut Solenoid 6- Pressure Reducing Valve 11- Steering Pump Delivery
Valve 7- Travel Motor Pressure Sensor
T5-5-16
(Blank)
T5-5-17
Components in Control Valve
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-18
11
4 14
41
18
35, 36
Front
T16W-03-03-030
1- Load Check Valve (Blade/ 12- Make-Up Valve (Travel Forward 23- Bypass Shut-Out Valve 34- Load Check Valve (Boom 2
Outrigger Tandem Circuit) Side) 24- Check Valve (Orifice) (Arm 2 Parallel Circuit)
2- Load Check Valve (Blade/ 13- Bucket Regenerative Circuit Parallel Circuit) 35- Aux. Flow Rate Control Valve
Outrigger Parallel Circuit) 14- Overload Relief Valve (Bucket 25- Load Check Valve (Arm 1 (Poppet Valve)
3- Check Valve (Main Relief Rod Side) Parallel Circuit) 36- Aux. Flow Rate Control Valve
Circuit) 15- Overload Relief Valve (Bucket 26- Load Check Valve (Arm 1 (Selector Valve)
4- Main Relief Valve Bottom Side) Tandem Circuit) 37- Overload Relief Valve
5- Auxiliary Flow Combiner Valve 16- Load Check Valve (Boom 1 27- Load Check Valve (Swing (Auxiliary)
6- Check Valve (Auxiliary Flow Parallel Circuit) Circuit) 38- Overload Relief Valve
Combiner Circuit) 17- Boom Regenerative Circuit 28- Arm Regenerative Valve (Auxiliary)
7- Check Valve (Main Relief 18- Overload Relief Valve (Boom (Selector Valve) 39- Load Check Valve (Bucket
Circuit) Bottom Side) 29- Arm Regenerative Circuit Parallel Circuit)
8- Check Valve (Flow Combiner 19- Overload Relief Valve (Boom 30- Overload Relief Valve (Arm 40- Overload Relief Valve (Blade/
Circuit) Rod Side) Bottom Side) Outrigger Rod Side)
9- Bucket Flow Rate Control Valve 20- Boom Anti-Drift Valve (Check 31- Overload Relief Valve (Arm 41- Overload Relief Valve (Blade/
(Selector Valve) Valve) Rod Side) Outrigger Bottom Side)
10- Bucket Flow Rate Control Valve 21- Boom Anti-Drift Valve (Selector 32- Arm Anti-Drift Valve (Check
(Poppet Valve) Valve) Valve)
11- Make-Up Valve (Travel Reverse 22- Load Check Valve (Arm 2 33- Arm Anti-Drift Valve (Selector
Side) Tandem Circuit) Valve)
T5-5-19
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-20
19 15 9, 10 12
39
6
23
Front T16W-03-03-031
30 37 40 5
T5-5-21
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-22
A B
C
C
D
D
E E
F F
G G
H
H
A B T16W-03-03-002
Cross Section A-A Cross Section B-B

8
13
Blade/
Outrigger Travel
Auxiliary Bucket
Boom 2
Boom 1
Arm 1
Arm 2
Swing
17
28
29 T16W-03-03-008 TCHB-03-03-001
T5-5-23
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-24
Cross Section C-C Cross Section D-D
Blade/ Travel
Outrigger
4 7 41 11
3 1
5
8 8 6 39
T16W-03-03-014 T16W-03-03-013
40 12
T5-5-25
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-26
Cross Section E-E Cross Section F-F
Boom 2 Boom 1
Auxiliary Bucket
38 14 31 21
20
35 10
9 34
36 16
17
T16W-03-03-012 T16W-03-03-011
37 15 19
T5-5-27
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-28
Cross Section G-G Cross Section H-H
Arm 1 Arm 2
Swing
33 18
28
32
22
25 27
26
24
29
23
T16W-03-03-010 T16W-03-03-009
30
T5-5-29
Layout of Positioning Control Valve (2-Piece Boom)
3 2
Control Valve
T5-5-30
Cross Section X-X

X
X T178-03-03-070 T198-03-03-003
1- Load Check Valve (Positioning 2- Load Check Valve (Positioning 3- Overload Relief Valve 4- Overload Relief Valve
Parallel Circuit) Tandem Circuit) (Positioning: Bottom Side) (Positioning: Rod Side)
T5-5-31
Pilot Port Pilot Valve Side

C
PH
E
A
D
M
B
H
SB
F G
P1
N
Pilot Valve Side
K I
SH J
DF
T178-03-06-016
SA L
Pilot Valve Side
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Swing Shockless Valve (Left Pilot Valve) Arm Roll-Out Pilot Pressure
Port D Swing Shockless Valve (Left Pilot Valve) Arm Roll-In Pilot Pressure
Port E Swing Shockless Valve (Left Pilot Valve) Left Swing Pilot Pressure
Port F Swing Shockless Valve (Left Pilot Valve) Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I - Plug
Port J - Plug
Port K Travel Shockless Valve (Travel Pilot Valve) Travel Reverse Pilot Pressure
Port L Travel Shockless Valve (Travel Pilot Valve) Travel Forward Pilot Pressure
Port M Blade/Outrigger Solenoid Valve Blade/Outrigger Pilot Pressure
Port N Auxiliary Solenoid Valve Auxiliary Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Shut-Off Solenoid Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Solenoid Valve Primary Pilot Pressure (Heat Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-5-32
Control Valve Side
1 3
Pressure Sensor (Auxiliary)

13 5
2 4
SK
Pressure Sensor (Swing) SE
8
14
Control Valve Side

7
6
9
10 SN
SL 11
T1F3-03-06-003
12 SP
Control Valve Side

Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10 - Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 - Plug
Port 14 - Plug
Port SE - Plug
Port SN - Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL - Plug
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
2-Piece Boom Specification Machine

Port SP Positioning Solenoid Valve Pump 1 Control Pressure
T5-5-33
fNOTE: Machine with front attachment (pulverizer 1 to 5

and crusher 1 to 5) attached.
Control Valve Side
14
Control Valve Side
SN
T1F3-03-06-003
Control Valve Side

Port Name Connecting to Note
Port 14 Auxiliary Flow Combiner Contorl Solenoid Valve Auxiliary Flow Combiner Valve Control Pressure
Port SN Pressure Reducing Valve Auxiliary Flow Combiner Valve Control Pressure
fNOTE: The auxiliary flow combiner control solenoid

valve and pressure reducing valve are installed only on
the machines equipped with the optional parts.
T5-5-34
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When

Remedy by Dr. ZX Remedy
Trouble Occurs.
- Retrial B Replace MC.
Although the engine control dial is Retrial B • Check the sensor connected to MC.
operated, the engine speed does not • Check the harness.
change. • Replace MC.
• The machine movement is slow. Retrial B • Check the CAN harness.
• The work brake is not operated. • Replace MC.
• The work mode alarm is displayed on
the monitor unit.
T1V1-05-01-102
• The travel speed does not change.
T5-6-3
Engine Failure
Fault Code Trouble Cause Influenced Control
11100-2 Abnormal Engine Speed Engine Speed: more than Speed Sensing Control
-1
4000 min
11101-3 Abnormal Engine Control Dial Voltage: more than 4.78 V Engine Control Dial Control
Sensor High Voltage
11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V Engine Control Dial Control
Sensor Low Voltage
T5-6-4

Trouble Occurs.
The machine movement is slow. Retrial B • Check the crank speed sensor.
(During speed sensing, the torque is • Check the cam angle sensor.
reduced.)
• Trouble condition with the key ON: Retrial B • Check the harness.
The engine speed is kept at idle • Replace the engine control dial.
speed.
• Trouble condition during operation:
The engine speed is kept at the
speed immediately before trouble.
• Trouble condition with the key ON: Retrial B • Check the harness.
The engine speed is kept at idle • Replace the engine control dial.
speed.
• Trouble condition during operation:
The engine speed is kept at the
speed immediately before trouble.
T5-6-5
Pump Failure
11200-3 Abnormal Pump 1 Delivery Voltage: more than 4.5 V • HP Mode Control
Pressure Sensor High Voltage • Travel Accelerator Control
• E Mode Control
• Auto-Power Lift Control
11200-4 Abnormal Pump 1 Delivery Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Travel Accelerator Control
• E Mode Control
11202-3 Abnormal Pump 2 Delivery Voltage: more than 4.5 V • HP Mode Control
Pressure Sensor High Voltage • E Mode Control
11202-4 Abnormal Pump 2 Delivery Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • E Mode Control
11203-3 Abnormal Pump 3 Delivery Voltage: more than 4.5 V • Steering Pump Torque
Pressure Sensor High Voltage Reduction Control
11203-4 Abnormal Pump 3 Delivery Voltage: less than 0.25 V • Steering Pump Torque
Pressure Sensor Low Voltage Reduction Control
11206-3 Abnormal Pump 1 Pump Control Voltage: more than 4.75 V • E Mode Control
Pressure Sensor High Voltage • Heater Control
11206-4 Abnormal Pump 1 Pump Control Voltage: less than 0.25 V • E Mode Control
Pressure Sensor Low Voltage • Heater Control
11208-3 Abnormal Pump 2 Pump Control Voltage: more than 4.75 V • E Mode Control
Pressure Sensor High Voltage • Heater Control
11208-4 Abnormal Pump 2 Pump Control Voltage: less than 0.25 V • E Mode Control
Pressure Sensor Low Voltage • Heater Control
T5-6-6

Trouble Occurs.
• Combined operation of arm roll-in and Retrial B • Check the harness.
boom raise or combined operation of • Replace the pump 1 delivery
arm-roll-in and swing: Arm speed is pressure sensor.
slow.
• Single operation of boom raise: Lifting
force is weak.
slow.
force is weak.
slow.
slow.
• The steering pump torque decrease Retrial B • Check the harness.
control is inactive. • Replace the steering pump delivery
pressure sensor.
• The steering pump torque decrease Retrial B • Check the harness.
control is inactive. • Replace the steering pump delivery
pressure sensor.
• Although speed normally returns to P Retrial B • Check the harness.
speed when lever is operated in E • Replace the pump 1 control
mode, speed stays at P speed in this pressure sensor.
failure.
failure.
failure.
failure.
T5-6-7
Pilot Failure
11301-3 Abnormal Swing Pilot Pressure Voltage: more than 4.75 V • Arm Regenerative Control
Sensor High Voltage • Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11301-4 Abnormal Swing Pilot Pressure Voltage: less than 0.25 V • Arm Regenerative Control
Sensor Low Voltage • Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11302-3 Abnormal Boom Raise Pilot Voltage: more than 4.75 V • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
• Attachment Flow Rate Control
(Optional)
11302-4 Abnormal Boom Raise Pilot Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Arm Regenerative Control
(Optional)
11303-3 Abnormal Arm Roll-In Pilot Voltage: more than 4.75 V • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
11303-4 Abnormal Arm Roll-In Pilot Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Arm Regenerative Control
T5-6-8

Trouble Occurs.
• Combined operation of arm-roll-in and Retrial B • Check the harness.
swing: Arm speed is slow. • Replace the swing pilot pressure
• In case of the machine equipped with sensor.
the swing alarm (optional) and when
swing alarm is effective, swing alarm
continues to sound even in no
swinging.
• Combined operation of arm-roll-in and Retrial B • Check the harness.
swing: Arm speed is slow. • Replace the swing pilot pressure
• In case of the machine equipped with sensor.
the swing alarm (optional) and when
swing alarm is effective, swing alarm
continues to sound even in no
swinging.
• During HP control, engine speed does Retrial B • Check the harness.
not increase in boom raise operation. • Replace the boom raise pilot
• Combined operation of arm roll-in and pressure sensor.
boom raise: Arm speed is slow.
force is weak.
not increase in boom raise operation. • Replace the boom raise pilot
boom raise: Arm speed is slow.
force is weak.
not increase in arm-roll-in operation. • Replace the arm roll-in pilot
swing: Arm speed is slow.
not increase in arm-roll-in operation. • Replace the arm roll-in pilot
swing: Arm speed is slow.
T5-6-9
11305-3 Abnormal Travel Voltage: more than 4.75 V • Auto-Idle Control

Forward Pilot • Idle Speed-Up Control
Pressure Sensor • ECO Control
High Voltage • Heater Control
• Pump 1 and 2 Flow Rate Limit Control
• Forward/Reverse Shifting Limit Control
• Attachment Flow Rate Limit Control
• Travel Alarm Control (Optional)
• Auto-Cruise Control (Optional)
11305-4 Abnormal Travel Voltage: less than 0.25 V • Auto-Idle Control
Forward Pilot • Idle Speed-Up Control
Pressure Sensor Low • ECO Control
Voltage • Heater Control
• Auto-Cruise Control (Optional)
11306-3 Abnormal Travel Voltage: more than 4.75 V • Auto-Idle Control
Reverse Pilot • Idle Speed-Up Control
Pressure Sensor • ECO Control
High Voltage • Heater Control
11306-4 Abnormal Travel Voltage: less than 0.25 V • Auto-Idle Control
Reverse pilot • Idle Speed-Up Control
• ECO Control
Pressure Sensor Low • Travel Accelerator Control
Voltage • Heater Control
T5-6-10

Trouble Occurs.
• When traveling forward at idle speed, Retrial B • Check the harness.
engine speed does not increase to the idle • Replace the travel forward pilot
speed-up speed. pressure sensor.
• When traveling forward, engine speed does
not return from auto idle speed.
not return from ECO speed.
• When operating the attachment with
traveling forward, the machine mistracks.
• In case of the machine equipped with the
travel alarm (optional), travel alarm
continues to sound even in no traveling.
• When traveling forward at idle speed, Retrial B • Check the harness.

engine speed does not increase. • Replace the travel forward pilot
• When traveling forward, engine speed does pressure sensor.
traveling forward, the machine mistracks.
• When traveling reverse at idle speed, Retrial B • Check the harness.

engine speed does not increase to the idle • Replace the travel reverse pilot
• When traveling reverse, engine speed does
traveling reverse, the machine mistracks.
• When traveling reverse at idle speed, Retrial B • Check the harness.

engine speed does not increase to the idle • Replace the travel reverse pilot
traveling reverse, the machine mistracks.
T5-6-11

11307-3 Abnormal Front Attachment Pilot Voltage: more than 4.75 V • Auto-Idle Control
Pressure Sensor High Voltage • Idle Speed-Up Control
• ECO Control
• Pump 1 and 2 Flow Rate Limit
Control
• Heater Control
11307-4 Abnormal Front Attachment Pilot Voltage: less than 0.25 V • Auto-Idle Control
Pressure Sensor Low Voltage • Idle Speed-Up Control
• ECO Control
Control
• Heater Control
11310-3 Abnormal Brake Pressure Voltage: more than 4.50 V • Work Brake Control
Sensor High Voltage • Auto-Cruise Control
(Optional)
11310-4 Abnormal Brake Pressure Voltage: less than 0.25 V • Work Brake Control
Sensor Low Voltage • Auto-Cruise Control
(Optional)
11311-3 Abnormal Brake Remaining Voltage: more than 4.50 V • Travel Mode Selection Control
Pressure Sensor High Voltage
11311-4 Abnormal Brake Remaining Voltage: less than 0.25 V • Travel Mode Selection Control
Pressure Sensor Low Voltage
T5-6-12

Trouble Occurs.
• When operating the front attachment at Retrial B • Check the harness.
idle speed, engine speed does not • Replace the front attachment pilot
increase to the idle speed-up speed. pressure sensor.
• When operating the front attachment,
engine speed does not return from
auto idle speed.
ECO speed.
• Although the front attachment is
operated while parking brake is
activated, buzzer does not sound.
• When operating the front attachment at Retrial B • Check the harness.
idle speed, engine speed does not • Replace the front attachment pilot
increase to the idle speed-up speed. pressure sensor.
auto idle speed.
ECO speed.
• Although the front attachment is
operated while parking brake is
activated, buzzer does not sound.
• Work brake is not does not work. Retrial B • Check the harness.
• Auto-cruise control cannot be • Replace the brake pressure sensor.
released.
• Work brake is not does not work. Retrial B • Check the harness.
• Auto-cruise control cannot be • Replace the brake pressure sensor.
released.
• After releasing the parking brake, Retrial B • Check the harness.
shifting fast/slow of the transmission • Replace the brake remaining
does not work. pressure sensor.
• After releasing the parking brake, Retrial B • Check the harness.
shifting fast/slow of the transmission • Replace the brake remaining
does not work. pressure sensor.
T5-6-13
Proportional Solenoid Valve Failure
11400-2 Abnormal Current Feedback of Current: Both of Higher Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit than 920 mA or Less
Control Solenoid Valve than 60 mA
11400-3 Abnormal Feedback High Current of Current: Higher than Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit 920 mA
11400-4 Abnormal Feedback Low Current of Current: Less than 56 Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit mA
11401-2 Abnormal Current Feedback of Current: Both of Higher • Speed Sensing Control
Torque Control Solenoid Valve than 920 mA or Less • Steering Pump Torque Decrease
than 60 mA Control
11401-3 Abnormal Feedback High Current of Current: Higher than • Speed Sensing Control
Torque Control Solenoid Valve 920 mA • Steering Pump Torque Decrease
Control
11401-4 Current: Less than 56 • Speed Sensing Control

Abnormal Feedback Low Current of
Torque Control Solenoid Valve mA • Steering Pump Torque Decrease
Control
11403-2 Abnormal Current Feedback of Current: Both of Higher Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm than 920 mA or Less
Regeneration) than 60 mA
11403-3 Abnormal Feedback High Current of Current: Higher than Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm 920 mA
Regeneration)
11403-4 Abnormal Feedback Low Current of Current: Less than 56 Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm mA
Regeneration)
11404-2 Abnormal Current Feedback of Current: Both of Higher • Power Digging Control
Solenoid Valve Unit (SG) (Relief than 920mA or Less • Auto-Power Lift Control
Pressure Control) than 60 mA
11404-3 Abnormal Feedback High Current of Current: Higher than • Power Digging Control
Solenoid Valve Unit (SG) (Relief 920 mA • Auto-Power Lift Control
Pressure Control)
11404-4 Abnormal Feedback Low Current of Current: Less than 56 • Power Digging Control
Solenoid Valve Unit (SG) (Relief mA • Auto-Power Lift Control
Pressure Control)
T5-6-14

Trouble Occurs.
In case the attachment flow rate is Retrial B • Check the harness.
limited, it cannot be limited.
Operation during abnormal high current: Retrial B • Check the harness.

• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Operation during abnormal low current: Retrial B • Check the harness.
• In case the attachment flow rate is
Machine overall operation is slow. Retrial B • Check the harness.

• The engine is stalled at slow idle.
• Engine speed: Middle to Fast: Engine
stall or large lug down
• Machine overall operation is slow.
Combined operation of boom raise and Retrial B • Check the harness.

arm roll-in with the front attachment
over ground, the boom is not raised
smoothly and the arm roll-in full-speed
is slow.
• Digging force (arm) becomes weak.

• Combined operation of boom raise
and arm roll-in with the front
attachment over ground, the boom is
not raised smoothly and the arm
roll-in full-speed is slow.
Pressure does not increase even if Retrial B • Check the harness.
power digging switch is on.

• Pressure always increases.

• Pressure does not increase even if
power digging switch is on.
T5-6-15
11410-2 Abnormal Current Feedback of Current: Both of Higher • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit than 920 mA or Less When Traveling At Creeper Mode
Control Solenoid Valve than 60 mA • Pump 1 Flow Rate Limit Control
• Attachment Flow Rate Limit
Control
11410-3 Abnormal Feedback High Current of Current: Higher than • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit 920 mA When Traveling At Creeper Mode
Control Solenoid Valve • Pump 1 Flow Rate Limit Control
Control
11410-4 Abnormal Feedback Low Current of Current: Less than 56 • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit mA When Traveling At Creeper Mode
Control Solenoid Valve • Pump 1 Flow Rate Limit Control
Control
11422-2 Abnormal Current Feedback of Current: Both of Higher • Travel Motor Displacement Angle
Travel Motor Displacement Angle than 920 mA or Less Control
Control Solenoid Valve than 60 mA • Travel Motor Excessive Rotation
Control
11422-3 Abnormal Feedback High Current of Current: Higher than • Travel Motor Displacement Angle
Travel Motor Displacement Angle 920 mA Control
Control Solenoid Valve • Travel Motor Excessive Rotation
Control
11422-4 Abnormal Feedback Low Current of Current: Less than 56 • Travel Motor Displacement Angle
Travel Motor Displacement Angle mA Control
Control Solenoid Valve • Travel Motor Excessive Rotation
Control
11423-2 Abnormal Current Feedback of Current: Both of Higher -
Travel Make-Up Solenoid Valve than 920 mA or Less
than 60 mA
11423-3 Abnormal Feedback High Current of Current: Higher than -
Travel Make-Up Solenoid Valve 920 mA
11423-4 Abnormal Feedback Low Current of Current: Less than 56 -

Travel Make-Up Solenoid Valve mA
T5-6-16

Trouble Occurs.





T5-6-17
11424-2 Abnormal Current Feedback of Current: Both of Higher • Auto Axle Lock Control
Solenoid Valve Unit (SI) (Axle Lock than 920 mA or Less
Selection) than 60 mA
11424-3 Abnormal Feedback High Current Current: Higher than • Auto Axle Lock Control
of Solenoid Valve Unit (SI) (Axle 920 mA
Lock Selection)
11424-4 Abnormal Feedback Low Current Current: Less than 56 • Auto Axle Lock Control
of Solenoid Valve Unit (SI) (Axle mA
Lock Selection)
11425-2 Abnormal Current Feedback of Current: Both of Higher • ECO Control
Solenoid Valve Unit (SF) (Work than 920 mA or Less • Idle Speed-Up Control
Brake) than 60 mA • Speed Sensing Control
• Brake Dragging Prevention
Control
11425-3 Abnormal Feedback High Current Current: Higher than • ECO Control
of Solenoid Valve Unit (SF) (Work 920 mA • Idle Speed-Up Control
Brake) • Speed Sensing Control
Control
11425-4 Abnormal Feedback Low Current Current: Less than 56 • ECO Control
of Solenoid Valve Unit (SF) (Work mA • Idle Speed-Up Control
Brake) • Speed Sensing Control
Control
T5-6-18

Trouble Occurs.



T5-6-19
CAN Data Reception Failure
11910-2 Actual Engine Speed Faulty harness • Speed Sensing Control

Sent from: ECM • Send to ICF
11911-2 Security Signal Faulty harness Theft Prevention Engine Speed,

Sent from: Monitor Unit Engine Torque
11914-2 Radiator Coolant Temperature Faulty harness Heater Control

Sent from: ECM
11915-2 Gate Lock Signal Faulty harness Heater Control
Sent from: Option Controller
11918-2 Work Mode Faulty harness • Attachment Operation Speed
Sent from: Monitor Unit Increase Control
• Attachment Operation Speed
Limit Control
• Attachment Pump Torque
Decrease Control
Control
(Optional)
• Breaker/Pulverizer/Crusher
Control (Optional)
11920-2 Fuel Flow Rate Faulty harness Fuel Flow Rate
Sent from: ECM
T5-6-20

Trouble Occurs.
Machine operation speed is slow. Retrial B • Check the harness.
(During speed sensing, torque is
decreased.)
Engine stall is displayed on e-Service.
When theft prevention is ON set by Dr. Retrial B • Check the harness.
ZX,
Engine speed = Slow idle
Pump torque = Minimum displacement
angle
Those values are fixed.
Heater control is inactive. Retrial B • Check the harness.
Heater control is inactive. Retrial B • Check the harness.
• Work Mode: Digging mode is fixed. Retrial B • Check the harness.

In case decreasing flow rate and speed
are set in ATT mode, stop this mode
control, or Work mode is not changed
from Digging mode to ATT mode.
• Work Mode Alarm is displayed on the
monitor unit.
T1V1-05-01-102
When fuel rate display is set on Retrial B • Check the harness.

monitor, "---" is displayed.
T5-6-21
Other Failures
*11502-2 Travel Motor Excessive Rotation Transmission rotation keeps -
over its threshold value for 2.0
sec.
11901-3 Hydraulic Oil Temperature Voltage: more than 4.52 V • Auto-Warming Up Control
Sensor High Voltage • Arm Regenerative Control
11901-4 Hydraulic Oil Temperature Voltage: less than 0.23 V • Auto-Warming Up Control
Sensor Low Voltage • Arm Regenerative Control
11921-2 Incorrect Odometer Value Faulty MC -
NOTE: *: Fault code 11502 is shown when travel

motor overturns.
Select the MC monitor item on Dr. ZX.
Check the counted travel motor excessive
rotations. (The travel motor is not faulty.)
Select retrial in order to erase the displayed
fault code.
T5-6-22
TROUBLESHOOTING/ Troubleshooting A
Symptoms in Machine Operation When Trouble Remedy by

Remedy
Occurs. Dr. ZX
- - -
In low temperature (Hydraulic oil temperature is less Retrial B • Check the harness.
than 0 °C (32 °F)), auto-warming up control is
impossible.
In low temperature (Hydraulic oil temperature is less Retrial B • Check the harness.
than 0 °C (32 °F)), auto-warming up control is
impossible.
Odometer value may increase after the key switch is Retrial B • Replace MC.
OFF.
T5-6-23
ECM FAULT CODE LIST
Sensor System
Fault
Trouble Cause
Code
636-2 Abnormal Cam Angle Sensor (No Signal) Although the crank signal is present, the cam signal is
not present.
636-2 Abnormal Cam Angle Sensor (Abnormal The pulse of cam signal is not matched.
Signal)
723-2 Abnormal Crank Speed Sensor (No Although the cam signal is present, the crank signal is
Signal) not present.
723-2 Abnormal Crank Speed Sensor The pulse of crank signal is not matched.
(Abnormal Signal)
636-7 Phase Mismatch of Cam Angle Sensor The right cam pulse is not present at the gap in the
crank.
172-3 Abnormal Intake Air Temperature Sensor Voltage at the intake air temperature sensor is beyond
(Abnormal High Voltage) 4.95 V in 3 minutes after the engine starts.
172-4 Abnormal Intake Air Temperature Sensor Voltage at the intake-air temperature sensor is below
(Abnormal Low Voltage) 0.1 V.
110-3 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is beyond
(Abnormal High Voltage) 4.85 V in 3 minutes after the engine starts.
110-4 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is below 0.1
(Abnormal Low Voltage) V
102-4 Abnormal Boost Pressure Sensor Voltage at the boost pressure sensor is beyond 4.9 V.
(Abnormal High Voltage)
102-3 Abnormal Boost Pressure Sensor Voltage at the boost pressure sensor is below 0.1 V
(Abnormal Low Voltage)
10001-3 Abnormal EGR Position (Brushless spec.) The condition which the output signal of EGR position
cannot be present in.
108-4 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is beyond
(Abnormal High Voltage) 3.8 V.
108-3 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is below
174-3 Abnormal Fuel Temperature Sensor Voltage at the fuel temperature sensor is beyond 4.85
(Abnormal High Voltage) V in 3 minutes after the engine starts.
174-4 Abnormal Fuel Temperature Sensor Voltage at the fuel temperature sensor is below 0.1 V.
T5-6-24
Presumptive Symptoms in Real Machine Fault Code

Assumptive Conditions at Backup
Operation (Tech 2)
• While the engine runs, there is nothing While the engine runs, operate according to P0340
abnormal with machine operation. standard of the crank sensor. When the engine
• After the engine is stalled, the re-start is stops, the start is impossible (in order to P0341
impossible. prevent the engine from damaging).
• The output power may decrease, white smoke Operate according to standard of the cam P0335
may occur and vibration may occur. sensor.
• The engine may be stalled. (If the cam senor is P0336
normal, the engine can re-start.)
• While the engine runs, there is nothing The timing chain and the belt does not turn P1345
abnormal with machine operation. smoothly but turn in reverse.
• After the engine is stalled, the re-start is
impossible.
Nothing special When starting: -10 °C (14 °F) (Start the engine P0113
although what state.)
When operating: 25 °C (77 °F) (Operate P0112
normally.)
Normal temperature: When starting, dark smoke When starting: -20 °C (-4 °F) (Start the engine P0118
may occur and engine combustion sound may be although what state.)
become loud. When operating: 80 °C (176 °F) (Operate P0117
While warming up with fresh air in low normally.)
temperature: Rough idle, engine stall or while
smoke may be occur.
Dark smoke occurs. Boost pressure cannot be corrected. P0238
P0237
There is influence to exhaust gas. As the sensor input is not certain, it cannot be P0487
controlled. Exhaust gas becomes bad.
Operate the engine with EGR valve fully open.
2
Dark smoke occurs at high altitude. Atmospheric pressure 80 kPa (0.8 kgf/cm , 12 P0108
psi) (2000 m above the sea)
P0107
Nothing special. When starting: -20 °C (-4 °F) (Start the engine P0183
although what state.)
When operating: 70 °C (158 °F) (Operate P0182
normally.)
T5-6-25
Fault
Trouble Cause
Code
157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is beyond
157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is below
100-4 Abnormal Engine Oil Pressure Sensor Voltage at the engine oil pressure sensor is beyond
100-3 Abnormal Engine Oil Pressure Sensor Voltage at the engine oil pressure sensor is below 0.1
(Abnormal Low Voltage) V.
105-3 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is beyond
(Abnormal High Voltage) 4.95 V over 5 minutes after the engine starts or when
coolant temperature is beyond 50 °C (122 °F).
105-4 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is below 0.1
(Abnormal Low Voltage) V.
T5-6-26

Operation (Tech 2)
The engine may be stalled. The output power The supply pump can not be controlled. P0193
decreases.
P0192
There is no influence when operating the Nothing special. P0523

machine.
P0522
There is no influence when operating the Nothing special. P1113

machine.
P1112
T5-6-27
Influence to Engine Operating Rank

Fault Code Trouble Performance (Current State) Remedy
(Presumption) A B C D
636-2 Abnormal Cam Angle Sensor (No No influence during
○ ○
Signal) operating
636-2 Abnormal Cam Angle Sensor After stopping, the
○ ○
(Abnormal Signal) re-start is impossible.
723-2 Abnormal Crank Speed Sensor (No No output power
○
Signal) decrease
723-2 Abnormal Crank Speed Sensor
○
(Abnormal Signal)
636-7 Phase Mismatch of Cam Angle No influence during
Sensor operating
○ ○
After stopping, the
re-start is impossible.
172-3 Abnormal Intake Air Temperature No output power
○
Sensor (Abnormal High Voltage) decrease
172-4 Abnormal Intake Air Temperature
○
Sensor (Abnormal Low Voltage)
110-3 Abnormal Coolant Temperature No output power
○
110-4 Abnormal Coolant Temperature
○
102-4 Abnormal Boost Pressure Sensor No output power
○
(Abnormal High Voltage) decrease
102-3 Abnormal Boost Pressure Sensor
○
10001-3 Abnormal EGR Position (Brushless No output power
○
spec.) change
108-4 Abnormal Atmospheric Pressure No output power
○
108-3 Abnormal Atmospheric Pressure
○
174-3 Abnormal Fuel Temperature Sensor No output power
○
(Abnormal High Voltage) decrease
174-4 Abnormal Fuel Temperature Sensor
○
157-3 Abnormal Common Rail Pressure Output power
○
Sensor (Abnormal High Voltage) decrease: 70%
157-4 Abnormal Common Rail Pressure
○
100-4 Abnormal Engine Oil Pressure No output power
○
Sensor (Abnormal High Voltage) change
100-3 Abnormal Engine Oil Pressure
○
T5-6-28
Influence to Engine
Fault Operating Rank
Trouble Performance Remedy
Code (Current State)
(Presumption)
105-3 Abnormal Boost Temperature Sensor No output power
○
(Abnormal High Voltage) change
105-4 Abnormal Boost Temperature Sensor
○
Operating Rank
A: Digging is operable.
B: Machine can travel with the boom raised.
(Steering is impossible.)
C: The engine only runs. (Travel, digging and
operation are impossible even in light load.)
D: The engine cannot stop / start.
IMPORTANT: When fault code 723-2 (abnormal

crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.
T5-6-29
External Device System
Fault Code Trouble Cause
10002-2 Abnormal EGR Valve Control Difference between the target valve lift and actual position is
beyond 20%.
1347-0 Open Circuit in Suction Control Valve The suction control valve drive current is beyond 2400 mA or
Drive System, Shorted Circuit In + B below 50 mA. Or, difference between the tartget current and
or GND actual current is 1000 mA or more.
651-3 Open Circuit in Injection Nozzle #1 No input signal of injector 1 monitor.

Drive System
Drive System
Drive System
654-3 Open Circuit In Injection Nozzle #4 No input signal of injector 4 monitor.
Drive System
T5-6-30

Operation (Tech 2)
There is influence to exhaust gas. EGR cannot be controlled. P0488
As exhaust gas becomes bad, EGR stops.
The engine may be stalled and the rotation The supply pump cannot be controlled. P0090
speed increases automatically and abnormally → Prevent the engine from increasing the rotation
according to open or shorted circuit condition. speed automatically and abnormally (Protect the
Dark smoke occurs. Output power is too large. engine).
Vibration of the engine is large, rough idle, #1 injector cannot be controlled. P0201
output power decrease, faulty increasing of → Stop drive pulse output of #1 injector.
rotation speed, output power decrease.
#2 injector cannot be controlled. P0202
→ Stop drive pulse output of #2 injector.
T5-6-31
Fuel System
157-0 Abnormal Common Rail Pressure Common rail pressure is beyond 185 MPa.
(First Stage)
157-0 Abnormal Common Rail Pressure The first stage “Abnormal common rail pressure” is approved
(Second Stage) common rail pressure is beyond 190 MPa.
157-2 Abnormal Common Rail Pressure When duty factor to the suction control valve is 40 % or more,
3
(Pump Over-Pressure) or target pressure to the suction control valve is 90 mm /sec
2
or less, actual rail pressure is 40 MPa (410 kgf/cm , 5820 psi)
higher than the target rail pressure.
633-7 Pressure Limiter Open The pressure limiter is open.
1240-1 No Pressure to Pump (Fuel Leakage) When duty factor to the suction control valve is 33 % or less,
3
or pressure to the suction control valve is 28000 mm /sec or
-1
more and engine speed is 1200 min , actual rail pressure is
2
50 MPa (510 kgf/cm , 7270 psi) lower than the target rail
pressure.
-1
1239-1 No Pressure to Pump (Fuel Leakage) When engine speed 900 min , actual rail pressure is 15 MPa
2
(150 kgf/cm , 2180 psi) or less.
T5-6-32

Operation (Tech 2)
Vibration of the engine may be large, rough idle, Prevention the injection system (pump) from P0088
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the rail pressure sensor by
occur, output power may be too large. over-pressure)
Vibration of the engine may be large, rough idle, Prevention the injection system from damage P0088
output power decrease may occur, faulty (Pressure is too much as rail is clogged.)
increasing of rotation speed, dark smoke may
occur, output power may be too large.
Vibration of the engine may be large, rough idle, Prevention the injection system (pump) from P0089
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the rail pressure sensor by
occur, output power may be too large. over-pressure)
Output power decrease. Rail pressure is beyond the allowable pressure. P1095
Vibration of the engine may be large, rough idle, Fuel leakage is too much. P1093
output power decrease may occur, faulty Difference between target rail pressure and actual
increasing of rotation speed, dark smoke may rail pressure is larger than the specification.
occur, output power may be too large. (Large deflection)
Vibration of the engine may be large, rough idle, Fuel leakage is too much. P0087
output power decrease may occur, faulty Actual rail pressure does not increase to the
increasing of rotation speed, dark smoke may required pressure.
occur, output power may be too large.
T5-6-33

Fault (Current)
Code
10002-2 Abnormal EGR Valve Control No output power
○
change
1347-0 Open Circuit in Suction Control Valve Output power
Drive System, Shorted Circuit in + B or decrease: 50% ○
GND
651-3 Open Circuit in Injection Nozzle #1 Output power
○
Drive System decrease: 15%
652-3 Open Circuit in Injection Nozzle #2 (Five cylinders drive.)
○
Drive System
653-3 Open Circuit in Injection Nozzle #3
○
Drive System
○
Drive System
○
Drive System
○
Drive System
Operating Rank
Influence to Engine (Current)
Fault
Code
157-0 Abnormal Common Rail Pressure (First Output power
○
Stage) decrease: 50%
○
(Second Stage) decrease: 50%
○
(Pump Over-Pressure) decrease: 50%
633-7 Pressure Limiter Open Output power
○
decrease: 50%
1240-1 No Pressure to Pump (Fuel Leakage) Output power ○
1239-1 No Pressure to Pump (Fuel Leakage) decrease: 50% ○
Operating Rank
B: Machine can travel with boom raised. (Steering is
impossible.)
T5-6-34
(Blank)
T5-6-35

110-0 Overheating Coolant temperature is beyond 120 °C (248 °F) when running
engine.
190-0 Overrunning -1
In case the engine speed is beyond 2500 min .
Fault code Trouble Cause

987-3 Abnormal Check Engine Lamp No monitor signal of the check engine lamp.
1485-2 Abnormal Main Relay System (ON is Voltage in the main relay system is 1 V or less with the main
impossible.) relay coil output ON
Although the main relay coil output is OFF, the main relay is
kept ON.
T5-6-36

Operation (Tech 2)
There is no influence when operating the Nothing special (The history of overheating is P1173
machine. recorded.)
Engine speed of the excavator may not increase Nothing special P0219
-1
2500 min or more.

Operation (Tech 2)
There is no influence when operating the Nothing special
machine. P0650
The engine cannot start. Nothing
P1625
Electrical power is kept supplying to the Nothing
machine.
T5-6-37
Operating Rank
Influence to Engine (Current)
Fault
Code
110-0 Overheating No output power

○
change
190-0 Overrunning No output power
○
change

Fault (Current)
Code
987-3 Abnormal Check Engine Lamp No output power
○
change
1485-2 Abnormal Main Relay System (ON is The engine stops. ○
impossible.) Nothing (The engine
cannot re-start
○ ○
according to battery
voltage.)
Operating Rank
impossible.)
T5-6-38
(Blank)
T5-6-39
Internal Circuit System
10005-1 Abnormal Charge Circuit (Bank 1) In case voltage at bank 1 of charge circuit in ECM is low.
10006-1 Abnormal Charge Circuit (Bank 2) In case voltage at bank 2 of charge circuit in ECM is low.
10008-2 Abnormal A/D Conversion A/D conversion cannot be done.

10007-2 Abnormal CPU Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)
1077-2 Abnormal IC for CPU Watching No change of RUN-SUB pulse in 20 msec.
628-2 Abnormal ROM ROM is broken.
10013-2 Abnormal EEPROM EEPROM is broken.
1079-2 Abnormal 5 V Power Source 1 When battery voltage is between 16 V and 32 V, voltage of
Voltage key switch power source is 5.5 V or more or 4.5 V or less.
10003-2 Abnormal Injection Nozzle Common No monitor signals of injectors 1, 3, 5.

1 Drive System
10004-2 Abnormal Injection Nozzle Common No monitor signals of injectors 2, 4, 6.
2 Drive System
T5-6-40

Operation (Tech 2)
Vibration of the engine may be large, rough idle, The injector cannot be controlled. P0611
output power decrease may occur, faulty → Stop output of drive signal at failed common
increasing of rotation speed may occur, the side
engine may be stalled. (Protect the engine from damage) P0612
Output power decrease, dark smoke occurs. All analogue sensor cannot be used. P1630
Output power decrease. CPU is broken. P0606
The engine cannot start. P0606
Output power decrease. Sub CPU is broken. P0601

The engine stops. Data of ROM cannot be read. P1603
There is no influence when operating the Data cannot be written to EEPROM. P1631
machine.
No backup. ← P1632
Same as Abnormal atmospheric and in-take ← P1633

temperature sensors.
Same as Abnormal coolant temperature, fuel ← P1634

temperature and hydraulic oil pressure sensors.
Same as Abnormal boost pressure and boost ← P1635

temperature sensors.
Same as Abnormal rail pressure and EGR ← P1261

position sensors.
Vibration of the engine may be large, rough idle, The injector cannot be controlled. P1262
output power decrease may occur, faulty → Stop output of drive signal at failed common
increasing of rotation speed may occur, the side
engine may be stalled. (Protect the engine from damage)
T5-6-41

Fault Code Trouble Performance (Current) Remedy
10005-1 Abnormal Charge Circuit (Bank 1) Output power ○ ○
10006-1 Abnormal Charge Circuit (Bank 2) decrease: 60%
(Three cylinders in ○ ○
operation.)
10008-2 Abnormal A/D Conversion Output power
○
decrease: 50%
10007-2 Abnormal CPU Output power
○
decrease: 50%
The engine cannot
○
start.
1077-2 Abnormal IC for CPU Watching Output power
○
decrease: 50%
628-2 Abnormal ROM The engine stops. ○
10013-2 Abnormal EEPROM No output power
○
decrease
1079-2 Abnormal 5 V Power Source 1 Voltage Idle Speed Operation ○
1080-2 Abnormal 5 V Power Source 2 Voltage No output power
○
decrease
○
change
○
decrease
10011-2 Abnormal 5 V Power Source 5 Voltage Output power
○ ○
decrease: 50%
10003-2 Abnormal Injection Nozzle Common 1 Output power
○ ○
Drive System decrease: 60%
10004-2 Abnormal Injection Nozzle Common 2 (Three cylinders in
○ ○
Drive System operation.)
Operating Rank
impossible.)
T5-6-42
(Blank)
T5-6-43
Communication System
639-2 Abnormal CAN Bus Line Detect the Bus Line OFF
639-3 Abnormal CAN Time Out In case the CAN data reception is impossible for
predetermined time.
T5-6-44
Presumptive Symptoms in Real Machine Fault code

Operation (Tech2)
The engine runs at idle speed. CAN communication is impossible. U2104
U2106
T5-6-45

Fault (Current)
Code
639-2 Abnormal CAN Bus Line ○
Idle Speed
639-3 Abnormal CAN Time Out ○
T5-6-46
(Blank)
T5-6-47
ICF FAULT CODE LIST
Fault Code Trouble Cause Remedy
14000-2 Abnormal CAN Data cannot be received Check for CAN communication bus line.
Communication due to the noise on the
CAN bus line.
14001-2 Flash Memory: The internal memory is After initializing the information C/U by using Dr.
Read / Write Error abnormal when the key ZX, retry in the troubleshooting.
switch is ON. If the error code is displayed after retry, ICF may
be broken.
Replace ICF.
NOTE: When initializing the information C/U,
all stored data is deleted.
14002-2 External RAM: The internal memory is After initializing the information C/U by using Dr.
Read / Write Error abnormal when the key ZX, retry in the troubleshooting.
switch is ON. If the error code is displayed after retrial, ICF may
be broken.
Replace ICF.
NOTE: When initializing the information C/U,
all stored data is deleted.
14003-2 EEPROM: Sum The internal memory is Retry in the troubleshooting by using Dr. ZX.
Check Error abnormal when the key If the error code is displayed after retrial, ICF may
switch is ON. be broken.
Replace ICF.
14006-2 Satellite Communication to the Check for the items below.
Communication satellite terminal cannot be 1. Check if the communication line is abnormal.
Terminal: done over 30 seconds. 2. Check if the electrical power source of
Communication communication terminal is abnormal.
Error • Electrical power source
• Fuses
3. Check if the satellite terminal is broken.
14008-2 Abnormal Internal The internal memory is Retry in the troubleshooting by using Dr. ZX.
RAM abnormal when the key If the error code is displayed after retrial, ICF may
switch is ON. be broken.
Replace ICF.
T5-6-48
SATELLITE TERMINAL FAULT CODE LIST

14100-2 Abnormal EEPROM Internal memory is abnormal. Replace the controller.
14101-2 Abnormal IB/OB Queue Internal memory is abnormal. Replace the controller.
14102-2 Abnormal Local Loop Back Data can not be received from Check the communication
satellite. antenna for satellite.
14103-2 Satellite cannot be found. Satellite can not be caught. Check the communication
antenna for satellite.
14104-2 Remote Loop Back Failure 1 Communication with satellite Replace the controller.
base station is impossible.
14105-2 Remote Loop Back Failure 2 Communication with satellite Replace the controller.
base station is impossible.
14106-2 Received data is not same with Received data is not same with Replace the controller.
sent data. sent data.
MONITOR UNIT FAULT CODE LIST
13303-2 Abnormal Thermistor Thermistor temperature is 85 °C Cool the monitor unit and so on
Temperature (185 °F) or more. until the internal temperature of
monitor unit is less than 85 °C
(185 °F).
13304-2 Abnormal REG Input H Level REG input level is H. Refer to the Troubleshooting flow
chart.
13306-2 Abnormal EEPROM EEPROM reading failure occurs. Replace the monitor unit when
displaying the fault code after
retrial.
13308-2 Abnormal CAN Communication Bus OFF occurs 5 times or Refer to CAN Harness Check
more. (T5-6-73 to 104).
13310-3 Shorted Circuit in Coolant Input 105±30 Ω or less continues Check coolant temperature
Temperature Sensor for 60 seconds. sensor and harness.
13311-3 Shorted Circuit in Fuel Level Input 3±1 Ω or less continues for Check fuel level sensor and
Sensor 60 seconds. harness.
13311-4 Open Circuit in Fuel Level Input 135±20 Ω or less continues Check fuel level sensor and
Sensor for 60 seconds. harness.
T5-6-49
OPTION CONTROLLER FAULT CODE LIST
Controller Hardware Failure

15500-4 Abnormal External Reference Faulty controller All Controls
Voltage
15501-2 Abnormal Read Of Initial Setting Faulty controller All Controls
Value (EEPROM)
15502-2 Abnormal EEPROM Faulty controller All Controls
15503-2 Abnormal RAM Faulty controller All Controls
15504-2 Abnormal A/D Conversion Faulty controller All Controls
15505-2 Abnormal CAN Communication Faulty controller • All Controls
Faulty CAN harness • Pulverizer/Crusher Control
• CAN Cycle Data Communication
15506-3 Abnormal Sensor Voltage Faulty controller All Controls
Faulty sensor
Faulty harness
T5-6-50
Symptoms in Machine Operation

When Trouble Occurs.
- Retrial B Replace the controller.

- Retrial B Check CAN harness.
Replace the controller.
T5-6-51
Pilot Pressure Failure
15510-3 Abnormal Assist Stroke 1 Sensor Voltage: more than 4.65 V Assist Control
High Voltage
15510-4 Abnormal Assist Stroke 1 Sensor Voltage: less than 0.35 V Assist Control
Low Voltage
15511-3 Abnormal Assist Stroke 2 Sensor Voltage: more than 4.65 V Assist Control
High Voltage
15511-4 Abnormal Assist Stroke 2 Sensor Voltage: less than 0.35 V Assist Control
Low Voltage
15514-3 Abnormal Positioning/Auxiliary Voltage: more than 4.55 V • Auxiliary Selection Switch: ON
Stroke 1 Sensor High Voltage Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15514-4 Abnormal Positioning/Auxiliary Voltage: less than 0.45 V • Auxiliary Selection Switch: ON
Stroke 1 Sensor Low Voltage Auxiliary Control
Positioning Control
15515-3 Abnormal Positioning/Auxiliary Voltage: more than 4.85 V • Auxiliary Selection Switch: ON
Stroke 2 Sensor High Voltage Auxiliary Control
Positioning Control
15515-4 Abnormal Positioning/Auxiliary Voltage: less than 0.15 V • Auxiliary Selection Switch: ON
Stroke 2 Sensor Low Voltage Auxiliary Control
Positioning Control
T5-6-52
Remedy by
Symptoms in Machine Operation When Trouble Occurs. Remedy
Dr. ZX
• Stop assist operation. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit.
• If positioning and auxiliary stroke 2 is neutral, positioning and auxiliary Retrial B Check the harness.
operation stops.
• If positioning and auxiliary stroke 2 is not neutral, positioning and auxiliary
operation is active with pressure decreasing by 40%.
• Display "Abnormal attachment operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
operation stops.
unit.
operation stops.
unit.
operation stops.
unit.
T5-6-53

15516-3 Abnormal Positioning/Assist Pi Pressure Voltage: more than 4.60 V • Positioning Control
Sensor High Voltage • Assist Control
15516-4 Abnormal Positioning/Assist Pi Pressure Voltage: less than 0.40 V • Positioning Control
Sensor Low Voltage • Assist Control
15517-3 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: more than 4.60 V • Outrigger/Blade Control

Pressure Sensor High Voltage • Auxiliary Control
15517-4 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: less than 0.40 V • Outrigger/Blade Control

Pressure Sensor Low Voltage • Auxiliary Control
15518-3 Abnormal Outrigger/Blade Stroke 1 Voltage: more than 4.55 V Outrigger/Blade Control
Sensor High Voltage
15518-4 Abnormal Outrigger/Blade Stroke 1 Voltage: less than 0.45 V Outrigger/Blade Control
Sensor Low Voltage
15519-3 Abnormal Outrigger/Blade Stroke 2 Voltage: more than 4.85 V Outrigger/Blade Control
Sensor High Voltage
15519-4 Abnormal Outrigger/Blade Stroke 2 Voltage: less than 0.15 V. Outrigger/Blade Control
Sensor Low Voltage
T5-6-54
Remedy by
Dr. ZX
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
monitor unit.
monitor unit.
monitor unit.
• If outrigger/blade stroke 2 is neutral, Retrial B Check the harness.
outrigger/blade operation stops.
• If outrigger/blade stroke 2 is not neutral,
outrigger/blade operation is active with pressure decreasing by 40%.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor
unit.
unit.
unit.
unit.
T5-6-55
Proportional Solenoid Valve Control Failure
15570-2 Abnormal When meeting the following conditions, • Outrigger/Blade Control
Outrigger/Blade/Auxiliary outrigger/blade/auxiliary pilot pressure is more • Auxiliary Control
Neutral than 1.2 MPa.
(Conditions)
• Outrigger/blade 1 and 2 solenoid valve
output is less than 0.5 MPa
• Auxiliary solenoid valve 1 and 2 output is
less than 0.5 MPa
15571-2 Abnormal When meeting either of the following • Outrigger/Blade Control
Outrigger/Blade/Auxiliary conditions, outrigger/blade/auxiliary pilot • Auxiliary Control
Operation pressure is less than 1.0 MPa.
(Conditions)
output is more than 2.2 MPa
• Auxiliary solenoid valve 1 and 2 output is
more than 2.2 MPa
15572-2 Abnormal When meeting the following conditions, • Positioning Control
Positioning/Assist Neutral positioning/assist pilot pressure is more than • Assist Control
1.2 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve output is
less than 0.5 MPa
• Assist 1 and 2 solenoid valve output is less
than 0.5 MPa
15573-2 Abnormal When meeting either of the following • Positioning Control
Positioning/Assist conditions, positioning/assist pilot pressure is • Assist Control
Operation less than 1.0 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve output is
more than 2.2 MPa
• Assist 1 and 2 solenoid valve output is more
than 2.2 MPa
15574-3 Abnormal Positioning/auxiliary stroke 1 +• Positioning Control
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 9.0 • Auxiliary Control
Signal Critical High V
Voltage
15574-4 Abnormal Positioning/auxiliary stroke 1 + • Positioning Control
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is less than 0.5 V • Auxiliary Control
Signal Critical Low
Voltage
15575-3 Abnormal Outrigger/Blade Outrigger/blade stroke 1 + outrigger/blade Outrigger/Blade Control
Sum Signal Critical High stroke 2 is more than 9.0 V
Voltage
Sum Signal Critical Low stroke 2 is less than 0.5 V
Voltage
T5-6-56
Remedy by
Dr. ZX
monitor unit.
• Outrigger/blade operation is active with pressure decreasing by 40%. Retrial B Check the harness.
• Positioning and auxiliary 1 operation is active with pressure decreasing by 40%.
• Display "Abnormal electric lever solenoid valve output warning" on the monitor
unit.
• Positioning 1 operation is active with pressure decreasing by 40%. Retrial B Check the harness.
• Assist 1 operation is active with pressure decreasing by 40%.
• Positioning control: Positioning operation stops. Retrial B Check the harness.

• Auxiliary control: Auxiliary operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit.
• Positioning control: Positioning operation stops. Retrial B Check the harness.
• Auxiliary control: Auxiliary operation stops.
• Outrigger/blade operation stops. Retrial B Check the harness.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit.
• Outrigger/blade operation stops. Retrial B Check the harness.
T5-6-57

Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 5.4 • Auxiliary Control
Signal High Voltage V and less than or equal to 9.0 V

Positioning/Auxiliary Sum positioning/auxiliary stroke 2 more than or • Auxiliary Control
Signal Low Voltage equal to 0.5 V and is less than 4.6 V

Sum Signal High Voltage stroke 2 is more than 5.4 V and less than or
equal to 9.0 V

Sum Signal Low Voltage stroke 2 more than or equal to 0.5 V and is
less than 4.6 V
20300-2 Abnormal Positioning And Abnormal positioning/auxiliary stroke 1, or • Auxiliary Selection

Auxiliary Operation Signal Abnormal positioning/auxiliary stroke 2, or Switch: ON
Warning Abnormal sum of positioning/auxiliary 1 and 2 Auxiliary Control
• Auxiliary Selection
Switch: OFF
Positioning Control
20301-2 Abnormal Outrigger/Blade Abnormal outrigger/blade stroke 1 or Outrigger/Blade Control
Operation Signal Warning Abnormal outrigger/blade stroke 2 or
Abnormal sum of outrigger/blade 1 and 2
20302-2 Abnormal Warning On Abnormal assist stroke 1 or Assist 1 Control

Assist Related Operation Abnormal assist stroke 2 All Electric Lever Control
Signal (Assist 2)
20303-2 Electric Lever Pilot Cut Some electric lever controls are abnormal in All Controls
Warning monitoring neutral.
T5-6-58
Remedy by
Dr. ZX
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B Check the harness.
with pressure decreasing by 40 %.
• If positioning and auxiliary stroke 2 is neutral, positioning operation stops.
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B Check the harness.
with pressure decreasing by 40 %.
• If positioning and auxiliary stroke 2 is neutral, positioning operation stops.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B Check the harness.
pressure decreasing by 40 %.
• If outrigger/blade stroke 2 is neutral, outrigger/blade operation stops.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B Check the harness.
pressure decreasing by 40 %.
• If outrigger/blade stroke 2 is neutral, outrigger/blade operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit. Retrial B Check the harness.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit. Retrial B Check the harness.
• Front attachment operation completely stops. Retrial B Check the harness.

monitor unit.
T5-6-59
Proportional Solenoid Valve Failure
15520-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Auxiliary Control
Value of Auxiliary 1 Proportional Valve 920 mA or Less than 60 mA
15520-3 Abnormal Feedback Value High Current of Current: Higher than 920 Auxiliary Control
Auxiliary 1 Proportional Valve mA
15520-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Auxiliary Control
Auxiliary 1 Proportional Valve
15521-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Auxiliary Control
Value of Auxiliary 2 Proportional Valve 920 mA or Less than 60 mA
15521-3 Abnormal Feedback Value High Current of Current: Higher than 920 Auxiliary Control
Auxiliary 2 Proportional Valve mA
15521-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Auxiliary Control
15522-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Outrigger/Blade Control
Value of Outrigger/Blade 1 Proportional 920 mA or Less than 60 mA
Valve
15522-3 Abnormal Feedback Value High Current of Current: Higher than 920 Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve mA
15522-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve
15523-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Outrigger/Blade Control
Value of Outrigger/Blade 2 Proportional 920 mA or Less than 60 mA
Valve
15523-3 Abnormal Feedback Value High Current of Current: Higher than 920 Outrigger/Blade Control
Outrigger/Blade 2 Proportional Valve mA
15523-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Outrigger/Blade Control
15524-2 Invalid and Abnormal Current Feedback Current: Both of Higher than • Positioning Control
Value of Swing Parking Release 920 mA or Less than 60 mA • Assist 1 Control
Proportional Valve • Assist Switch Control
15524-3 Abnormal Feedback Value High Current of Current: Higher than 920 • Positioning Control
Swing Parking Release Proportional Valve mA • Assist 1 Control
• Assist Switch Control
15524-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA • Positioning Control
Swing Parking Release Proportional Valve • Assist 1 Control
• Assist Switch Control
T5-6-60

Remedy
Occurs. Dr. ZX
Auxiliary operation stops. Retrial B Check the harness.
Outrigger/blade operation stops. Retrial B Check the harness.
Swing parking release is impossible. Retrial B Check the harness.
Swing parking is always released. Retrial B Check the harness.
Swing parking release is impossible. Retrial B Check the harness.
T5-6-61

15525-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist 1 Control
Value of Assist 1 Proportional Valve mA or Less than 60 mA
15525-3 Abnormal Feedback Value High Current Current: Higher than 920 mA Assist 1 Control
of Assist 1 Proportional Valve
15525-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist 1 Control
15526-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist 1 Control
15526-3 Abnormal Feedback Value High Current Current: Higher than 920mA Assist 1 Control
15526-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist 1 Control
15527-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist Switch Control
15527-3 Abnormal Feedback Value High Current Current: Higher than 920 mA Assist Switch Control
15527-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist Switch Control
15528-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist Switch Control
15528-3 Abnormal Feedback Value High Current Current: Higher than 920 mA Assist Switch Control
15528-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist Switch Control
T5-6-62

Remedy
Occurs. Dr. ZX
Assist 1 operation stops. Retrial B Check the harness.
Assist switch operation stops. Retrial B Check the harness.
T5-6-63

15529-2 Invalid and Abnormal Current Feedback Current: Both of higher than 920 Positioning Control
Value of Positioning 1 Proportional mA or Less than 60 mA
Valve
15529-3 Abnormal Feedback Value High Current Current: Higher than 920mA Positioning Control
of Positioning 1 Proportional Valve
15529-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Positioning Control
of Positioning1 Proportional Valve
15530-2 Invalid and Abnormal Current Feedback Current: Both of higher than 920 Positioning Control
Value of Positioning 2 Proportional mA or Less than 60 mA
Valve
15530-3 Abnormal Feedback Value High Current Current: Higher than 920mA Positioning Control
15530-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Positioning Control
T5-6-64
Symptoms in Machine Operation When Trouble Remedy by Remedy

Occurs. Dr. ZX
Positioning operation stops. Retrial B Check the harness.
T5-6-65
CAN Data Reception Failure
Fault code Trouble Cause Influenced Control

15565-2 Unreceived Work Mode Unreceived for 2000 ms • Pulverizer Control
Sent from: MC • Crusher Control
15566-2 Unreceived ATT 1 and 2 Optional Unreceived for 10 sec • Pulverizer Control
Selection • Crusher Control
Sent from: MC
15567-2 Unreceived ATT 3 and 4 Optional Unreceived for 10 sec • Pulverizer Control
Selection • Crusher Control
Sent from: MC
15568-2 Unreceived ATT 5 Optional Selection Unreceived for 10 sec • Pulverizer Control
Sent from: MC • Crusher Control
15577-2 Unreceived Actual Engine Speed Unreceived for 10 sec All Electric Lever Control
Sent from: ECM
T5-6-66
Remedy by
Symptoms in Machine Operation When Trouble Occurs Remedy
Dr. ZX
Work mode control is inactive (Always digging mode). Retrial B Check the harness.
• Secondary pilot relief control solenoid valve: Always Retrial B Check the harness.
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
OFF
OFF
• Electric lever: Engine stop control Retrial B Check the harness.
T5-6-67
STEERING COLUMN MONITOR FAULT CODE
Symptoms in
Influenced Machine Remedy
Control Operation When by Dr. ZX
Trouble Occurs.
16000-2 Abnormal CAN Faulty steering - - Retrial B Check the CAN
communication column monitor harness.
Faulty CAN harness
T5-6-68
(Blank)
T5-6-69
MC FAULT CODES 11000 TO 11002

11000-2 Abnormal EEPROM Faulty MC
11001-2 Abnormal RAM Faulty MC
11002-2 Abnormal A/D Convesion Faulty MC
YES * Faulty MC.
Check if engine and machine

operate normally.
Faulty MC.
NO
* After retrial, if the engine and the machine operate

normally with the fault code shown, the machine can
be operated.
T5-6-70
MC FAULT CODE 11003

11003-3 Abnormal Sensor Voltage Faulty MC
IMPORTANT: Fault code 11003-3 (Abnormal sen-

sor voltage) is shown with other
fault code, diagnose fault code
11003-3 first.
YES Faulty sensor.
Disconnect all sensor

connectors for displayed
Shorted circuit in harness with
fault code and retry. Disconnect all con- YES continuity between MC and
Check if fault code nectors at MC side. sensor.
11003-3 disappears. Check for continuity
between terminals
NO #1 and #3 (harness
end) of connector.
Faulty MC.
NO
· Key switch: OFF
Connector (Harness end of connector viewed from the

open end side)
• Pressure Sensor (Boom Raise, Arm Roll-Out, • Pump 1 Delivery Pressure Sensor
(Optional)/Arm Roll-In, Front Attachment, Swing, • Pump 2 Delivery Pressure Sensor
Travel Forward/Reverse, Auxiliary (Optional), Po- • Steering Pump Delivery Pressure Sensor
sitioning (Optional))
• Pump 1 Control Pressure Sensor
• Pump 2 Control Pressure Sensor
T1V1-05-07-101
T1V1-05-07-102
T5-6-71
MC FAULT CODE 11004

11004-2 Abnormal CAN Communication Faulty MC
Dr.ZX
Satellite Terminal
(Optional)
Monitor Unit
ICF
Option MC
Controller
CAN Harness
Steering
Column ECM
Monitor
TCJB-02-01-001
• Check the CAN harness between the controllers.

(Refer to CAN Harness Check on T5-6-73 to 104.)
T5-6-72
CAN HARNESS CHECK
• Check the wiring connections first.
Open circuit in CAN

NO harness between
MC and ECM.
YES Check for continuity in
CAN harness between
MC and ECM. Check for continuity
· Key switch: OFF in CAN harness be-
tween MC and To A
· Refer to CAN Har- YES
Check for continuity in ness Continuity monitor unit.
YES CAN harness between
Check on T5-6-78.
MC and ICF. · Key switch: OFF
· Refer to CAN Har-
· Key switch: OFF ness Continuity
· Refer to CAN Har- Check on T5-6-80.
ness Continuity
Retry by using Dr. ZX. Check on T5-6-79. Open circuit in CAN
Check if fault code harness between
11004-2 is displayed. NO MC and ICM.
Normal.
NO
T5-6-73
YES
YES Check for continuity in
CAN harness between
MC and option con-
troller. Open circuit in CAN
harness between
Check for continuity in · Key switch: OFF MC and option con-
NO
CAN harness between · Refer to CAN Har- troller.
YES ness Continuity
MC and steering col-
umn monitor. Check on T5-6-82.
· Key switch: OFF Open circuit in CAN

· Refer to CAN Har- harness between
ness Continuity MC and steering
A Check on T5-6-81. NO
column monitor.
Open circuit in CAN

harness between
NO MC and monitor unit.
T5-6-74
Shorted circuit in
CAN harness be-
YES tween ground circuit
and CAN circuit.
Disconnect all con-
nectors of MC, ICF,
ECM, monitor unit, Shorted circuit in
steering column CAN harness be-
YES
monitor and option tween electric power
controller. circuit and CAN cir-
Check for continuity cuit.
Check for continuity
between power cir-
between ground cir-
cuit and CAN circuit
cuit and CAN circuit NO Shorted circuit in
of each controller. of MC, ICF, ECM,
Check for continuity YES CAN harness be-
monitor unit, steering
column monitor and between key signal tween electric
· Key switch: OFF option controller. circuit and CAN cir- key-signal circuit and
· Refer to Discontinuity cuit of MC, ICF, CAN circuit.
Check between CAN · Key switch: OFF NO ECM, monitor unit,
Circuit and Ground · Refer to Discontinuity steering column
Check between CAN Check for continuity
Circuit on T5-6-84 to monitor and option
Circuit and Power between High and
91. controller.
Low sides of CAN To B
Circuit on T5-6-92 to NO
99. · Key switch: OFF harness.
· Refer to Discontinuity
Check between CAN · Key switch: OFF
Circuit and Key Signal · Refer to Discontinu-
Circuit on T5-6-100 to ity Check in CAN
103. Harness on
T5-6-104.
T5-6-75
YES Shorted circuit in

CAN harness.
YES Faulty MC.

B
Connect all MC
connectors except
connector MC-C.
Check if resistance
NO between terminals YES Faulty ICF.
#C4 and #C15 of
harness end of con-
nector MC-C is within
Connect MC con-
60±10 Ω.
nector.
· Key switch: OFF Disconnect connec-
tor ICF-C in ICF.
NO Check if resistance YES Faulty ECM.
between terminals
#C5 and #C11 of Connect ICF con-
harness end is within nector.
60±10 Ω. Disconnect ECM
connector.
Check if resistance Connect ECM con-
· Key switch: OFF NO nector.
Connector between terminals
#18 and #37 of har- Disconnect connec-
MC Connector MC-C tor monitor-B in
ness end is within
(Harness end) 120±10 Ω. monitor unit.
#C4 #C15 NO Check if resistance
· Key switch: OFF between terminals
C1 C10
#B6 and #B7 of har-
ness end is within
120±10 Ω.
C23 C31 · Key switch: OFF
ICF Connector ICF-C

#C5
(Harness end)
#C11 T1V1-05-04-002
Monitor Unit Connector Monitor-B
(Harness end)
ECM Connector
#B7 #B6
(Harness end) #18 #37
T1GR-05-04-002 T183-05-04-013
T5-6-76
YES
Faulty monitor unit.
YES
Faulty steering column
Connect monitor unit monitor.
connector.
Disconnect connector 2
in steering column
NO monitor.
Connect steering col-
Check if resistance be- YES
umn monitor connector. Faulty option control-
tween terminals #1 and
Disconnect connector C ler.
#9 of harness end is
in option controller.
within 60±10 Ω.
Check if resistance be-
NO tween terminals #C10
· Key switch: OFF
and #C22 of harness
end is within 60±10 Ω. Failure in any control-
NO
ler.
· Key switch: OFF
Steering Column Monitor Connector 2 Option Controller Connector C

(Harness end) (Harness end)
C1 C10
#9 #C10
#1 #C22
TCJB-05-06-001
C23 C31
T5-6-77
CAN Harness Continuity Check
IMPORTANT: Before continuity check, trun the

key switch OFF.
• Between MC and ECM

• CAN Harness (High Side)
Check for continuity between terminal #C4 (har-
ness end) of connector MC-C in MC and terminal
#18 (harness end) of connector in ECM.
• CAN Harness (Low Side)

Check for continuity between terminal #C15
(harness end) of connector MC-C in MC and ter-
minal #37 (harness end) of connector in ECM.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ECM Connector
(Harness end)
#18 #37
T1GR-05-04-002
T5-6-78
• Between MC and ICF
#C5 (harness end) of connector ICF-C in ICF.

minal #C11 (harness end) of connector ICF-C in
ICF.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ICF Connector ICF-C

(Harness end) #C5
T1V1-05-04-002
#C11
T5-6-79
• Between MC and Monitor Unit
#B7 (harness end) of connector monitor-B in the
monitor unit.

minal #B6 (harness end) of connector monitor-B
in the monitor unit.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31

(Harness end)
#B7 #B6
T183-05-04-013
T5-6-80
• Between MC and Steering Column Monitor
#1 (harness end) of connector 2 in the steering
column monitor.

minal #9 (harness end) of connector 2 in the
steering column monitor.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
Steering Column Monitor Connector 2

(Harness end)
#9
#1
TCJB-05-06-001
T5-6-81
• Between MC and Option Controller
#C10 (harness end) of connector C in the option
controller.

minal #C22 (harness end) of connector C in the
option controller.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
Option Controller Connector C

(Harness end)
C1 C10
#C10
#C22
C23 C31
T5-6-82
(Blank)
T5-6-83
Discontinuity Check between CAN Circuit and
Ground Circuit Connector
Connector MC-C
IMPORTANT: Before continuity check, turn the key (Harness end)
switch OFF.
#C4
In case of continuity, the circuit be- C1 C10
tween CAN circuit and ground cir-
cuit is shorted.
In case of discontinuity, the circuit is
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Ground Cir- Connector MC-A
cuit (Harness end)
• Check for continuity between terminal #C4 (har- #A2
ness end) of connector MC-C and terminal #A2
(harness end) of connector MC-A.
• Check for continuity between terminal #C4 (har-

(harness end) of connector MC-A. #A13
T183-05-04-008

ness end) of connector MC-C and terminal #B8
(harness end) of connector MC-B. Connector MC-B
(Harness end)
• Check for continuity between terminal #C4 (har- #B8
(harness end) of connector MC-B.
#B18
T183-05-04-021
T5-6-84
• MC
Between CAN Circuit (Low Side) and Ground Circuit Connector
• Check for continuity between terminal #C15 Connector MC-C
(harness end) of connector MC-C and terminal (Harness end)
#A2 (harness end) of connector MC-A.
#C15
• Check for continuity between terminal #C15 C1 C10
(harness end) of connector MC-C and terminal
• Check for continuity between terminal #C15 C23 C31

#B8 (harness end) of connector MC-B. Connector MC-A
(Harness end)
• Check for continuity between terminal #C15 #A2
#B18 (harness end) of connector MC-B.
#A13
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-6-85
• ECM
Between CAN Circuit (High Side) and Ground Cir- ECM Connector
cuit (Harness end)
• Check for continuity between terminals #18 and #18 #43
#1 (harness end).
#4
• Check for continuity between terminals #18 and #3

#3 (harness end).

T1GR-05-04-002
#4 (harness end).
• Check for continuity between terminals #18 and

#43 (harness end).

#62 (harness end).
• ECM
Between CAN Circuit (Low Side) and Ground Circuit
#1 (harness end).

#3 (harness end). ECM Connector
(Harness end)
#37 #43
#4 (harness end). #4
#3
#43 (harness end).
T1GR-05-04-002
#62 (harness end).
T5-6-86
• ICF
Between CAN Circuit (High Side) and Ground Cir- ICF Connector ICF-C
cuit (Harness end) #C5
• Check for continuity between terminals #C5 and
#C14 (harness end) of connector ICF-C.

#C15 (harness end) of connector ICF-C. T1V1-05-04-002
#C14 #C15
• ICF
Between CAN Circuit (Low Side) and Ground Circuit ICF Connector ICF-C
• Check for continuity between terminals #C11 and (Harness end)

#C15 (harness end) of connector ICF-C. T1V1-05-04-002
#C14 #C15 #C11
• Monitor Unit
Between CAN Circuit (High Side) and Ground Circuit Monitor Unit Connector Monitor-B
• Check for continuity between terminals #B7 and (Harness end)
#B11 (harness end) of connector monitor unit-B.
#B7
• Monitor Unit #B11

T183-05-04-013
Between CAN Circuit (Low Side) and Ground Circuit

• Check for continuity between terminals #B6 and
#B11 (harness end) of connector monitor unit-B.
(Harness end)
#B6
T183-05-04-013
#B11
T5-6-87
Between CAN Circuit (High Side) and Ground Cir- Steering Column Monitor Connector 1
cuit (Harness end)
• Check for continuity between terminal #1 (har-
ness end) of connector 2 and terminal #1 (har-
ness end) of connector 1.
#7
• Check for continuity between terminal #1 (har- #1

TCJB-05-06-002

Between CAN Circuit (Low Side) and Ground Circuit Steering Column Monitor Connector 2
• Check for continuity between terminal #9 (har- (Harness end)
#9
#1
ness end) of connector 1. TCJB-05-06-001
T5-6-88
(Blank)
T5-6-89
Between CAN Circuit (High Side) and Ground Cir- Connector
cuit Connector C
• Check for continuity between terminal #C10 (Harness end)
(harness end) of connector C and terminal #A2
(harness end) of connector A. C1 C10
#C10
• Check for continuity between terminal #C10
(harness end) of connector A. C23 C31

(harness end) of connector C and terminal #A25 Connector A
(harness end) of connector A. (Harness end)
#A2
(harness end) of connector C and terminal #B8
(harness end) of connector B.

#A13
(harness end) of connector C and terminal #B18 T183-05-04-008
• Check for continuity between terminal #C10 Connector B

(harness end) of connector C and terminal #B25 (Harness end)
(harness end) of connector B. #B8
#B25
#B18
T183-05-04-021
T5-6-90
Between CAN Circuit (Low Side) and Ground Circuit Connector
• Check for continuity between terminal #C22 Connector C
(harness end) of connector C and terminal #A2 (Harness end)
(harness end) of connector A.
C1 C10
(harness end) of connector C and terminal #A13 #C22
C23 C31
(harness end) of connector A. Connector A
(Harness end)

(harness end) of connector C and terminal #B18 #A25
#A13
(harness end) of connector B. T183-05-04-008

(harness end) of connector C and terminal #B25 Connector B
(harness end) of connector B. (Harness end)
#B8
#B25
#B18
T183-05-04-021
T5-6-91
Power Circuit Connector
Connector MC-C
switch OFF. #C4
tween CAN circuit and power circuit
is shorted.
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Power Circuit Connector MC-A
• Check for continuity between terminal #C4 (har- (Harness end)

T183-05-04-008

(harness end) of connector MC-B. Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-92
• MC
Between CAN Circuit (Low Side) and Power Circuit Connector
• Check for continuity between terminal #C15 Connector MC-C
(harness end) of connector MC-C and terminal (Harness end)
#A1 (harness end) of connector MC-A. #C15
C1 C10
C23 C31
#B7 (harness end) of connector MC-B. Connector MC-A
(Harness end)
(harness end) of connector MC-C and terminal #A1
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-93
• ECM
Between CAN Circuit (High Side) and Power Circuit ECM Connector
• Check for continuity between terminals #18 and (Harness end)
#2 (harness end). #18 #5

#5 (harness end).
• ECM #2
T1GR-05-04-002
Between CAN Circuit (Low Side) and Power Circuit

#2 (harness end).
ECM Connector
(Harness end)
#5 (harness end).
• ICF
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminals #C5 and #2
T1GR-05-04-002

ICF Connector ICF-C
(Harness end)
#C5
• ICF #C2
Between CAN Circuit (Low Side) and Power Circuit #C1
T1V1-05-04-002
ICF Connector ICF-C

(Harness end)
#C2
#C1
T1V1-05-04-002
#C11
T5-6-94
• Monitor Unit
Between CAN Circuit (High Side) and Power Circuit Monitor Unit Connector Monitor-B
• Check for continuity between terminal #B7 (har- (Harness end)
ness end) of connector monitor-B and terminal
#A16 (harness end) of connector monitor-A. #B7
T183-05-04-013
Monitor Unit Connector Monitor-A

(Harness end)
• Monitor Unit
Between CAN Circuit (Low Side) and Power Circuit T183-05-05-001
• Check for continuity between terminal #B6 (har- #A16

ness end) of connector monitor-B and terminal
#A16 (harness end) of connector monitor-A.

(Harness end)
#B6
T183-05-04-013

(Harness end)
T183-05-05-001
#A16
T5-6-95
Between CAN Circuit (High Side) and Power Circuit Steering Column Monitor Connector 2

ness end) of connector 2 and terminal #12 (har- #1
TCJB-05-06-001

(Harness end)
#12
#6
• Steering Column Monitor TCJB-05-06-002
Between CAN Circuit (Low Side) and Power Circuit

#9
TCJB-05-06-001

(Harness end)
#12
#6
TCJB-05-06-002
T5-6-96
(Blank)
T5-6-97
Between CAN Circuit (High Side) and Power Circuit Connector
C1 C10
• Check for continuity between terminal #C10 #C10
C23 C31
Connector A
(harness end) of connector B. #A1

T183-05-04-008
Connector B
(Harness end)
#B7
#B17
#B24 T183-05-04-021
T5-6-98
Between CAN Circuit (Low Side) and Power Circuit Connector
C1 C10
(harness end) of connector C and terminal #A12 #C22
C23 C31
(harness end) of connector B. Connector A
(Harness end)

(harness end) of connector C and terminal #B24 #A12
T183-05-04-008
Connector B
(Harness end)
#B7
#B17
#B24 T183-05-04-021
T5-6-99
Key Signal Circuit Connector
Connector MC-C
switch OFF. #C4
tween CAN circuit and key signal
circuit is shorted.
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Key Signal Connector MC-B
Circuit (Harness end)
• Check for continuity between terminal #C4 (har- #B16
T183-05-04-021
• MC Connector
Between CAN Circuit (Low Side) and Key Signal Connector MC-C
• Check for continuity between terminal #C15 #C15
(harness end) of connector MC-C and terminal C1 C10
C23 C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
T5-6-100
• ECM
Between CAN Circuit (High Side) and Key Signal ECM Connector
#18 #24
#24 (harness end) of connector.
T1GR-05-04-002
• ECM ECM Connector

Between CAN Circuit (Low Side) and Key Signal
(Harness end)
Circuit #37 #24
#24 (harness end) of connector.
T1GR-05-04-002
• ICF
Between CAN Circuit (High Side) and Key Signal ICF Connector ICF-C
Circuit (Harness end) #C5
#C7 (harness end) of connector ICF-C. #C7
T1V1-05-04-002
• ICF
Between CAN Circuit (Low Side) and Key Signal ICF Connector ICF-C
#C7
T1V1-05-04-002
#C11
T5-6-101
• Monitor Unit
Between CAN Circuit (High Side) and Key Signal Monitor Unit Connector Monitor-B
• Check for continuity between terminal #B7 (har-
ness end) of connector monitor-B and terminal #B7
T183-05-04-013

(Harness end)
#A7
T183-05-05-001
• Monitor Unit
Between CAN Circuit (Low Side) and Key Signal Monitor Unit Connector Monitor-B
• Check for continuity between terminal #B6 (har-
ness end) of connector monitor-B and terminal #B6
T183-05-04-013

(Harness end)
#A7
T183-05-05-001
T5-6-102
Between CAN Circuit (High Side) and Key Signal Connector
Circuit Connector C
(harness end) of connector B. C1 C10
#C10
C23 C31
Connector B
(Harness end)
#B16
T183-05-04-021
• Option Controller Connector

Between CAN Circuit (Low Side) and Key Signal Connector C
(harness end) of connector C and terminal #B16 C1 C10
#C22
C23 C31
Connector B
(Harness end)
#B16
T183-05-04-021
T5-6-103
Discontinuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key

switch OFF.
In case of continuity, the circuit be-
tween CAN (High side) circuit and
CAN (Low side) circuit is shorted.
normal.
• Connector MC-C • Connector Monitor Unit-B

Check for continuity between terminals #C4 and Check for continuity between terminals #B6 and
#C15 (harness end) of connector MC-C in MC. #B7 (harness end) of connector monitor B in the
monitor unit.

MC Connector MC-C (Harness end)
(Harness end)
#B7 #B6
#C4 #C15
C1 C10
C23 C31 T183-05-04-013
• Connector 2 of Steering Column Monitor

• Connector ECM
Check for continuity between terminals #1 and #9
Check for continuity between terminals #18 and
(harness end) of connector 2.
#37 (harness end) of connector ECM.
ECM Connector (Harness end)
(Harness end)
#18 #37
#9
#1
TCJB-05-06-001
T1GR-05-04-002 • Connector C of Option Controller

Check for continuity between terminals #C10 and
• Connector ICF-C #C22 (harness end) of connector C.
Check for continuity between terminals #C5 and
#C11 (harness end) of connector ICF-C in ICF. Option Controller Connector C
(Harness end)
ICF Connector ICF-C

(Harness end) #C5 C1 C10
#C10
#C22
C23 C31
T1V1-05-04-002
#C11
T5-6-104
MC FAULT CODE 11100

-1
11100-2 Abnormal Engine Speed Engine speed: 4000 min or more
• Actual engine speed which ECM sends by using

CAN bus line.
Diagnose ECM.
T5-6-105
MC FAULT CODE 11101

11101-3 Abnormal Engine Control Dial Voltage: more than 4.78 V
Sensor High Voltage
11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V
Sensor Low Voltage
Open circuit in har-
Disconnect connector NO ness between MC
MC-C of MC. and engine control
YES Check for continuity dial.
between terminal #C1
(harness end) of
Check if voltage be- connector and termi- To A
1. With connector of switch
panel connected, insert tween terminals #1 and nal #2 (harness end) YES
of switch panel.
a test probe into the YES #3 (harness end) of
back side of connector connector of switch Open circuit in har-
in terminal #2. panel is 5±0.5 V. Check if voltage be- ness between MC
YES and engine control
When rotating engine tween terminal #1
control dial, check if · Key switch: ON (harness end) of dial (terminal #3).
voltage becomes speci- connector of switch
fication. panel and machine
NO
2. Disconnect connector of becomes specifica- Open circuit in har-
switch panel. Check if tion. ness between MC
resistance between ter- NO and engine control
minals #1 and #3 (switch · Key switch: ON dial (terminal #1).
panel end) of connector · Specification: 5±0.5 V
is 5±0.5 kΩ.
Faulty engine control
NO dial.
· Specification: Refer to
the following table.
Specification of Engine Control Dial

YES Faulty MC.
Slow Idle 0.3 to 1.0 V Check if voltage between
Fast Idle 4.0 to 4.7 V terminal #C1 (harness
A end) of connector MC-C
Connector (Harness end of connector viewed from the and machine is 0 V.
Shorted circuit in
open end side) harness between MC
MC Connector MC-C · Key switch: ON NO and engine control
dial.
#C1
C1 C10
C23 C31
Switch Panel
#3 #2 #1
T5-6-106
MC FAULT CODE 11200

11200-3 Abnormal Pump 1 Delivery Pressure Voltage: more than 4.5 V
Sensor High Voltage
11200-4 Abnormal Pump 1 Delivery Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Disconnect connector
MC-D of MC. Open circuit in har-
Check for continuity be- ness between MC
NO
tween terminal #D10 and pump 1 delivery
(harness end) of con- pressure sensor.
YES nector and terminal #2
(harness end) of con-
nector of pump 1 delivery
Disconnect connector pressure sensor. To A
of pump 1 delivery YES
pressure sensor. Check if voltage be-
NO Check if voltage be- Open circuit in har-
tween terminal #1 (har-
tween terminals #1 and ness end) of connector ness between MC
#3 (harness end) of YES and pump 1 delivery
of pump 1 delivery
connector is 5±0.5 V. pressure sensor and pressure sensor
Switch pump 1 delivery (terminal #3).
pressure sensor with machine becomes
pump 2 delivery pres- NO specification.
sure sensor and retry. · Key switch: ON Open circuit in har-
Check if fault code is ness between MC
switched. · Key switch: ON NO and pump 1 delivery
· Specification: 0.25 V or more, pressure sensor
4.5 V or less (terminal #1).
Faulty pump 1 deliv-

YES ery pressure sensor.
YES Faulty MC.

Check if voltage between
terminal #D10 (harness
A end) of connector MC-D
and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pump 1 delivery
pressure sensor.
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-D Pump 1 Delivery Pressure Sensor
#D10
3 2 1
T183-05-04-009
T5-6-107
MC FAULT CODE 11202

Sensor High Voltage
Sensor Low Voltage
MC-D of MC.
NO ness between MC
between terminal #D4
and pump 2 delivery
pressure sensor.
nector of pump 2 deliv-
ery pressure sensor. To A
Disconnect connector YES
NO of pump 2 delivery Check if voltage be- Open circuit in har-
pressure sensor. tween terminal #1 ness between MC
Check if the voltage (harness end) of YES and pump 2 delivery
between terminal #1 connector of pump 2 pressure sensor
and #3 (harness end) delivery pressure (terminal #3).
Switch pump 1 delivery of connector is 5±0.5 sensor and machine
pressure sensor with V. NO becomes specifica- Open circuit in har-
pump 2 delivery pres- tion. ness between MC
sure sensor and retry. · Key switch: ON
NO and pump 2 delivery
Check if fault code is
· Key switch: ON pressure sensor
switched.
· Specification: 0.25 V or more, (terminal #1).
4.5 V or less
YES ery pressure sensor.
YES Faulty MC.

terminal #D4 (harness end)
A of connector MC-D and
machine is 0 V.
Shorted circuit in
harness between MC
pressure sensor.
MC Connector MC-D o Pump 2 Delivery Pressure Sensor
#D4
3 2 1
T183-05-04-009
T5-6-108
MC FAULT CODE 11203

Sensor High Voltage
Sensor Low Voltage
Check for continuity NO ness between MC
between terminal #D3 and pump 3 delivery
YES
nector and terminal #2
Disconnect connector nector of pump 3 deliv- To A
of pump 3 delivery ery pressure sensor. YES
pressure sensor.
NO Check if voltage be- Check if voltage be- Open circuit in har-
tween terminals #1 and tween terminal #1 ness between MC
Switch pump 3 delivery (harness end) of con-
pressure sensor with #3 (harness end) of YES and pump 3 delivery
connector is 5±0.5 V. nector of pump 3 de- pressure sensor
pump 2 delivery pres- livery pressure sensor
sure sensor and retry. (terminal #3).
and machine becomes
Check if fault code is · Key switch: ON NO specification. Open circuit in har-
switched.
ness between MC
and pump 3 delivery
NO
· Key switch: ON pressure sensor
4.5 V or less
ery pressure sensor.
YES
YES Faulty MC.

terminal #D3 (harness end)
A of connector MC-D and
machine is 0 V.
Shorted circuit in
harness between MC
pressure sensor.
MC Connector MC-D Pump 3 Delivery Pressure

Sensor
#D3
3 2 1
T183-05-04-009
T5-6-109
MC FAULT CODE 11206

11206-3 Abnormal Pump 1 Control Pressure Voltage: more than 4.75 V.
Sensor High Voltage
11206-4 Abnormal Pump 1 Control Pressure Voltage: less than 0.25 V.
Sensor Low Voltage
between terminal #D11 and pump 1 control
Disconnect connector nector of pump 1 con-
of pump 1 control trol pressure sensor. To A
pressure sensor. YES
tween terminals #1 and tween terminal #1 ness between MC
#3 (harness end) of (harness end) of YES and pump 1 control
connector is 5±0.5 V. connector of pump 1 pressure sensor
Switch pump 1 control control pressure (terminal #3).
pressure sensor with sensor and machine
pump 2 control pressure · Key switch: ON
NO becomes specifica- Open circuit in har-
sensor and retry. Check tion. ness between MC
if fault code is switched. and pump 1 control
NO pressure sensor
· Key switch: ON (Terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pump 1 control
YES pressure sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pump 1 control
pressure sensor.
MC Connector MC-D Pump 1 Control Pressure Sensor
1 2 3
#D11
T183-05-04-009
T5-6-110
MC FAULT CODE 11208

11208-3 Abnormal Pump 2 Control Pressure Voltage: more than 4.75 V
Sensor High Voltage
11208-4 Abnormal Pump 2 Control Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Check for continuity ness between MC
NO
between terminal #D14 and pump 2 control
Disconnect connector nector for pump 2 con- To A
of pump 2 control trol pressure sensor.
Switch pump 1 control tween terminals #1 and ness between MC
tween terminal #1
pressure sensor with #3 (harness end) of YES and pump 2 control
(harness end) of
pump 2 control pressure connector is 5±0.5 V. pressure sensor
connector of pump 2
sensor and retry. Check control pressure (terminal #3).
if fault code is switched. · Key switch: ON sensor and machine
NO becomes specifica- Open circuit in har-
tion. ness between MC
and pump 2 control
NO pressure sensor
· Key switch: ON
4.75 V or less
Faulty pump 2 control
YES pressure sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pump 2 control
pressure sensor.
MC Connector MC-D Pump 2 Control Pressure Sensor
#D14
1 2 3
T183-05-04-009
T5-6-111
MC FAULT CODE 11301

11301-3 Abnormal Swing Pilot Pressure Voltage: more than 4.75 V
Sensor High Voltage
11301-4 Abnormal Swing Pilot Pressure Voltage: less than 0.25 V
Sensor Low Voltage
MC-C of MC.
between terminal #C13 Open circuit in har-
NO ness between MC
nector and terminal #2 and pressure sensor.
YES (harness end) of con-
nector of pressure
sensor.
Disconnect connector To A
of pressure sensor. YES
Check if voltage be-
tween terminals #1 and
NO
#3 (harness end) of Check if voltage be-
connector is 5±0.5 V. tween terminal #1 Open circuit in har-
(harness end) of ness between MC
· Key switch: ON connector of pressure YES and pressure sensor
sensor and machine (terminal #3).
Switch pressure sensor becomes specifica-
with other pressure tion.
sensor and retry. Check NO Open circuit in har-
if fault code disappears.
ness between MC
and pressure sensor
· Key switch: ON NO
(terminal #1).
4.75 V or less
Faulty pressure sen-
YES sor.
YES Faulty MC.

terminal #C13 (harness
and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON and pressure sensor.
NO
MC Connector MC-C Pressure Sensor (Swing)

#C13
C1 C10
1 2 3
C23 C31
T5-6-112
MC FAULT CODE 11302

11302-3 Abnormal Boom Raise Pilot Pres- Voltage: more than 4.75 V
sure Sensor High Voltage
11302-4 Abnormal Boom Raise Pilot Pres- Voltage: less than 0.25 V
sure Sensor Low Voltage
Disconnect connector Open circuit in har-

MC-C of MC. NO ness between MC
Check for continuity and pressure sensor.
YES between terminal #D15
Disconnect connector (harness end) of con- To A
of pressure sensor. nector of pressure YES
Check if voltage be- sensor.
tween terminal #1 and
NO #3 (harness end) of
connector is 5±0.5 V. Check if voltage be-
tween terminal #1 Open circuit in har-
(harness end) of
· Key switch: ON YES ness between MC
connector of pressure and pressure sensor
sensor and machine (terminal #3).
with other pressure NO tion.
sensor and retry. Check Open circuit in har-
if fault code disappears. ness between MC
NO and pressure sensor
· Key switch: ON
(terminal #1).
4.75 V or less
YES sor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
· Key switch: ON NO harness between MC
and pressure sensor.
MC Connector MC-D Pressure Sensor (Boom Raise)
1 2 3
#D15
T183-05-04-009
T5-6-113
MC FAULT CODE 11303

11303-3 Abnormal Arm Roll-in Pilot Pressure Voltage: more than 4.75 V
Sensor High Voltage
11303-4 Abnormal Arm Roll-in Pilot Pressure Voltage: less than 0.25 V
Sensor Low Voltage

YES between terminal #C3
(harness end) of con- To A
Disconnect connector nector of pressure
of pressure sensor. YES
sensor.
NO tween terminal #1 and
#3 (harness end) of
connector is 5±0.5 V. Check if voltage be-
tween terminal #1
(harness end) of Open circuit in har-
· Key switch: ON connector of pressure YES ness between MC
sensor and machine and pressure sensor
becomes specifica- (terminal #3).
Switch pressure sensor
sensor and retry. Check ness between MC
if fault code disappears. and pressure sensor
· Key switch: ON NO
(terminal #1).
4.75 V or less
YES sor,
YES Faulty MC,

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pressure sensor.
MC Connector MC-C Pressure Sensor

(Arm Roll-In)
#C3
C1 C10
1 2 3
C23 C31
T5-6-114
MC FAULT CODE 11305

11305-3 Abnormal Travel Forward Pilot Voltage: more than 4.75 V
11305-4 Abnormal Travel Forward Pilot Voltage: less than 0.25 V

YES
(harness end) of con- To A
nector of pressure YES
Disconnect connector sensor.
of pressure sensor.
Check if voltage be- Open circuit in har-
NO Check if voltage be-
tween terminal #1 and YES ness between MC
#3 (harness end) of tween terminal #1 and pressure sensor
connector is 5±0.5 V. (harness end) of (terminal #3).
Switch pressure sensor connector of pressure
with other pressure · Key switch: ON NO sensor and machine
sensor and retry. Check becomes specifica- Open circuit in har-
if fault code disappears. tion. ness between MC
NO and pressure sensor
· Key switch: ON
4.75 V or less
YES sor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
MC Connector MC-C Pressure Sensor (Travel Forward)

#C2
C1 C10
1 2 3
C23 C31
T5-6-115
MC FAULT CODE 11306

11306-3 Abnormal Travel Reverse Pilot Voltage: more than 4.75 V
11306-4 Abnormal Travel Reverse Pilot Voltage: less than 0.25 V
MC-C of MC.
Check for continuity Open circuit in har-
NO ness between MC
(harness end) of con- and pressure sensor.
nector of pressure
To A
sensor.
Disconnect connector YES
of pressure sensor. Check if voltage be- Open circuit in har-
NO Check if voltage between terminal #1 ness between MC
tween terminal #1 and (harness end) of YES
#3 (harness end) of and pressure sensor
connector of pressure (terminal #3).
connector is 5±0.5 V. sensor and machine
sensor and retry. Check · Key switch: ON Open circuit in har-
if fault code disappears. ness between MC
· Key switch: ON NO and pressure sensor
4.75 V or less
YES sor.
YES Faulty MC.

terminal #C11 (harness end)
A of connector MC-C and
machine is 0 V.
Shorted circuit in
harness between MC
MC Connector MC-C Pressure Sensor (Travel Reverse)
C1 C10
1 2 3
#C11
C23 C31
T5-6-116
MC FAULT CODE 11307

11307-3 Abnormal Front Attachment Pilot Voltage: more than 4.75 V
Pressure Sensor High voltage
11307-4 Abnormal Front Attachment Pilot Voltage: less than 0.25 V
Pressure Sensor Low voltage
MC-C of MC. Open circuit in har-
between terminal #C12 and pressure sensor.
YES (harness end) of con-
Disconnect connector nector of pressure To A
of pressure sensor. sensor. YES
tween terminal #1 and
NO
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON YES ness between MC
tween terminal #1 and pressure sensor
(harness end) of con- (terminal #3).
nector of pressure
Switch pressure sensor NO sensor and machine
with other pressure becomes specification. Open circuit in har-
sensor and retry. Check ness between MC
if fault code disappears. NO and pressure sensor
· Key switch: ON
4.75 V or less
YES sor.
YES Faulty MC.

and machine. Shorted circuit in
Check if the voltage is 0 V. harness between MC
NO and pressure sensor.
· Key switch: ON
MC Connector MC-C Pressure Sensor (Front Attachment)
#C12
C1 C10
1 2 3
C23 C31
T5-6-117
MC FAULT CODE 11310

11310-3 Abnormal Brake Pressure Sensor Voltage: more than 4.75 V
High Voltage
11310-4 Abnormal Brake Pressure Sensor Voltage: less than 0.25 V
Low Voltage
MC-C of MC. Open circuit in har-
Check for continuity NO
ness between MC
between terminal #D12 and brake pressure
YES (harness end) of con- sensor.
Disconnect the connec- nector of brake pres- To A
tor of brake pressure sure sensor. YES
sensor. Check if voltage
NO between terminal #1
and #3 (harness end) Check if voltage be- Open circuit in har-
of connectoris 5±0.5 V. tween terminals #1 ness between MC
YES
(harness end) of con- and brake pressure
nector of brake pres- sensor (terminal #3).
· Key switch: ON sure sensor and ma-
Switch brake pressure
sensor with pump 1 de- NO chine becomes speci-
livery pressure sensor fication. Open circuit in har-
and retry. Check if fault ness between MC
NO and brake pressure
code is switched. · Key switch: ON sensor (terminal #1).
4.5 V or less
Faulty brake pressure
YES sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and brake pressure
sensor.
MC Connector MC-D Brake Pressure Sensor
#D12
3 2 1
T183-05-04-009
T5-6-118
MC FAULT CODE 11311

11311-3 Abnormal Brake Remaining Pres- Voltage: more than 4.75 V
sure Sensor High Voltage
11311-4 Abnormal Brake Remaining Pres- Voltage: less than 0.25 V
sure Sensor Low Voltage
MC-C of MC.
Check for continuity Open circuit in har-
between terminal #C24 NO ness between MC
(harness end) of con- and brake remaining
YES nector and terminal #2 pressure sensor.
Disconnect connector nector of brake remain-
of brake remaining ing pressure sensor. To A
NO Check if voltage be- Open circuit in har-
tween terminals #1 and Check if voltage be-
ness between MC
#3 (harness end) of tween terminal #1
(harness end) of con- YES and brake remaining
connector is 5±0.5 V. pressure sensor
Replace brake remain- nector of brake re-
(terminal #3).
ing pressure sensor with maining pressure
· Key switch: ON sensor and machine
pump 1 delivery pres- NO Open circuit in har-
sure sensor and retry. becomes specification.
ness between MC
Check if fault code is and brake remaining
switched. · Key switch: ON NO pressure sensor
4.5 V or less
Faulty brake remain-

YES ing pressure sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and brake remaining
pressure sensor.
MC Connector MC-C Brake Remaining Pressure Sensor
C1 C10
3 2 1
C23 C31
#C24
T5-6-119
MC FAULT CODE 11400

11400-2 Abnormal Current Feedback of Current: Both of Higher than
Maximum Pump 2 Flow Rate Limit 920 mA or Less than 60 mA
11400-3 Abnormal Feedback High Current of Current: Higher than 920 mA
11400-4 Abnormal Feedback Low Current of Current: Less than 56 mA
Switch connectors of Faulty maximum pump 2

maximum pump 2 flow NO
flow rate limit control
rate limit control solenoid valve.
YES solenoid valve and
torque control solenoid
valve.
Faulty MC.
Check if fault code of
torque control solenoid YES
Check for continuity in
harness between MC valve is displayed.
and maximum pump 2
solenoid valve.
· Between terminal #A22
of connector MC-A in
MC and terminal #1 of Open circuit in harness.
connector in maximum NO
pump 2 flow rate limit
control solenoid valve.
MC and terminal #2 of
connector in maximum
control solenoid valve

open end side)
MC
Connector MC-A
#A16 #A22
T183-05-04-008
T1V1-05-04-003
T5-6-120
MC FAULT CODE 11401

Torque Control Solenoid Valve 920 mA or Less than 60 mA
Torque Control Solenoid Valve
Switch connectors of
torque control solenoid NO Faulty torque control
valve and maximum solenoid valve.
YES control solenoid valve.
maximum pump 2 flow Faulty MC.
rate limit control solenoid YES
Check for continuity in valve is displayed.
harness between MC
and torque control
solenoid valve.
connector in torque Open circuit in harness.
control solenoid valve. NO
connector in torque

open end side)
MC
Connector MC-A
#A19
#A30
T183-05-04-008
T1V1-05-04-003
T5-6-121
MC FAULT CODE 11403

Solenoid Valve Unit (SC) (Arm 920 mA or Less than 60 mA
Regeneration)
Solenoid Valve Unit (SC) (Arm
Regeneration)
Solenoid Valve Unit (SC) (Arm
Regeneration)
solenoid valve unit (SC) NO Faulty solenoid valve unit
(arm regeneration) and (SC) (arm regeneration).
YES other solenoid valve
unit (SF, SG or SI).
Check if fault code of Faulty MC.
switched solenoid valve
unit is displayed. YES
harness between MC
and solenoid valve unit
(SC) (arm regeneration).
Open circuit in harness.
connector in solenoid
valve unit (SC) (arm NO
regeneration)
valve unit (SC) (arm
regeneration)

open end side)
MC
Connector MC-A
#A24
#A18
T183-05-04-008
Solenoid Valve Unit (SC)

(Arm Regeneration)
T1V1-05-04-003
T5-6-122
MC FAULT CODE 11404

Solenoid Valve Unit (SG) (Relief 920 mA or Less than 60 mA
Pressure Control)
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Switch connectors of Faulty solenoid valve unit

solenoid valve unit NO
(SG) (relief pressure
(SG) (relief pressure control).
YES control) and other
solenoid valve unit (SF,
SC or SI).
Faulty MC.
switched solenoid valve YES
unit is displayed.
harness between MC
(SG) (relief pressure
control).
of connector MC-A in Open circuit in harness.
connector in solenoid NO
valve unit (SG) (relief
pressure control)
valve unit (SG) (relief
pressure control)

open end side)
Connector MC-A of MC
#A4 #A8
T183-05-04-008
Solenoid Valve Unit (SG)

(Relief Pressure Control)
T1V1-05-04-003
T5-6-123
MC FAULT CODE 11410

Maximum Pump 1 Flow Rate Limit 920 mA or Less than 60 mA
Switch connectors of Faulty maximum pump 1

maximum pump1 flow NO
rate limit control solenoid valve.
YES solenoid valve and
torque control solenoid
valve.
Faulty MC.
torque control solenoid YES
harness between MC valve is displayed.
and maximum pump 1
solenoid valve.
MC and terminal #1 of Open circuit in harness.
connector in maximum NO
connector in maximum

open side)
MC
Connector MC-A
#A5
#A31
T183-05-04-008
T1V1-05-04-003
T5-6-124
MC FAULT CODE 11422

Travel Motor Displacement Angle 920 mA or Less than 60 mA
Travel Motor Displacement Angle
NO Faulty travel motor

Disassemble and check displacement angle
travel motor displacement control solenoid valve.
YES angle control solenoid
valve.
Check for continuity in Check for abnormality. Faulty MC.
harness between MC YES
and travel motor
displacement angle
connector in travel Open circuit in harness.
motor displacement
NO
angle control solenoid
valve.
connector in travel
motor displacement
angle control solenoid
valve

open end side)
MC Connector MC-A
T183-05-04-008
#A29 #A32
Travel Motor Displacement Angle Control Solenoid Valve
TCJB-05-06-004
T5-6-125
MC FAULT CODE 11424

Solenoid Valve Unit (SI) (Axle Lock 920 mA or Less than 60 mA
Selection)
Solenoid Valve Unit (SI) (Axle Lock
Selection)
Solenoid Valve Unit (SI) (Axle Lock
Selection)
solenoid valve unit (SI) Faulty solenoid valve unit
NO
(axle lock selection) (SI) (axle lock selection).
and other solenoid
YES valve unit (SF, SC or
SG).
switched solenoid valve YES
Check for continuity in unit is displayed.
harness between MC
(SI) (axle lock selection).
valve unit (SI) (axle lock NO
selection).
valve unit (SI) (axle lock
selection).

open end side)
MC Connector MC-A
#A14
#A21 T183-05-04-008
Solenoid Valve Unit (SI)

(Axle Lock Selection)
T1V1-05-04-003
T5-6-126
MC FAULT CODE 11425

Solenoid Valve Unit (SF) (Work 920 mA or Less than 60 mA
Brake)
Solenoid Valve Unit (SF) (Work
Brake)
Solenoid Valve Unit (SF) (Work
Brake)
solenoid valve unit (SF) NO Faulty solenoid valve unit
(Work Brake) and other (SF) (work brake).
YES solenoid valve unit (SC,
SG or SI).
Check for continuity in switched solenoid valve
unit is displayed. YES
harness between MC
(SF) (work brake).
valve unit (SF) (work
brake). NO
valve unit (SF) (work
brake).

open end side)
MC Connector MC-A
#A9
#A15
T183-05-04-008
Solenoid Valve Unit (SF)

(Work Brake)
T1V1-05-04-003
T5-6-127
MC FAULT CODES 11910 TO 11920

11910-2 Actual Engine Speed Faulty harness
Sent from: ECM
11911-2 Security Signal Faulty harness
Sent from: Monitor Unit
11914-2 Radiator Coolant Temperature Faulty harness
Sent from: ECM
11915-2 Gate Lock Signal Faulty harness
Sent from: Option Controller
11918-2 Work Mode Faulty harness
Sent from: Monitor Unit
11920-2 Fuel Flow Rate Faulty harness
Sent from: ECM
NOTE: If fault codes 11910 to 11920 are displayed,

the CAN harness between MC and source
controller may be faulty.
Refer to CAN Harness Check on T5-6-73
to 104 and check the CAN harness.
T5-6-128
MC FAULT CODE 11901

11901-3 Hydraulic Oil Temperature Sensor Voltage: more than 4.52 V
High Voltage
11901-4 Hydraulic Oil Temperature Sensor Voltage: less than 0.23 V
Low Voltage
Connect terminals #1
YES Faulty MC.
and #2 (harness end)
of connector in
hydraulic oil
temperature sensor by Connect terminal #D6
YES using a clip. Open circuit in harness
(harness end) of YES between MC and
Disconnect connector connector MC-D in
MC-D from MC. hydraulic oil temperature
MC to machine. sensor (terminal #1).
Check for continuity Check for continuity
Disconnect connector of between terminals #D2
hydraulic oil temperature NO between terminals #2
and #D6 (harness end) (harness end) of
sensor. Open circuit in harness
of connector MC-D.
Check if resistance at connector in hydraulic between MC and
oil temperature NO hydraulic oil temperature
sensor end connector is
specification. sensor and machine. sensor (terminal #2).
the table below. Faulty hydraulic oil
NO temperature sensor.
Specification of Hydraulic Oil Temperature Sensor

Hydraulic Oil Resistance (kΩ)
Temperature
°C (°F)
-20 (-4) 16.2±1.6
0 (32) (5.88)
20 (68) 2.45±0.24
40 (104) (1.14)
60 (140) (0.534)
80 (176) 0
MC Connector MC-D
#D2
Hydraulic Oil Temperature Semsor
1 2
#D6 T183-05-04-009
T5-6-129
ECM FAULT CODES 100 TO 190
NOTE: If ECM fault code is displayed, refer to the

other manual "Engine Troubleshooting
Manual" and check the engine.
Engine
Fault Code Troubleshooting
Fault Code Trouble
(TECH2) Manual
Reference Page
Abnormal Engine Oil Pressure Sensor (Abnormal Low
100-3 P0522 1E-393
Voltage)
Abnormal Engine Oil Pressure Sensor (Abnormal High
100-4 P0523 1E-399
Voltage)
102-3 Abnormal Boost Pressure Sensor (Abnormal Low Voltage) P0237 1E-331
102-4 Abnormal Boost Pressure Sensor (Abnormal High Voltage) P0238 1E-339
Abnormal Boost Temperature Sensor (Abnormal High 1E-450
105-3 P1113
Voltage)
105-4 Abnormal Boost Temperature Sensor (Abnormal Low Voltage) P1112 1E-443
Abnormal Atmospheric Pressure Sensor (Abnormal Low
108-3 P0107 1E-228
Voltage)
Abnormal Atmospheric Pressure Sensor (Abnormal High
108-4 P0108 1E-235
Voltage)
110-0 Overheating P1173 1E-456
Abnormal Coolant Temperature Sensor (Abnormal High
110-3 P0118 1E-261
Voltage)
Abnormal Coolant Temperature Sensor (Abnormal Low
110-4 P0117 1E-255
Voltage)
157-0 Abnormal Common Rail Pressure (First stage) P0088 1E-212
157-0 Abnormal Common Rail Pressure (Second stage) P0088 1E-212
157-2 Abnormal Common Rail Pressure (Pump Over-Pressure) P0089 1E-217
Abnormal Common Rail Pressure Sensor (Abnormal High
157-3 P0193 1E-287
Voltage)
Abnormal Common Rail Pressure Sensor (Abnormal Low
157-4 P0192 1E-281
Voltage)
Abnormal Intake Air Temperature Sensor (Abnormal High
172-3 P0113 1E-247
voltage)
Abnormal Intake Air Temperature Sensor (Abnormal Low
172-4 P0112 1E-241
Voltage)
174-3 Abnormal Fuel Temperature Sensor (Abnormal High Voltage) P0183 1E-274
174-4 Abnormal Fuel Temperature Sensor (Abnormal Low Voltage) P0182 1E-268
190-0 Overrunning P0219 1E-329
T5-6-130
Engine
Fault Code Troubleshooting
Fault Code Trouble
(TECH2) Manual
Reference Page
628-2 Abnormal ROM P0601 1E-407
633-7 Pressure Limiter Open P1095 1E-433
636-2 Abnormal Cam Angle Sensor (No Signal) P0340 1E-358
636-2 Abnormal Cam Angle Sensor (Abnormal Signal) P0341 1E-365
636-7 Phase Mismatch of Cam Angle Sensor P1345 1E-512
639-2 Abnormal CAN Bus Line U2104 1E-541
639-3 Abnormal CAN Time Out U2106 1E-546
651-3 Open Circuit in Injection Nozzle #1 Drive System P0201 1E-294
723-2 Abnormal Crank Speed Sensor (No Signal) P0335 1E-346
723-2 Abnormal Crank Speed Sensor (Abnormal Signal) P0336 1E-352
987-3 Abnormal Check Engine Lamp P0650 1E-419
1077-2 Abnormal IC for CPU Watching P0606 1E-411
1079-2 Abnormal 5 V Power Source 1 Voltage P1631 1E-526
1080-2 Abnormal 5 V Power Source 2 Voltage P1632 1E-529
1239-1 No pressure to pump (Fuel leakage) P0087 1E-204
1240-1 No pressure to pump (Fuel leakage) P1093 1E-424
Open Circuit in Suction Control Valve Drive System,
1347-0 P0090 1E-222
Shorted circuit in +B or GND.
1485-2 Abnormal Main Relay System (ON is impossible.) P1625 1E-517
IMPORTANT: When fault code 723-2 (abnormal

crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.
T5-6-131
Engine Troubleshooting
Fault Code
Fault Code Trouble Manual
(TECH2)
Reference Item
10001-3 Abnormal EGR Position (Brushless spec.) P0487 1E-381
10002-2 Abnormal EGR Valve Control P0488 1E-387
10003-2 Abnormal Injection Nozzle Common 1 Drive System P1261 1E-466
10004-2 Abnormal Injection Nozzle Common 2 Drive System P1262 1E-476
10005-1 Abnormal Charge Circuit (Bank 1) P0611 1E-413
10006-1 Abnormal Charge Circuit (Bank 2) P0612 1E-416
10007-2 Abnormal CPU P0606 1E-411
10008-2 Abnormal A/D Conversion P1630 1E-524
10009-2 5 V Power Source 3 Voltage P1633 1E-532
10013-2 Abnormal EEPROM P0603 1E-409
T5-6-132
ICF FAULT CODES 14000 TO 14003

14000-2 Abnormal CAN Communication Execute retry B in self-diagnosing.
If this error code is displayed after retrial, check the following
item.
• Check the CAN communication line (harness).
14001-2 Flash Memory: Read / Write Error Execute retry B in self-diagnosing and execute the following
14002-2 External RAM: Read / Write Error item.
• Execute “Information C/U: Initialize”.
14003-2 EEPROM: Sum Check Error Execute retry B in self-diagnosing.
If this error code is displayed after retrial, check the following
item.
• Execute “Control Data: Initialize”.
• Execute “Enter Model and Serial No.”.
T5-6-133
INFORMATION C/U: INITIALIZE

Controller. Push Information C/U. Push OK.
To the
lower
T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024


Push Start. Setup. Push Information C/U: Initialize.
To the
lower
T1V7-05-03-025 T1V7-05-03-026 T1V7-05-03-027

Screen
Push Init and the controller
operating data is initialied. Push
ESC and return to Information C/U: Push OK and return to Information Push ESC and return to Main
Various Setup Screen. C/U: Various Setup Screen. Menu Screen.
Init
ESC
T1V7-05-03-028 T1V7-05-03-029 T1V7-05-03-027
Information C/U: Initialize Screen Information C/U: Various Setup

Screen
T5-6-134
CONTROL DATA: INITIALIZE

To the
lower
T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024


Push Start. Setup. Push Control Data: Initialize.
To the
lower
T1V7-05-03-025 T1V7-05-03-026 T1V7-05-03-027

Screen
Push Init and the controller control
data is initialied. Push ESC and
return to Information C/U: Various Push OK and return to Information Push ESC and return to Main
Setup Screen. C/U: Various Setup Screen. Menu Screen.
Init
ESC
T1V7-05-03-033 T1V7-05-03-034 T1V7-05-03-027

Control Data: Initialize Screen Information C/U: Various Setup
Screen
T5-6-135
ENTER MODEL AND SERIAL No.

To the
lower
T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024


Push Start. Setup. Push Enter Model and Serial No.
To the
lower
T1V7-05-03-025 T1V7-05-03-026 T1V7-05-03-027

Screen
Push OK after inputting model and
Push Exec and model and serial serial No. and return to Enter
No. can be input. Model and Serial No. Screen.
Push ESC and return to Push ESC and return to
Information C/U: Various Setup Information C/U: Various Setup Push ESC and return to Main
Screen. Screen. Menu Screen.
Exes ESC
ESC
OK
T1V7-05-03-030 T1V7-05-03-031 T1V7-05-03-027

Enter Model and Serial No. Screen Information C/U: Various Setup
Screen
T5-6-136
ICF FAULT CODES 14006, 14008

14006-2 ICF: Satellite Communication Execute retry B in self-diagnosing.
Terminal: Communication Error If this error code is displayed after retrial, check the following
item.
• Check the communication line.
• Check the power source line of satellite terminal.
• Check the fuse.

14008-2 ICF: Abnormal Internal RAM Execute retry B in self-diagnosing.
If this error code is displayed after retrial, replace the
controller.
Fault Code 14006-2 Connector (Harness end of connector viewed from the
• Check the communication line open end side)
1. Check for continuity between terminal #A8
(harness end) of connector ICF-A in ICF and
terminal #10 (harness end) of connector A in
satellite terminal. ICF
Connector ICF-A
2. Check for continuity between terminal #A9 #A8
(harness end) of connector ICF-A in ICF and #A9
satellite terminal.
#A31
3. Check for continuity between terminal #A31
(harness end) of connector ICF-A in ICF and Satellite Terminal
Connector A
terminal #2 (harness end) of connector B in
satellite terminal.
10 9 8 7 6 5 4 3 2 1
• Check the power source line of satellite terminal 20 19 18 17 16 15 14 13 12 11
1. Check the battery power
Check if voltage between terminal #2 (harness Satellite Terminal
end) of connector A in satellite terminal and Connector B
machine is 24 V.
2. Check the main power 8 7 6 5 4 3 2 1
With the key switch ON, check if voltage between 16 15 14 13 12 11 10 9
satellite terminal and machine is 24 V.
3. Check the ground circuit
Check for continuity between terminals #11 and
#12 (harness end) of connector A in satellite
terminal.
T5-6-137
SATELLITE TERMINAL FAULT CODES 14100 TO 14106

14100-2 Abnormal EEPROM Execute retry B in self-diagnosing.
14101-2 Abnormal IB/OB Queue If this error code is displayed after retrial, replace the
controller.
14102-2 Abnormal Local Loop Back Check the communication antenna of satellite terminal.
14103-2 Satellite cannot be found.
14104-2 Remote Loop Back Failure 1 Execute retry B in self-diagnosing.
14105-2 Remote Loop Back Failure 2 If this error code is displayed after retrial, replace the
controller.
14106-2 Received data is not same with sent
data.
• Fault Codes 14102-2 and 14103-2 Satellite Terminal
TCJB-05-04-001
Communication
Antenna
GPS Antenna
T1V1-05-06-004
T5-6-138
MONITOR UNIT FAULT CODE 13303

13303-2 Abnormal Thermistor Temperature Cool the monitor unit and so on until the internal temperature
of monitor unit is less than 85 °C (185 °F).
• The screen of monitor unit becomes dark.
YES Normal.
Cool monitor unit. Check

YES
if the screen of monitor
unit becomes normal.
Check if temperature
NO
around monitor unit is
high.

NO
T5-6-139

13304-2 Abnormal REG Input H Level Refer to the following.
NOTE: *As terminal L in the regulator is a

waterproof type connector, it is difficult to
measure voltage.
Measure voltage at terminal R in starter
relay.
Check for continuity at terminal R in starter
relay and terminal L in the regulator in
advance.
Less than 33.5 V Faulty monitor unit.

Less than Measure voltage at
33.5 V terminal #C7 of
connector monitor-C.
Open circuit in harness
· Engine: Running between terminal L in
Measure voltage at 33.5 V or higher regulator and monitor
terminal L *in unit.
regulator.
Faulty regulator or faulty
alternator.
33.5 V or higher

open end)
Starter Relay
E
S R
Monitor Unit
Connector Monitor-C
6 1
12 7
#C7
T5-6-140
MONITOR UNIT FAULT CODES 13306 AND 13308

13306-2 Abnormal EEPROM Replace the monitor unit when displaying the fault code after
retrial.
13308-2 Abnormal CAN Communication Refer to CAN Harness Check (T5-6-73 to 104).
T5-6-141

13310-2 Shorted Circuit in Coolant Check the coolant temperature sensor and harness.
Temperature Sensor
With terminal of coolant

temperature sensor Shorted circuit in harness
YES YES between monitor unit and
disconnected, disconnect
connector monitor-C in sensor.
monitor unit.
Check for continuity between
terminal #C8 (harness end) of Faulty monitor unit.
Check if resistance of connector in monitor unit and NO
coolant temperature machine.
sensor is specification.
Faulty coolant temperature
NO sensor.

Coolant Temperature °C Resistance
(°F) (kΩ)
25 (77) 7.6±0.76
40 (104) 4.0±0.35
50 (122) 2.7±0.22
80 (176) 0.92±0.07
95 (203) 0.56±0.04
105 (221) 0.42±0.03
120 (248) 0.28±0.01

open end side)
Monitor Unit
Connector Monitor-C
6 1
12 7
#C8
T5-6-142

13311-3 Shorted Circuit in Fuel Level Sensor Check fuel level sensor and harness.
13311-4 Open Circuit in Fuel Level Sensor Check fuel level sensor and harness.
YES Shorted circuit in harness

between monitor unit and
sensor.
With connector of fuel
level sensor
YES disconnected, disconnect
connector monitor-C in
monitor unit.
Check for continuity Connect terminal #1
between terminal #C2 (harness end) of YES Faulty monitor unit.
(harness end) of connector in fuel level
NO sensor to machine.
connector in monitor unit
and machine. Check for continuity
Check if resistance of between terminal #C2
fuel level sensor is (harness end) of Open circuit in harness
specification. connector in monitor unit NO between monitor unit and
and machine. sensor.
Faulty fuel level sensor.

NO
Fuel Sensor
Float Float Position Resistance (Ω)

Upper Limit (FULL) 10+0-4
3/4 26
FULL
1/2 38±5
R381.9 1/4 53
257 mm
Alarm Level 85±3
3/4
Lower Limit (EMPTY) 90+10-0
93 mm
70.5 mm
open end side)
204 mm 1/2
Monitor Unit
Connector Monitor-C
Fuel Sensor
1/4
338 mm
1 2
#C2
EMPTY
T178-05-05-001
6 1
12 7
T5-6-143
PILOT SHUT-OFF LEVER ALARM
Pilot shut-off lever alarm is displayed on the

monitor unit screen.
YES Faulty pilot shut-off

switch.
Check if pilot shut-off
switch is bent or
damaged.
Faulty harness.
NO
Pilot Shut-Off Pilot Shut-Off

Lever Switch
T1V1-05-06-005
T5-6-144
OPTION CONTROLLER FAULT CODES 15500 TO 15504

15500-4 Abnormal External Reference Voltage Faulty controller
15501-2 Abnormal Read of Initial Setting Value Faulty controller
(EEPROM)
15502-2 Abnormal EEPROM Faulty controller
15503-2 Abnormal RAM Faulty controller
15504-2 Abnormal A/D Conversion Faulty controller
YES * Faulty option controller.
Check if engine and machine

operate normally
Faulty option controller.
NO
* After retrial, if the engine and the machine operate

normally with the fault code shown, the machine
can be operated.
T5-6-145
OPTION CONTROLLER FAULT CODE 15505

15505-2 Abnormal CAN Communication Faulty controller
Faulty CAN harness
NOTE: If fault code 15505 is displayed, the CAN

harness between MC and source controller
may be faulty.
T5-6-146

15506-3 Abnormal Sensor Voltage Faulty controller
Faulty sensor
Faulty harness
YES Faulty sensor.
Disconnect all sensor

connectors for displayed
fault code and retry.
Check if fault code Disconnect all YES
15506-3 disappears. Shorted circuit in harness with
connectors at option continuity between option
controller side. controller and sensor.
NO between terminals #1
and #3 (harness end) of
connector. Faulty option controller.
NO
· Key switch: OFF

open end side)
• Pressure Sensor (Positioning) (Optional) • Electric Lever (Blade/Outrigger,
• Pressure Sensor (Auxiliary) (Optional) Auxiliary/Positioning)
T1V1-05-07-102
TCJB-05-06-005
T5-6-147

15510-3 Abnormal Assist Stroke 1 Sensor High Voltage: more than 4.65 V
Voltage
15510-4 Abnormal Assist Stroke 1 Sensor Low Voltage: less than 0.35 V
Voltage
Check if voltage
between terminal # C YES Faulty option
20 (harness end) of controller.
YES connector C of option
Disconnect connector controller and machine
C of option controller. 0 V. Shorted circuit in
Check for continuity harness between
YES between terminal #C1 NO option controller and
(harness end) of · Key switch: ON right grip (assist
connector and terminal switch).
#7 (harness end) of
connector of right grip. Open circuit in
Disconnect connector of harness between
right grip. option controller and
Check if voltage NO
right grip (assist
between terminals #5 switch).
connector is 5±0.5 V. Open circuit in
Check if voltage
between terminal #7 YES harness between
· Key switch: ON
(harness end) of option controller and
connector for right grip right grip (assist
and machine is switch) (terminal #5).
NO specification.
Open circuit in
harness between
· Key switch: ON option controller and
NO
· Specification: 0.25 V or more, right grip (assist
4.75 V or less switch) (terminal #7).
Right Grip Connector

#C20
#C1 C1 C10
C23 C31
TCJB-05-06-006
T5-6-148

15511-3 Abnormal Assist Stroke 2 Sensor High Voltage: more than 4.65 V
Voltage
15511-4 Abnormal Assist Stroke 2 Sensor Low Voltage: less than 0.35 V
Voltage
Check if voltage
between terminal #C6 YES Faulty option
(harness end) of controller.
controller and machine
is 0 V. Shorted circuit in
C of option controller.
Check for continuity harness between
YES between terminal #C NO option controller and
· Key switch: ON right grip (assist
(harness end) of
connector and terminal switch).
#7 (harness end) of
connector of right grip. Open circuit in
Disconnect connector of harness between
right grip. option controller and
Check if voltage NO
right grip (assist
between terminals #5 switch).
Check if voltage Open circuit in
· Key switch: ON between terminals #7 YES harness between
(harness end) of option controller and
connector of right grip right grip (assist
and machine is switch) (terminal #5).
NO specification.
Open circuit in
harness between
· Key switch: ON NO option controller and
· Specification: 0.25 V or more, right grip (assist
4.75 V or less switch) (terminal #7).
Right Grip Connector

#C6
#C1 C1 C10
C23 C31
TCJB-05-06-006
T5-6-149

15514-3 Abnormal Positioning/Auxiliary Stroke 1 Voltage: more than 4.55 V
Sensor High Voltage
15514-4 Abnormal Positioning/Auxiliary Stroke 1 Voltage: less than 0.45 V
Sensor Low Voltage
Check if voltage
YES Faulty option controller.
between terminal
#C19 (harness end) of
Disconnect connector C YES connector C option
of option controller. controller and machine Shorted circuit in
Check for continuity 0 V. harness between
between terminal #C1 option controller and
YES (harness end) of NO electric lever
· Key switch: ON (auxiliary/positioning).
connector and terminal
#2 (harness end) of
Disconnect connector connector of electric Open circuit in harness
of electric lever lever between option
(auxiliary/positioning). (auxiliary/positioning). controller and electric
Check if voltage NO lever
between terminals #2 (auxiliary/positioning).
of connector is 5±0.5 V. Check if voltage Open circuit in between
between terminal #2 option controller and
(harness end) of YES electric lever
· Key switch: ON
connector of electric (auxiliary/positioning)
lever (terminal #4).
(auxiliary/positioning)
and machine is
NO
specification. Open circuit in n
harness between
· Specification: 0.25 V or more, electric lever
4.75 V or less (auxiliary/positioning)
(terminal #2).
Option Controller Connector C Electric Lever (Auxiliary/Positioning)
#C19
#C1 C1 C10
C23 C31
TCJB-05-06-005
T5-6-150

15515-3 Abnormal Positioning/Auxiliary Stroke 2 Voltage: more than 4.85 V
Sensor High Voltage
15515-4 Abnormal Positioning/Auxiliary Stroke 2 Voltage: less than 0.15 V
Sensor Low Voltage
Check if voltage
between terminals YES Faulty option controller.
Disconnect connector C YES connector C of option
of option controller. controller and Shorted circuit in
Check for continuity machine. harness between
between terminal #C1 Check if voltage is 0 V. option controller and
YES (harness end) of NO electric lever
connector and terminal · Key switch: ON (auxiliary/positioning).
#2 (harness end) of
Disconnect connector connector of electric Open circuit in harness
of electric lever lever between option
(auxiliary/positioning). (auxiliary/positioning). controller and electric
Check if voltage NO lever
between terminals #2 (auxiliary/positioning).
Check if voltage
connector is 5±0.5 V. Open circuit in harness
between terminal #2
(harness end) of between option
· Key switch: ON connector of electric YES controller and electric
lever lever
(auxiliary/positioning) (auxiliary/positioning)
and machine is (terminal #4).
NO specification.
between option
· Key switch: ON NO controller and electric
lever
4.75 V or less
(auxiliary/positioning)
(terminal #2).
Option Controller Connector C Electric Lever (Auxiliary/Positioning)
#C17
#C1 C1 C10
C23 C31 TCJB-05-06-005
T5-6-151

15516-3 Abnormal Positioning/Assist Pi pressure Voltage: more than 4.60 V
Sensor High Voltage
15516-4 Abnormal Positioning/Assist Pi pressure Voltage: less than 0.40 V
Sensor Low Voltage

Disconnect connector C NO
of option controller. between option
Check for continuity controller and pressure
YES sensor.
(harness end) of
connector and terminal To A
#2 (harness end) of YES
of pressure sensor.
connector of pressure
Check if voltage
sensor.
between terminals #1
NO and #3(harness end) of
Check if voltage
· Key switch: ON between terminal #1 YES Open circuit in harness
(harness end) of between option
Switch pressure sensor connector of pressure controller and pressure
with other pressure sensor and machine is sensor (terminal #3).
sensor and retry. Check NO specification.
if fault code disappears. Open circuit in harness
between option
· Key switch: ON NO controller and pressure
· Specification: 0.25 V or more, sensor (terminal #1).
4.75 V or less
Faulty pressure
YES sensor.

A end) of connector C and
machine is 0 V.
Shorted circuit in
harness between
pressure sensor.
Option Controller Connector C Pressure Sensor (Positioning)
#C16
C1 C10
T1V1-05-07-102
C23 C31
T5-6-152

15517-3 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: more than 4.60 V
15517-4 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: is less than 0.40 V

Disconnect connector C NO between option
of option controller. controller and pressure
Check for continuity sensor.
YES
(harness end) of
Disconnect connector connector and terminal To A
of pressure sensor. #2 (harness end) of YES
Check if voltage connector of pressure
between terminals #1 sensor.
NO and #3 (harness end)
of connector is 5±0.5
V. Open circuit in harness
Check if voltage between option
· Key switch: ON between terminal #1 YES controller and pressure
(harness end) of sensor (terminal #3).
connector of pressure
Switch pressure sensor sensor and machine is
NO specification. Open circuit in harness
with other pressure
sensor and retry. Check if between option
fault code disappears. · Key switch: ON NO controller and pressure
· Specification: 0.25 V or more, sensor (terminal #1).
4.75 V or less
Faulty pressure
YES sensor.

end) of connector C and
A machine is 0 V.
Shorted circuit in
harness between
pressure sensor.
Option Controller Connector C Pressure Sensor (Auxiliary)

#C15
C1 C10
T1V1-05-07-102
C23 C31
T5-6-153

15518-3 Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: more than 4.55 V
High Voltage
15518-4 Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: less than 0.45 V
Low Voltage
Check if voltage
between terminal YES Faulty option controller.
Disconnect connector C YES connector C of option
Check for continuity is 0 V. harness between option
between terminal #C1 controller and electric
YES (harness end) of NO lever (blade/outrigger).
connector and terminal · Key switch: ON
#2 (harness end) of
connector of electric
Disconnect connector lever (blade/outrigger). Open circuit in harness
of electric lever between option
(blade/outrigger). NO controller and electric
Check if voltage lever (blade/outrigger).
and #4 (harness end) of Open circuit in harness
connector is 5±0.5 V. Check if voltage
between terminal #2 between option
· Key switch: ON (harness end) of YES controller and electric
connector of electric lever (blade/outrigger)
lever (blade/outrigger) (terminal #4).
and machine is
NO specification.
between option
· Key switch: ON NO controller and electric
· Specification: 0.25 V or more, lever (blade/outrigger)
4.75 V or less (terminal #2).
Option Controller Connector C Electric Lever (Blade/Outrigger)
#C18
#C1 C1 C10
C23 C31 TCJB-05-06-005
T5-6-154

15519-3 Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: more than 4.85 V
High Voltage
15519-4 Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: less than 0.15 V
Low Voltage
Check if voltage
YES Faulty option
between terminal
#C28 (harness end) of controller.
Disconnect connector C
Check for continuity is 0 V. harness between
between terminal #C1 option controller and
YES NO electric lever
(harness end) of · Key switch: ON
connector and terminal (blade/outrigger).
#2 (harness end) of
connector of electric Open circuit in
Disconnect connector of lever (blade/outrigger). harness between
electric lever option controller and
(blade/outrigger). NO electric lever
Check if voltage (blade/outrigger).
and #4 (harness end) of Open circuit in
connector is 5±0.5 V. harness between
Check if voltage YES option controller and
· Key switch: ON between terminal #2 electric lever
(harness end) of (blade/outrigger)
connector of electric (terminal #4).
lever (blade/outrigger)
NO
and machine is Open circuit in
specification. harness between
· Specification: 0.25 V or more, electric lever
4.75 V or less (blade/outrigger)
(terminal #2).
Option Controller Connector C Electric Lever (Blade/Outrigger)
#C1 C1 C10
C23 C31 TCJB-05-06-005

#C28
T5-6-155

15570-2 Abnormal Outrigger/Blade/Auxiliary Neutral When meeting the any following conditions,
outrigger/blade/auxiliary pilot pressure is
more than 1.2 MPa.
(Conditions)
• Auxiliary solenoid valve 1 and 2 output
is less than 0.5 MPa
YES Faulty auxiliary solenoid valve

1 or 2 (stuck spool).
YES Disassemble and check

auxiliary solenoid valve
1 or 2.
Check for abnormality. Faulty blade/outrigger solenoid
Set pilot shut-off lever
to LOCK position and NO valve 1 or 2 (stuck spool).
retry.
Check if fault code
disappears.
· Engine: Running YES Faulty pressure sensor.
Switch pressure
sensor with other
pressure sensor and
NO retry. Check if fault
code disappears.
NO
T5-6-156

15571-2 Abnormal Outrigger/Blade/Auxiliary When meeting either of the any following
Operation condition, outrigger/blade/auxiliary pilot
pressure is less than 1.0 MPa.
(Conditions)
• Auxiliary solenoid valve 1 and 2 output
is more than 2.2 MPa
• All of auxiliary solenoid valves 1, 2 and

blade/outrigger solenoid valves 1, 2 may not
become faulty at the same time.
• Therefore when the fault code is displayed, the
pressure sensor or the controller may be faulty.
• Refer to "FAULT CODE 15517".
T5-6-157

15572-2 Abnormal Positioning/Assist Neutral When meeting the any following conditions,
positioning/assist pilot pressure is more than
1.2 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve
• Assist 1 and 2 solenoid valve output
is less than 0.5 MPa
YES Faulty assist solenoid valve 1

or 2 (stuck spool).
YES Disassemble and check

assist solenoid valve 1
or 2.
Check for abnormality. Faulty positioning solenoid
Set pilot shut-off lever valve 1 or 2 (stuck spool).
to LOCK position and NO
retry.
Check if fault code
disappears.
· Engine: Running YES Faulty pressure sensor.

Switch pressure
sensor with other
pressure sensor and
NO retry.
Check if fault code
disappears.
NO
T5-6-158

15573-2 Abnormal Positioning/Assist Operation When meeting either of the following
conditions, positioning/assist pilot pressure
is less than 1.0 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve
• Assist 1 and 2 solenoid valve output
is more than 2.2 MPa
• All of assist solenoid valves 1, 2 and positioning

solenoid valves 1, 2 may not become faulty at the
same time.
• Therefore when the fault code is displayed, the
pressure sensor or the controller may be faulty.
• Refer to "FAULT CODE 15516".
T5-6-159
OPTION CONTROLLER FAULT CODES 15574-3 AND 15578-3

15574-3 Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/
Critical High Voltage auxiliary stroke 2 is more than 9.0 V
High Voltage auxiliary stroke 2 is more than 5.4 V and
less than or equal to 9.0 V
YES Faulty electric lever.

of electric lever
(auxiliary/positioning).
Connect terminal #2
of connector by using a
clip or others and retry.
Check if fault code YES Shorted circuit in harness with
Disconnect connector C
disappears. continuity.
of option controller.
between following
NO terminals (harness end)
of connector.
· Between terminal #C19 of NO
connector C and terminal #3
of connector of electric lever
· Between terminal #C17 of
connector C and terminal #1
of connector of electric lever
Electric Lever Option Controller Connector C

(Auxiliary/Positioning)
#C17 #C19
C1 C10
TCJB-05-06-005
C23 C31
T5-6-160

Critical Low Voltage auxiliary stroke 2 is less than 0.5 V
15578-4 Abnormalr Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/

Low Voltage auxiliary stroke 2 is more than or equal to
0.5 V and less than 4.6 V

Disconnect connector of
electric lever
(auxiliary/positioning).
Connect terminals #2 and
#1 (harness end) of
connector by using a clip
or others. Disconnect connector C
Connect terminals #2 and of option controller and
#3 (harness end) of connector of electric YES Faulty option controller.
connector by using a clip lever
or others. Retry and (auxiliary/positioning).
Check if fault code Check for continuity
disappears. between following
NO
terminals (harness end)
of connector. Open circuit in harness without
NO continuity.
· Between terminal #C19
of connector C and
terminal #3 of connector
of electric lever
of connector C and
of electric lever

#C17 #C19
C1 C10
C23 C31
TCJB-05-06-005
T5-6-161

15575-3 Abnormal Outrigger/Blade Sum Signal Outrigger/blade stroke 1 + outrigger/blade
Critical High Voltage stroke 2 is more than 9.0 V
High Voltage stroke 2 is more than 5.4 V and less than or
equal to 9.0 V
of electric lever
(blade/outrigger).
of connector by using
a clip or others.
Retry and Check if Disconnect connector C YES Shorted circuit in with
fault code disappears. of option controller. continuity.
between following
NO terminals (harness end)
of connector.
· Between terminal #C18 of NO
connector C and terminal
#3 of connector of electric
lever
· Between terminal #C28 of
connector C and terminal
#1 of connector of electric
lever

(Blade/Outrigger)
#C18
C1 C10
C23 C31
TCJB-05-06-005 #C28
T5-6-162

Critical Low Voltage stroke 2 is less than 0.5 V
15579-4 Abnormal Outrigger/Blade Sum Signal Low Outrigger/blade stroke 1 + outrigger/blade
Voltage stroke 2 is more than or equal to 0.5 V and
less than 4.6 V

electric lever
(blade/outrigger).
#1 (harness end) of
or others.
#3 (harness end) of Disconnect connector C
of option controller and YES Faulty option controller.
or others. connector of electric
Retry and check if fault lever (blade/outrigger).
code disappears. Check for continuity
NO between following
terminals (harness end)
of connector. Open circuit in without
NO continuity.
of connector C and
of electric lever
of connector C and
of electric lever

#C18
C1 C10
C23 C31
TCJB-05-06-005
#C28
T5-6-163

20300-2 Abnormal Positioning/Auxiliary Operation Abnormal positioning/auxiliary stroke 1, or
Signal Warning Abnormal positioning/auxiliary stroke 2, or
Abnormal sum of positioning/auxiliary 1 and 2
20301-2 Abnormal Outrigger/Blade Operation Abnormal outrigger/blade stroke 1 or
Signal Warning Abnormal outrigger/blade stroke 2 or
Abnormal sum of outrigger/blade 1 and 2
20302-2 Abnormal Warning on Abnormal assist stroke 1 or Abnormal assist
Assist Related Operation Signal stroke 2
20303-2 Electric Lever Pilot Some electric lever controls are abnormal in
Cut Warning monitoring neutral.
• If this fault code is displayed, all related fault

codes are displayed at the same time.
• Refer to all fault codes and check them.
T5-6-164
TROUBLEHOOTING / Troubleshooting A

15520-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Auxiliary 1 Proportional Valve than 60 mA
15520-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA
15520-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA
Switch connector of NO Faulty auxiliary solenoid

auxiliary solenoid valve 1 valve 1.
YES with connector of auxiliary
solenoid valve 2.
Check if fault code for
auxiliary solenoid valve 2 Faulty option controller.
is displayed. YES
Check for continuity of
harness between option
controller and auxiliary
solenoid valve 1.
of connector A of option
controller and terminal
#1 of connector of
auxiliary solenoid valve 1 NO
#2 of connector of
auxiliary solenoid valve 1

open end side)
Option Controller Connector A
#A19 #A22
T183-05-04-008
Auxiliary Solenoid Valve 1
T1V1-05-04-003
T5-6-165

Value of Auxiliary 2 Proportional Valve than 60 mA
Switch connector of NO Faulty auxiliary solenoid

auxiliary solenoid valve 2 valve 2.
YES with connector of auxiliary
solenoid valve 1.
auxiliary solenoid valve 1 Faulty option controller.
is displayed. YES
controller and auxiliary
solenoid valve 2.
controller and terminal #1
of connector of auxiliary
solenoid valve 2 NO
of connector of auxiliary
solenoid valve 2

open end side)
#A15 #A23
T183-05-04-008
Auxiliary Solenoid Valve 2
T1V1-05-04-003
T5-6-166

Value of Outrigger/Blade 1 Proportional than 60 mA
Valve
Switch connector of
NO Faulty blade/outrigger
blade/outrigger solenoid solenoid valve 1.
valve 1 with connector
YES of blade/outrigger
solenoid valve 2. Check
if the fault code for Faulty option controller.
blade/outrigger solenoid
valve 2 is displayed. YES
controller and
valve 1.
· Between terminal #A32 of
connector A of option Open circuit in harness.
of connector of NO
valve 1
connector A of option
of connector of
valve 1

open end side)
Option Controller Connector A Blade/Outrigger Solenoid Valve 1
#A7
T1V1-05-04-003
#A32
T183-05-04-008
T5-6-167

Value of Outrigger/Blade 2 Proportional than 60 mA
Valve
Switch connector of NO Faulty blade/outrigger

blade/outrigger solenoid solenoid valve 2.
valve 2 with connector of
YES blade/outrigger solenoid
valve 1.
Check if fault code for Faulty option controller.
blade/outrigger solenoid YES
Check for continuity of valve 1 is displayed.
controller and
valve 2.
connector A of option Open circuit in harness.
of connector of NO
valve 2
of connector of
valve 2

open end side)
Option Controller Connector A Blade/Outrigger Solenoid Valve 2
#A4
#A24 T1V1-05-04-003
T183-05-04-008
T5-6-168

Value of Swing Parking Release than 60 mA
Proportional Valve
Swing Parking Release Proportional Valve
Swing Parking Release Proportional Valve
Faulty swing parking

Switch connector of NO brake release solenoid
swing parking brake valve.
YES release solenoid valve
with connector of
valve 1. Faulty option controller.
Check for continuity of Check if fault code for YES
harness between option blade/outrigger solenoid
controller and swing valve 1 is displayed.
parking brake release
solenoid valve.
controller and terminal #1 Open circuit in harness.
of connector of swing NO
solenoid valve
of connector of swing
solenoid valve

open end side)
Option Controller Connector A Swing Parking Brake Release Solenoid Valve
#A17
T1V1-05-04-003
#A31 T183-05-04-008
T5-6-169

Value of Assist 1 Proportional Valve than 60 mA
Assist 1 Proportional Valve
Switch connector of assist NO Faulty assist solenoid

solenoid valve 1 with valve 1.
YES connector of assist
solenoid valve 2.
assist solenoid valve 2 is Faulty option controller.
displayed. YES
controller and assist
solenoid valve 1.
#1 of connector of Open circuit in harness.
assist solenoid valve 1 NO
#2 of connector of

open end side)
#A16
#A30 T183-05-04-008
Assist Solenoid Valve 1
T1V1-05-04-003
T5-6-170

Switch connector of assist NO Faulty assist solenoid

solenoid valve 2 with valve 2.
solenoid valve 1.
assist solenoid valve 1 is Faulty option controller.
displayed. YES
solenoid valve 2.
· Between terminal
#A21 of connector A of
option controller and
terminal #1 of
connector of assist NO
solenoid valve 2
of connector A of
terminal #2 of
connector of assist
solenoid valve 2

open end side)
#A5 #A21
T183-05-04-008
T1V1-05-04-003
T5-6-171

NO Faulty assist solenoid

Switch connector of assist valve 3.
solenoid valve 3 with
YES
connector of assist
solenoid valve 4.
assist solenoid valve 4 is YES
Check for continuity of displayed.
solenoid valve 3.
#1 of connector of Open circuit in harness.
assist solenoid valve 3 NO
#2 of connector of

open end side)
#A10
#A29 T183-05-04-008
T1V1-05-04-003
T5-6-172

NO Faulty assist solenoid

Switch connector of assist valve 4.
solenoid valve 4 with
solenoid valve 3.
assist solenoid valve 3 is YES
Check for continuity of displayed.
solenoid valve 4.
of connector A of
terminal #1 of Open circuit in harness.
connector of assist NO
solenoid valve 4
· Between terminal
#A14 of connector A of
terminal #2 of
connector of assist
solenoid valve 4

open end side)
#A14 #A8
#A29 T183-05-04-008
T1V1-05-04-003
T5-6-173

Value of Positioning 1 Proportional Valve than 60 mA
Positioning 1 Proportional Valve
Switch connector of NO Faulty positioning

positioning solenoid solenoid valve 1.
YES positioning solenoid
valve 2.
positioning solenoid YES
controller and
positioning solenoid
valve 1.
of connector of positioning NO
solenoid valve 1
of connector of positioning
solenoid valve 1

open end side)
#A6
#A11
T183-05-04-008
Positioning Solenoid Valve 1
T1V1-05-04-003
T5-6-174

Value of Positioning 2 Proportional Valve than 60 mA
Switch connector of NO Faulty positioning

positioning solenoid solenoid valve 2.
YES positioning solenoid
valve 1.
positioning solenoid YES
controller and
positioning solenoid
valve 2.
of connector of positioning NO
solenoid valve 2
of connector of positioning
solenoid valve 2

open end side)
#A3 #A9
T183-05-04-008
Positioning Solenoid Valve 2
T1V1-05-04-003
T5-6-175

15565-2 Unreceived Work Mode Unreceived for 2000 ms
Sent from: MC
15566-2 Unreceived ATT 1 and 2 Optional Selection Unreceived for 10 sec
Sent from: MC
15567-2 Unreceived ATT 3 and 4 Optional Selection Unreceived for 10 sec

Sent from: MC
15568-2 Unreceived ATT 5 Optional Selection Unreceived for 10 sec

Sent from: MC
15577-2 Unreceived Actual Engine Speed Unreceived for 10 sec

Sent from: ECM
NOTE: If fault codes 15565 to 15577 are displayed,

the CAN harness between MC and source
controller may be faulty.
Refer to CAN Harness Check o T5-6-73 to
104 and check the CAN harness.
T5-6-176
STEERING COLUMN MONITOR FAULT CODE 16000

16000-2 Abnormal CAN Communication Faulty steering column monitor
Faulty CAN harness
NOTE: If fault code 16000-2 is displayed, the CAN

harness between MC and source controller
may be faulty.
T5-6-177
(Blank)
T5-6-178
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code

is displayed on the service menu (built-in diagnosing
system) in monitor unit and the diagnosing by Dr. ZX
although the machine operation is abnormal. When
the fault code is displayed, refer to the troubleshooting
A group and diagnose.
On the front section pages of this group are the tables
indicating the relationship between machine trouble
symptoms and related parts which may cause such
trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tablesHow to Read the
Troubleshooting Flow Charts
• How to read troubleshooting flowchart

YES (OK)
(2)
• After checking or measuring item (1), select either YES (OK)
・ (1) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
・ Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
· Key switch: ON
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 8) in this section.
・ • Use the service menu (built-in diagnosing system) in the monitor unit or the
diagnosing system / monitor function in Dr. ZX.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
NOTE: For all connector shown in this group,

harness end connector viewed from the
open end side are shown
Harness
Harness End
Connector
Open End Side T6L4-05-03-001
T5-7-1
RELATIONSHIP BETWEEN MACHINE .
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts Pump 1 Delivery
Item Engine Control Dial Pump Control Pressure Sensor
Pressure Sensor
• Instructs engine target • Monitors pump control pressure • Monitors pump
speed. in order to control E mode control. delivery pressure in
order to control HP
mode, auto-power lift
Function and travel accelera-
tion controls.
• As below • No signals arrive to MC. • If pump delivery

pressure sensor
Symptoms in control output is 0 or 5 V, fol-
system when trouble lowing symptoms will
be presented by
occurs. back-up mode func-
tion.
• Trouble when starting • Although operating lever at E • HP mode is
engine: Engine speed is kept mode, engine speed does not reach inoperable.
at slow idle speed. (Engine P speed. • Boom raise
can top by key switch.) power is weak during
• Trouble when running digging operation.
engine: • During com-
Engine speed is kept at bined operation of
speed just before trouble. arm roll-in and swing,
arm speed is slow.
Symptoms in machine
operation when trouble
occurs.
By Fault Code 11101 11206, 11208 11200

Monitor Item: Requested Engine Monitor Item: Pump 1 Flow Control Monitor Item: Pump 1
Speed, EC Dial Angle (Possible Pressure, Pump 2 Flow Control Pres- Delivery Pressure (Pos-
By Monitor to display by built-in diagnosing sure (Possible to display by built-in di- sible to display by
Evalua- Function system) agnosing system) built-in diagnosing sys-
tem)
tion
By Using Test
- - -
Harness
Others - - -
• Evaluation by Dr. ZX • Possible to
• 0.25 or less: open circuit in judge if sensor is
harness malfunction or har-
NOTE - • 4.75 or more: shorted circuit in ness is faulty by
harness switching pump 2
and 3 sensors.
Descriptions of Control T2-2 T2-2 T2-2
(Operational Principle
Section in T/M)
T5-7-2
Pump 2 Delivery Steering Pump Delivery Pressure Sensor Pressure Sensor

Pressure Sensor Pressure Sensor (Travel Forward) (Travel Reverse)
• Monitors pump delivery • Monitors pump delivery • Monitors travel for- • Monitors travel for-
pressure in order to control HP pressure in order to control ward pilot pressure in or- ward pilot pressure in or-
mode, and arm regenerative steering pump torque decrease der to control auto-idle, der to control auto-idle,
controls. control. idle speed-up, travel idle speed-up, travel
acceleration, speed acceleration, speed
sensing, forward/reverse sensing, forward/reverse
selection controls. selection controls.
• If pump delivery pressure • As below • No signals arrive to • No signals arrive to
sensor output is 0 or 5 V, fol- MC. MC.
lowing symptoms will be pre-
sented by back-up mode func-
tion.
• HP mode is inoperable. • Engine stalls if pump torque • Although accelerator • Although accelerator
• During combined opera- is increased. pedal is fully depressed pedal is fully depressed
tion of arm roll-in and swing, and machine travels for- and machine travels re-
arm speed is slow. ward, engine speed does verse, engine speed does
not increase. not increase.
• Although machine • Although machine
travels forward with travels reverse with
auto-idle switch ON, en- auto-idle switch ON, en-
gine speed does not in- gine speed does not in-
crease. crease.
• Although operating • Although operating
pedal with engine speed pedal with engine speed
control mode selection control mode selection
switch in pedal position, switch in pedal position,
engine speed does not in- engine speed does not in-
crease. crease.
• When machine trav- • When machine trav-
els at slow idle speed, en- els at slow idle speed, en-
gine may hunt. gine may hunt.
• Although machine • Although machine
travels forward at slow travels reverse at slow
idle, engine speed does idle, engine speed does
not increase. not increase.
11202 11203 11305 11306
Monitor Item: Pump 2 Delivery Monitor Item: Pump 3 Delivery Monitor Item: Travel Forward Monitor Item: Travel Reverse
Pressure (Possible to display by Pressure Pilot Pressure (Possible to Pilot Pressure (Possible to
built-in diagnosing system) display built-in diagnosing display built-in diagnosing
system). system).
Monitor pressure change Monitor pressure change
while traveling forward. while traveling reverse.
- - - -
- - - -
• Possible to judge if sen- • Possible to judge if sensor • Possible to judge if • Possible to judge if
sor is malfunction or harness is is malfunction or harness is faulty pressure sensor is faulty or pressure sensor is faulty or
faulty by switching pump 1 and by switching pump 1 and 2 sen- port is clogged by switch- port is clogged by switch-
3 sensors. sors. ing pressure sensor with ing pressure sensor with
another pressure sensor. another pressure sensor.
T2-2 T2-2 T2-2 T2-2
T5-7-3
Parts Pressure Sensor Pressure Sensor

Item Pressure Sensor (Swing)
(Front Attachment) (Boom Raise)
• Monitors front attachment • Monitors swing pilot pressure • Monitors boom raise pilot
pilot pressure in order to in order to control arm re- pressure in order to control
control auto-idle, idle generative control. HP mode, arm regenerative
speed-up and parking brake and auto power lift controls.
Function alarm controls.
• When pressure sensor (front • No signals arrive to MC. • No signals arrive to MC.
attachment) or harness be-
Symptoms in control tween pressure sensor and
system when trouble MC is faulty, MC judges that
pressure sensor (front at-
occurs. tachment) is ON.
• Although any front attach- • During arm level crowding • Although boom is raised at
ment is operated with operation, arm speed is HP mode, engine speed
auto-idle switch is ON, en- slightly slow. does not increase.
gine speed does not in- • Arm speed becomes slightly
crease. slower than normal in boom
• When front attachment is raise and arm roll-in opera-
operated at slow idle speed, tion as arm regenerative
engine may hunt. control does not work. (Not
• When parking brake is ap- remarkable)
Symptoms in machine plied and when front at- • Arm roll-in and boom raise
operation when trouble tachment is operated, buzzer speeds become slightly
occurs. does not sound. slower at the beginning
stage of arm level crowding
operation.
• Boom raise power is weak.
(Not remarkable)
By Fault Code 11307 11301 11302

Monitor Item: Front Pilot Pres- Monitor Item: Swing Pilot Monitor Item: Boom Raise Pilot
sure (Possible to display built-in Pressure (Possible to display Pressure (Possible to display
diagnosing system). built-in diagnosing system) built-in diagnostic system).
By Monitor Monitor pressure change while Monitor pressure change while Monitor pressure change while
Function operating front attachment. swinging upper-structure. operating front attachment.
Evalua-
tion
By Using Test
Harness - - -
Others - - -
• Possible to judge if pressure • Possible to judge if pressure • Possible to judge if pressure
sensor is faulty or port is sensor is faulty or port is sensor is faulty or port is
NOTE clogged by switching pres- clogged by switching pres- clogged by switching pres-
sure sensor with another sure sensor with another sure sensor with another
pressure sensor. pressure sensor. pressure sensor.

(Operational Principle Sec-
tion in T/M)
T5-7-4
Pressure Sensor Pressure Sensor Pressure Sensor

(Arm Roll-In) (Auxiliary) (Optional) (Positioning) (Optional)
• Monitors arm roll-in pilot • Monitors attachment pilot • Monitors attachment pilot • Monitors bake operating
pressure in order to control pressure when attachment is pressure when attachment is pressure in order to control
HP mode, arm regenerative installed in order to control installed in order to control work brake.
and auto power lift controls. attachment operation speed positioning and assist con-
increase, pump 1 and pump trols
2 flow rate limit and auxiliary
flow rate controls.
• No signals arrive to MC. • No signals arrive to MC and • No signals arrive to option • No signals arrive to MC.
option controller. Electric controller. Electric lever pilot
lever pilot cut-off control is cut-off control is done by op-
done by option controller. tion controller.
• Although arm is • When attachment is • When positioning or • Work brake is inoper-

rolled-in at HP mode, en- operated, engine speed does assist is operated, engine able.
gine speed does not in- not increase. speed does not increase.
crease. • When attachment is • When attachment is
• Arm speed is slow in operated, operation speed operated, operation speed
arm level crowding opera- decreases. decreases.
tion. • All operations are inop- • All operations are inop-
erable except travel opera- erable except travel opera-
tion. tion.
• Electric Lever Solenoid • Electric Lever Solenoid
Valve Output Warning is dis- Valve Output Warning is dis-
played on monitor unit. played on monitor unit.
• Buzzer sounds con- • Buzzer sounds con-
tinuously. tinuously.
11303 11517 11516 11310

Monitor Item: Arm Roll-In Pilot Monitor Item: ATT Control Pilot Monitor Item: Posn/Assist Pilot Monitor Item: Brake Pressure
Pressure (Possible to dis- Pressure (Possible to display Monitor Pressure (Possible to (Possible to display built-in di-
played built-in diagnosing built-in diagnosing system). display built-in diagnosing sys- agnosing system)
system). Monitor pressure change while tem) Monitor pressure change while
Monitor pressure change while operating attachment. Monitor pressure change while depressing brake pedal.
rolling arm in. operating attachment.
- - - -
- - - -
• Possible to judge if • Possible to judge if • Possible to judge if • Possible to judge if
pressure sensor is faulty or pressure sensor is faulty or pressure sensor is faulty or pressure sensor is faulty or
port is clogged by switching port is clogged by switching port is clogged by switching port is clogged by switching
pressure sensor with an- pressure sensor with another pressure sensor with another brake pressure sensor with
other pressure sensor. pressure sensor. pressure sensor. pump 1, 2, 3 delivery pres-
sure sensors.
T2-2 T2-2 T2-2 T2-2
T5-7-5
Parts Brake Remaining Boom Bottom

Item Pressure Sensor Solenoid Valve Unit (SF)
Pressure Sensor
• Monitors accumulated • Monitors Boom cylinder • Shifts bake valve by pilot
pressure of accumulator for bottom pressure in order to pressure in order to control
brake in order to control control (overload alarm con- work brake control.
travel motor selection control. trol (optional).
Function
• No signals arrive to MC. • No Signal arrive to MC. • Ifsolenoid valve unit (SF) is
not activated, pressure at
Symptoms in control port SE becomes 0 MPa (0
system when trouble kgf/cm2).
occurs.
• Parking brake cannot be re- • Condition is always overload. Abnormal low current:
leased. • Overload alarm is displayed • Work brake does not operate.
• Travel speed is turned to on monitor unit.
fast/slow speed. • Overload alarm sounds. Abnormal high current:
• Work brake is kept applied.
• Machine cannot travel.
Symptoms in machine
occurs.
By Fault Code 11311 11425 -

Monitor Item: Brake Remain Monitor Item: Implement Brake Monitor Item: Boom Bottom
By Monitor Pressure P/S/V Output Pressure
Function
Evalua-
tion • Install lamp harness (ST
By Using Test 7226). Check output signals
- from MC and harness condi- -
Harness tion.
Others - - -
• Possible to judge if
pressure sensor is faulty or
port is clogged by switching
NOTE brake pressure sensor with
- -
pump 1, 2, 3 delivery pres-
sure sensors.
T2-2 T2-2 T2-2
Descriptions of Control
Section in T/M)
T5-7-6
Max. Pump 1 Flow Rate Max. Pump 2 Flow Rate

Solenoid Valve Unit (SC) Solenoid Valve Unit (SI) Limit Control Solenoid Valve Limit Control Solenoid
• Routes return oil from arm cylin- • Is shifted when axle lock or • When machine is traveling • Limits maximum
V l flow rate
der rod side to bottom side when auto axle lock is selected by in travel creeper mode, or of pump 2 when operating
rolling arm in order to increase brake switch. Shifts operat- when attachment and front front attachment.
arm speed. ing check valve of axle lock attachment are operated,
cylinder in order to control maximum flow rate of pump
auto axle lock control. 1 is restricted in order to
control pump 1 flow rate
limit control in travel creeper
speed mode, pump 1 flow
rate limit and attachment
flow rate limit control.
• If solenoid valve unit (SC) is not • If solenoid valve unit (SI) is · If max. pump 1 flow rate limit • If max. pump 2 flow rate
activated, pressure at port SC not activated, pressure at control solenoid valve is not limit control solenoid valve
becomes 0 MPa (0 kgf/cm2). Arm port SI becomes 0 MPa (0 activated, pressure at output is not activated, pressure at
regenerative control will not op- kgf/cm2). port becomes 0 MPa (0 output port becomes 0 MPa
erate at this time. kgf/cm2). (0 kgf/cm2).
Abnormal low current: Abnormal low current: Abnormal low current: Abnormal low current:
• All operation speeds become • Axle lock is not released. • When attachment, front at- • When front and front at-
slow. tachment and superfine tachment are operated, op-
Abnormal high current: travel are operated, operat- erating speed becomes
Abnormal high current: • Axle lock is kept in released ing speed becomes fast. fast.
• Arm speed becomes fast as arm condition.
regenerative control is always • Condition when front at- Abnormal high current: Abnormal high current:
operated. tachment is operated is un- • Travel, bucket, arm and • Arm, boom and swing
stable. boom speeds become slow speeds become slow as
as maximum flow rate of maximum flow rate of pump
pump 1 decreases. 2 decreases.
11403 11424 11410 11400

Monitor Item: Arm Regenerative P/S Monitor Item: Axle Lock Output Monitor Item: Pump 1 Flow Monitor Item: Pump 2 Flow
Valve Output (Possible to display by Rate Limit P/S/V Out Rate Limit P/S/V Out
built-in diagnosing system)
• Install
lamp harness (ST 7226). • Install lamp harness (ST
Check output signals from MC 7226). Check output signals
and harness condition. from MC and harness con- - -
dition.
- - - -
- - - -
T2-2 T2-2 T2-2 T2-2
T5-7-7
Parts Torque Control Pilot Shut-Off

Solenoid Valve Auxiliary Solenoid Valve
Item Solenoid Valve
• Supplies control pressure to • Opens and closes pilot cir- • Is operated by signal from
pumps 1 and 2 in order to do cuit. option controller and sup-
speed sensing control. plies pressure oil from pilot
Function pump to control valve spool
in order to control auxiliary
control.
• If torque control solenoid • As below • When trouble occurs, sole-

valve is not activated, output noid valve output is 0 by
pressure of solenoid valve is electric lever pilot cut-off
Symptoms in control sys- 0 MPa (0 kgf/cm2). control. When operating
tem when trouble occurs. auxiliary, operating speed
becomes slow.
Abnormal low current: Solenoid valve is closed: Abnormal low current:

• All operation speeds become • All actuators are not oper- • When operating auxiliary,
slow. ated. (Pilot pressure oil is operating speed becomes
not supplied to pilot value.) slow.
Abnormal high current:
• Engine may stall while travel- Solenoid valve is open: Abnormal high current:
ing at slow idle speed. • Pilotpressure oil is always • All operations are inoper-
supplied to pilot value. able except travel operation.
• Alarm is displayed on
Symptoms in machine op- monitor unit and buzzer
eration when trouble oc- sounds.
curs.
By Fault Code 11401 15520, 15521 -

Monitor Item: Pump Torque P/S Monitor Item: Posn/Aux 1, 2
Valve Output (Possible to display Operation, Aux 1, 2 P/S/V
by built-in diagnosing system) (Possible to display by built-in
diagnosing system)
By Monitor Monitor voltage and pressure -
Evalua- Function changes while operating lever.
tion
By Using Test
- - -
Harness
Others - - -
NOTE - - -

Section in T/M)
T5-7-8
Blade/Outrigger Swing Parking Brake

Positioning Solenoid Valve Assist Solenoid Valve Release Solenoid Valve
Solenoid Valve
• Is operated by signal from option • Is operated by signal from • Is operated by signal from • Is operated by signal from
controller and supplies pressure option controller and sup- option controller and sup- option controller and sup-
oil from pilot pump to control plies pressure oil from pilot plies pressure oil from pilot plies pressure oil from pilot
valve spool in order to control pump to control valve spool pump to control valve spool pump to control valve spool
positioning control. in order to control in order to control assist in order to control position-
blade/outrigger control. control. ing and assist controls.
• When trouble occurs, solenoid • When trouble occurs, sole- • When trouble occurs, sole- • When trouble occurs, sole-
valve output is turned OFF by noid valve output is turned noid valve output is turned noid valve output is turned
electric lever pilot cut-off control. OFF by electric lever pilot OFF by electric lever pilot OFF by electric lever pilot
When operating positioning, op- cut-off control. When op- cut-off control. When op- cut-off control.
erating speed becomes slow. erating blade/outrigger, operating assist, operating
erating speed becomes speed becomes slow.
slow.
Abnormal low current: Abnormal low current: Abnormal low current: • All operations are inoper-
• When operating positioning, op- • When operating • When operating assist, op- able except travel opera-
erating speed becomes slow. blade/outrigger, operating erating speed becomes tion.
speed becomes slow. slow. • Alarm is displayed on
Abnormal high current: monitor unit and buzzer
• All operations are inoperable Abnormal high current: Abnormal high current: sounds.
except travel operation. • All operations are inoper- • All operations are inoper-
• Alarm is displayed on monitor able except travel opera- able except travel opera-
unit and buzzer sounds. tion. tion.
• Alarm is displayed on • Alarm is displayed on
monitor unit and buzzer monitor unit and buzzer
sounds. sounds.
15529, 15530 15522, 15523 15525, 15526 15524

Monitor Item: Posn/Aux 1, 2 Opera- Monitor Item: Outrigger/Blade Monitor Item: Assist 1, 2 Op- Monitor Item: Swing Parking
tion, Positioning 1, 2 P/S/V (Possi- 1, 2 Operation, Blade 1, eration, Assist 1, 2 P/S/V Release
ble to display by built-in diagnosing 2/Outrigger 1, 2 P/S/V (Possi- (Possible to display by built-in Monitor voltage and pressure
system) ble to display by built-in diag- diagnosing system) change while operating lever.
Monitor voltage and pressure nosing system) Monitor voltage and pressure
changes while operating lever. Monitor voltage and pressure changes while operating lever.
changes while operating lever.
- - - -
- - - -
- - - -
T2-2 T2-2 T2-2 T2-2
T5-7-9
Parts Auxiliary Flow Rate Control Auxiliary Flow Combiner Selector Valve Control
Item Solenoid Valve (Optional) Solenoid Valve (Optional) Solenoid Valve (Optional)
• Restricts flow rate to auxiliary • Activates during auxiliary op- • Activates when attachment
spool during combined operation and shifts spool in “selector valve returning to
eration and improves oper- auxiliary flow combining hydraulic oil tank” is selected
ability. valve. and shifts selector valve
spool.
Function
• Ifauxiliary flow rate control • If auxiliary flow combiner so- • If selector valve control so-
solenoid valve is not acti- lenoid valve is not activated, lenoid valve is not activated,
Symptoms in control vated, pressure at output port pressure at output port be- pressure at output port be-
system when trouble becomes 0 MPa (0 kgf/cm2). comes 0 MPa (0 kgf/cm2) comes 0 MPa (0 kgf/cm2)
when operating attachment. when attachment “selector
occurs. valve returning to hydraulic
oil tank” is selected.
Abnormal low current: • Speed does not increase • Breaker stroke becomes few.
• If valve is bound fully open, during single operation of at-
boom does not raise during tachment.
3-combined operation of
boom raise.
Abnormal high current:
• If valve is bound fully closed,
attachment speed becomes
slow during single operation.
Symptoms in machine
occurs.
By Fault Code - - -
By Monitor
- - -
Evalua- Function
tion Using Test
- - -
Harness
Others - - -
When pedal is depressed,
pressure in the right piping hose
NOTE - - occurs.

Section in T/M)
T5-7-10
Secondary Pilot Relief Pressure Hydraulic Oil Travel Speed

Travel N Sensor
Control Solenoid Valve (Optional) Temperature Sensor Mode Switch
• Activates when attachment • Detects travel motor speed • Monitors hydraulic oil tem- • Shifts fast/slow speed selec-
“secondary pilot relief pres- and sends a signal to speed perature in order to control tion solenoid valve by shifting
sure ON” is selected and display meter. auto-warming up and arm travel speed mode switch
shifts secondary pilot relief • Travel motor speed is de- regenerative controls. (Fast/Slow) in order to control
pressure control valve spool. tected to activate the super- travel speed mode selection
fine travel speed, to prevent control.
travel motor from excessive
rotation, and/or to restrict
forward/reverse shifting.
• If secondary pilot relief pres- • Speed display meter does not • If circuit breakage occurs, • When open or shorted circuit
sure control solenoid valve is operate. system operates as if hydrau- occurs in switch, fast/slow
not activated, pressure at • Travel speed, travel motor lic oil temperature is 120 °C speed selection solenoid
output port becomes 0 MPa excessive rotation, and/or the (Dr. ZX or monitor will not in- valve is held in either fast or
(0 kgf/cm2) when attachment forward/reverse shifting re- dicate 120 °C in diagnosis slow position.
“secondary pilot relief pres- striction control is inoperable. operation).
sure ON” is selected.
• Relief set pressure in auxiliary • Speed display meter does not • Although oil temperature is • Although travel speed mode
circuit does not decrease. operate. lower than 0 °C, switch is in fast position,
• When descending a slope, auto-warming up control does travel speed dose not change
engine speed is not reduced. not operate so that engine into Fast.
runs at idle speed when en- • Although travel speed mode
gine is started. switch is in slow position,
• When hydraulic oil tempera- travel speed dose not change
ture is lower than 10 °C, arm into Slow.
regenerative control is inop-
erable.
- - 11901 -
Monitor Item: Vehicle Speed Monitor Item: Hydraulic Oil Monitor Item: Transmission H/L
(Possible to display by built-in Temperature (HOT) SW
-
diagnosing system) (Possible to display by built-in
diagnosing system)
- - - -
- - - -
• If temperature is extremely
low (below -20°C), control
- - system is in-operable. -
T2-2 T2-2 T2-2 T2-2
T5-7-11
Parts Engine Speed Control

Item FNR Switch Brake Switch
• Shifts travel forward/reverse • Shifts engine speed control • Shifts parking brake, axle
Pi cut-off solenoid valve by mode by operating switch in lock, auto axle lock and
shifting FNR switch in order order to control engine con- OFF operating brake switch.
to control travel for- trol dial, accelerator pedal
Function ward/reverse selection limit and travel creeper speed
and travel pilot pressure controls.
controls.
• When open or shorted cir- • Depending on failure of • Depending on failure of
cuit occurs in switch, FNR switch, engine control mode switch, brake mode is held
Symptoms in control switch is held in N position. is held. (Engine control dial, (parking brake, axle lock,
system when trouble pedal and creeper modes) auto axle lock and OFF)
occurs.
• Although FNR switch is in N • Although engine speed • Although parking brake po-
position, indicator (N) on control mode selection sition is selected, the park-
steering column monitor switch is turned to pedal ing brake is not operable.
does not light. mode, engine speed cannot • Although axle lock position
• Although FNR switch is in F be controlled by accelerator is selected, axle cylinder is
or R position, machine does pedal. not locked.
not travel. • Although engine speed • Although machine travels in
• Although FNR switch is in R control mode selection auto axle lock position, axle
position, back light does not switch is turned to creeper lock cylinder is not released.
Symptoms in machine light. mode, travel creeper speed • Although OFF position is
operation when trouble mode is not operable. selected, either parking
brake or axle lock is oper-
occurs. able.
By Fault Code - - -
Monitor Item: Slight Travel SW, Monitor Item: Parking Brake Monitor Item: Transmission
By Monitor Pedal EC SW SW, Axle Lock Control State H/L SW
Evalua- Function
tion
By Using Test
- - -
Harness
Others - - -
NOTE - - -
T2-2 T2-2 T2-2

Section in T/M)
T5-7-12
Power Mode Switch Power Mode Switch

MC Auto-Idle Switch
(HP Mode) (E Mode)
• Controls engine, pump and • Activates auto-idle control. • Activates HP mode. • Selects E mode.
valve operation. ON: 0 V → Auto-idle is operable. ON: 0 V → HP mode control ON: 0 V → E mode
OFF: 5 V → Inoperable. OFF: 5 V → Normal OFF: 5 V → Normal
• Depending on trouble situa- • As below • As below • As below

tions, control system mal-
function may differ. (The fol-
lowing symptoms in machine
operation indicates that MC
logic circuit has failed.)
• Although engine starts, speed Open circuit: Open circuit: Open circuit:
stays slow. • Auto-idle is inoperable. • Although HP mode is se- • Even if E mode is selected,
• As pump displacement is held Shorted circuit: lected, HP mode is inoper- engine speed doesn’t de-
at minimum, all actuator • Although auto-idle switch is able. crease.
speeds are slow. OFF, auto-idle control is al- Shorted Circuit: Shorted Circuit:
ways done. • Although HP mode switch is • Engine speed does not in-
turned OFF, HP mode is not crease to the maximum.
deactivated. Attachment Auto-idle control is inoper-
speed increase control (op- able.
tional) becomes inoperable.
11000, 11001, 11002. Other fault

codes may be displayed. - - -
Monitor Item: Auto-Idle SW Monitor Item: HP Mode SW Monitor Item: E/P SW
-
- - - -
- - - -
• Before suspecting a failure in
MC, be sure to check fuses in
control system. If any sensor - - -
in 5 V system is shorted, fault
code11003 will be displayed.
T2-1 T2-2 T2-2 T2-2
T5-7-13
Parts Work Brake Release Outrigger Selection Pilot Shout-Off

Item Switch Switch
• Release work brake and • Shifts blade/outrigger main • Activates pilot shut-off sole-
makes machine travel in order relay 1 and pilot shut-off so- noid valve.(Turns pilot shut-off
to control work brake control. lenoid valve by shifting switch relay ON.)
Function in order to control ON: Pump control (positive con-
blade/outrigger, pilot cut-off trol) of pumps 1, 2 is activated.
controls. OFF: Minimum pump flow rate
• No signals arrive to MC. • Depending on failure of • As below

switch, each mode (OFF, pilot
Symptoms in control cut-off, ON) is held.
system when trouble
occurs.
• Although brake pedal is de- • When outrigger selection Open circuit:

pressed during work brake switch is turned to OFF or pi- • Pilot shout-off switch is al-
operation, work brake is not lot cut-off position, and when ways OFF.
released. lever is operated, • Pilot shut-off solenoid valve is
blade/outrigger is activated. not shifted.
• When outrigger selection • Although lever is operated
switch is turned to pilot cut-off with pilot shut-off lever in
position, and when lever is UNLOCK position, all actuator
operated, front attachment or are not operated.
Symptoms in machine blade/outrigger is activated. Short Circuit:
operation when trouble • When outrigger selection • Pilot shout-off switch is al-
switch is turned to ON posi- ways ON.
occurs. tion, blade/outrigger is not ac- • Engine does not start.
tivated. • If shorted circuit occurs while
starting engine, operate lever
with pilot shut-off lever in
LOCK position so actuator is
operated.
By Fault
- - -
Code
By Monitor Monitor Item: Electric Lever Pilot Monitor Item: Gate Lock Signal Monitor Item: E/P SW
Evalua- Cut
tion Function
Using Test - - -
Harness
Others - - -
NOTE - - -
T2-2 T2-2 T2-5

Section in T/M)
T5-7-14
Bucket Flow Rate Boom Flow Rate Auxiliary Flow Rate

Control Valve Control Valve Boom Regenerative Valve
Control Valve
• Restricts oil flow raise to • Is shifted by pilot pressure • Is shifted by pilot pressure • Prevents boom cylinder hesi-
bucket during 3-combined from boom lower meter-in cut from auxiliary flow rate con- tation by routing return oil
operation of bucket, arm valve. trol solenoid valve. from boom cylinder bottom
roll-in and boom raise and • Limits flow rate to boom 1 side to rod side.
makes boom raise. spool during combined
operation and improves
combined operation.
• If switch valve is bound with • As below • If spool is bound or spring is • As below
valve activated, bucket circuit broken, orifice does not
is always restricted. change.
• If poppet valve is bound at • If valve is fully opened, boom • If valve is bound at fully • If check valve is kept closed,
fully closed position or if lower speed is fast during closed position, attachment boom is not smoothly low-
switch valve is bound when combined operation. speed becomes slow. ered.
poppet valve is fully closed, • If valve is fully closed, • If valve is bound at fully • If check valve is kept open,
bucket speed becomes slow. machine cannot be raised off opened position, boom does machine cannot be raised off
• If poppet valve is bound at ground. not raise during 3-combined ground.
fully opened position or if operation of swing, arm roll-in
switch valve is bound when and boom raise.
poppet valve is fully opened,
boom does not raise during
3-combined operation of
bucket, arm roll-in and boom
raise.
- - - -
- - - -
- - - -
- - - -
- - - -
T3-3 T3-3 T3-3 T3-3
T5-7-15
Parts Bucket Regenerative

Arm Regenerative Valve Arm Anti-Drift Valve
Item Valve
• Is shifted by pilot pressure • Prevents bucket cylinder • Check valve in arm roll-in re-
from solenoid valve unit (SC). hesitation by routing return oil turn circuit is forcibly opened
• Increases arm speed by from bucket cylinder rod side and arm move only when arm
routing return oil from arm to bottom side. is rolled in. Prevents arm from
Function cylinder rod side to bottom drifting due to oil leaks in
side. control valve.
• Arm regenerative function is • As below • If switch valve is bound,

inoperable. check valve does not open.
Symptoms in control
system when trouble
occurs.
• Arm speed is extremely slow • If check valve is kept closed, • If check valve is kept closed,
during arm level crowding bucket is not smoothly rolled arm roll-in speed becomes
operation while arm regen- in. slow.
erative valve is kept closed. • If check valve is kept open, • If check valve is kept open,
• The lever operated first is bucket power is weak. front attachment drift in-
given priority during com- creases due to oil leaks in
bined operation of arm roll-in control valve.
and swing while arm regen- • Arm moves jerky or arm
erative valve is kept open. speed becomes slow de-
Symptoms in machine pending on valve bound con-
operation when trouble ditions.
occurs.
By Fault
- - -
Code
Evalua- By Monitor - - -
tion Function
Using Test - - -
Harness
Others - - -
NOTE - - -
T3-3 T3-3 T3-3

Section in T/M)
T5-7-16
Auxiliary Flow Pump 1 Flow Rate

Boom Anti-Drift Valve Combiner Valve Bypass Shut-Out Valve Control Valve
• Check valve in boom lower • Is shifted by pilot pressure from • Supplies pressure oil from • Supplies flow rate control
return circuit is forcibly auxiliary flow combiner pump 1 to auxiliary spool pressure Pi to pump 1 regulator
opened and makes boom solenoid valve when and positioning control in response to lever stroke
move only when boom is attachment mode (secondary valve when auxiliary or po- when boom (raise/lower), arm
lowered. Prevents boom pulverizer, hydraulic crusher) of sitioning is operated. (roll-out/in), bucket (roll-out/in),
from drifting due to oil leaks travel speed “ON” is selected. travel, auxiliary or positioning is
in control valve. • Supplies pressure oil from operated.
pump 1 to auxiliary spool.
• If switch valve is bound, • As below • As below • As below
check valve does not open.
• If check valve is kept closed, • If switch valve is kept closed, • If spool is bound at fully • If spool is bound in fully open
boom does not lower. attachment speed does not open position, single at- position, although control lever
• If check valve is kept open, become fast during single tachment operation speed is in neutral, pump 1 swash
front attachment drift in- auxiliary operation. becomes slow. angle is tilted to maximum.
creases due to oil leaks in • If switch valve is kept open, • If spool is bound at fully • If spool is bound in fully open
control valve. attachment speed does not closed position, main relief position, pump 1 control pres-
• Boom moves jerky or arm become slow when attachment valve continues to relieve sure sensor monitors maximum
speed becomes slow de- mode (HSB breaker, NPK with all control levers posi- pressure.
pending on valve bound breaker) of travel speed “OFF” tioned in neutral. • If spool is bound in fully closed
conditions. is selected. • When all control levers are position, although control lever
in neutral, pump 1 pressure is operated, pump 1 swash
is higher than pump 2 pres- angle is held to minimum.
sure according to bound (Bucket speed is very slow.)
spool conditions. • If spool is bound in fully open
position, pump 1 control pres-
sure sensor can not monitor
the pump control pressure.
- - - -
- - - -
- - - -
- - - -
- - - -
T3-3 T3-3 T3-3 T3-9
T5-7-17
Parts Pump 2 Flow Rate Swing Parking Brake Bucket Flow Rate Control
Item Control Valve Release Spool Valve Control Spool
• Supplies flow rate control • Is shifted by boom, arm, • Is shifted by arm roll-in pilot
pressure Pi to pump 2 regula- bucket, swing, auxiliary or pressure. Supplies boom raise
tor in response to lever stroke blade/outrigger pilot pressure. pilot pressure to bucket flow
Function when boom (raise), arm Supplies swing parking brake rate control valve.
(roll-out/in), swing (right/left), release pressure.
auxiliary or blade/outrigger is
operated.
• As below • As below • As below
Symptoms in control sys-
tem when trouble
occurs.
• If spool is bound in fully open • If spool is bound in fully open • If spool is bound in fully open
position, although control lever position, swing parking brake is position, bucket speed
is in neutral, pump 2 swash kept released. (Machine becomes slow when combined
angle is tilted to maximum. vibrates while traveling.) operation of boom raise and
• If spool is bound in fully open • If spool is bound in fully open bucket is made. (Bucket flow
position, pump 2 control position, pressure sensor (front rate control is inoperable.)
pressure sensor monitors attachment) is always ON. • If spool is bound in fully closed
maximum pressure. Thus, engine speed does not position, boom does not raise
• If spool is bound in fully closed decrease when control lever is during 3-combined operation of
Symptoms in machine position, although control lever in neutral during auto-idle bucket, arm roll-in and boom
operation when trouble is operated, pump 2 swash control. raise.
occurs. angle is held to minimum. • If spool is bound in fully closed
(Swing speed is very slow.) position, swing parking brake is
• If spool is bound in fully open kept applied. (Dragging is felt.)
position, pump 2 control pres- • If spool is bound in fully closed
sure sensor can not monitor position, pressure sensor (front
pump control pressure. attachment) is always OFF.
Thus, engine speed does not
increase when control lever is
operated during auto-idle con-
trol.
By Fault
- - -
Code
Evalua- By Monitor - - -
tion Function
By Using Test - - -
Harness
Others - - -
NOTE - - -
T3-9 T3-9 T3-9

Section in T/M)
T5-7-18
Accumulator Transmission Control

Steering Valve Brake Valve
Charging Valve Solenoid Valve
• Supplies pressure oil from • Supplies pressure oil to • Charges pressure oil into • Shifts parking brake and
steering pump to steering front/rear axle brakes in accumulator provided in fast/slow in transmission.
cylinder in proportion to proportion to brake pedal brake circuit. Holds charged
steering wheel rotation. depression. pressure oil for set period of
time.
• Pressure oil is not supplied to • As below • Pressure oil is not charged • As below
steering cylinder in proportion into accumulator.
to steering wheel rotation. • Brake circuit oil pressure
However, steering valve acts stays low.
as a pump, steering cylinder
can be operated.
• Turning force of steering • Although brake pedal is • Service brake is not operable. • If fast/slow speed selection
wheel increases. depressed, brake is not • Service brake does not work solenoid valve is bound in
applied. effectively. neutral, parking brake is kept
• Although brake pedal is not applied although shift switch
operated, brake is applied. is operated.
• If fast/slow speed selection
solenoid valve is bound, Hi/Lo
shifting of transmission is not
achieved although travel
mode switch is operated.
- - - -
- - - -
- - - -
- - - -
- - - -
T3-10 T3-11 T2-4, T3-12 T2-2, T3-13
T5-7-19
Parts Blade/Outrigger Cylinder Travel Forward Pi Cut Travel Reverse Pi Cut

Item Solenoid Valve Solenoid Valve Solenoid Valve
• Releases operate check • Cut travel forward pilot • Cut travel reverse pilot
valve provided in pressure and prevents pressure and prevents
blade/outrigger cylinder. machine from traveling machine from traveling
forward when FNR switch is reverse when FNR switch is
Function in N or R position in order to in N or F position in order to
control forward/reverse control forward/reverse
selection limit and travel selection limit and travel
pilot pressure cut-off pilot pressure cut-off
controls. controls.
• When solenoid valve is • As below • As below
bound, operate check valve
does not open or close.
Symptoms in control system
when trouble occurs.
• Although blade/outrigger • If valve is closed: • If valve is closed:

lever or blade/outrigger Although FNR switch is in N Although FNR switch is in N
switch is operated, position, machine travels position, machine travels
blade/outrigger cylinder is forward. reverse.
not operated. • If valve is open: • If valve is open:
Although FNR switch is in F Although FNR switch is in R
position, machine does not position, machine does not
travel forward. travel reverse.
Symptoms in machine
occurs.
By Fault Code - - -
By Monitor - - -
Function
Evaluation
By Using Test - - -
Harness
Others - - -
NOTE - - -
Descriptions of Control T2-2, T3-12 T2-2 T2-2

Section in T/M)
T5-7-20
Secondary Pilot Relief Pressure

Selector Valve (Optional)
Control Valve (Optional)
• Is shifted by pilotpressure from selector • Is shifted by pilot pressure from
valve control solenoid valve. secondary pilot relief pressure control
solenoid valve.
• If spool is bound or spring is broken, • If spool is bound or spring is broken, relief

pressure oil from breaker does not return circuit in breaker is blocked.
to hydraulic oil tank.
• Breaker stroke becomes few. • Reliefset pressure in auxiliary circuit

does not decrease.
- -
- -
- -
- -
- -
T2-2 T2-2
T5-7-21
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine

troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting

Trouble Symptom E-1 E-2 E-3
Starter does not rotate. Although starter rotates, When engine control dial is
Part engine does not start. fully rotated, engine stalls.
When engine control dial is
fully rotated, engine speed is
slow.
MC z z
ECM { z
ICF {
Monitor Unit z {
Pump 1 Delivery Pressure Sensor
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Hydraulic Oil Temperature Sensor
Key Switch z
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Starter Cut Relay z
ECM Main Relay
Battery Relay z
Glow Plug Relay
Engine Electrical Equipment
Engine Unit z z
Pump Regulator
Swing Parking Brake
Release Spool (Signal Control Valve)
Check batteries.
Remark
T5-7-22
NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the
described provided that each trouble same time, find out all faulty components
occurs independently. while checking all suspected components
in each trouble symptom.
E-4 E-5 E-6 E-7

Although engine control dial is Engine speed does not Faulty HP mode. Although key switch is turned
rotated, engine speed does not increase when engine starts. OFF, engine does not stop.
changed.
z z z {
z z { z
z
z
z
z
z {
z
z : Related, required to check

{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-7-23
E-8 E-9 E-10

Trouble Symptom
Faulty auto-idle. Faulty E mode. When traveling or operating
front attachment at slow
idle, engine hunts.
Part
MC z z z
ECM { { {
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor z
Pump 2 Delivery Pressure Sensor z
Pump 1 Control Pressure Sensor z
Pump 2 Control Pressure Sensor z
Pressure Sensor (Travel) {
Pressure Sensor (Front Attachment) {
Key Switch
Engine Control Dial
Auto-Idle Switch z
Power Mode Switch z
Torque Control Solenoid Valve {
Starter Cut Relay
ECM Main Relay
Battery Relay
Glow Plug Relay
Engine Unit z
Pump Regulator
Swing Parking Brake
Release Spool (Signal Control Valve)
z
Remark
T5-7-24
E-11 E-12 E-13 E-14

Although operating attachment When attachment mode is Engine stalls during operation Engine is difficult to start at low
at attachment mode, engine selected, engine speed does not under adverse condition such as temperature.
speed does not increase. decrease. at high altitude.
z z z
{ { z z
{ {
z
{ z
{ z
z
Check batteries.

T5-7-25
E-15 E-16
Trouble Symptom
Although depressing Although depressing
accelerator pedal during accelerator pedal during
travel operation, engine digging operation,
speed does not change. engine speed does not
Part change.
MC (Main Controller) z z
ECM
Pressure Sensor (Travel Forward) { {
Pressure Sensor (Travel Reverse) {
Pressure Sensor (Front Attachment)
Travel N Sensor {
Auto-Idle Switch
Power Mode Switch
Brake Switch z z
FNR Switch z z
Travel Speed Mode Switch {
Engine Speed Control Mode Selection
Switch
z z
Battery Relay
Glow Plug Relay
Engine Unit
Pump Regulator
Remark
T5-7-26
(Blank)
T5-7-27
All Actuator System Troubleshooting

A-1 A-2 A-3
Trouble Symptom
All actuator speeds are slow. All actuators are not Single swing operation
operated. speed becomes slow. Arm
speed is slightly slow during
arm level crowding.
Part
MC z
ECM {
Monitor Unit {
Torque Control Solenoid Valve z
Pilot Shut-Off Solenoid Valve z
Pilot Shut-Off Lever z
Pilot Shut-Off Relay z
Security Relay z
Spool
Main Relief Valve {
Arm 1 Flow Rate Control Valve
Main Pump z z
Regulator { z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control Valve
(Signal Control Valve)
z
Control Spool (Signal Control Valve)
Remark
T5-7-28
A-4 A-5 A-6

Travel is not operated during Although control lever is turned Actuator speed is faster than
single travel operation. Single to neutral, actuator does not normal.
bucket operation speed stop. Precise control cannot be
becomes slow. Boom is not performed.
raised properly during arm level
crowding.
z
z z
z z

T5-7-29
Front Attachment System Troubleshooting

F-1 F-2 F-3 F-4
Trouble Symptom
All front attachment Some cylinder are Arm speed is slow Bucket is slightly
actuator operations not operated or during combined slow during bucket
are weak. speeds are slow. operation. During roll-in single
combined operation operation.
of boom raise and Bucket does not
arm roll-in, boom move smoothly
raise speed is slow. during bucket roll-in
Arm speed is slow single operation.
during arm level
Part crowding.
MC z
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SC) z
Pump 1 Delivery Pressure Sensor {
Pump 2 Delivery Pressure Sensor {
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Power Digging Switch
Spool z
Main Relief Valve z
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve z
Boom Flow Rate Control Valve
Bucket Flow Rate Control Valve z
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve
(Signal Control Valve) z {
Shuttle Valve
(Signal Control Valve) z z
Bucket Flow Rate Control Valve Control
Spool (Signal Control Valve)
Pilot Valve z
Cylinder
Remark
T5-7-30
F-5 F-6 F-7 F-8

When starting to move When starting to move When boom raise or Front attachment drifts
during combined during combined arm roll-out is remarkably.
operation, arm does operation, boom does operated, boom or arm
not smoothly move. not smoothly move. starts to move after
Arm starts to move Boom starts to move slightly moving
slightly slow during arm slightly slow during downward.
roll-in single operation. boom lower single
These troubles often operation.
occur when
temperature is low.
z
z
z
z
z z z
z z z
{

T5-7-31
Front Attachment System Troubleshooting

F-12 F-13 F-14
Trouble Symptom
Attachment speed is Attachment speed is Attachment speed is
fast during combined fast during combined fast during combined
operation of attachment operation of attachment operation of attachment
(optional) and front (optional) and front (optional) and front
attachment (when attachment (when attachment (when
pulverizer or crusher is breaker attached with vibrating hammer is
Part used). auxiliary flow combiner used).
line is used).
MC z z z
Auxiliary Flow Rate Control Solenoid Valve z
Auxiliary Flow Combiner Solenoid Valve z
Maximum Pump 1 Flow Rate Limit Control Solenoid z
Pressure Sensor (Auxiliary) z z z
Pressure Sensor (Travel Forward) z
Pressure Sensor (Travel Reverse) z
Pressure Sensor (Arm Roll-Out) z z
Auxiliary Flow Rate Control Valve z
Auxiliary Flow Combiner Valve z
Remark

NOTE: The trouble symptoms in this table are

described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
T5-7-32
Swing System Troubleshooting
S-1
Trouble Symptom
Swing is slow or unmoving.
Part
MC (Main Controller)
Solenoid Valve Unit (SC)
Pump Device
Spool
Load Check Valve
Swing Parking Brake Release Spool
z
z
Arm 1 Flow Rate Control Valve Control
Spool (Signal Control Valve)
Shuttle Valve (Signal Control Valve) {
Swing Device z
Travel Device
Center Joint
Pilot Valve z
Remark

T5-7-33
Travel System Troubleshooting

T-1 T-2 T-3 T-4
Trouble Symptom
Machine does not Machine does not Forward/reverse When releasing
travel. travel forward or travel speeds are accelerator pedal,
reverse. slow. Travel power is hydraulic brake is not
weak. applied.
Part (Macnine runs away.)
MC z z z z
Monitor Unit
Main Pump {
Regulator {
Solenoid Valve Unit (SF) z
z z
Travel Mode Selector Solenoid
Valve
z z
Fast Speed Selection Relay
Slow Speed Selection Relay
FNR Switch { z
Travel Speed Mode Switch {
Brake Switch {
Engine Speed Control Mode
Selection Switch
z
Work Brake Release Switch z
Brake Remaining Pressure Sensor
Travel N Sensor {
Control Valve z z z z
Travel Shockless Valve z z
Accumulator Charging Valve
Brake Valve
Transmission z {
Front Axle z {
Rear Axle z {
Travel Motor z z z z
Center Joint z z
Pilot Valve z
Axle Lock Cylinder
Operate Check Valve (Axle Lock
Cylinder)
Remark
T5-7-34
T-5 T-6 T-7

Travel mode (fast/slow) Axle lock is not Axle lock is not
does not shift. released. operable.
z z z
z z
z
z
z
{
z
z z
{ {
z z

{ : Related. However, in case this component fails, other trouble NOTE: The trouble symptoms in this table are
symptom will be more noticeable so that this component will not described provided that each trouble
be the direct cause of the trouble concerned. occurs independently.
T5-7-35
Brake System Troubleshooting

B-1 B-2 B-3
Trouble Symptom
Parking brake is not operable Service brake is not operable, Work brake is not work
(not applied). or is not applied effectively. operable.
Part
MC z z
ECM {
Monitor Unit
Main Pump
Regulator
Solenoid Valve Unit (SF) z z
Travel Mode Selector Solenoid
Valve
{
FNR Switch {
Travel Speed Mode Switch
Brake Switch z
Work Brake Release Switch {
Brake Pressure Sensor z
Brake Remaining Pressure Sensor {
Travel N Sensor {
Control Valve
Travel Shockless Valve
Accumulator Charging Valve z
Brake Valve z z
Transmission {
Front Axle z {
Rear Axle z {
Travel Motor
Center Joint
Pilot Valve
Remark

T5-7-36
Steering System / Other System Troubleshooting

H-1 H-2 O-1 O-2
Trouble Symptom
Although steering wheel Although steering wheel Wiper is not operable. Air Conditioner is
is rotated, steering is is rotated, steering is faulty.
heavy. impossible.
Part
Steering Pump z
Steering Valve z z
Center Joint z
Front Axle { {
Other Electrical Equipment z z
Remark

T5-7-37
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
IMPORTANT: As electric current from the key

switch is not routed to the starter
relay except with the pilot shut-off
lever in the UNLOCK position and
with the brake switch in the P (park-
ing brake) position, the starter does
not rotate. (Refer to the SYSTEM /
Electrical System group.)
YES Faulty starter cut relay.
• This trouble has nothing to do with the electronic
control system such as MC.
• Check the wiring connections first. Switch starter cut relay Disconnect starter cut
YES with other general re- relay.
lay. Check if voltage at
Check if starter rotates. terminals #1 and #3
· Key switch: START NO nector is 24 V.
Check if voltages at · Monitor unit: Primary
YES terminals #5 and #6 in screen · Key switch: START
key switch are 24 V. · Monitor unit: Primary
screen
· Key switch: START
· Monitor unit: Primary Check for continuity YES Faulty key switch.
screen between positive ter-
Check if primary minal in battery and
screen or password NO terminal #1 in key Faulty harness between
input screen is dis- switch. NO battery and key switch.
played on monitor unit.
· Key switch: ON Disconnect connector
YES Faulty monitor unit.
monitor-A in monitor
NOTE: As for the YES unit.
password Check if battery volt- Check if voltage be- Open circuit in harness
setup type age and electrolyte tween terminal #A7 between monitor unit
NO
machine, density are normal, (harness end) of con- and key switch.
NO
and fusible link (45 A) nector and machine is
the pass- is not blown. 24 V or more.
word input
· Voltage: 24 V or more · Key switch: ON
screen is Density: 1.26 or more Faulty battery.
displayed. NO Faulty fusible link.
Key Switch:
Battery Relay:
Terminal A
T105-07-04-002
T178-05-04-001
T5-7-38
Faulty starter, or faulty

YES harness between starter
and battery relay.
YES Check if voltage at
terminal A in battery
relay is 24 V.
Check if voltage at Faulty battery relay.
YES terminal #2 (harness NO
end) of connector in
Disconnect connector starter cut relay is 0
of starter relay 2. V.
Connect terminal S Shorted circuit in harness
(harness end) of con- between starter cut relay
YES nector to machine. NO and emergency stop
Check for continuity switch.
between terminal #4
nector in starter cut
relay and machine. Open circuit in harness
between starter cut relay
NO and starter relay.

between key switch and
NO starter cut relay.

open end side)
Monitor Unit Starter Cut Relay Starter Relay

Connector Monitor-A
#A7
E
S R
T183-05-05-001 T183-05-04-003
T5-7-39
E-2 Although starter rotates, engine does not
start.
YES Faulty ECM main relay.
Connect terminal #1
(harness end) of
connector in ECM
Switch ECM main main relay to ma-
relay with other gen- Connect terminal #5 YES
chine.
eral relay. (harness end) of con- Check for continuity
Check if engine nector in ECM main re- between terminals
starts. lay to machine. #21, #40 (harness
YES Disconnect connector in end) of connector in
ECM. ECM and machine.
Disconnect ECM main Check for continuity
relay from connector. between terminals #2,
Check if voltage be- #5 (harness end) of Open circuit in harness
connector and machine. between ECM main relay
NO tween terminal #3 NO and ECM.
nector and machine is
specification. Open circuit in harness
· Specification: 24V between key switch and
NO
ECM main relay.
· Check if fuse #8 is
blown.

open end side)
ECM Main Relay ECM Connector #21 #24 #5
T183-05-04-003
T1GR-05-04-002
#40 #2
T5-7-40
Disconnect con- YES Open circuit in harness

nector ICF-C in between key switch and
ICF. Check if monitor unit.
YES voltage between
terminal #C7 Check if fuse #18 is blown.
Disconnect
(harness end) of
connector MC-B
connector and Open circuit in harness
in MC.
machine is speci- between key switch and
YES Check if voltage
fication. NO ICF.
between terminal
#B16 (harness · Key switch: ON Check if fuse #18 is blown.
end) of connec- · Specification: 24
tor and machine V
Check if voltage Open circuit in harness
YES between terminal is specification.
between key switch and
#24 (harness · Key switch: ON NO
MC.
Check for conti- end) of connector · Specification: 24
nuity between in ECM and ma- V Check if fuse #18 is blown.
YES terminal #2 (har- chine is specifica-
ness end) of con- tion.
nector in ECM Open circuit in harness
· Key switch: ON
main relay and between key switch and
· Specification: 24 NO
machine. ECM.
V
Check if fuse #18 is blown.
Faulty ground in ECM

NO main relay.

between ECM main relay
NO and ECM.
Connector MC-B Connector ICF-C

#B16
B1 B8
T1V1-05-04-002
#C7
B19 B25
T5-7-41
E-3 When engine control dial is fully rotated, en-
gine stalls.
When engine control dial is fully rotated, en-
gine speed is slow.
Related MC Fault Code: 11003-3, 11004-2
YES Faulty MC, or faulty CAN

between MC and ECM.
Check if fault code is
displayed.
· MC or ECM cannot Refer to Engine Trouble-
be selected on con- NO shooting Manual.
troller diagnosing by
using Dr. ZX.
T5-7-42
E-4 Although engine control dial is rotated, en-
gine speed does not change.
Related MC Fault Code: 11004-2, 11101-3, 11101-4
Faulty engine control dial,

YES or open circuit in harness
between engine control
dial and MC.
Check if fault code 11101-3 or
11101-4 is displayed. Monitor
engine control standard volt-
age (dial angle) by using Dr.
YES Faulty CAN between MC
ZX.
and ECM.
Check if voltage is normal.
· Standard voltage Check if fault code 11004-2 is
Slow idle position: 0.3 to 1 V NO displayed at the same time.
Fast idle position: 4.0 to 4.7 V
· Possible to display by built-in · Possible to display on MC
diagnosing system. monitor by using Dr. ZX.
Faulty MC.
NO
T5-7-43
E-5 Engine speed does not increase when en-
gine starts.
• Refer to the pages for the Auto Warming Up Con-

trol in the SYSTEM / Control System group in the
T/M (Operational Principle).
0 °C or higher
when starting Normal.
NO Monitor oil temperature. Faulty key switch, or

YES open circuit in harness
· Monitor item: Hydraulic between key switch and
Monitor key switch. MC.
oil temperature Check if displayed “ky”
· Possible to display by is highlighted in re-
Check if fault code built-in diagnosing sys- 0 °C or lower sponse to key switch
11901-3 or 11901-4 tem. when starting operation.
is displayed. To A
NO
· Monitor item: Key switch
Faulty hyd. oil tempera-

ture sensor, or open cir-
YES cuit in harness between
hyd. oil temperature
sensor and MC.
NO Faulty MC.
Check if fault code

A 11004-2 is dis-
played at the same
time.
Refer to fault code 11004

YES in Troubleshooting A.
T5-7-44
(Blank)
T5-7-45
E-6 Faulty HP mode
• Even if power mode switch is turned to the HP

mode position, HP mode is not operated. (General
mode normally operates.)
Related MC Fault Codes: 11004-2, 11200-3,

11200-4, 11202-3, 11202-4, 11302-3, 11302-4,
11303-3, 11303-4
• The sensors detect the conditions necessary to • Refer to the pages for HP Mode Control in the
operate HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sors fails, HP mode becomes ineffective. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check the wiring connections first.
and pump 1 and 2 delivery pressure sensors are
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected.
Faulty power mode

NO switch or open circuit in
harness between power
mode switch and MC.
Monitor power mode

switch.
NO Check if indication is
changed when power
mode switch is turned
to HP mode.
Faulty MC.
· Monitor item: HP mode YES
SW
· Possible to display by
Check if fault code is built-in diagnosing
displayed. system. Faulty corresponding
NO sensor, or open circuit in
harness between MC and
sensor.
Check if fault code

11004-2 is displayed at
YES the same time.

T5-7-46
• Although the power mode switch is not turned to HP
mode, HP mode is operated.
• Boom raise and arm roll-in must be operated

when the average delivery pressures of pump 1
and 2 are high, if HP mode control is performed.
The sensors related to this condition may not be
faulty at the same time.
Shorted circuit in harness

YES between MC and power
mode switch.
Monitor power mode

switch.
Check if “HP” is dis- YES Faulty ECM.
played.
· Monitor item: HP
mode SW Check if fault code
· Possible to display by NO 11004-2 is displayed.
built-in diagnosing
system.
· Power mode switch: Faulty MC.
P mode
NO
T5-7-47
E-7 Although key switch is turned OFF, engine
does not stop. (If the engine does not stop,
stop engine by turning the emergency stop
switch ON located under the seat stand.
Then, begin inspection.)
• Probably the symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Although engine control dial is rotated, engine
speed does not change” may come up. Perform
troubleshooting for these symptoms.
YES Faulty key switch.
Check if voltage at
terminal #5 in key
switch is 24 V. Shorted circuit in
NO
· Key switch: OFF harness between key
switch and ECM.
in ECM.
tween terminal #24
NO (harness end) of con-
nector and machine is
0 V.
Faulty ECM.
· Key switch: OFF YES
Key Switch
#24
ECM Connector
(Harness end)
T1GR-05-04-002
T105-07-04-002
T5-7-48
(Blank)
T5-7-49
E-8 Faulty auto-idle system
• Although control lever is turned to neutral, auto-idle

is not operated.
Related MC Fault Code: 11004-2, 11304-3, 11304-4,

11307-3, 11307-4
Related ECM Fault Code: 639-2, 639-3
• If trouble symptoms E1 to E8 are recognized, • Refer to the pages for Auto-Idle Control in the
perform the troubleshooting of these troubles SYSTEM / Control System group in the T/M (Op-
first. erational Principle).
• Although failure in pressure sensors (travel for- • Check the wiring connections first.
ward/reverse and front attachment) may have
relevance to malfunction of the auto-idle control.
However, if these sensors fail, other operating
functions will also be affected.
Check if fault code

YES
11004-2 is dis-
played.
Check if fault code
YES for MC or ECM is
displayed.
Monitor auto-idle
switch. Faulty MC.
YES Check if ON/OFF is NO
shifted when
auto-idle switch is
Check if auto-idle is shifted. Open circuit in har-
displayed on monitor ness between
unit. · Monitor item: NO auto-idle switch and
Auto-idle SW MC.
· Auto-idle switch: ON
Disconnect connec-
tor monitor-B in YES Faulty auto-idle
monitor unit. switch.
between terminal
NO #B18 (harness end) Open circuit in har-
of connector and ness between
machine. NO auto-idle switch and
· Auto-idle switch: ON monitor unit.

open end side)
Connector Monitor-B
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
#B18
T5-7-50
Refer to fault code

YES
11004 in Trouble-
shooting A.
Refer to Engine
YES
Troubleshooting
Manual.
Check if fault code
639-2 or 639-3 is
NO displayed. Faulty corresponding
sensor, or open cir-
NO cuit in harness be-
tween MC and sen-
sor.
T5-7-51
• Although auto-idle switch is turned OFF, auto-idle is
operated.
Shorted circuit in
YES harness between MC
MC-B in MC and con- and auto-idle switch.
nector in switch panel.
between terminal #B6 Refer to fault code
(harness end) of con- YES
11004 in Trouble-
nector MC-B and ma- shooting A.
chine. Check if fault code
NO 11004-2 is displayed.
· Auto-idle switch: OFF
Faulty MC.
NO

open end side)
Connector MC-B
#B6
B1 B8
B19 B25
T5-7-52
(Blank)
T5-7-53
E-9 Faulty E mode
• Although power mode switch is turned to the E

mode position, engine speed does not change. (En-
gine speed does not decrease.)

11202-3, 11202-4, 11206-3, 11206-4, 11208-3,
11208-4
• If trouble symptoms E-1 to E-9 are recognized, • Pump 1, 2 control pressure sensors and pump 1,
perform the troubleshooting of these troubles 2 delivery pressure sensors are also engaged in
first. the E mode control. However, if these sensors fail,
• The sensors detect the conditions necessary to other operating functions will be also affected.
operate E mode. Therefore, if any of these sen- • Refer to the pages for E Mode Control in the
sors fails, E mode becomes ineffective. SYSTEM / Control System group in the T/M (Op-
erational Principle).
Faulty power mode

NO switch, or open circuit in
harness between power
mode switch and MC.
Monitor power mode

switch.
When power mode
NO
switch is turned to E
mode, check if indica-
tion is changed.
Faulty MC.
· Monitor item: E/P SW
· Possible to display by YES
built-in diagnosing
Check if fault code is system.
displayed.
Faulty corresponding
NO sensor, or open circuit in
harness between MC and
sensor.
Check if fault code

11004-2 is displayed.
YES

T5-7-54
• Although power mode switch is not turned to E
mode, engine speed decreases.
• Required engine speed from the engine control

-1
dial must be beyond 1800 min when the pump
control pressures of pump 1 and 2 are low or the
average delivery pressures of pump 1 and 2 are
high, if E mode control is performed. The sensors
related to this condition may not be faulty at the
same time.

NO between MC and power mode
switch, or faulty power mode
switch.
Monitor power mode switch.
Check if “E” is displayed. YES Refer to fault code 11004 in
Troubleshooting A.
· Monitor item: E/P SW
· Possible to display by built-in Check if fault code
diagnosing system. YES 11004-2 is displayed.
· Power mode switch: P mode Faulty MC.
NO
T5-7-55
E-10 When traveling or operating front attach-
ment at slow idle, engine hunts.

11307-3, 11307-4
• Although the failure in pressure sensors (travel

forward/reverse and front attachment) may have
relevance to malfunction of idle speed-up control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptom and
related part on page T5-7-2.)
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).
YES Faulty engine unit or

faulty ECM.
· Set idle speed increasing
Set engine control dial to Min. in MC by using Dr. ZX.
Check if engine speed is
faster than increased idle YES Refer to fault code 11004
speed. in Troubleshooting A.
· Monitor item:
Check if fault code
Requested engine speed
· Possible to display by built-in
diagnosing system.
Faulty MC.
NO
· Set idle speed increasing
in MC by using Dr. ZX.
T5-7-56
E-11 Although operating attachment at attach-
ment mode, engine speed does not in-
crease.

• Refer to the pages for Attachment Operation
• In case trouble symptoms E-1 to E-11 are recog- Speed Increase Control in the SYSTEM / Control
nized, perform the troubleshooting of these trou- System group in the T/M (Operational Principle).
bles first. • Check the wiring connections first.
• Although the failure in pressure sensor (auxiliary)
and power mode switch may have relevance to
the malfunction of attachment operation speed
increase control. However, if these sensor and
switches fail, other operating functions will also be
affected.
NO Normal (Set to “Increase

(+)”.)
Check if attachment
speed adjustment
NO has been set to “In-
crease (+)” on “Pa- YES
rameter Change” in Monitor attachment To A
Dr. ZX. control pilot pressure.
Check if pressure
Check if attachment YES varies in response to
speed adjustment lever stroke. Faulty auxiliary pressure
has been set to “De-
· Monitor item: ATT NO sensor.
crease (-)” on “Pa-
rameter Change” in control pilot pressure
Dr. ZX.
Normal (If P speed is set

to decrease, this control
YES system is deactivated.)
YES Refer to fault code 11004

in Troubleshooting A.
Fault code 11004-2 or

A 11918-2 is displayed.
Faulty MC.
NO
T5-7-57
E-12 When attachment mode is selected, engine
speed does not decrease.
• If trouble symptoms E-1 to E-11 are recognized,

perform the troubleshooting of these troubles be-
forehand.
• Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
YES Refer to fault code 11004

in Troubleshooting A.
Check if fault code

YES
11004-2 or 11918-2 is
displayed.
Faulty MC.
Check if attachment NO
speed adjustment has
been set to “Decrease
(-)” on “Parameter
Change” in Dr. ZX.
Normal (Set to “Decrease

NO (-)”.)
T5-7-58
(Blank)
T5-7-59
E-13 Engine stalls during operation under ad- Test Harness (ST 7226)
verse condition such as at high altitude. When operating corresponding control lever and
switch: ON
11401-2, 11401-3, 11401-4
• If speed sensing control is not operated, the en-

4
gine will stall under adverse operating conditions.
3
• Check the wiring connections first. 50
150 50 50
1 2 2 1
T107-07-06-015
YES Faulty torque control

solenoid valve.
Disconnect harness of
Check if fault code torque control sole-
NO
11401-2, 11401-3 or noid valve.
11401-4 is displayed. Monitor torque control NO Connect test harness
solenoid valve output. (ST 7226) between
Install pressure gauge solenoid valve and
to output port so that harness.
pressure is measured Check if test harness
by pressure gauge and lamp lights.
Dr. ZX.
NO
Monitor actual engine Check if both meas-
speed. ured pressure values
Check if engine speed by pressure gauge and
is abnormal. Dr. ZX vary identically. Disassemble and
· Monitor item: Pump YES check regulator.
· Monitor item: torque P/S valve output
Actual engine speed · Refer to the Opera-
· Possible to display by tional Performance
built-in diagnosing sys- Test section.
tem.
YES Refer to fault code
11004 in Trouble-
shooting A.
Check if fault code
11004-2 or 11100-2 is
YES displayed. YES Refer to Engine Trou-
bleshooting Manual.
Check if fault code
Faulty MC.
NO
T5-7-60
YES Faulty torque control so-

lenoid valve.

between torque control
NO solenoid valve and MC.
T5-7-61
E-14 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, engine is difficult to start or does not
start even if pre-heated.)
Related MC Fault Code: None
• Check if electricity is routed to the glow plugs. • Check the battery.

Check the glow plugs for any abnormality. • Check the wiring connections first.
• The pre-heat system operates only when coolant
temperature is below 20 °C (68 °F).
YES Faulty sensor.
coolant temperature sensor.
Check if voltage at glow plug YES Faulty ECM.
is 20 to 24 V.
· Key switch: ON Disconnect connector in
ECM. Connect terminal #4
(harness end) of connector
NO to machine. Check if prob-
lem is corrected.
· Connect to machine from Measure each glow plug
the back of connector by NO resistance.
using a clip with the con-
nector connected. · Key switch: OFF
· Before measuring, re-
move copper plates
connecting each glow
plug.
• Measurement of Glow Plug Voltage and Resistance

Voltage Check Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V Specification: 10 Ω or less
T105-07-04-006 T105-07-04-007
T5-7-62
∞Ω Faulty glow plug.
NO Faulty glow plug relay, or

faulty harness between
Connect connector in glow plug relay and glow
glow plug relay. Connect plug.
YES terminal #4 (harness end)
of connector to machine.
Check if voltage at glow
plug is 20 to 24 V.
· Key switch: ON
between glow plug relay
YES and ECM.
Disconnect connector in
glow plug relay.
Check if voltages at termi-
10 Ω or less nals #1 and #3 (harness
end) of connector in glow
plug relay are 20 to 24 V.
· Key switch: ON If terminal #1 is 0 V, open
circuit in harness be-
tween glow plug relay
and battery. If terminal #3
is 0 V, open circuit in
NO harness between glow
plug relay and terminal M
in key switch.

blown.
T5-7-63
E-15 Although depressing accelerator pedal
during travel operation, engine speed does Connector (Harness end of connector viewed from the
not change. open end side)
• Check that: Switch Panel

Brake Switch: OFF or Axle Lock Position
●
Engine Speed Control Mode Selection Switch:
Pedal Mode Position
FNR Switch: F or R Position
#1
• Faulty pressure sensor (travel forward/reverse)
may be the cause of this problem. In this case,
other functions should become abnormal.
YES Faulty MC.
YES Monitor FNR (R)

switch. Check if ON
is displayed.
Faulty FNR switch.
· FNR switch: R NO
Check if neutral
indicator on steering Faulty brake switch, or
YES shorted circuit in harness
column monitor
lights. between MC and terminal
Monitor parking #3 in brake switch.
· Key switch: ON YES brake switch. Check
· FNR switch: F or R if ON is displayed.
· Brake switch: Faulty MC.
except P (parking NO
Monitor pedal EC brake)
switch. Check if ON
NO is displayed. Disconnect connec-
YES Faulty engine speed con-
tor in switch panel. trol mode selection switch.
· Engine speed control Check if voltage be-
mode selection switch: tween terminal #1
Pedal (harness end) of
NO connector and ma- Open circuit in harness
chine is 5 V. between MC and engine
NO speed control mode selec-
· Key switch: ON tion switch.
T5-7-64
E-16 Although depressing accelerator pedal
during digging operation, engine speed
does not change. Connector (Harness end of connector viewed from the
open end side)
• Check that:
Switch Panel
Work Brake: Operable
FNR Switch: N Position ●
Engine Speed Control Mode Selection Switch:
Pedal Mode Position
• Faulty pressure sensor (travel forward/reverse) #11
may be the cause of this problem. In this case,
other functions should become abnormal.
NO Faulty FNR switch, or

faulty harness between
MC and FNR switch.
Monitor FNR (F) swit-

ch and FNR (R)
switch. Faulty brake switch, or
Check if OFF is dis-
played. Monitor implement between MC and terminal
YES brake state. #3 in brake switch.
FNR switch: N Check if ON is dis-
played.
Faulty MC.
· Brake switch: NO
Monitor pedal EC
Axle lock or Auto axle
switch.
lock
YES Check if ON is dis-
played. Faulty engine speed con-
Disconnect connec- YES
· Engine speed control tor in switch panel. trol mode selection switch.
mode selection switch: Check if voltage be-
Pedal tween terminal #11
NO (harness end) of
connector and ma- Open circuit in harness
chine is 5V. between MC and engine
NO speed control mode
· Key switch: ON switch.
T5-7-65
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.

11401-2, 11401-3, 11401-4
• Reduction in pump 1 and 2 flow rate due to some • Although speed is satisfactory, and when power is
reasons or faulty pilot system (A-2) may cause weak, refer to the troubleshooting for faulty main
this trouble. relief valve (F-1).
• Check fuse of the torque control solenoid valve. • Check the wiring connections first.
Faulty torque control so-

lenoid valve, or open
YES circuit in harness be-
tween MC and torque
Check if fault code

YES 11401-2, 11401-3 or
11401-4 is displayed.
YES Faulty CAN between MC
and ECM, or faulty MC.
NO Check if fault code

Check if primary pilot 11004-2, 11100-2 or
11910-2 is displayed. Faulty pump device.
pressure is normal. NO
· Fully boom raised or fully
arm rolled-in
· Monitor item:
Boom raise pilot pres-
sure, Arm roll-in pilot YES Faulty pilot pump, or
pressure clogged pilot filter.
Adjust, disassemble
and clean pilot relief
valve.
NO Check if same symp-
tom appears.
End.
NO
T5-7-66
A-2 All actuator are not operated.
• The pilot shut-off circuit or the electric lever circuit • When the key switch is turned to the START posi-
may be faulty. tion with the engine stop switch in the ON position,
• If the alarm is displayed on the monitor unit, refer the starter rotates.
to Troubleshooting A. Refer to the pages for the Electrical System group
• When the key switch is turned to the START posi- / SYSTEM in the T/M (Operational Principle).
tion with the pilot shut-off lever in the LOCK posi-
tion, the starter does not rotate.
YES Faulty pilot shut-off relay.
Switch pilot shut-off

YES Faulty security relay.
relay with other gen-
eral relay.
Check if actuator can
be operated.
Connect terminal #2
· Pilot shut-off lever: Switch security relay (harness end) of con-
LOCK position with other general nector in pilot shut-off
relay. solenoid valve to ma-
NO Check if actuator can chine.
YES
be operated. Disconnect connector To A
Disconnect connec- in pilot shut-off relay.
· Pilot shut-off lever: tor in pilot shut-off Check for continuity
LOCK position solenoid valve. between terminal #2
Check if voltage be- (harness end) of con-
NO tween terminal #1 nector and machine.
(harness end) of
connector and ma-
chine is 24 V. Open circuit in harness
between pilot shut-off
· Key switch: ON NO solenoid valve and bat-
tery relay.
blown.
· Check if fusible link 65
Connector (Harness end of connector viewed from the A is blown.
open end side)
Pilot Shut-Off Relay Pilot Shut-Off Solenoid Valve

Security Relay
T1V1-05-04-103
#1 #2
T183-05-04-003
T5-7-67

between terminal #2
YES (harness end) of
connector in security
Check for continuity relay and machine.
between terminal #3
YES
Connect terminal #5 (harness end) of
(harness end) of con- connector in security
nector in pilot shut-off relay and machine.
Faulty ground in security
relay to machine.
YES Disconnect security NO relay.
relay.
between terminal #4
nector and machine. Open circuit in harness
Check if voltage between pilot shut-off
YES between terminal NO relay and security relay.
#1 (harness end) of
connector in pilot
A shut-off relay and
machine is 24 V.

NO relay and battery relay.

NO solenoid valve and pilot
shut-off relay.
T5-7-68
Faulty monitor unit, or

between monitor unit and
security relay.
Connect connector YES Faulty pilot shut-off sole-

monitor-B. noid valve.
YES between terminal #2
(harness end) of
connector in pilot
shut-off relay and Faulty monitor unit.
Check for continuity machine. NO
YES between terminals · Pilot shut-off lever:
#B12 and #B19 UNLOCK position
(harness end) of
Connect terminal #2 connector monitor-B.
(harness end) of con- Open circuit in harness
nector in pilot shut-off between terminals #B12
relay to machine. and #B19 (harness end)
Disconnect connector of connector monitor-B,
monitor-B in monitor NO
or faulty pilot shut-off
NO unit. lever.
between terminal #2
nector and machine.
NO relay and monitor unit.

open end side)
Pilot Shut-Off Relay

Connector Monitor-B
#B2
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T183-05-04-003
#B19 #B12
T5-7-69
A-3 Single swing operation speed becomes slow.
Arm speed is slightly slow during arm level
crowding. (All problems occur at the same
time.)
• The pump 2 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the
swing motors, which are driven by pressure oil
from pump 2, moves very slow.
• Pressure oil from pump 1 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, during level crowding operation, pres-
sure oil is routed to the boom prior to the arm so
that arm speed becomes very slow.
• Refer to the SYSTEM / Hydraulic System group in
the T/M (Operational Principle).
YES Faulty pump 2 regulator.
Monitor pump 2 flow

control pressure.
Check if pressure in-
creases in proportion to
swing lever stroke.
Bound pump 2 flow rate
· Monitor item: Pump 2 control valve in signal con-
flow control pressure NO trol valve.
built-in diagnosing sys-
tem.
T5-7-70
A-4 Travel is operated during single travel op-
eration. Single bucket operation speed be-
comes slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
• The pump 1 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the
travel motor and bucket cylinder, which are actu-
ated by pressure oil from pump 1, moves very
slow.
• Pressure oil from pump 2 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, in level crowd operation, pressure oil is
routed to the arm prior to the boom so that boom
is scarcely raised.
YES Faulty pump 1 regulator.
Monitor pump 1 flow

control pressure.
creases in proportion to
accelerator pedal stroke.
Bound pump 1 flow rate
· Monitor item: Pump 1 flow control valve in signal control
control pressure NO valve.
tem.
T5-7-71
A-5 Although control lever is turned to neutral,
actuator does not stop.
• Bound spool in the pilot valve or bound main

spool in the control valve is suspected.
YES Faulty pilot valve.
· When control lever is in neu-

tral, pilot pressure is routed to
spool end in control valve.
Check if actuator stops when
pilot shut-off lever is turned to
LOCK position.
Faulty control valve.

NO
· Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-7-72
A-6 Actuator speed is faster than normal
Precise control cannot be performed.
• The pump 1 or 2 flow rate is maximized due to

some reasons.
Therefore, the maximum flow rate is supplied and
actuator speed is faster though the control lever
does not reach the full stroke.
YES Faulty pump regulator.
Monitor pump control pressures

of pump 1 and 2.
Check if pressure changes in
response to lever operation.
Bound pump flow rate control
· Pump 1: Bucket operation valve in signal control valve.
· Pump 2: Swing operation NO
· Monitor item:
Pump 1 flow control pressure
Pump 2 flow control pressure
diagnosing system.
T5-7-73
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator operations are

weak.
• If operating speeds are extremely slow, pump

control may be malfunctioning (A-3, A-4). Faulty
pilot system may also cause this trouble.
34.3 to 36.3 MPa Main relief valve should be nor-

2
(350 to 370 kgf/cm , 4990 to 5280 psi) mal.
Find out cause of trouble by
tracing other trouble symptoms.
Monitor pump 1 and 2 deliv-

ery pressures.
· Monitor item: Pump 1 and 2 de-
livery pressures
· Possible to display by built-in Adjust main relief valve.
diagnosing system.
· Relieve boom, arm and bucket Less than 34.3 MPa
2
circuits. (Less than 350 kgf/cm , 4990 psi)
· Power mode switch: P
· Work mode: Digging
T5-7-74
F-2 Some cylinders are not operated or speeds
are slow.
• When other actuators (travel and swing) operate

normally, the pilot pump (primary pilot pressure) is
considered to be normal.
• If single bucket operation speed is slow, refer to
F-4.
• If single arm roll-in operation speed is slow, refer
to F-5.
• If single boom lower operation speed is slow, refer
to F-6.
YES Bound control valve
spool, or faulty cylinder
(faulty seal kit).
YES Check if overload

relief pressure is nor-
mal.
Monitor pump control Faulty overload relief

pressure. NO valve.
YES Check if pump con-
trol pressure
changes smoothly
while moving control
lever slowly.
· Monitor item: Faulty shuttle valve in
Pump 1 flow pres- NO signal control valve.
Measure or monitor sure, pump 2 flow
secondary pilot pressure
pressure. · Possible to display
Check if secondary by built-in diagnos-
pilot pressure is ing system.
normal.
· Secondary pilot
pressure: YES Bound shockless valve
Refer to the Opera- spool in signal control
tional Performance valve.
Check if secondary
Test section.
pilot pressure at inlet
· Monitor item:
Boom raise pilot NO port to signal control
valve. Faulty pilot valve.
pressure, arm roll-in
pilot pressure. · In case cylinders NO
· Possible to display by other than boom are
built-in diagnosing abnormal, skip this
system. step and go NO.
T5-7-75
F-4 Arm speed is slow during combined opera-
tion. Arm speed is slow during arm level
crowding.
Related MC Fault Code: 11202-3, 11202-4, 11301-3, • Refer to the pages for the SYSTEM / Control
11301-4, 11302-3, 11302-4, 11303-3, 11303-4, System group / Arm Regenerative Control in the
11403-2, 11403-3, 11403-4 T/M (Operational Principle).
Disconnect harness in Faulty solenoid valve

YES
solenoid valve unit (SC). unit (SC).
Connect test harness
NO (ST 7226) between so-
lenoid valve unit (SC)
and harness. Check if Open circuit in harness
Monitor solenoid valve between solenoid valve
unit (SC) output. Install lamp lights. NO
unit (SC) and MC.
pressure gauge to port · Combined operation of
NO SC. boom raise and arm
Check if both measured roll-in.
values by pressure
gauge and Dr. ZX vary YES Faulty arm regenerative
identically. valve.
Check if arm regenera-
· Monitor item: Arm regen- tive valve at 5-spool side
erative P/S valve output YES in control valve is scored
Find out cause of trou-
Check if fault code · Combined operation of or bound.
ble by tracing other
is displayed. boom raise and arm NO trouble symptoms.
roll-in
· Measurement: Refer to
the Operational perform-
ance Test section.
Faulty corresponding
sensor, or faulty MC.
YES between MC and sen-
sor.
T5-7-76
F-4 Bucket is slightly slow during bucket roll-in
single operation. Bucket does not move
smoothly during bucket roll-in single opera-
tion.
• Bucket flow rate control valve or bucket regen-

erative valve may be faulty.
• Refer to the COMPONENT OPERATION / Control
Valve group in the T/M (Operational Principle).
Faulty bucket regenera-

YES tive valve. (Disassemble,
clean or replace.)
Check if bucket re-
YES generative valve in
Install pressure gauge
bucket spool is
to hose SK connecting
bound or scored. Find out cause of trouble
signal control valve to
bucket flow rate control by tracing other trouble
NO symptoms.
valve in control valve.
NO When relieving during
3-combined operation
of boom raise, arm
roll-in and bucket
roll-in, check if pres- Bound bucket flow rate
Check if bucket flow sure is 3.9 MPa (40 control valve control
2
rate control valve in kgfcm ). NO spool in signal control
control valve is valve.
bound or scored.
Faulty bucket flow rate

control valve. (Disassem-
YES ble, clean or replace.)
Signal Control Valve (Control Valve Side)
Hose SK
Bucket Flow Rate

T178-03-06-015 Control Valve T16W-03-03-032
T5-7-77
F-5 When starting to move during combined
operation, arm does not smoothly move.
Arm starts to move slightly slow during arm
roll-in single operation. These troubles often
occur when temperature is low.

YES Faulty arm regenerative

valve. (Disassemble,
clean or replace.)
NO Check if arm regenera-
tive valve is bound or
scored.
Find out cause of trouble
by tracing other trouble
Check if arm anti-drift valve is NO symptoms.
bound or scored.
Faulty arm anti-drift valve.

(Disassemble, clean or
YES replace.)
F-6 When starting to move during combined

operation, boom does not move smoothly.
Boom starts to move slightly slow during
boom lower single operation.

Faulty boom lower me-
NO ter-in cut valve. (Disas-
semble, clean or replace.)
Check if boom lower
NO
meter-in cut valve is Find out cause of trouble
NO
bound or scored. by tracing other trouble
Check if boom re- symptoms.
Check if boom generative valve is
YES bound or scored.
anti-drift valve is
Faulty boom regenerative
bound or scored.
valve. (Disassemble,
YES clean or replace.)
Faulty boom anti-drift

YES valve. (Disassemble,
clean or replace.)
T5-7-78
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
YES Faulty anti-drift valve.

YES Check if anti-drift valves
(arm and boom) are
bound or scored.
Check if load check valve in Oil leaks in cylinder.

control valve is normal. NO
· Disassemble / Visual
Inspection
Faulty load check valve.
NO
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side
of the boom cylinder flows back into the
circuit through the load check valve so (B)
that the boom cylinder temporarily is re- When Load Check
tracted. Valve is Faulty:
2. As oil pressure and flow rate from the (A)
pump is low, if oil leaks from bottom side
(A) to rod side (B) due to faulty boom
cylinder piston or cylinder barrel, the
boom cylinder is temporarily retracted
during the initial stage of operation. In
addition, cylinder force is reduced. The
cylinder drift increases in this case.
T105-07-04-012
T5-7-79
F-8 Front attachment drifts remarkably.
YES Normal.
Correctly adjust emer-

NO
gency valve and lock it
Check if each front Check if emergency up.
attachment cylin- valve at boom 1 sec-
der drift is within tion in control valve Check if symptom is
NO
specification. 4-spool side is cor- deleted when overload
rectly adjusted. relief valve is tempo-
YES rarily switched with
Check if cylinder drift another overload relief
is reduced when pilot valve.
shut-off lever is
NO turned to LOCK po-
sition.
Faulty pilot valve.

YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tips onto
the ground.
2. Remove the hoses from the boom cylinder rod

side. Drain oil from the hoses and cylinders. (Plug
the disconnected hose ends.)
3. Retract the arm cylinder and lift the bucket off the
ground. If oil flows out of the hose removed pipe
ends and the boom cylinders are retracted at this T216-05-04-001
time, oil leaks in the boom cylinders. In case no oil
flows out of the hose removed pipe ends but the
boom cylinders are retracted, oil leaks in the con-
trol valve.
T5-7-80
Emergency Valve
NO Scored control valve

spool, broken spring, or
loose spool end.
NO Check if oil leaks

in cylinders.
Faulty cylinder. (Replace

seal kit.)
YES
Faulty overload relief T16W-03-03-032

YES valve.
TCGB-05-07-001
Adjustment Procedure:
Loosen screw (1) fully and tighten lock nut (2).
: 4 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
T5-7-81
F-9 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
When pulverizer or crusher is used.

• Check the wiring connections first. Open circuit in har-
NO ness between MC and
Disconnect connec- pressure sensor (aux-
tor MC-D in MC. iliary).
YES Check for continuity
between terminal
Disconnect connector #D5 (harness end) of Check if voltage be-
in pressure sensor connector and ter- tween terminal #D5
(auxiliary). minal #2 (harness (harness end) of con-
Check if voltage be- end) of connector in nector MC-D and
NO tween terminals #1 pressure sensor YES
machine is 0 V.
and #3 (harness end) (auxiliary).
of connector is 5±0.5 · Key switch: ON
V.
Switch pressure · Key switch: ON
sensor (auxiliary) Check if voltage be-
with other pressure tween terminal #1 Open circuit in har-
YES ness between MC and
sensor. (harness end) of
Check if fault code connector in pres- pressure sensor (aux-
for switched pres- iliary) (terminal #3).
NO sure sensor (auxil-
sure sensor is dis- iary) and machine is
played. between 0.25 and Open circuit in har-
4.75 V. ness between MC and
· Key switch: ON pressure sensor (aux-
NO
iliary) (terminal #1).

YES sor (auxiliary).

open end side)
Pilot Pressure Sensor (Auxiliary)
Pilot Pressure Sensor (Arm Roll-Out)
MC
Connector MC-A
#A7 #A23
T1V1-05-07-102
Auxiliary Flow Rate Control

Solenoid Valve
MC
Connector MC-D T183-05-04-008
#D5
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-82
Disconnect connec- Check if voltage be-
tor MC-D in MC. YES tween terminal #D9
Check for continuity (harness end) of To A
between terminal connector MC-D and
Disconnect connec- YES #D9 (harness end) of machine is 0 V.
tor in pressure sen- connector and ter- · Key switch: ON
sor (arm roll-out). minal #2 (harness
NO Check if voltage be- end) of connector in Open circuit in harness
Switch pressure tween terminals #1 pressure sensor (arm between MC and pressure
sensor (arm roll-out) and #3 (harness end) roll-out). NO
sensor (arm roll-out).
with other pressure of connector is 5±0.5
YES sensor.
V.
Check if fault code
for switched pres- · Key switch: ON Open circuit in harness
Check if voltage be- YES between MC and pressure
sure sensor is dis- tween terminal #1
played. sensor (arm roll-out) (ter-
(harness end) of minal #3).
connector in pressure
NO sensor (arm roll-out)
and machine is be-
tween 0.25 and 4.75 Open circuit in harness
V. between MC and pressure
NO sensor (arm roll-out) (ter-
· Key switch: ON minal #1).
Faulty pressure sensor

(arm roll-out).
YES

between MC and pressure
NO sensor (auxiliary).
Faulty auxiliary flow rate

YES
Check if auxiliary flow
YES rate control solenoid
valve is bound or Faulty auxiliary flow rate
scored. YES
Check if auxiliary control valve in control
Check for continuity in flow rate control valve.
harness between MC valve in control
YES and auxiliary flow rate NO valve is bound or
control solenoid valve. Faulty MC.
scored.
NO
· Between terminal
#A23 of connector Open circuit in harness
A MC-A in MC and ter- between MC and auxiliary
minal #1 of connector flow rate control solenoid
in auxiliary flow rate NO
valve.
connector in auxiliary
flow rate control sole-
noid valve Shorted circuit in harness
between MC and pres-
NO sure sensor (arm
roll-out).
T5-7-83
attachment.
When breaker attached with auxiliary flow com- Shorted circuit in har-
biner line is used. NO ness between MC and
• Check the wiring connections first. pressure sensor (aux-
Disconnect connec- iliary).
tor MC-D in MC.
YES Check if voltage be- Switch pressure sen-
tween terminal #D5 sor (arm roll-out) with
(harness end) of other pressure sen-
Disconnect connector connector and ma- YES sor.
in pressure sensor chine is 0 V. Check if fault code for
(auxiliary). · Key switch: ON switched pressure
NO Check if voltage be- sensor is displayed.
tween terminals #1
Switch pressure of connector is 5±0.5 Open circuit in har-
sensor (auxiliary) V. YES ness between MC and
with other pressure · Key switch: ON pressure sensor (aux-
sensor. Check if voltage be- iliary) (terminal #3).
Check if fault code tween terminals #1
for switched pres- (harness end) of
sure sensor is dis- connector in pres- Open circuit in har-
played. NO sure sensor (auxil- ness between MC and
iary) and machine is pressure sensor (aux-
NO
between 0.25 and iliary) (terminal #1).
4.25 V.
· Key switch: ON

YES sor (auxiliary).
Connector (Harness end of connector viewed from the open

end side)
・ Pilot Pressure Sensor (Auxiliary) MC
・ Pilot Pressure Sensor (Arm Roll-Out) Connector MC-A
#A7 #A23
T1V1-05-07-102
Auxiliary Flow Combiner Solenoid Valve MC T183-05-04-008
Connector MC-D
#D5
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-84

NO between MC and pres-
sure sensor (arm
roll-out).
MC-D in MC. Check if Disconnect connector
YES MC-B in MC and con-
voltage between ter- Check if auxiliary flow
Disconnect connector minal #D9 (harness nector in auxiliary flow NO combiner solenoid
in pressure sensor end) of connector and combiner solenoid valve is bound or To A
(arm roll-out). machine is 0 V. valve. scored.
NO Check if voltage be- Check for continuity
tween terminals #1 YES between terminals #1
and #3 (harness end) and #2 (harness end) Shorted circuit in harness
of connector is 5±0.5 of connector in auxil- between MC and auxil-
V. iary flow combiner
solenoid valve. YES iary flow combiner sole-
· Key switch: ON noid valve.

Check if voltage be- YES between MC and pres-
tween terminal #1 sure sensor (arm roll-out)
(harness end) of con- (terminal #3).
nector in pressure
NO sensor (arm roll-out)
and machine is be-
tween 0.25 and 4.75
V.
NO sure sensor (arm roll-out)
· Key switch: ON (terminal #1).

YES (arm roll-out).
YES Faulty auxiliary flow

combiner solenoid valve.
A Faulty auxiliary flow

YES
Check if auxiliary flow combiner valve.
combiner valve in
NO control valve is bound
or scored. Faulty MC.
NO
T5-7-85
attachment.
When vibrating hammer is used. Disconnect connec-

• Check the wiring connections first. tor MC-D in MC. Open
MC circuit in harness
と圧力センサ(予
NO
Check for continuity between
備)間のハーネス断線MC and pres-
sure sensor (auxiliary).
YES between terminal
#D5 (harness end) of
connector and ter-
minal #2 (harness Checkコネクタのハー
MC-D if voltage be-
end) of connector in tween terminal #D5
ネス側コネクタ#D5端
Disconnect connector (harness
子と本体間の電圧を測 end) of con-
pressure sensor.
in pressure sensor YES 定するMC-D and
nector
(auxiliary). 電圧は 0Visか
machine between 0
NO Check if voltage be- V.
1-
tween terminals #1
and #3 (harness end) · キースイッチ:
Key switch: ONON
Switch pressure of connector is be-
sensor (auxiliary) tween 5±0.5. Open
MC circuit in harness
と圧力センサ(予
with other pressure · Key switch: ON YES between MC and pres-
備)(#3 端子)間のハー
sensor. Check if voltage be- sure
ネス断線 sensor (auxiliary)
Check if fault code tween terminal #1 (terminal #3).
for switched pres- (harness end) of
sure sensor is dis- connector in pres-
played. NO sure sensor (auxil- Open circuit in harness
iary) and machine is MC と圧力センサ(予
between 0.25 and between MC and pres-
NO 備)(#1 端子)間のハー
sure sensor (auxiliary)
4.75 V. ネス断線
(terminal #1).
· Key switch: ON 1

YES (auxiliary).

open end side)
Pilot Pressure Sensor (Auxiliary) MC MC
Pilot Pressure Sensor (Travel Forward) Connector MC-A Connector MC-C
#A5
T1V1-05-07-102
#A31 T183-05-04-008 T1V1-05-07-103

Maximum Pump 1 Flow Rate Limit MC
Control Solenoid Valve Connector MC-D
#D5
T1V1-05-04-003
T183-05-04-009
T5-7-86
YES
To A
Disconnect connector YES tween terminal #C2
in pressure sensor (harness end) of con-
(travel forward). nector MC-C and
NO Check if voltage be- machine is 0 V. Shorted circuit in harness
tween terminals #1 · Key switch: ON between MC and pres-
Switch pressure sen- and #3 (harness end) NO sure sensor (travel for-
sor (travel forward) of connector is 5±0.5 ward).
YES with other pressure V.
sensor. · Key switch: ON
Check if fault code for Open circuit in harness
switched pressure Check if voltage be- YES between MC and pres-
sensor is displayed. tween terminal #1 sure sensor (travel for-
(harness end) of con- ward) (terminal #3).
nector in pressure
NO sensor (travel forward)
and machine is be- Open circuit in harness
tween 0.25 and 4.75 between MC and pres-
V.
NO sure sensor (travel for-
· Key switch: ON ward) (terminal #1).

(travel forward).
YES

NO sure sensor (auxiliary).
in maximum pump 1 YES Faulty maximum pump 1
flow rate limit control flow rate limit control
solenoid valve. solenoid valve.
YES Check if current be-
tween terminals #1
of connector is be-
tween 56 mA and 920
harness between MC
mA.
A and maximum pump 1
Faulty MC.
flow rate limit control · Key switch: ON
solenoid valve. NO
· Between terminal
#A31 of connector Open circuit in harness
MC-A in MC and ter- between MC and maxi-
NO mum pump 1 flow rate
minal #1 of connector
in maximum pump 1 limit control solenoid
flow rate limit control valve.
solenoid valve
connector in maxi-
mum pump 1 flow rate
limit control solenoid
valve
T5-7-87
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• Check whether the pilot system is faulty or the • If left travel speed is also slow, refer to A-3.
main circuit is faulty.
• If other functions (front attachment and travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system is displaying a
problem, the cause of trouble may exist in the
circuit after pilot valve.
Check if swing motor

YES parking brake release
valve is scored or
bound.
Check if parking brake
YES release pressure is
approx. 3.9 MPa (40
2
kgf/cm ).
Monitor pump control · Relieve arm circuit. Faulty swing parking

pressure. · Monitor item: brake release spool in
Front pilot pressure NO signal control valve.
YES While slowly operating
swing lever, check if · Possible to display by
pump control pressure built-in diagnosing sys-
varies smoothly. tem.
Monitor secondary · Monitor item:
pilot pressure. Pump 2 flow control
Check if secondary pressure
pilot pressure is nor- · Possible to display by Bound pump 2 flow rate
mal. built-in diagnosing sys- control valve in signal
tem. NO control valve.
· Specification:
Refer to the Opera-
tional Performance
Test section.
· Monitor item: Faulty pilot valve.
Swing pilot pressure NO
tem.
T5-7-88
YES Faulty swing reduction

gear.
YES Check if swing motor drain

oil amount is normal.
· Measurement: Faulty swing motor.
NO Check if swing relief
Refer to the Operational NO
pressure is normal.
Performance Test section.
· Relieve swing circuit.
· Monitor item: Pump 2
delivery pressure
built-in diagnosing sys- Faulty swing relief valve.
tem. NO
· Specification:
Refer to the Opera-
tional Performance
Test section.
Faulty swing motor park-
YES ing brake release valve.
T5-7-89
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Machine does not travel.
• The travel system is inoperable unless the fol- • Air mixing in the transmission hydraulic circuit
lowing conditions are met. may cause the parking brake to drag. Bleed air
FNR Switch: F or R position from the transmission by referring to T5-7-130.
Brake Switch: OFF, Auto Axle Lock or Axle Lock • When other actuators (front attachment and
position swing) operate normally, the pilot pump, pilot filter
• Failure in the transmission and/or axle (front and pilot relief valve are considered to be normal.
and/or rear) may be the cause of the trouble. • Check the wiring connections first.
Check if a noise is emitted from each section.
• Check if parking brake indicator (P), work brake
indicator (S) in the monitor unit and neutral indi-
cator (N) in the steering column monitor are OFF.
Monitor implement
YES brake state.
Check if ON is dis-
played.
Monitor pump 1 deliv-

ery pressure by using
NO Dr. ZX.
creases according to
travel operation.
Faulty control valve
· Monitor item: Pump 1 NO (bound spool).
delivery pressure
the Operational Per-
formance Test section.
Disconnect connectors in
travel forward/reverse Pi cut
solenoid valve.
Check if symptoms disap-
pear.
YES Faulty MC.
Monitor FNR switch.

Check if indication is
YES changed by shifting
switch.
· Monitor item:
FNR (F) SW,
FNR (R) SW
Faulty FNR switch.
NO
T5-7-90
YES Faulty work brake release

switch.
Monitor work brake

release switch.
YES
Check if ON is dis-
played.
· Monitor item:
YES Disconnect connector in Implement brake de- Faulty MC.
solenoid valve unit (SF). active
Check if symptoms dis- NO
appear.
Faulty solenoid valve unit

NO (SF) (bound).
YES Faulty Travel mode selection

solenoid valve (bound).
Monitor fast/slow selec-

tion relays.
Check if OFF is dis- YES Faulty brake switch.
NO
played.
· Monitor item:
T/M change (high speed) Monitor parking brake
T/M change (low speed) switch.
· FNR switch: N NO Check if ON is dis-
played.
· Brake switch: except
P (parking brake) Faulty MC.
NO
T5-7-91
T-2 Machine does not travel forward and re-
verse.
• Failure in the transmission and/or axle (front

and/or rear) may be the cause of the trouble.
Check if a noise is emitted from each section.
• When other actuators (front attachment and
swing) operate normally, the pilot pump, pilot filter
and pilot relief valve are considered to be normal.
NO Check travel spool in

Switch relief valves at control valve for abnor-
mality.
NO forward and reverse
sides in travel motor.
Check if symptoms are
Monitor pump 1 delivery switched.
pressure by using Dr. ZX.
YES
Check if travel for-
ward/reverse relief pres-
sure is normal.
· Refer to the Operational Faulty travel motor relief
Performance Test section.
YES valve.
Monitor FNR switch.

Check if ON is dis- Faulty travel shockless
played when turning valve.
YES
FNR switch to F or R.
· Monitor item:
FNR (F) SW,
FNR (R) SW
Faulty FNR switch, or

open circuit in harness
between MC and FNR
NO
switch.
T5-7-92
YES Faulty counterbalance

valve.
Check counterbalance
NO
valve in travel motor for
abnormality. YES Faulty make-up valve.
Check make-up valve for

abnormality.
NO
Faulty center joint.
NO
Faulty control valve

(bound spool).
YES
T5-7-93
T-3 Forward/reverse travel speeds are slow.
Travel power is weak.
• If the travel motor displacement angle control so- • When other actuators (front attachment and
lenoid valve is faulty, fault code 11422 is dis- swing) operate normally, the pilot pump, pilot filter
played. and pilot relief valve is considered to be normal.
• Failure in the transmission and/or axle (front • Pump 1 flow rate reduction may be the cause of
and/or rear) may be the cause of the trouble. this trouble when bucket single operation speed is
Check if a noise is emitted from each section. slow. Refer to A-3.
• Air mixing in the transmission hydraulic circuit • Check the wiring connections first.
may cause the parking brake to drag. Bleed air
from the transmission by referring to T5-7-130.
NO
Check travel spool in

NO
control valve for ab-
normality.
Faulty control valve.
YES
Monitor slight travel SW
NO by using Dr. ZX.
Check if ON is dis-
played. NO Faulty engine speed control
Disconnect connector mode selection switch.
· Engine speed control
mode selection switch: in switch panel.
Pedal or Dial Monitor slight travel
YES SW by using Dr. ZX.
Check if ON is dis- Faulty MC, or shorted circuit
played. in harness between MC and
YES engine speed control mode
Check if fault code selection switch.
11422 is displayed.
Refer to Troubleshooting A.
YES
T5-7-94
YES Faulty center joint.

Measure drain amount
from travel motor.
Check if drain amount
is normal.
· Refer to the Opera- Faulty travel motor.
tional Performance NO
Test section.
T5-7-95
T-4 When releasing accelerator pedal, hydraulic
brake is not applied. (Machine runs away.)
• If the travel motor displacement angle control so-

lenoid valve is faulty, fault code 11422 is dis-
played.
• Similar symptom may appear when the travel pilot
valve, travel shuttle valve and/or travel spool is
faulty.
NO Faulty control valve.
Check if counterbal-
NO ance valve in travel
motor is abnormal.
Faulty counterbalance valve.

Switch relief valves at
YES
YES forward and reverse
sides in travel motor.
switched.
Faulty travel motor relief

Monitor vehicle speed. YES valve.
Check if speed is
changed according to
accelerator pedal op-
eration.
Faulty travel N sensor, or
faulty harness between MC
NO and travel N sensor.
T5-7-96
(Blank)
T5-7-97
T-5 Travel mode (fast/slow) does not shift.
Travel Mode Selection
• Air mixed in the transmission hydraulic circuit Solenoid Valve
may prevent the transmission from being shifted. Port B Port K
Bleed air from the transmission by referring to
T5-7-130.
• Set the FNR switch in the F or R position. Set the
brake switch in the position other than the parking
position. Perform the troubleshooting.
TCJB-05-07-003
NO
Install pressure gauge to
ports B and K in transmis-
sion changeover solenoid
valve.
YES Check if pressure at each
port varies as shown be-
low when travel speed
mode switch is operated.
Monitor fast speed · Travel speed mode switch: Slow
selection relay and →Pressure at port B: 0 MPa
slow speed selection →Pressure at port K: 3.0 MPa Faulty transmission.
YES relay. · Travel speed mode switch: Fast
When shifting travel →Pressure at port B: 3.0 MPa YES
speed mode switch, →Pressure at port K: 0 MPa
check if ON is dis-
played respectively.
· Monitor item:
T/M selection (Fast)
T/M selection (Slow)
When shifting travel
speed mode switch, Faulty fast/slow speed selec-
check if slow speed tion relay.
indicator in steering NO
column monitor is
ON/OFF normally.
· Travel speed mode

switch: Slow
→Indicator: ON
· Travel speed mode
switch: Fast
→Indicator: OFF
Faulty travel speed mode

switch, or faulty harness be-
NO tween MC and travel speed
mode switch.
T5-7-98
Open circuit in harness between

NO travel mode selection solenoid
valve and fast/slow speed
selection relay.
in travel mode
selection solenoid
valve. Faulty travel mode selection
YES
Check if voltage at solenoid valve (bound spool).
terminal #2 (each
harness end) of With connector in travel
connector is 24 V. mode selection solenoid
valve disconnected, check
· Travel speed mode YES for continuity between
switch: Slow terminal #1 (harness end) of
→Green-yellow line connector and machine. Open ground circuit in harness
· Travel speed mode NO to travel mode selection
switch: Fast solenoid valve.
→Brown-white line
Connector (Harness end of connector viewed from the open

end side)
Travel Mode
Selection Solenoid
Valve Travel Mode Selection Solenoid Valve
Fast Speed Side Slow Speed Side
TCJB-05-07-002
TCJB-05-06-004 TCJB-05-06-004
Brown-White Yellow-Green
First Speed Side Slow Speed Side Line Line
T5-7-99
T-6 Axle lock is not released.
• Check that the brake switch is in the OFF position

first.
YES
Refer to troubleshooting A.
Faulty operate check valve (axle

Check if fault code is YES lock cylinder), or open circuit in
harness between MC and solenoid
11424 is displayed.
value unit (SI).
· Brake switch:
Auto axle lock
or Axle lock
Monitor brake switch.
Check if OFF is
NO displayed.
· Monitor item:
Parking brake SW
Axle lock control state
Faulty brake switch, or shorted
circuit in harness between MC and
NO brake switch.
T5-7-100
T-7 Axle lock is not operable.
• Check that the brake switch is in the auto axle lock

or axle lock position first.
YES
Refer to troubleshooting A.
Faulty operate check valve (axle

YES lock cylinder), or shorted circuit in
Check if fault code is harness between MC and solenoid
11424 is displayed. value unit (SI).
· Brake switch:
Auto axle lock
or Axle lock
Monitor brake switch.
NO Check if OFF is
displayed.
· Monitor item:
Axle lock control state Faulty brake switch, or open circuit
· Brake switch: in harness between MC and brake
NO switch.
Auto axle lock or Axle
lock
T5-7-101
BRAKE SYSTEM TROUBLESHOOTING
B-1 Parking brake is not operable (not applied).
• Bleed air from the transmission by referring to

T5-7-130 before starting troubleshooting.
• If the fast/slow speeds do not change, refer to “T-5
Travel mode (fast/slow) does not shift”.
YES Faulty MC.
Monitor parking brake

switch.
Check if ON is
displayed.
· Brake switch:
P (parking brake) position YES Faulty brake switch.
in brake switch.
NO of connector.
Monitor parking brake
switch.
Check if ON is
displayed. Open circuit in harness
between MC and brake
NO switch.

open end side)
Brake Switch
TCJB-05-07-004
T5-7-102
B-2 Service brake is not operable, or is not
applied effectively.
• The front and rear wheel service brake circuits are

independently designed each other. When either
the front or the rear wheel brake circuit fails,
overall service brake system will not operate
properly.
• Check the brake lining and the accumulator for
any abnormalities, and bleed air from the brake
system by referring to operator’s manual and
T5-7-131 before starting the troubleshooting.
• When other actuators (front attachment, travel
and swing) operate normally, the pilot pump is
NO Faulty accumulator charging

valve.
Monitor brake remain

pressure.
Check if pressure is
12.7 MPa or more. YES Faulty brake system at axle
side.
Monitor brake pressure.

YES Check if pressure is 6 MPa or
more. Faulty brake valve.
NO
· Brake pedal: Fully operated
diagnosing system.
T5-7-103
B-3 Work brake is not operable.
• Check if the brake switch is in the auto axle lock or

axle lock position first.
• When the brake switch is in the auto axle lock or
axle lock position, the work brake is applied.
When the brake switch is in the auto axle lock or
axle lock position and if the work brake is not
applied, the circuit in harness between MC and
brake switch may be open.
• When the speedometer is normal, the travel N
sensor may be normal.
• When other actuators (front attachment, travel
and swing) operate normally, the pilot pump is

11425-3, 11425-4.
YES Faulty solenoid valve
unit (SI).
YES Monitor implement

brake state.
Check if ON is
displayed.
Faulty MC.
YES Monitor brake NO
pressure. Check if
pressure is 6.0 MPa or
more.
· Depress brake pedal
fully. Faulty brake valve.
Monitor axle lock · Possible to display by NO
control state. built-in diagnosing
Check if ON is system.
displayed.
· Brake switch: Auto axle
lock or Axle lock Faulty brake switch.
NO
T5-7-104
STEERING SYSTEM TROUBLESHOOTING
H-1 Although steering wheel is rotated, steering

is heavy.
• Check the steering filter first.
YES Faulty steering pump.
Disconnect hoses from

delivery ports of steering
pump and pilot pump.
Connect hoses each
other to the other side. YES Faulty steering valve.
improved. Monitor steering pump by
using Dr. ZX.
NO Check if pressure is normal.
Faulty relief valve in steering
· Monitor item: Pump 3 delivery NO valve.
pressure
H-2 Although steering wheel is rotated, steering

is impossible.
• Although the steering valve does not have enough

pressure oil from the steering pump, the machine
can turn the left and right.
• If the machine cannot turn the left and right, center
joint maybe faulty.
• If only one side (left or right) can turn, the center
joint or the overload relief valve in the steering
valve maybe faulty.
T5-7-105
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is not operated.
Checking Instructions
• The wiper is driven by electric power routed via • When the front window is open, the wiper is not
the relay circuit. The relay circuit is controlled by operated.
the monitor unit. In case the wiper is not operated, Check that the front window is closed securely.
first check if the wiper relay is activated. Next,
check if electric power is routed to the wiper mo-
tor.
YES
Switch wiper relay with Faulty wiper relay.
NO other general relay. Disconnect connector YES
Check if wiper is oper- monitor-A in monitor Faulty monitor unit.
ated. unit.
· Key switch: ON Connect terminal #A2
NO (harness end) of con-
nector to machine. Open circuit in harness
Disconnect wiper relay. between wiper relay and
Check for continuity NO monitor unit.
Check if wiper relay between terminal #A2
is turned ON/OFF (harness end) of con-
according to INT. nector and machine.
position of wiper
switch. YES
Close front window. Faulty wiper motor.
· Key switch: ON Disconnect connector
· Wiper switch: INT YES in wiper motor.
Open front window. Check if voltage be-
tween terminals B and Open circuit in harness
L (harness end) of between window con-
tween terminals B NO
connector is 24 V. tact and wiper motor.
YES and L at window
contact in cab end is · Key switch: ON
24 V. · Wiper switch: ON
· Key switch: ON Open circuit in harness
· Wiper switch: ON NO between wiper relay and
window contact.
T5-7-106
Window Contact (Cab end) Connector

Wiper Motor (Harness end)
INT. Position Setting Time
Slow Speed 8 seconds
Middle Speed 6 seconds B L
Fast Speed 3 seconds

S E
T1V1-05-07-005
Monitor Unit
Connector Monitor-A (Harness end) #A2
T183-05-05-001
Wiper Driving Circuit
Wiper Motor Wiper Relay
Main
Window Contact ↑
T1V1-05-07-004
T5-7-107
O-2 Air Conditioner is faulty
The air conditioner operation system has a

self-diagnosing function. This system performs the
diagnosis by 8-steps as shown in the flow chart be-
low: Check Model Confirmation, Display Function
Confirmation, Present Trouble Diagnosing, Past
Trouble Diagnosing, Sensing Temperature Display,
and Component Operation Check, Correction of the
Set Temperature and Selection of Celsius and Fahr-
enheit Temperature Indication.
Normal Operation
Turn key switch ON while pushing air

conditioner switch and mode switch.
Keep pushing OFF switch

for more than 3 seconds. STEP 0
Check Model Confirmation
Push lower side fan switch. Push upper side fan switch.
Keep pushing OFF switch STEP 1
for more than 3 seconds. Display Function
Confirmation
Keep pushing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Keep pushing OFF switch STEP 3 Keep pushing air conditioner

for more than 3 seconds. Past Trouble switch for more than 3 seconds.
Diagnosing
Sensing Temperature
Display
Component Operation Check
Push AUTO switch and Push AUTO Push A/C Push A/C switch and
lower side fan switch. Switch and switch and upper side fan switch.
upper side lower side
fan switch. fan switch.
Keep pushing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
for more than 3 seconds.
Self-Diagnosis
T5-7-108
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pushing the air condi-
tioner switch and mode switch on air conditioner con-
trol panel.
STEP 0 Check Model Confirmation

The liquid crystal display (LCD) indicates the ma-
chine model name this system can diagnose. T178-05-08-001
Mode Switch OFF Switch

• The LCD will indicate “Sd” as the check model
name.
• Select next step in order to be performed by oper-
ating the switch as described below.
• Upper side fan switch: To proceed to Step 1
• Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
pushed after the check model is displayed.
STEP 1 Display Function Confirmation

Turn all indicators ON in order to check indicator
bulbs.
• The LCD panel and all switch indicators light.

• Select the next step in order to be performed by op-
erating the switches as follows:
• Push the upper side of fan switch: To proceed to
“STEP 2.”
• Push the lower side of fan switch: To return to
“STEP 0.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-109
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.
• In case any abnormalities are present, the LCD in-

dicates the fault codes. If more than one fault code
is detected, the following fault code is displayed af-
ter flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Open Circuit Shorted Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient 23 −23
Temperature
Sensor
Outdoor Ambient 24 −24
Temperature
Sensor
Coolant Tem- 25 −25
perature Sensor
∗
Solar Radiation 26 −26
Sensor
∗
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of open circuit.
“STEP 3.”
“STEP 1.”
(Normal function is resumed)
T5-7-110
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
• In case any abnormalities occurred in the past, the

LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is dis-
played after flashing (0.5 seconds) twice. T178-05-08-001
Fault Code OFF Switch
Open circuit Shorted Circuit
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient
Temperature 23 −23
Sensor
Outdoor Ambient
Temperature 24 −24
Sensor
Coolant Tem- 25 −25
perature Sensor
Solar Radiation −26
Sensor
• When the air conditioner switch is kept pushing for
more than 3 seconds, the failure records are de-
leted. After this operation, the air conditioner switch
indicator flashes 5 times. Then, the self-diagnosing
system is deactivated. (Normal functions are re-
sumed.)
“STEP 4.”
“STEP 2.”
T5-7-111
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
by each temperature sensor (excluding the insulation
sensor).
• The sensing temperature detected by the in-cab

ambient temperature sensor, outdoor ambient tem-
perature sensor and coolant temperature sensor are
displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.) T178-05-08-001
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant tem-
perature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
“STEP 5.”
“STEP 3.”
T5-7-112
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
• Each time the fresh air vent switch is pushed, the

component to be checked is selected in order.
Check which component has been selected by re-
ferring to No. indicated on the LCD. (Refer to table
1.) T178-05-08-001
• Operating pattern of the selected component is
Fresh Air Vent switch OFF Switch
shifted at an interval of 10 seconds. Operating pat-
tern is cycled. (Refer to table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
• Push the AUTO switch and upper side of fan
switch: To proceed to “STEP 6-1”.
• Push the A/C switch and upper side of fan switch:
To proceed to “STEP 6-2”.
“STEP 4.”
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5” and “H” are in-
damper: 0% (fully closed) → dicated next to the decimal point respec-
50%*→ 100% (fully opened) tively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow vol-
M(Lo) → M(Hi) → Hi ume light.
Air Vent Location 53 Selects air vent: Front*→ Indicator corresponding to selected air
Front/Rear → Front/Foot → Foot vent lights.
Fresh / Circulation 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
Air Vent Selection tion* → Fresh mode light.
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
→ OFF OFF: Indicator is extinguished.
T5-7-113
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
• Each time when the top or bottom of temperature

control switch is pushed, temperature correction,
displayed on the LCD window, can be changed.
• Actually controlled temperature is the normally set
temperature plus the set temperature correction.
For instance, when the normally set temperature is
25°C (77 °F) and set temperature correction is -1°C T178-05-08-001
(-34 °F), the actually controlled temperature be- OFF Switch

comes 24°C (75 °F).
• Push the AUTO switch and lower side of fan
switch: To return to “STEP 5.”
T5-7-114
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Selection of Celsius and Fahrenheit Temperature In-
dication.
• Each time when the fresh air vent switch is pushed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
• Temperature is displayed at the top of LCD window
as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001
C F Fresh Air Vent Switch OFF Switch

• Push the Air Conditioner Switch and lower side of
fan switch: To return to “STEP 5.”
T5-7-115
ÄPlease fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with
your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.

(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
Symptom No cool air (2) Pressure (To be measured at gauge manifold)
No warm air Low Pressure
Others High Pressure
Uncontrollable air volume (3) Which parts have been replaced ?
Symptom Air flows in Hi mode only 1
No air flows
2
Small air volume
Others
Uncontrollable vent hole ∗ Before replacing the control amplifier, be sure to
Symptom Vent hole isn’t selected check that the connectors are correctly connected
while repeatedly disconnecting and reconnecting
Others
connectors.
Abnormal panel indication
Faulty Indica- Vent Hole
tor A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-7-116
Refrigerant Quantity....................... 900±50 g
3
Compressor Oil Quantity................ 210 cm
T5-7-117
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
does not respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Heater unit emits hot air.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost forms. Thermistor does not cool.
flow volume is reduced.
Thermistor cools.
T5-7-118
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of expansion valve. Readjust or replace expansion valve.
Clogged expansion valve. Remove clog, or replace receiver and/or expansion

valve.
Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps by using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Improper adjustment (excessive open) of expansion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve). Replace.
Improper water stop valve wire adjustment and/or faulty stop

valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside air induction

Repair.
type).
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

Air is mixed in system.
ceiver dryer.
Incorrect thermistor location. Correct thermistor location.
Gas leaks from case. Seal gaps by using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermistor cord.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-7-119
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer contact
noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or suc-
tion gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-7-120
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.

Replace if loud.
No functional problem exists.

Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in L
mode for more than 10 minutes, flush smell out by condensed water.
T5-7-121
Compressor
Compressor does not rotate. Clutch terminal voltage is normal 24 V.
Inoperable
cooling Clutch terminal voltage is low.
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and

low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints by using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) by using gas
blower mo- detector.
tor rotate. (Refer to NOTE 1, 2
on page T5-7-125.)
Stain on exterior.
Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2

months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

High pressure side is pressor in liquid form.)
slightly low and low pres-
sure side is high.
No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through Others

sight glass.
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-7-118.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-7-122
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Open or shorted circuit in core cable.
Shaft does not rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-7-118.
Broken valve (Refer to NOTE 3 on page T5-7-125.)
Replace.
Blown gasket (Refer to NOTE 3 on page T5-7-125.)
Check and adjust

Excessive oil. oil level.
T5-7-123
Compressor
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-7-118.
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-7-124
Broken clutch bearing due to overly tightened belt. Replace.
Shaft does n’o rotate.

Replace.
Shaft rotates draggy.
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit

Saggy belt. Troubleshooting Table on
page T5-7-120.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Troubleshooting Table on
Loose screws. page T5-7-120.
NOTE:
1. Do not quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm ) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.
T5-7-125
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting

method to find the trouble location by exchanging the
suspected part/component with another part
/component having identical characteristics.
Pump 2 Pump 1
Many sensors and solenoid valves used on this ma- (5-Spool (4-Spool
chine are identical. Therefore, by using this Section) Section)
switch-check method, faulty part/component, and/or
harness can be easily found.
PP2 PP1
Example: Abnormal pump 1 delivery pressure sensor
high voltage (MC fault code: 11200-3)
Check Method:
1. Switch two delivery pressure sensors located as
Figure A
shown in figure A to figure B.
2. Retry troubleshooting. T157-07-04-006
Result:
In case abnormal pump 2 delivery pressure sensor
high voltage is displayed (MC fault code 11202-3), the
pump 1 delivery pressure sensor is considered to be
faulty.
Pump 2 Pump 1
(5-Spool (4-Spool
In case abnormal pump 1 delivery pressure sensor Section) Section)
high voltage (MC fault code 11200-3) is displayed, the
pump 1 delivery pressure sensor harness is consid-
ered to be faulty. PP1 PP2
Figure B T157-07-04-006
T5-7-126
Applicability of Switch-Check Method
Fault Code Trouble Applicability

11000-2 Abnormal EEPROM Not Applicable
11001-2 Abnormal RAM
11002-2 Abnormal A/D Conversion
11003-3 Abnormal Sensor Voltage Not Applicable
11004-2 CAN Communication Error Not Applicable
11100-2 Abnormal Engine Speed Not Applicable
11101-3 Abnormal Engine Control Dial Sensor High Voltage Not Applicable
11101-4 Abnormal Engine Control Dial Sensor Low Voltage
11200-3 Abnormal Pump 1 Delivery Pressure Sensor High Voltage Applicable
11200-4 Abnormal Pump 1 Delivery Pressure Sensor Low Voltage (Harness/Sensor)
11202-3 Abnormal Pump 2 Delivery Pressure Sensor High Voltage
11202-4 Abnormal Pump 2 Delivery Pressure Sensor Low Voltage
11203-3 Abnormal Pump 3 Delivery Pressure Sensor High Voltage
11203-4 Abnormal Pump 3 Delivery Pressure Sensor Low Voltage
11206-3 Abnormal Pump 1 Control Pressure Sensor High Voltage Applicable
11206-4 Abnormal Pump 1 Control Pressure Sensor Low Voltage (Harness/Sensor)
11208-3 Abnormal Pump 2 Control Pressure Sensor High Voltage
11208-4 Abnormal Pump 2 Control Pressure Sensor Low Voltage
11301-3 Abnormal Swing Pilot Pressure Sensor High Voltage Applicable
11301-4 Abnormal Swing Pilot Pressure Sensor Low Voltage (Harness/Sensor)
11302-3 Abnormal Boom Raise Pilot Pressure Sensor High Voltage
11302-4 Abnormal Boom Raise Pilot Pressure Sensor Low Voltage
11303-3 Abnormal Arm Roll-In Pilot Pressure Sensor High Voltage
11303-4 Abnormal Arm Roll-In Pilot Pressure Sensor Low Voltage
11305-3 Abnormal Travel Forward Pilot Pressure Sensor High Voltage
11305-4 Abnormal Travel Forward Pilot Pressure Sensor Low Voltage
11306-3 Abnormal Travel Reverse Pilot Pressure Sensor High Voltage
11306-4 Abnormal Travel Reverse Pilot Pressure Sensor Low Voltage
11307-3 Abnormal Front Attachment Pilot Pressure Sensor High Voltage
11307-4 Abnormal Front Attachment Pilot Pressure Sensor Low Voltage
11310-3 Abnormal Brake Pressure Sensor High Voltage Applicable
11310-4 Abnormal Brake Pressure Sensor Low Voltage (Harness/Sensor)
11311-3 Abnormal Brake Remaining Pressure Sensor High Voltage
11311-4 Abnormal Brake Remaining Pressure Sensor Low Voltage
T5-7-127

11400-2 Abnormal Feedback Current of Maximum Pump 2 Flow Rate Limit Applicable (Harness)
11400-3 Abnormal Feedback High Voltage of Maximum Pump 2 Flow Rate
11400-4 Abnormal Feedback Low Voltage of Maximum Pump 2 Flow Rate
11401-2 Abnormal Feedback Current of Torque Control Solenoid Valve
11401-3 Abnormal Feedback High Voltage of Torque Control Solenoid Valve
11401-4 Abnormal Feedback Low Voltage of Torque Control Solenoid Valve
11410-2 Abnormal Feedback Current of Maximum Pump 1 Flow Rate Limit
11410-3 Abnormal Feedback High Voltage of Maximum Pump 1 Flow Rate
11410-4 Abnormal Feedback Low Voltage of Maximum Pump 1 Flow Rate
11403-2 Abnormal Feedback Current of Solenoid Valve Unit (SC) Applicable
11403-3 Abnormal Feedback High Voltage of Solenoid Valve Unit (SC) (Harness/Solenoid Valve)
11403-4 Abnormal Feedback Low Voltage of Solenoid Valve Unit (SC)
11424-2 Abnormal Feedback Current of Solenoid Valve Unit (SI)
11424-3 Abnormal Feedback High Voltage of Solenoid Valve Unit (SI)
11424-4 Abnormal Feedback Low Voltage of Solenoid Valve Unit (SI)
11425-2 Abnormal Feedback Current of Solenoid Valve Unit (SF)
11425-3 Abnormal Feedback High Voltage of Solenoid Valve Unit (SF)
11425-4 Abnormal Feedback Low Voltage of Solenoid Valve Unit (SF)
11422-2 Abnormal Feedback Current of Travel Motor Displacement Angle Not Applicable
11422-3 Abnormal Feedback High Voltage of Travel Motor Displacement
Angle Control Solenoid Valve
11422-4 Abnormal Feedback Low Voltage of Travel Motor Displacement
Angle Control Solenoid Valve
11423-2 Abnormal Feedback Current of Travel Make-Up Solenoid Valve Applicable
11423-3 Abnormal Feedback High Voltage of Travel Make-Up Solenoid (Harness/Solenoid Valve)
Valve
11423-4 Abnormal Feedback Low Voltage of Travel Make-Up Solenoid Valve
T5-7-128

11910-2 Actual Engine Speed Not Applicable
11911-2 Security Signal Not Applicable
11914-2 Radiator Coolant Temperature Not Applicable
11915-2 Gate Lock Signal Not Applicable
11918-2 Word Mode Not Applicable
11920-2 Fuel Flow Rate Not Applicable
11502-2 Travel Motor Excessive Rotation Not Applicable
11901-3 Abnormal Hydraulic Oil Temperature Sensor High Voltage Not Applicable
11901-4 Abnormal Hydraulic Oil Temperature Sensor Low Voltage
11921-2 Incorrect Odometer Value Not Applicable
T5-7-129
BLEEDING AIR FROM TRANSMISSION
2 1
IMPORTANT: Release any pressure in the
transmission after removing/installing
the pipe lines or hoses, or changing
the hydraulic oil. If air is mixed in the
transmission gearshift circuit,
malfunction of the transmission may
result.
NOTE: Bleed air by two or more persons. TCJB-01-02-020
1. Start the engine. Park the machine on level firm

ground. Lower the bucket onto the ground.
2. Perform the following steps. Apply the work
brake.
• Set the brake switch to the auto axle lock or axle
lock position. 3
• Depress the brake pedal fully.
NOTE: If the brake switch is the P (parking brake)
position, air bleeding work cannot be
performed.
3. Insert transparent vinyl tube (3) at the end of air

bleed plugs (1, 2) of the transmission. Put the
other one end into transparent container (4) filled
4
with hydraulic oil.
4. Switch travel speed mode switch (5) fast
speed/slow speed 4 to 5 times.
5. Fast speed side: M202-07-023
Set travel speed mode switch (5) to the fast

speed position. Loosen air bleed plug (1).
Slow speed side:
Set travel speed mode switch (5) to the slow
speed position. Loosen air bleed plug (2). Fast Speed 5
6. Discharge air in hydraulic oil. Tighten the air
bleed plug after 15 to 20 seconds. Slow Speed
7. Repeat steps 4 to 5 until air bubbles stop coming
out with the hydraulic oil. (About 4 to 5 times)
8. Tighten the air bleed plug.
TCJB-04-03-001
T5-7-130
BLEEDING AIR FROM BRAKE (AXLE)
IMPORTANT: If air is mixed in the brake system,

the brake function is reduced, 1
possibly resulting in serious hazard.
Be sure to bleed air from the brake
system after disconnecting and
reconnecting the pipe lines, or
changing the hydraulic oil. Bleed air
until hydraulic oil of approx. 500 mL
(0.13 US gal.) is drained from each
wheel (4 places) after air bubbles
disappear.
NOTE: Bleed air by two or more persons.
1. Set the brake switch in the steering column

monitor to the P (parking) position. Start the
engine. Increase the brake pressure.
MCBB-07-044
2. Insert transparent vinyl tube (2) at the end of air
bleed plug (1). Put the other one end into
transparent container (3) filled with hydraulic oil.
3. Depress brake pedal (4) repeatedly several times. 1
Then, depress and hdd brake pedal (4) fully.
4. In step 3, loosen air bleed plug (1) and drain the
hydraulic oil with air for several seconds.
5. Tighten air bleed plug (1).
6. Repeat steps 3 to 5 until air bubbles stop coming
2
out with the hydraulic oil.
NOTE: Although hydraulic oil of 500 mL (0.13 US
gal.) is drained, if air bubbles are still
remaining in the hydraulic oil, continuously
repeat steps 3 to 5.
7. Repeat steps 3 to 5 for the other 3 places. 3
IMPORTANT: After bleeding air from all four

places, bleed air from all four places M202-07-023
once more. After bleeding air by

steps 3 to 5 twice, make sure that air
is completely bled.
MCBB-01-008
T5-7-131
EMERGENCY BOOM LOWERING
PROCEDURE (WITHOUT HOSE RUPTURE
VALVE)
CAUTION: Do not stay under the boom

during operation.
2 1 Boom 1
If the engine stalls and cannot be restarted, lower the

boom to lower the bucket to the ground referring to
the emergency boom lowering procedure stated
below.
1. Remove rubber caps (1, 2) from the boom 1

section at 4-spool side in the control valve.
2. Attach a ring spanner or spanner onto lock nut (8).
Rotate to the left and remove lock nut (8).
: 17 mm
3. Put hexagonal wrench into screw (7). Rotate to
the right until screw (7) stops.
: 4 mm
4. Attach a ring spanner or spanner onto lock nut (5).
Rotate to the left and loosen lock nut (5) slightly.
: 17 mm
5. Put hexagonal wrench into screw (6). Rotate
screw (6) to the right and lower the boom while
adjusting the lowering speed. T16W-03-03-032
: 4 mm
6. Do not remove snap ring (3) and washer (4) at 1
this time. Do not rotate screw (6) too strong, or 3
washer (4) may be deformed. 6
7. After the boom is lowered onto the ground, rotate
4
screws (6, 7) to the left into the position that are
2
pulled completely. Rotate screw (7) to 1/8 turn 5
right. Tighten lock nuts (5, 8). 7
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8
NOTE: If not tightening securely, leakage may
increase. Tighten completely with the
torque specifications.
8. Do not install rubber caps (1, 2) to the different

place.
NOTE: Install screws (7, 6) in this order.
TCGB-05-07-001
T5-7-132
ATTACHMENT CIRCUIT PRESSURE
RELEASE PROCEDURE
As for the machine, attached with the attachment, the

accumulator is equipped between the pilot pump and
the pilot valve.
Set the pilot shut-off lever to the UNLOCK position.

After stopping the engine with the engine stop switch
and when operating the control lever, the accumulator
will perform pressure release procedure in the pilot
circuit.
Travel Pilot Left Pilot Valve Right Pilot Valve

Valve
Pilot Shut-Off
Solenoid Valve
Control Valve
Accumulator
Pilot Pump
Engine TCJB-05-07-005
T5-7-133
(Blank)
T5-7-134
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Remove the harness from the negative terminal
side in battery first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table below.
In cases on the design sheet where two colors are
indicated for one wire, the left initial stands for
base color, while the right initial stands for marking
color.
Code Color Code Color

R Red W White
L Blue G Green
Or Orange Lg Light
green
Y Yellow B Black
Br Brown P Pink
Gr Gray V Violet
NOTE: • Code BW indicates a black base wire

with white fine-line marking.
• Initials “O” and “Or” both stand for the
color orange.
• Wires with longitudinal stripes printed on
them are not color coded. Do not
confuse them with color coded wires.
T5-8-1
3. Precautions for connecting and disconnecting
terminal connectors.
• When disconnecting the harnesses, grasp
them by their connectors. Do not pull on the Correct Incorrect
wire itself. Release the lock first before
attempting to separate connectors, if a lock is
provided. (Refer to “Instructions for
Disconnecting Connectors on page T5-8-3.)
• The water-resistant connectors keep water out. T107-07-06-001
If water enters them, water will not easily drain

from them. When checking the water-resistant
connectors, take extra care not to allow water
to enter the connectors. In case water should
enter the connectors, reconnect only after the
connectors are thoroughly dried. Correct
• Before connecting terminal connectors, check
Rust
that no terminals are bent or coming off. In
addition, as most connectors are made of brass, Incorrect
(Deformation)
check that no terminals are rusting.
• When connecting terminal connectors provided Incorrect
with a lock, insert them together until the lock (Separation)
“clicks.” T107-07-06-002
• Pull the harness near the connector in order to
check if it is correctly connected.
4. Precaution for using a circuit tester.

• Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
Wind a Piece of Wire Tester Probe
be measured, voltage range and current
polarity.
• Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram. Sharpen the end of the Wire
When the connector size is very small, and the T107-07-06-003
standard probe size is too large to be used for

testing, wind a fine piece of sharpened wire or a
pin around the probe to make the test easier.
• When checking the connector by using a tester,
insert a tester probe from the harness end of
connector in order not to damage the terminal
inside connector.
T5-8-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push, Unlock and Separate Type
NOTE: 1. Connectors will not be easily separated

even if the lock is pushed while being
pulled. Push the lock first before pulling
the connectors.
2 The lock is located on female side
connector (harness end side).
T107-04-05-002
• Raise Lock, Pull and Separate Type
Locations of This Type Connector

Starter Relay
• Pull and Separate Type

T107-04-05-003
IMPORTANT: Before pulling and separating,

release the lock of connector in the
solenoid valve by using a pair of
pincers.

Dr. ZX
T107-04-05-004
• Push, Unlock, and Switch the Lever Type

Cab Harness to Main Harness
ECM
T1J1-05-08-003
T5-8-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester in centerline of the fuse box are connected to
order to correctly inspect fuse continuity by following the power source, while terminals located
the instructions described below. away from center of the fuse box are
connected to loads (accessories).
1. Turn the key switch ON. Therefore, test all fuses in the same
When the key switch is turned ON, current from method except for the glow relay circuit
key switch terminal M activates the battery relay fuse. Check the glow relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the and follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of tester to the vehicle
frame. Touch the terminals located away from
center of the fuse box with the positive probe of
tester one at a time. When normal continuity of a
fuse is intact, the tester will indicate 20 to 25 V
(battery voltage).
30 40
10 20
29 39
9 19
28 38
8 18
27 37
7 17
26 36
6 16
25 35
5 15
24 34
4 14
23 33
3 13
22 32
2 12
21 31
1 11
M178-07-034
M178-07-034
T5-8-4
Fuse No. Capacity Connected to Fuse No. Capacity Connected to

1 20 A Boom Light Relay 21 10 A Clearance Light Relay (Right)
2 10 A Wiper Relay, Washer Relay, 22 10 A Head Light Relay (Right)
Wiper Motor
3 20 A Compressor Relay, Heater 23 10 A High-Beam Relay
Relay
4 10 A Pilot Shut-Off Solenoid Valve, 24 10 A Flasher, Turn Signal Light
Pilot Shut-Off Relay, Security Relay (Left) / (Right), Hazard
Relay, MC Solenoid Valve Switch
Power
5 5A Optional 1, Travel Alarm, 25 15 A Stop Light Relay
Auxiliary Power
6 10 A Optional 2 26 10 A −
7 10 A − 27 10 A Steering Column Monitor
Power
8 30 A ECM Main Relay 28 10 A Slow Speed Selection Relay,
Fast Speed Selection Relay,
Condenser (Pulse Signal
Conversion), Travel N Sensor
9 10 A Security Horn, Security Horn 29 10 A Outrigger Main Relay 1, Travel
Relay, Radio (Backup Power) Forward Pi Cut Solenoid Valve,
Travel Reverse Pi Cut
Solenoid Valve
10 5A MC/ICF Backup Power 30 10 A Assist (Optional), Power
Digging Relay
11 10 A Horn Relay 31 10 A Clearance Light Relay (Left)
12 10 A Cab Light, Radio Power 32 10 A Head Light Relay (Left)
13 10 A Cigarette Lighter 33 10 A Heater Seat (Optional)
14 10 A Fuel Pump 34 10 A Seat Compressor (Optional)
15 10 A Auxiliary 35 15 A Rotary Beacon Light (Optional)
16 5A Glow Plug Relay 36 10 A Rear Cab Light (Optional)
17 5A Air Conditioner Unit Power, 37 10 A Option Controller Power
Compressor Relay, Heater
Relay, Blower Hi Relay
18 5A MC/ECM/ICF/Monitor Unit/ 38 10 A Front Cab Light (Optional)
Option Controller/
Satellite Communication
Terminal Power ON Signal
19 10 A Monitor Unit Backup Power, 39 10 A Option Controller/
Buzzer Power Satellite Communication
Terminal Backup Power
20 5A Optional 3 40 10 A Front Cab Light
T5-8-5
FUSIBLE LINK INSPECTION
Battery Relay
Inspection
1. Visually inspect the fusible link.
Replacement
1. Remove the negative cable from the battery.

2. Pull out the fusible link. Replace the fusible link.
3. Install the negative cable to the battery.
Fusible Link M178-07-049
Fusible Link
T111-04-05-015
T5-8-6
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace To Battery Relay

the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging

system.
T162-05-06-005
T5-8-7
HOW TO CHECK ALTERNATOR Monitor Unit
Generally, if the alternator has generated electricity,

alternator alarm will disappear.
If the alternator alarm displays while the engine is
running, the alternator might be defective.
How to Check Alternator

1. Turn the key switch to the ON position. Confirm
that the alternator alarm is displayed.
2. Measure voltage between terminals B and E of

the alternator.
If the measured voltage is around 24 V, the
Alternator Alarm
alternator circuit can be considered normal. TCJB-05-02-050
If the measured voltage is low, a shortage in

battery capacity or looseness of the wire
connectors of alternator circuit might be the cause
of the malfunction.
When voltage is 0 V, the wiring between fuse box
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
B
3. Next, start the engine and measure voltage
generated while as the alternator rotates. As
described above, measure voltage between
terminals B and E on the side of alternator.
If voltage is around 28 V, the alternator is
operating normally.
If the rated voltage is not being generated (around E
24V), there is some trouble with the alternator or
the regulator.
T157-07-06-003
T5-8-8
CONTINUITY CHECK Harness
Single-line continuity check A a

Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity Ω
NOTE: When the one end connector is far apart

from the other, connect one end of
connector (A) to the machine chassis using Connect to the A a
machine.
a clip. Then, check continuity of the
harness through the vehicle frame as
illustrated.
Ω
To machine
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
A a
Single-line short-circuit check x Short-circuit
Disconnect both end connectors of the harness and between the
harness and
check continuity between one end connector of the the machine.
harness and the vehicle frame: Ω
If the ohm-meter reading is:
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
Multi-line continuity check First short-circuit (Clip)

Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end a
A
connector, as illustrated. Then, check continuity B b
between terminals (a) and (b) at the other connector. C c
If the ohm-meter reading is ∞ Ω, either line (A) - (a),
Second
or (B) - (b) is in discontinuity. To find out which line is short-circuit
discontinued, conduct the single line continuity
check on both lines individually, or, after changing
Ω
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).
T107-07-05-004
Short-circuit between
NOTE: By conducting the multi-line continuity harnesses
check twice, it is possible to find out which
line is discontinued. With terminals (A) and A a
(C) short-circuited, check continuity B X
b
between terminals (a) and (c). C c
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity.
Multi-line short-circuit check Ω

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C). T107-07-05-005

0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines.
T5-8-9
VOLTAGE AND CURRENT
MEASUREMENT
Turn key switch ON so that the specified voltage

(current) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether the
measured voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the
location to be measured from either power
source or actuator side. Thereby, the faulty
location in the circuit will be found.
Black Probe (Negative) of Tester:
To ground to the vehicle frame
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine Key Switch Location to be Measured Specification

Power Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and (E): Battery Power 20 to 25 V
Stopped OFF Between (5) and (E): Fusible Link 20 to 25 V
Stopped OFF Between (1) and (E): Backup Current* 6 mA
Preheating Circuit
Stopped ON or START Between (6) and (E): Key Switch 20 to 25 V
Stopped ON or START Between (7) and (E): Glow Plug 20 to 25 V
Charging Circuit
Fast Speed ON Between (8) and (E): Alternator (B) / Generating 26 to 30 V
Voltage
Fast Speed ON Between (9) and (E): Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (10) and (E): Fuse Box / Starter Relay (R) 26 to 30 V
/ Generating Voltage
Fast Speed ON Between (11) and (E): Generating Voltage 13 to 30 V
Fast Speed ON Between (12) and (E): Monitor Unit (C7) 13 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed ON Between (8) and (E): Alternator (B) 26 to 30 V
Idle Speed ON Between (11) and (E): Starter Relay (R) 13 to 30 V
Idle Speed ON Between (13) and (E): Load Damp Relay 26 to 30 V
Idle Speed ON Between (9) and (E): Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (14) and (E): Auxiliary 20 to 25 V
Stopped ON Between (15) and (E): Cigarette Lighter 20 to 25 V
Stopped ON Between (16) and (E): Radio, Cab Light 20 to 25 V
Stopped ON Between (17) and (E): Battery Relay 20 to 25 V
*Before measurement, disconnect the negative cable from the battery.
T5-8-10
Key Switch
Fuse
Box
5
1 2 3 4 6
17
Load
Damp
Relay
Battery Relay
Battery
13 10 14 15 16
9
Starter
Relay
11
8 7
Glow Plug Relay
Alternator
Glow
Plug
12
C7
Monitor
Unit
TCJB-05-08-001
T5-8-11
Engine Key Switch Location to be Measured Specification

Starting Circuit
Started START Between (18) and (E): Key Switch 20 to 25 V
Started START Between (19) and (E): Battery Relay (Coil) 20 to 25 V
Started START Between (20) and (E): Battery Relay (Switch) 20 to 25 V
Started START Between (21) and (E): Starter (B) 20 to 25 V
Started START Between (22) and (E): Starter (C) 20 to 25 V
Started START Between (23) and (E): Starter Relay (S) 20 to 25 V
Started START Between (24) and (E): Starter Cut Relay 20 to 25 V
Started START Between (25) and (E): Fuse Box 20 to 25 V
Started START Between (26) and (E): Fuse Box 20 to 25 V
Started START Between (27) and (E): ICF(C7) 20 to 25 V
Started START Between (28) and (E): Monitor Unit (A7) 20 to 25 V
Started START Between (29) and (E): MC(B16) 20 to 25 V
Started START Between (30) and (E): ECM(24) 20 to 25 V
Started START Between (31) and (E): Option Controller (B16) 20 to 25 V
Started START Between (32) and (E): ECM Main Relay 5V
Started START Between (33) and (E): ECM Main Relay 20 to 25 V
T5-8-12
25 26 18
Starter
Cut Relay
19
Battery
20 24 Fuse
Starter Box
21
Starter
Relay 22
23
32
ECM
Main
Relay
33
Option
24 B16 A7 C7 B16
TCJB-05-08-001
30 29 28 27 31
T5-8-13
Key
Engine Location to be Measured Specification
Switch
Pilot Shut-Off Circuit
Stopped ON Between (34) and (E): Fuse Box 20 to 25 V
Stopped ON Between (35) and (E): Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (36) and (E): Pilot Shut-Off Solenoid Valve 20 to 25 V
Stopped ON Between (37) and Ground: Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (38) and (E): Security Relay 20 to 25 V
T5-8-14
34
Battery
Battery Relay
Fuse Box
36
Pilot
Shut-Off
Solenoid
Security Pilot
Relay Shut-Off
Relay
38 37 35
TCJB-05-08-001
T5-8-15
Fuse
5 Voltage Circuit
Power Signal or
• Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame 1 2
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 on the
machine harness end connector and the vehicle
frame (ground).
• Key switch: ON V
• Tester black terminal (negative):
Connected to the vehicle frame (ground)
• Tester red terminal (positive):
Connected to terminal #1
T107-07-05-006
Power
Evaluation: Three Polarities
Source Signal Ground
If the measuring voltage is within 5±0.5 volts, the 1 2 3
circuit up to terminal #1 is normal.
• Voltage between terminal #1 and the ground

terminal T107-07-05-007
Disconnect the sensor connector with the key switch

OFF. Two Polarities
1 2
Measure voltage between terminal #1 on the
machine harness end connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities).
V
• Key switch: ON
• Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or #3)
• Tester red terminal (positive):
Connected to terminal #1 T107-07-05-008
Evaluation: Three Polarities

If the measured voltage is within 5±0.5 volt, the 1 2 3
circuit up to terminal #1 or the ground terminal
(terminal #2 or #3) is normal.
T107-07-05-009
T5-8-16
CHECK BY FALSE SIGNAL

Two Polarities
Turn the key switch OFF. Disconnect the sensor (Hydraulic Oil Temperature Sensor)
connector. Turn the key switch ON. Connect terminal (Fuel Sensor)
1 2
#1 (power source) of machine harness end connector
to terminal #2 (signal). (Power voltage is used as a
false signal.) Check this state by using the monitor
function of Dr. ZX. When the maximum value is
displayed, MC and the circuit up to the machine
harness end connector are normal. If “ON” is displayed,
the pressure switch circuits are normal. Connect
IMPORTANT: Do not connect terminal #1 or #2 to

terminal #3 or to the vehicle frame
(ground) when checking a T107-07-05-010
three-polarity connector. Three Polarities

(Pressure Sensor)
(Pump Delivery Pressure Sensor)
NOTE: Some kinds of sensors can be monitored (Pump Control Pressure Sensor) 1 2 3
by the service menu of monitor (the built-in (Brake Pressure Sensor)
diagnosing system). (Brake Remaining Pressure Sensor)
(Boom Bottom Pressure Sensor)
Connect
T107-07-05-011
T5-8-17
TEST HARNESS
Install a test harness between connectors. Check the

circuit condition depending on whether the test
harness lamp lights or extinguishes during operation.
Parts Number 4283594 (ST 7126)

Use in order to check a single-line (discontinuity
and/or voltage).
During Operation: Lamp is ON. To Measuring Point.

To Ground
T107-07-05-012
Parts Number 4283594 (ST 7126)
Parts Number (ST 7226)

Use in order to check the solenoid valve unit circuits.
4
When the corresponding control lever or switch is 3
50
operated: Lamp is ON. 50
150 50
1 2 2 1
Parts Number (ST 7226) T107-07-06-015
T5-8-18
MEMO
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Fax: 81-29-831-1162

PUBLICATION NO.:
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more re-
FAX: visions are requested, use the comment column)

REPLY:

THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
1. ELECTRICAL CIRCUIT DIAGRAM (STANDARD)

(ZX140W-3: Up to serial No.002747/ ZX140W-3-AMS: Up to serial No.021417)
ELECTRICAL CIRCUIT DIAGRAM (STANDARD)
(ZX140W-3: Serial No.002748 and up/ ZX140W-3-AMS: Serial No.021418 and up)
2. ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)

ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)
3. CONNECTORS
CAB HARNESS
4. CAB HARNESS (PRODUCTION APRIL 2010 AND UP)

CAB HARNESS
5. ENGINE HARNESS
FLOOR HARNESS
6. MONITOR HARNESS
CHASSIS HARNESS
7. LEFT CONSOLE HARNESS

LEFT CONSOLE HARNESS
8. AUXILIARY / POSITIONING SELECT HARNESS

THE ATTACHED DIAGRAM LIST
9. BLADE / OUTRIGGER HARNESS

LICENSE PLATE HARNESS
10. POSITIONING HARNESS

PRESSURE SENSOR (POSITIONING) HARNESS
11. SWING PARKING BRAKE RELEASE HARNESS
12. ENGINE SUB HARNESS (1)

ENGINE SUB HARNESS (2)
13. BACK LAMP RELAY HARNESS

BACK LAMP RELAY HARNESS
14. HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM, FULLY OPTIONAL)

HYDRAULIC CIRCUIT DIAGRAM (MONOBLOCK BOOM, FULLY OPTIONAL)
NOTE: As for the optional harness diagram, refer

to “e-Cabinet”.
Attach to Vol. No.: TTCEB-E-00, TTCFA-E-00, TTCGB-E-00, TTCJB-E-00
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 ELECTRICAL CIRCUIT DIAGRAM (STANDARD)
(ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
(ZX190W-3: Up to serial No.002535/ ZX190W-3-AMS: Up to serial No.020271/ ZX190W-3M: Up to serial No.031128/
ZX190W-3DH: Up to serial No.002531)
(ZX210W-3: Up to serial No.002539/ ZX210W-3-AMS: Up to serial No.020140/ ZX220W-3M: Up to serial No.041128/
ZX220W-3DH: Up to serial No.001110)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 ELECTRICAL CIRCUIT DIAGRAM (STANDARD) (ZX170W-3: Serial No.003827 and up/ ZX170W-3-AMS: Serial No.020817 and up)
(ZX190W-3: Serial No.002536 and up/ ZX190W-3-AMS: Serial No.020272 and up/ZX190W-3M: Serial No.031129 and up/ZX190W-3DH: Serial No.002532 and up)
(ZX210W-3: Serial No.002540 and up/ ZX210W-3-AMS: Serial No.020141 and up/ZX220W-3M: Serial No.041129 and up/ ZX220W-3DH: Serial No.001111 and up)
Attach to Vol. No.: TTCEB-E-00, TTCFA-E-00, TTCGB-E-00, TTCJB-E-00 (ZX140W-3: Up to serial No.002747/ ZX140W-3-AMS: Up to serial No.021417)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL) (ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
(ZX190W-3: Up to serial No.002535/ ZX190W-3-AMS: Up to serial No.020271/ ZX190W-3M: Up to serial No.031128/ ZX190W-3DH: Up to serial No.002531)
Attach to Vol. No.: TTCEB-E-00, TTCFA-E-00, TTCGB-E-00, TTCJB-E-00 (ZX145W-3: Serial No.010339 and up/ ZX145W-3-AMS: Serial No.020118 and up)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL) (ZX170W-3: Serial No.003827 and up/ ZX170W-3-AMS: Serial No.020817 and up)
(ZX190W-3: Serial No.002536 and up/ ZX190W-3-AMS: Serial No.020272 and up/ ZX190W-3M: Serial No.031129 and up/ ZX190W-3DH: Serial No.002532 and up)
(ZX210W-3: Serial No.002540 and up/ ZX210W-3-AMS: Serial No.020141 and up/ ZX220W-3M: Serial No.041129 and up/ ZX220W-3DH: Serial No.001111 and up)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 CAB HARNESS (ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 CAB HARNESS (PRODUCTION APRIL. 2010 AND UP) (ZX145W-3: Up to serial No.010338/ ZX145W-3-AMS :Up to serial No.020117)
(ZX190W-3: Up to serial No.002535/ ZX190W-3-AMS: Up to serial No.020271/
ZX190W-3M: Up to serial No.031128/ ZX190W-3DH: Up to serial No.002531)
(ZX210W-3: Up to serial No.002539/ ZX210W-3-AMS: Up to serial No.020140/
ZX220W-3M: Up to serial No.041128/ ZX220W-3DH: Up to serial No.001110)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 CAB HARNESS (ZX170W-3: Serial No.003827 and up/ ZX170W-3-AMS: Serial No.020817 and up)
(ZX190W-3: Serial No.002536 and up/ ZX190W-3-AMS: Serial No.020272 and up/ZX190W-3M: Serial No.031129 and up/ZX190W-3DH: Serial No.002532 and up)
(ZX210W-3: Serial No.002540 and up/ ZX210W-3-AMS: Serial No.020141 and up/ZX220W-3M: Serial No.041129 and up/ ZX220W-3DH: Serial No.001111 and up)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 LEFT CONSOLE HARNESS
Attach to Vol. No.: TTCEB-E-00, TTCFA-E-00, TTCGB-E-00, TTCJB-E-00 (ZX140W-3: Serial No.002748 and up/ ZX140W-3-AMS: Serial No.021418 and up)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 LEFT CONSOLE HARNESS (ZX145W-3: Serial No.010339 and up/ ZX145W-3-AMS: Serial No.020118 and up)
(ZX190W-3: Serial No.002536 and up/ ZX190W-3-AMS: Serial No.020272 and up/
ZX190W-3M: Serial No.031129 and up/ZX190W-3DH: Serial No.002532 and up)
ZX220W-3M: Serial No.041129 and up/ ZX220W-3DH: Serial No.001111 and up)
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 BACK LAMP RELAY HARNESS
Attach to Vol. No. : TTCEB-E-00, TTCFA-E-00, TTCGB-E-00, TTCJB-E-00
ZAXIS140W-3/145W-3/170W-3/190W-3/210W-3/220W-3 BACK LAMP RELAY HARNESS
ZX190W-3M: Serial No.031129 and up/ZX190W-3DH: Serial No.002532 and up)
ZX220W-3M: Serial No.041129 and up/ ZX220W-3DH: Serial No.001111 and up)
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INTRODUCTION
TO THE READER
age.):
TEL: 81-29-832-7084
FAX: 81-29-831-1162
• Please refer to the materials listed below in addition • The Engine Manual
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5

Group Number
Section Number
IN-01
INTRODUCTION
NOTATIONS

death.
• NOTE:
know-how.
heavy parts.
UNITS USED
this manual.
From From
mm ft 0.003281 MPa psi 145.0
L US qt 1.057 kW HP 1.341
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION

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

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

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

of information.
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
• Learn how to operate the machine and its controls correctly
and safely.
• Allow only trained, qualified, authorized personnel to oper- SA-003
ate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, func-
tion, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or equip-
ment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are intended to
illustrate basic safety procedures of machines. However it is
impossible for these safety messages to cover every hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES

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

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

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

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

• Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or
uncomfortably loud noises.
006-E01A-0434
SA-434
SA-3
SAFETY
INSPECT MACHINE
• Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
007-E01A-0435 SA-435
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal ac-
cident.
• Do not leave parts and/or tools lying around the operator’
s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly start-
ing a fire.
• Refrain from listening to the radio, or using music head-
phones or mobile telephones in the cab while operating
the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the tem-
perature in the cab increases, the lighter may explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS

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

• A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the op-
erator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear
SA-378
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR LEAV-

ING OPERATOR’S SEAT
• Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
• Before leaving the machine, be sure to first lower the
front attachment to the ground and then move the pilot
control shut-off lever to the LOCK position. Turn the key
switch OFF to stop the engine.
• Before leaving the machine, close all windows, doors, and
access covers and lock them up.
SA-5
SAFETY

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

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

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine. SA-083
• Use appropriate illumination. Check that all lights are op-
erable before operating the machine. If any faulty illumi-
nation is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressur-
ized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
SA-293
036-E01A-0293-3
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• NEVER start the engine while standing on the track or on
ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-084
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow the
instructions shown in the “OPERATING THE ENGINE” chap-
ter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
S013-E01A-0032
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
014-E01B-0427
SA-091
SA-7
SAFETY
PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equip-
ment appropriate for the job, such as a hard hat, etc.
when operating the machine.
• Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
• When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M202-05-014
SA-8
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from fall-
ing and to prevent the ground, stockpiles, or banks from
collapsing.
• Make a work plan. Use machines appropriate to the work
and job site.
• Reinforce ground, edges, and road shoulders as necessary.
Keep the machine well back from the edges of excava-
tions and road shoulders.
• When working on an incline or on a road shoulder, em- SA-085
ploy a signal person as required.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
• Make sure the worksite has sufficient strength to firmly sup-
port the machine.
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicu-
lar to the cliff face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
• Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on a soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm M202-05-015
enough to easily support the machine.
• Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with ma-
chine movements.
SA-9
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS, FOPS

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

FOPS: Falling Object Protective Structure
SA-686
PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

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

• Incorrect steering wheel/forward/reverse pedal operation
may result in serious injury death.
• Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when steering wheel is operated to
the front.
SA-092
017-E01A-0491
SA-10
SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the steer-
ing wheel/forward/reverse switch direction corresponds to
the direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.
• Driving on a slope may cause the machine to slip or over-

SA-090
turn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 35 degrees or steep-
er slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket fac-
ing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, imme-
diately lower the bucket to the ground and stop.
SA-288
AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the ground.
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 5 min-
utes to cool down the engine.
• Stop the engine and remove the key from the key switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
SA-278
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND SWING

ACCIDENTS
• If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
• Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW SA-383
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
• Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
• Keep windows, mirrors, and lights clean and in good con-
dition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility SA-384
decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the
021-E01A-0494
SA-12
SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
• A person may be hit severely by the swinging front attach-
ment or counterweight and/or may be crushed against an
other object, resulting in serious injury or death.
• Keep all persons clear from the area of operation and
machine movement.
• Before operating the machine, set up barriers to the sides
and rear area of the bucket swing radius to prevent any-
one from entering the work area.
022-E01A-0386
M202-05-014
NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
023-E01A-0487 SA-682
AVOID UNDERCUTTING
• Always confirm that ground conditions are strong enough
to support the machine weight when operating near a cliff.
Operate the machine with the chassis frame positioned
perpendicular to the cliff face so that the machine can more
easily evacuate if the cliff face collapses.
• If the footing starts to collapse and if retreat is not pos-
sible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.
024-E01A-0488 SA-683
SA-13
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-
CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL
RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
• The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to the ma-
SA-088
chine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging loads.
• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become
soft and make ground travel unstable.
025-E03B-0463
SA-684
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing
026-E01A-0519
SA-685
SA-14
SAFETY
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
• Before digging check the location of cables, gas lines, and
water lines.
• Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
• If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
• Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities. SA-086
027-E01A-0382
OPERATE WITH CAUTION

• If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
• Take care to avoid hitting overhead obstacles with the
boom or arm.
028-E01A-0389 SA-087
SA-15
SAFETY
AVOID POWER LINES

• Serious injury or death can result if the machine or front at-
tachments are not kept a safe distance from electric lines.
• When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
• Check and comply with any local regulations that may ap-
ply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-089
029-E01A-0381
PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop op-
eration, and lower the bucket to the ground. Evacuate to
a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed safety
devices are found, operate the machine only after repair-
ing them.
SA-1241
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be struck
by the falling load or may be crushed underneath it, result-
ing in serious injury or death.
• When using the machine for craning operations, be sure
to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the travel
motors at the rear.
• Move the load slowly and carefully. Never move it sud-
denly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
032-E01A-0132
SA-014
SA-16
SAFETY
PROTECT AGAINST FLYING DEBRIS

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

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position. SA-093
• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.
HANDLE FLUIDS SAFELY−AVOID FIRES

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

SA-018
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontane-
ously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-17
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading or un-
loading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe trans-
portation.
• Select an appropriate truck or trailer for the machine to
be transported.
• Be sure to use a signal person.
• Always follow the following precautions for loading or
unloading:
Less than 15°
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the SA-094
machine weight.
3. Turn auto-idle switch OFF.
4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck or
trailer using the front attachment functions when driving
up or down the ramp.
6. Never steer the machine while on the ramp. If the travel-
ing direction must be changed while the ramp, unload
the machine from the ramp, reposition the machine on
the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a Less than 15°
sudden bump. Take care when traveling over it.
SA-095
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the TRANS-

PORTING section.
035-E07A-0454
SA-18
SAFETY
PRACTICE SAFE MAINTENANCE

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

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5 min-
utes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving SA-028
the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
• If a maintenance procedure must be performed with the

engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 100˚ angle
between the boom and arm. Securely support any ma-
chine elements that must be raised for service work.
• Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the SA-527
“MAINTENANCE” chapter in the operator’s manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable detergent
oil. Never use highly flammable oil such as fuel oil and
gasoline to clean parts or surfaces.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02C-0520
SA-19
SAFETY
• Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
• Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.
• Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
SS3076175 SS2045102
SUPPORT MACHINE PROPERLY

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

• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
503-E01B-0344
SA-344
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
• Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
504-E01A-0034 SA-034
SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can cause seri-
ous injury or death.
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
• When inflating tires, use a chip-on chuck and exten-sion
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
it available.
• Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
• Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and SA-249
may result in tire explosion.
521-E02A-0249
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO NOT
remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all pres-
sure to be released before removing the cap.
SA-039
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
• Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
505-E01B-0498
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
• Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
• Avoid this hazard by relieving pressure before disconnect-
ing hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this type
of injury immediately. Any fluid injected into the skin
SA-031
must be surgically removed within a few hours or gan-
grene may result.
507-E03A-0499
SA-292
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or hoses.
SA-019
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.
operation for loose, kinked, hardened or frayed electrical
cables and wires.
operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine
daily and by removing spilled or accumulated flammables
immediately.
Check Key Switch:

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

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393
SA-24
SAFETY
EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the following
way:
• Stop the engine by turning the key switch to the OFF
position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with the
emergency evacuation hammer to escape from the cab. SA-393
Refer the explanation pages on the Emergency Evacuation
Method.
18-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES

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

• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and pre-
pared area. Store flammable objects in a safe place before
starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
• After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
523-E01A-0818
SA-25
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near pres-
surized fluid lines, resulting in severe burns to yourself and
bystanders.
• Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
• Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary fire-
resistant guards to protect hoses or other materials before
engaging in welding, soldering, etc..
AVOID APPLYING HEAT TO LINES CONTAINING SA-030
FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flam-
mable fluids.
• Clean them thoroughly with nonflammable solvent be-
fore welding or flame cutting them.
510-E01B-0030
REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area. Dis-
pose of paint and solvent properly.
• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with
SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
SA-26
SAFETY
BEWARE OF ASBESTOS DUST

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

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

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

• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the instructions described on the container for
proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
SA-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

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

• Improperly disposing of waste can threaten the environ-
ment and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source.
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
516-E01A-0226
SA-28
SAFETY
BEFORE RETURNING THE MACHINE TO THE CUS-

TOMER
• After maintenance or repair work is complete, confirm that:
• The machine is functioning properly, especially the safety
systems.
• Worn or damaged parts have been repaired or replaced
S517-E01A-0435
SA-435
SA-29
SAFETY
(Blank)
SA-30
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 7 Pilot Valve
Group 10 Shockless Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Motor
Group 3 Center Joint
All information, illustrations and speci-
fications in this manual are based on Group 5 Axle
the latest product information available Group 6 Axle Lock Cylinder
at the time of publication. The right is
reserved to make changes at any time Group 7 Operate-Check Valve
without notice.
Group 9 Transmission Changeover Solenoid Valve
Group 10 Propeller Shaft
SECTION 4 FRONT ATTACHMENT
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Group 1 Front Attachment
Tokyo, Japan
Group 2 Cylinder
All rights reserved
Group 3 Hose-Rupture Valve
Group 4 Operate-Check Valve
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Electric Lever
Group 2 Control System Group 6 Transmission
Group 3 ECM System Group 7 Axle
Group 4 Hydraulic System Group 8 Travel Motor
Group 5 Electrical System Group 9 Signal Control Valve
Group 13 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Monitor Unit
Group 2 Standard Group 3 Dr. ZX
Group 3 Engine Test Group 4 ICF
Group 4 Excavator Test Group 5 Component Layout
Group 5 Component Test Group 6 Troubleshooting A
SECTION 1
GENERAL
— CONTENTS —
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ................................................ W1-1-1
Maintenance Standard Terminology ......... W1-1-7
Group 2 Tightening
Tightening Torque Specification.................. W1-2-1
Torque Chart................................................ W1-2-2
Piping Joint .................................................. W1-2-5
Periodic Replacement of Parts ................. W1-2-9
Group 3 Painting
Painting ................................................... W1-3-1
Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleeding Air from Hydraulic Oil tank ...........W1-4-1
CEBW-1-1
(Blank)
CEBW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the

area for disassembling work.
W1-1-1
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
• Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic
clean and dry.
motor housing, damage to the mo-
• If an anti-corrosive agent has been used on a
tor may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
W1-1-2
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
WCJB-01-04-001
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-3
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019
uneven wear.
(3) Check O-ring (B) for tears, breaks,

deformation or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect
(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B
b b
a=b a≠b
W110-03-05-004
W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016
lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
CAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may re- Damaged Appearance
Broken Sewing Thread
sult. Be sure to visually check the nylon sling
for any damage before using.
2. Before using a nylon sling, visually check the ny-

lon sling for any damage corresponding to exam- W162-01-01-002
Scuffing
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.
W1-1-7
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Engine cushion rubber mounting nut 14 4 22 140 (14.0) (103)
Engine cushion rubber mounting bolt 16 2 24 235 (24) (175)
2
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
19 30 (3.1) (22)
22 40 (4.1) (30)
ORS and metal face seal fittings for hydraulic hoses and
5 27 95 (9.7) (70)
piping
32 140 (14.3) (105)
36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 4 22 140 (14.0) (103)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 10 30 500 (51) (370)
10
10 Swing motor mounting bolt (Hex. 7 8 65 (6.6) (48)
Wrench)
11 Battery mounting nut 10 2 17 50 (5.1) (37)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
13 Swing bearing mounting bolt to upperstructure 18 30 27 400 (41.0) (295)
Swing bearing mounting bolt to chassis 16 36 24 270 (27.5) (200)
14 Center joint lock mounting bolts Ú 16 5 24 270 (27.5) (200)
15 Transmission mounting bolts Ú 20 3 30 550 (56.0) (410)
16
16 Travel motor mounting bolts Ú (Hex. 4 14 270 (27.5) (200)
Wrench)
17 Propel shaft mounting nuts Ú 10 32 14 76 (8) (60)
19 Rear axle mounting bolts Ú 20 8 30 560 (57) (410)
20 Wheel pin nuts 20 40 30 500 (51) (370)
6 - 10 10 (1) (7.4)
21 Cover mounting bolt 10 - 17 50 (5.1) (37)
12 - 19 90 (9.2) (66)
10.3 to (1.05 to (7.59 to
22 Flexible master coupling of piping 8 4 pairs 13
12.4 1.26) 9.11)
23 T-bolt clamp of low pressure piping - - 11 6.0 (0.6) (4.3)
Ú Apply LOCTITE to the threads. 2.Make sure bolt and nut threads are clean
NOTE 1.Apply lubricant (e.g. white zinc B dis- before installing.
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
(Except for Sprocket mounting bolt.)
W1-2-1
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040
correctly when assembling the machine or compo-

nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092
Socket Bolt
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2)
M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5)
M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)
W1-2-2
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-3
Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
WRONG
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008
an air wrench often causes tight- RIGHT WRONG

ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
RIGHT RIGHT WRONG

ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-4
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°
30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
2. Scratches or other damage to

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Wrench Size Wrench Size mm Tightening

Description mm Torque
Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5, 18)
19 19 29.5 (3.0, 21.5)
22 22 39 (4.0, 28.5)
27 27 78 (8.0, 58)
32 32 137 (14.0,101)
36 36 175 (18.0, 129)
41 41 205 (21.0,1 51)
37°female 17 14 24.5 (2.5, 18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 78 (8.0, 58)
32 27 137 (14.0, 101)
36 32 175 (18.0, 129)
41 36 205 (21.0, 151)
NOTE: Tightening torque of 37° male coupling without union is similar
to tightening torque of 37° female.
W1-2-5
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with a

new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly in Hose Fittings
8 1
O-ring groove (e). Tightening nut (9) M104-07-033
with O-ring (6) displaced will damage

O-ring (6), resulting in oil leakage.
3. Take care not to damage O-ring
groove (e) or sealing surface (10). Wrench Size Wrench Size Tightening Torque
Damage to O-ring (6) will cause oil mm mm
leakage. Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)
4. If nut (9) is loose and oil is leaking, 19 17 29.5 (3.0, 21.5)
do not re-tighten nut (9). Replace 22 19 69 (7.0, 51)
O-ring (6) with a new one and check 27 22 93 (9.5, 69)
that O-ring (6) is correctly seated in 32 27 137 (14.0, 101)
place, tighten nut (9). 36 30, 32 175 (18.0, 129)
41 36 205 (21.0, 151)
46 41 205 (21.0, 151)
W1-2-6
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types 30°
of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread pitch

and thread type (tapered or straight) are
the correct type before using any Male Tapered Thread Male Straight Thread
screw-in connection.
W105-01-01-018
Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male and
female threads, so as to prevent any leaks between
threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of dirt or
damage.
Apply seal tape around threads as shown. Wrap seal tape
in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs de-

pending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-7
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, pos-
sibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked W105-01-01-011
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being WRONG RIGHT
kinked. Rubbing Against
Each Other
If hoses rub against each other, wear to the
hoses will result, leading to hose rupture. Take
necessary measures to protect hoses from rub-
bing against each other.
W105-01-01-012
Take care so that hoses do not come into contact

WRONG RIGHT
with moving parts or sharp objects.
Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-8
PERIODIC REPLACEMENT OF PARTS
The parts listed below deteriorate as the machine ages

and are worn out or fatigued by repeated loads, resulting
in possible severe personal injury and/or machine trouble.
The service life of these parts cannot be detected
through machine operation or visual inspection.
Therefore, these parts should be replaced at regular in-
tervals even if no abnormalities are noticed. In case any
abnormalities are found on a part at any time regardless
of its specified replacement interval, immediately replace
the part.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Pump delivery hose Every 2 years
Base Machine
Swing hose Every 2 years
Hydraulic
Travel Hose Every 2 years
System
Boom cylinder line hose Every 2 years
Front-End Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings
and gaskets, when replacing hoses.
W1-2-9
(Blank)
W1-2-10
GENERAL / Painting
PAINTING
Painting specification
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Main frame HG Beige Deep
Internal parts Black
• Front attachment YR-01 [TAXI yellow]
• Track (including swing bearing) N1.0 [Black]
• Floor plate M/F Cation (allowed)
Final painted color

• Inside and outside surface of cab HG Beige Deep
• Shaded area on cab outside Shining Silver
• Right window guards, U-Bolt [KANSAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black)]
• Lever (Pilot shut-off, foot rest) High Grade Black
• Engine cover TAXI Yellow
• Cover, Step HG Beige Deep
• Handrail on upperstructure right side HG Beige Deep
• Mirror stay: cab side, right side High Grade Black
• Nonslip cover KANSAI PAINT Amilac 1400 (Deep Black)
• Rear camera cover HG Beige Deep
• Head light bracket HG Beige Deep
W1-3-1
GENERAL / Painting
Paint all circumference

in the hinge swing
Mirror Stay position shining silver
Shaded Area
[Shining Silver]
Engine Cover
Camera Cover
Decal
[TAXI Yellow]
WCEB-01-03-001
Head Light Bracket
Decal Mirror Stay Handrail Right Side Cover

[Shining Silver]
WCEB-01-03-002
Decal Step Head Light Bracket Mirror Stay

[TAXI Yellow]
W1-3-2
GENERAL / Painting
Align with the panel

[Shining Silver]
Panel Door Panel Behind the

Door
10
Painting Area of the Door W178-01-03-005
YR-01(TAXI Yellow)
WCEB-01-03-003 Section A
Detail B
Nonslip Cover
KANSAI PAINT
Amilac 1400
(Deep Black)
WCEB-01-03-004
Upper Side of Frame
IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, take care not
to pour washing liquid directly on
them. The ambient temperature
should not exceed 70 °C (158 °F)
when painting and drying.
W1-3-3
GENERAL / Painting
(Blank)
W1-3-4
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Place the machine on a firm, level surface and WCJB-01-04-001
lower the bucket to the ground.
2. Stop the engine. Push the air bleed valve (1) on 2

the air breather to release any remaining pressure
from hydraulic oil tank (3).
3. Remove cap (2) of hydraulic oil tank (3).
WCEB-01-04-001
4. Connect a vacuum pump with the hole removed
cap (2) to maintain negative pressure in the
Vacuum Pump
hydraulic oil tank (3).
NOTE: Be sure to run the vacuum pump Hose
continuously while working.
Adapter
W562-02-03-008
W1-4-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)
W1-4-2
MEMO
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SECTION 2
UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab Group 5 Control Valve
Removal and Installation of Cab ............ W2-1-1 Removal and Installation of
Dimensions of Cab Glass .................... W2-1-12 Control Valve ........................................W2-5-1
Disassembly of Control Valve
Group 2 Counterweight 4-Spool Side .......................................W2-5-12
Removal and Installation of
Disassembly of Control Valve
Counterweight ...................................... W2-2-1
5-Spool Side .......................................W2-5-20
Group 3 Main Frame Assembly and Disassembly of
Removal and Installation of 4-Spool Side and 5-Spool Side...........W2-5-26
Main Frame .......................................... W2-3-1 Assembly of Control Valve
4-Spool Side .......................................W2-5-28
Group 4 Pump Device Assemble of Control Valve
Removal and Installation of 5-Spool Side .......................................W2-5-36
Pump Device ........................................ W2-4-1 Removal and Installation of Positioning
Disassembly of Pump Device .............. W2-4-10 Control Valve ......................................W2-5-43
Assembly of Pump Device ................... W2-4-22 Disassembly of Positioning
Disassembly of Regulator .................... W2-4-42 Control Valve ......................................W2-5-44
Assembly of Regulator......................... W2-4-44 Assembly of Positioning
Structure of Pilot Pump ........................ W2-4-46 Control Valve ......................................W2-5-46

Swing Device ........................................W2-6-1
Disassembly of Swing Device ................W2-6-6
Assembly of Swing Device ...................W2-6-14
Disassembly of Swing Motor ..............W2-6-22
Assembly of Swing Motor .....................W2-6-26
Disassembly of Valve Unit ....................W2-6-32
Assembly of Valve Unit.........................W2-6-34
Structure of Swing Dampener Valve.....W2-6-36
Maintenance Standard..........................W2-6-37
CEBW-2-1
Group 7 Pilot Valve Group 12 Pilot Shut-Off Solenoid Valve
Removal and Installation of Pilot Valve.. W2-7-1 Removal and Installation of Pilot
Removal and Installation of Shut-Off Solenoid Valve......................W2-12-1
Travel Pilot Valve................................ W2-7-11 Structure of Pilot Shut-Off
Disassembly of Front/Swing Solenoid Valve ....................................W2-12-3
Pilot Valves......................................... W2-7-16
Assembly of Front/Swing Pilot Valves.. W2-7-20
Disassembly of Travel and
Steering Valve.....................................W2-13-1
Auxiliary/Positioning Pilot Valves ....... W2-7-24
Assembly of Travel and Group 14 Brake Valve
Auxiliary/Positioning Pilot Valves ....... W2-7-26 Removal and Installation of
Brake Valve.........................................W2-14-1
Disassembly of Brake Valve .................W2-14-4
Assembly of Brake Valve......................W2-14-8
Electric Lever........................................ W2-8-1
Disassembly of Electric Lever................ W2-8-8 Group 15 Accumulator Charge Valve
Assembly of Electric Lever................... W2-8-10 Removal and Installation of
Accumulator Charge Valve .................W2-15-1
Group 9 Signal Control Valve Structure of Accumulator
Removal and Installation of Signal
Charge Valve ......................................W2-15-4
Control Valve ........................................ W2-9-1
Structure of Signal Control Valve ........... W2-9-6
Group 10 Shockless Valve

Shockless Valve ................................. W2-10-1
Structure of Swing Shockless Valve .... W2-10-6
Structure of Travel Shockless Valve .... W2-10-8

Removal and Installation of 3-Spool
Solenoid Valve Unit ............................ W2-11-1
Structure of 3-Spool Solenoid Valve
Unit ..................................................... W2-11-5
Disassembly and Assembly of
3-Spool Solenoid Valve Unit.............. W-2-11-6
Removal and Installation of Solenoid Valve
Unit (For Electric Lever Operation) .... W2-11-8
Structure of Solenoid Valve Unit
(For Electric Lever Operation).......... W2-11-12
1-Spool Solenoid Valve Unit............. W2-11-13
Structure of 1-Spool Solenoid
Valve Unit ......................................... W2-11-15
CEBW-2-2
UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB
Removal
CAUTION: Seat (1) weight: 40 kg (90 lb)

1 2 3 4 5
1. Remove sems bolts (4) (2 used) from safety belts
(6) (2 used). Remove safety belts (6) (2 used)
from brackets (5) (2 used).
: 16 mm
WCEB-02-01-001
4 5 2 3
WCEB-02-01-017
2. Remove socket bolts (3) (4 used) from seat (1).

Remove seat (1) from plate (2). 3 1
: 6 mm
2
WCEB-02-01-002
7
3. Remove mat (8) from the inside of cab (7).
8 WCEB-02-01-003
W2-1-1
4. Remove sems bolts (10) (2 used) from cover (9).
: 13 mm
10
W1JB-02-01-004
5. Remove caps (11) (6 used) from cover (9).

Remove screws (12) (6 used) from cover (9). 7
6. Remove cover (9) from cab (7). 11, 12
11, 12
7. Remove sems bolts (16) (4 used) from cover (14). W1JB-02-01-005

Remove cover (14) from brackets (13, 15). 13
: 17 mm
14
WCEB-02-01-008
16 16 15
8. Remove sems bolts (17) (5 used) from bracket 13

13 17
(13). Move the bracket (13) assembly forward
from bracket (15).
: 13 mm, 17 mm
17
15
17 WCEB-02-01-018 WCEB-02-01-019
W2-1-2
9. Remove screws (19) (2 used) from cover (18). 18 19
Remove cap (20) and screw (21) from cover (18).
Remove cover (18) from cab (7).
W1JB-02-01-001
20, 21 7
22 7
10. Remove sems bolts (23) (2 used) from bracket
(24). Remove bracket (24) from cab (7) and duct
(22). Remove duct (22) from bracket (15).
: 13 mm 23
24
15
WCEB-02-01-016
23
25
11. Open cover (25).
WCEB-02-01-005
CAUTION: Cover (25) weight: 20 kg (45 lb) 25

26, 27, 28
12. Attach a nylon sling onto cover (25). Hoist and

hold cover (25). 29
13. Remove nuts (26) (4 used), spring washers (27)

(4 used) and washers (28) (4 used) from cover
(25). Remove cover (25) from support (29).
: 17 mm
WCEB-02-01-007
W2-1-3
14. Disconnect vinyl hose (31) from washer tank (30). 30
Cap the open ends.
31 WCEB-02-01-006
32
15. Remove clamps (33) (3 used) from the outside of
the cab (7) rear. Disconnect connectors (32) (5 33
used).
WCEB-02-01-014
34 35
Remove cover (35) from main frame (36). 36
: 17 mm
WCEB-02-13-001
17. Remove anchor bolt (39), washer (38) and spacer

(37) from cab (7) and main frame (36).
: 32 mm 7
37
38
WCEB-02-01-013
36 39
W2-1-4
CAUTION: Cab (7) weight: 550 kg (1220 lb) Lifting 42 7 Lifting

Bracket Bracket
18. Attach a nylon sling onto the bracket in cab (7).
Hold cab (7).
19. Remove nuts (40) (4 used) and washers (41) (4

used) from cab (7).
: 24 mm
40, 41
20. Remove socket bolts (42) (6 used) from cab (7). 40, 41
: 8 mm
42
21. Remove bolts (43) (5 used) and washers (44) (5
used) from cab (7). 40, 41
: 17 mm W1JB-02-01-006
43, 44 42
CAUTION: Cab (7) weight: 550 kg (1220 lb)
22. Remove cab (7) from main frame (36).
36
WCEB-02-01-009
W2-1-5
Installation
CAUTION: Cab (7) weight: 550 kg (1220 lb)
1. Attach a nylon sling onto cab (7). Hoist and align

cab (7) with the mounting hole on main frame
(36).
36
WCEB-02-01-009
2. Install cab (7) to main frame (36) with nuts (40) (4

Lifting 42 7 Lifting
used) and washers (41) (4 used). Bracket Bracket
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
3. Install cab (7) to main frame (36) with socket bolts

(42) (6 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
40, 41
40, 41
4. Install cab (7) to main frame (36) with bolts (43) (5
used) and washers (44) (5 used).
42
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 40, 41
W1JB-02-01-006
43, 44 42
5. Install duct (22) to bracket (15). 22 7
6. Install bracket (24) to cab (7) and duct (22) with

sems bolts (23) (2 used).
: 13 mm 23
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
24
15
WCEB-02-01-016
23
W2-1-6
7. Install cover (18) to cab (7) with screws (19) (2 18 19
used). Install cover (18) to cab (7) with screw (21).
Install cap (20) to screw (21).
20, 21 7 W1JB-02-01-001
8. Align the bracket (13) assembly with the mounting 13

hole on bracket (15). Install the bracket (13) 13 17
assembly to bracket (15) with sems bolts (17) (5
used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 17
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
15
17 WCEB-02-01-018 WCEB-02-01-019
9. Install cover (14) to brackets (13, 15) with sems 13

bolts (16) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
14
WCEB-02-01-008
16 16 15
10. Install cover (9) to cab (7) with screw (12) (6 used). 7
Install caps (11) (6 used) to screws (12) (6 used).
11, 12
11, 12
W1JB-02-01-005
W2-1-7
11. Install cover (9) to cab (7) with sems bolts (10) (2
used). 7
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
9
10
W1JB-02-01-004
12. Connect connectors (32) (5 used). Secure

32
connectors (32) (3 used) with clamps (33) (3
used). 33
WCEB-02-01-014
13. Secure cab (7) to main frame (36) with anchor bolt
(39), washer (38) and spacer (37).
: 32 mm 7
: 550 N⋅m (55 kgf⋅m, 406 lbf⋅ft)
37
38
WCEB-02-01-013
36 39
34 35
14. Install cover (35) to main frame (36) with sems 36

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-13-001
W2-1-8
15. Connect vinyl hose (31) to washer tank (30). 30
31 WCEB-02-01-006
CAUTION: Cover (25) weight: 20 kg (45 lb) 25

26, 27, 28
16. Attach a nylon sling onto cover (25). Hoist and
align cover (25) with the mounting hole on support 29
(29). Secure cover (25) to support (29) with
washers (28) (4 used), spring washers (27) (4
used) and nuts (26) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-01-007
17. Shut cover (25). 25
WCEB-02-01-005
3 1
18. Install seat (1) to plate (2) with socket bolts (3) (4
used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
2
WCEB-02-01-002
W2-1-9
19. Install safety belts (6) (2 used) to brackets (5) (2 1 2 3 4 5
used) with sems bolts (4) (2 used).
: 16 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-01-001
4 5 2 3
WCEB-02-01-017
7
20. Install mat (8) to the inside of cab (7).
8 WCEB-02-01-003
W2-1-10
(Blank)
W2-1-11
DIMENSIONS OF CAB GLASS
Black Ceramic
NOTE: Unit: mm (1 mm=0.039 in) 115 Coating Range
70
21
107
60 2-R50 2-R50
C0.5 2-R250
2-R127 2-R20
2-R10
70
C0.5
106.6 A
Black Ceramic W1JB-02-01-013 1081
Coating Surface R50
R2975 (4 mm)
Section A R800
φ28
R75 B
R120
Black
R40 268
Ceramic 20 70
Coating
Surface 16.5
50 W1JB-02-01-011
2R-5
271 21
214 21
847
Black Ceramic
Coating Range
R1075
W1JB-02-01-009
C
372.9
(4 mm)
22
50
54.1 25 W1JB-02-01-012
25 84
865
C0.5
R2
W1JB-02-01-014 W1JB-02-01-019
C0.5
Black Ceramic
Coating Surface
Section C
Section B
W2-1-12
NOTE: Unit: mm (1 mm=0.039 in)
360.7
4-R4
3-R4
2-φ12.2 +0.5
(4 mm) 139.7 -0
R150 6445
50 (4 mm)
50 WCEB-02-01-012 40±0
631
37 228.2
50
50 WCEB-02-01-011
383.2
312.6
C0.5
4Ｒ-4
C0.5
R2800
Black Ceramic
Coating Surface
(4 mm)
Section A W1JB-02-01-013
644.5
40±0.5
WCEB-02-01-004
228.2
93°
50
50 WCEB-02-01-010
460.2
Glass Mark (Back)
860.8
Black Ceramic 833
Coating Range 506
63.5 581
50 438.5 26.5
2-φ21 353.5
2-R4
R150 64.5
R2854
R50 109.5 336
R25 102.5
A
498.5 448 1
R58 R75 (4 mm) R60 152.5
R250 185
R964 R103
R5031 34
R42 R329
R10
118
R5004 82
327.5
R10 R60 W1JB-02-01-018
17 173
W2-1-13
Black Ceramic
Coating Range
R30 30
39
29
652
87.5 (4 mm) R200
87.5
R200
R500 R500 A
R50 185 185
45
70
R50
4-R10 205
848 W1JB-02-01-021
WCEB-02-01-015
567.5 Black Ceramic

Coating Range
496
123.5 80 59.5
C0.5
3-R4 85
75.5 100 R25
C0.5 R25
R20 R25 R25 B
Black Ceramic W1JB-02-01-013 87.7° R75
Coating Surface
Section A R4139.5
887 1008
1099
1145.5
R4044.5
1127.3 19.5
(4 mm)
R40
R35
C0.5 R100
R35
R550
R135 φ83
13°
A
W1JB-02-01-014 228
112
C0.5 109°
105
65° R250
R20 102°
Section B R70 R60
W1JB-02-01-017
76
140
78.5 57 195
447
483
W2-1-14
C1
C1
Black Ceramic W1JB-02-01-013
Coating Surface
Section A
W1JB-02-01-009
1646.47
1599.44
187 Black Ceramic Coating Range 313.6
R20
80 50
106 R300
2-R25
R2145 50
R30
696.73 R75
50
1230
R2940
900
(5 mm) 1205
A
R25
90 1496.7
40 R30
R3025
1636.3
R30 R50
R20 158 R10
873.14
R2875
150 145
R575 R50
R125
R1040 R30 R50
R1525 28°
W1JB-02-01-020
R55 R30
393
400
807.65
963.7
W2-1-15
Removal of Cab Glass
Right-Hand Glass
Procedures to Remove Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass
CAUTION: When removing the broken or

cracked glass, the glass shards may cause
serious injury.
Before removing, use the gummed tape or
something like in order to paste the broken or
cracked glass and reinforce them. Remove
the glass pieces away.
W1JB-02-01-009
1. Remove the resin panel, garnish and spacer

around the glass. Rear Glass
Rear
Left-Hand
Garnish Glass
Garnish
2. Prick a hole in the adhesive by using an awl (or

cutter knife). Lower Door Resin Panel WCEB-02-01-015
Glass
3. Pass a piano wire (or a wire) through the hole.
Cab
Cab Glass
Awl
Adhesive W1SE-02-01-033
Piano Wire
(or Metal Wire)
W1SE-02-01-034
W2-1-16
4. Wind the both ends of piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut the adhesive between cab and glass.
Remove the glass from the cab. Cab Glass (Cab Outside)
NOTE: Cut off the middle of adhesive between Cab Glass

glass and cab.
Piano wire is easily broken if a part of piano
wire turns hot. Change the position and cut
the adhesive.
Adhesive
(Cab Inside)
W1SE-02-01-035
W2-1-17
Installation of Cab Glass
Right-Hand Glass
Procedures to Install Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass
1. Cut off residual adhesive at the cab side to make

1 to 2 mm (0.04 to 0.08 in) deep all around by
using a cutter knife or similar.
NOTE: Do not damage the cab paint.
W1JB-02-01-009
Rear Glass
Lower Door Rear Left-Hand W1JB-02-01-010

Glass Glass
Cab
2. Clean the cutting edge of adhesive at cab side by

Cutter Knife
using white spirit.
Cut off adhesive by 1 to 2 mm

（0.04 to 0.08 in） deep.
W1SE-02-01-036
IMPORTANT: Primer should be shaken for about 1

minute and mix thoroughly before Cab
Apply Primer 24 by
opening the cap. using a brush.
After opening Primer, apply Primer
as quickly as possible and replace Cutting Edge of
the cap immediately after using. Adhesive at Cab
After opening Primer, all the Side
contents should be used within 180
W1SE-02-01-038
days (or 2 hours with the cap off).
3. Apply Primer for paint (Sika Aktivator DM-1) to the
cutting edge of adhesive at cab side by using a
brush. Wait for about 15 minutes in order to let it
dry by itself.
NOTE: The painting primer should be applied
evenly in order to leave no blemishes.
W2-1-18
4. Clean the mating edge of new glass by using 11. Suck, raise the glass by using sucker lifter
clean rag and ethyl alcohol. 4355282 (refer to W2-1-21), and adhere it to the
cab within 5 minutes.
IMPORTANT: Primer (Sika Primer Z06G+P) should NOTE: Install the glass while aligning the spacer
be shaken for about 1 minute and position on the glass. Remove all adhesive
mix thoroughly before opening the except the mounting surface, before
cap. solidifying by using white spirit.
After opening Primer, apply Primer
as quickly as possible and replace
the cap immediately after using. 12. Secure the glass by using the gummed tape until
After opening Primer, all the the adhesive becomes solid in order to prevent
contents should be used within 180 them from being mispositioned or coming off.
days (or 2 hours with the cap off). (Refer to W2-1-20.)
5. Apply Primer for glass (Sika Primer Z06G+P) to NOTE: Time for adhesive (Sika Tack-Drive) to
the cutting edge of adhesive at cab side by using become solid: 8 hours (just for reference)
a brush. Wait for about 15 minutes in order to let it
dry by itself.
(As for the position to apply Primer, refer to
W2-1-21.)
6. Install the spacer with facing to the glass surface

by using the instant adhesive.
(As for the positions to install spacers A, B and C
dam rubber, refer to W2-1-21.)
7. Cut off the nozzle of adhesive cartridge (Sika

Tack-Drive) into V-shaped by using a knife. (Refer
to W2-1-21.)
8. Remove the seal of cartridge. Install the V-shaped

nozzle.
9. Install the cartridge to the manual coking gun.
10. Evenly apply adhesive to the old adhesive left at

cab side.
(As for the position to apply adhesive, refer to
W2-1-21.)
W2-1-19
Rear Glass Right-Hand Glass
350 500
250 300
100
200
200 200 500
200
200 200
250 300
W1JB-02-01-029
200
200
100
100 W1JB-02-01-030
Rear Left-Hand Glass
150 200
Lower Door Glass

200
500
200
W1JB-02-01-035
W1JB-02-01-038
W2-1-20
NOTE: Unit: mm Spacer C

(1 mm=0.039 in) Spacer B
Spacer A 20
2
6
20 6
4 R0.5
20 6 4
8 78°
R8 75° R10
4 6 R0.5
3
R5 84°
6 R0.5 12 10.5
Two Side W1JB-02-01-024

3 Adhesive Tape
Two Side W1JB-02-01-023
10.5
Adhesive Tape
W1JB-02-01-022
Dam Rubber
30 6.4
W1JB-02-01-025
Lower Door Grass
Rear Left-Hand Glass

Right-Hand Glass
Suction Lifter
Spacer A
Rubber
Dam
Rubber
Spacer B Spacer A
Spacer B
Spacer A Dam W1JB-02-01-039
Rubber
Spacer B
Rear Glass
Spacer C
W1JB-02-01-027
W1JB-02-01-026
W1JB-02-01-042
8 to 9 mm
13 to 15 mm
Adhesive
Cut nozzle
end into
V-shaped.
W1SE-02-01-027
Apply adhesive
9 evenly.
12 Remove
the seal.
W1JB-02-01-031
Adhesive
W1SE-02-01-043
Cartridge
Panel
W1SE-02-01-028
W2-1-21
13. The required amount (just for reference) of adhesive and primer
Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack-Drive Sika Aktivator DM-1 Sika Primer 206G+P
(Sika Tack-Drive) (Sika Aktivator DM-1) 30 ml Bottle
310 ml Cartridge 250 ml Can
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Door Glass 150 ml 0.5 ml 0.45 ml
Rear Left-Hand Glass 250 ml 0.65 ml 0.6 ml
Rear Right-Hand Glass 100 ml 1 ml 0.9 ml
Rear Glass 210 ml 0.5 ml 0.45 ml
W2-1-22
Installation of Upper Door Glass
Sash
1. Before installing the glass, remove the garnish Assembly
around sash assembly from the cab inside for
easy removal. Push the sash assembly by hands
and remove the sash outside.
Garnish
2. Install glass A and glass B into the sash grooves.
3. Install the sash assembly, which the glass is

Glass A Glass B
installed on, onto the door from the outside of cab.
Secure the sash assembly at the inside of cab by W1JB-02-01-010
using the garnish.
W2-1-23
Installation of Upper Front Glass
Adhere the glass in the same method as
right-hand glass.
1. Stick seal (1) to the lower side of front upper glass
by using Cemedine Super X.
Stick and secure both right and left ends (the
thicker part) of seal (1) to the glass by using
Cemedine Super X.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.
NOTE: Cemedine Super X Black No.8008

Glue-state adhesive, tubed
IMPORTANT: The upper front glass is

arched-fringed. When replacing the
glass, contact with the nearest
HITACHI Office and replace it as an
assembly.
W1JB-02-01-034
Cemedine Super Upper Cemedine Super X Upper

X Seal Here Glass Glass
Seal (1) Seal (1)

Lower Lower
Glass Glass
W1JB-02-01-032 W1JB-02-01-033
W2-1-24
UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT
Removal
1. Open cover (1). 1
WCEB-02-02-008
2 3 4
2. Disconnect connector (2) and plug (7).
5
3. Remove sems bolt (5) from clip (6). Remove
wiring (4) and clip (6) from counterweight (3).
: 17 mm 6
7
WCEB-02-02-001
8
4. Open cover (8).
WCEB-04-02-005
9
5. Disconnect connector (9).
WCEB-02-02-002
W2-2-1
WCEB-04-01-005
11
WCEB-02-02-003
CAUTION: Counterweight (3) weight: 3000 kg

(6620 lb) 12
3
8. Remove caps (12) (2 used) from counterweight
(3). Install the sling bolts to the holes.
NOTE: Sling bolt (B-36, M36, Pitch: 4.0 mm)
9. Attach a wire rope to the sling bolts. Hoist and

hold counterweight (3).
CAUTION: Be careful to avoid getting your

13
hand caught by reaction bar on the power
wrench.
14
used) from counterweight (3) by using a power WCEB-02-02-004
wrench.
: 41 mm
3
11. Hoist and remove counterweight (3) from main
frame (15).
13
14
15 WCEB-02-02-005
W2-2-2
Installation
CAUTION: Counterweight (3) weight: 3000 kg

(6620 lb)
3
1. Hoist and align counterweight (3) with the
mounting holes on main frame (15).
2. Temporary install counterweight (3) to main frame

(15) with bolts (14) (4 used) and washers (13) (4 13
used).
14
15 WCEB-02-02-005
CAUTION: Be careful to avoid getting your

hand caught by reaction bar on the power 3
wrench.
3. Remove the wire rope and the sling bolts from

counterweight (3). Tighten bolts (14) (4 used) by
using a power wrench and torque wrench.
: 41 mm
: 1150 N⋅m (118 kgf⋅m, 848 lbf⋅ft)
Torque
Wrench
Power WCEB-02-02-006
Wrench
4. Install caps (12) (2 used) to counterweight (3). 12
WCEB-02-02-007
W2-2-3
5. Connect connectors (9, 11). 9 11
WCEB-02-02-002 WCEB-02-02-003
8
6. Shut covers (8, 10).
WCEB-04-02-005
10
WCEB-04-01-005
7. Secure wiring (4) to counterweight (3) with clip (6)

3 4
and sems bolt (5).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 5
WCEB-02-02-001
W2-2-4
8. Connect connector (2) and plug (7).
2
7
WCEB-02-02-001
9. Shut cover (1).
WCEB-02-02-008
W2-2-5
(Blank)
W2-2-6
UPPERSTRUCTURE / Main Frame
REMOVAL AND INSTALLATION OF MAIN
FRAME
CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
Removal Counterweight
CAUTION: Counterweight weight: 3000 kg

(6620 lb)
Washer
1. Remove the counterweight.
(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.) Bolt
: 41 mm
WCEB-02-02-005
Monoblock Boom
CAUTION: The front attachment assembly

weight:
Monoblock boom: 2000 kg (4410 lb)
2-piece boom: 2415 kg (5330 lb)
2. Remove the front attachment assembly.

FRONT ATTACHMENT on W4-1-1.)
: 27 mm, 30 mm, 36 mm
WCEB-02-03-001
2-Piece Boom
WCEB-02-03-002
W2-3-1
CAUTION: Center joint weight: 93 kg (210 lb)

Slip Ring Bolt Connector
3. Remove the bolt, stopper and slip ring from the

center joint. Disconnect the hose from the center
joint. (Refer to REMOVAL AND INSTALLATION
OF CENTER JOINT on W3-3-1.) Hose
: 10 mm, 24 mm, 27 mm
Stopper
Center Joint WCEB-03-03-001
Wire Rope
CAUTION: Upperstructure weight: 4000 kg
(8820 lb)
IMPORTANT: Do not damage the engine due to

the wire ropes attached from the
rear side of the frame.
4. Attach the wire ropes onto the rear side of the
frame and the boom mounting part. Take up slack
of the wire rope.
NOTE: If the chain block is used, it is not only Rear Side of Frame WCEB-02-03-003
easy to adjust the length of wire rope, but

Wire Rope
also easy to level the center of gravity.
WCEB-02-03-005
5. Put the matching marks on the upperstructure

and the outer race of the swing bearing.
Remove the swing bearing mounting bolt.
: 27 mm
6. Adjust a chain block in order to level the center of

gravity. Hoist and remove the frame.
WCEB-02-03-004
Bolt
W2-3-2
Installation
CAUTION: Upperstructure weight: 4000 kg

(8820 lb)
1. Attach the wire ropes onto the frame. Adjust the

chain block in order to level the center of gravity.
Hoist and place the frame onto the undercarriage.
(Refer to the Removal procedures.)
2. Align the matching marks on the upperstructure

and the outer race of the swing bearing.
Install and temporarily tighten the mounting bolts
for the swing bearing. Remove the wire ropes.
Tighten the mounting bolts for the swing bearing.
: 27 mm
: 400 N·m (41 kgf·m, 295 lbf·ft)
Bolt WCEB-02-03-004
3. Connect the hoses (15 used) to the center joint. Slip Ring Connector
Bolt
: 17 mm
: 24.5 N·m (2.5 kgf·m, 18 lbf·ft)
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
: 22 mm Hose
: 39 N·m (4 kgf·m, 29 lbf·ft)
: 27 mm
: 78 N·m (8 kgf·m, 58 lbf·ft)
: 36 mm Stopper
: 175 N·m (18 kgf·m, 129 lbf·ft)
4. Apply LOCTITE #262 onto the bolts (5 used).

Install the stopper to the center joint with the bolts Center Joint WCEB-03-03-001
(5 used).
: 24 mm
: 265 N·m (27 kgf·m, 195 lbf·ft)
5. Install the slip ring to the stopper.

: 10 mm
: 3.3 to 4.2 N·m
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)
W2-3-3
CAUTION: Counterweight weight: 3000 kg

(6620 lb) Counterweight
6. Install the counterweight.

(Refer to RRMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 41 mm Washer
: 1400 N·m (143 kgf·m, 1033 lbf·ft)
Bolt
WCEB-02-02-005
Monoblock Boom
CAUTION: The front attachment assembly
weight:
7. Install the front attachment assembly to the

upperstructure. Add hydraulic oil.
FRONT ATTACHMENT on W4-1-1.)
: 27 mm
: 93 N·m (9.5 kgf·m, 69 lbf·ft)
: 30 mm
: 540 N·m (55 kgf·m, 398 lbf·ft)
: 36 mm
: 175 N·m (18 kgf·m, 129 lbf·ft)
WCEB-02-03-001
8. Start the engine. Set the front attachment in 2-Piece Boom

posture for checking hydraulic oil level. Check for
hydraulic oil level and any oil leakage.
WCEB-02-03-002
W2-3-4
UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE

AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 1
Removal
1. Open cover (1).
WCEB-02-04-005
2, 3
Remove cover (2) from cover (3) and support (5).
: 17 mm
WCEB-02-04-020
6 7 8
Remove cover (7) from main frame (8).
: 17 mm
WCEB-02-04-001
W2-4-1
4. Disconnect hoses (13) (7 used) from filters (14) (7
used). Cap the open ends. Attach an identification 10, 11 12 13 14
tag onto the disconnected hoses for assembling.
: 17 mm, 19 mm, 27 mm 9

clip (11) from cover (9). 13
: 17 mm
WCEB-02-04-006
7. Disconnect connectors (17) (7 used) from pump 16 17

device (20).
8. Remove socket bolts (15) (8 used) and split

flanges (19) (4 used). Disconnect hoses (18) (2
used) from pump device (20). Cap the open ends.
: 10 mm
15 18
15
WCEB-02-04-006
19 20 19
20 21 22
9. Disconnect hose (16) from suction pipe (21). Cap
the open ends.
: 41 mm
10. Remove socket bolts (22) (4 used) from suction 17 17

pipe (21). Disconnect suction pipe (21) from pump
device (20).
: 10 mm 16
21
WCEB-02-04-009
W2-4-2
11. Disconnect hoses (24) (2 used) from regulators
(23) (2 used). Cap the open ends. 23
: 19 mm
24
WCEB-02-04-007
12. Remove socket bolts (27) (2 used) from clips (26)

(2 used). Remove clips (26) (2 used) from
connectors (25) (2 used) and pump device (20). 20
: 6 mm
13. Disconnect hoses (28) (3 used) from pilot pump

(30). Cap the open ends. Attach an identification
: 27 mm

Remove the cover (9) assembly from cover (3) WCEB-02-04-009
and support (5). 28 25, 26, 27

: 17 mm
9
30
29
3
5
WCEB-02-04-006
29
20
15. Remove socket bolts (32) (8 used). Remove split
flanges (31) (4 used). Disconnect hoses (33) (2
used) from pump device (20). Cap the open ends. 31
: 8 mm
32
33
WCEB-02-04-009
W2-4-3
16. Remove sems bolts (34) (2 used) from plate (35). 34 35 20
Remove plate (35) and the bracket (36) assembly
from pump device (20).
: 17 mm
36
WCEB-02-04-008
17. Remove nuts (38) (2 used), spring washers (39) 38, 39, 40
(2 used) and bolts (40) (2 used) from clamp (42).
Make muffler (37) free from exhaust pipe (41).
: 19 mm
37
CAUTION: The muffler (37) assembly weight:
23 kg (51 lb)
18. Attach a nylon sling onto muffler (37). Hoist and 41

hold muffler (37).
42
(44). Remove the muffler (37) assembly from
44 43 20 WCEB-02-04-002
pump device (20).
20
CAUTION: Pump device (20) weight: 164 kg
Eyebolt
(362 lb) Mounting
Hole
WCEB-02-04-003
20. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

pump device (20). Attach a nylon sling onto the
eyebolt. Hoist and hold pump device (20).
45
21. Remove sems bolts (46) (3 used) from pump
device (20). Remove pump device (20) from
engine (45).
: 17 mm
46
20 WCEB-02-04-002
W2-4-4
Installation
CAUTION: Pump device (20) weight: 164 kg 20

(362 lb)
Eyebolt
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to Mounting
pump device (20). Attach a nylon sling onto Hole
eyebolt. Hoist and hold pump device (20).
WCEB-02-04-003
2. Align pump device (20) with the mounting hole on

engine (45). Install pump device (20) to engine
(45) with sems bolts (46) (3 used).
: 17 mm 37 45
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)
CAUTION: The muffler (37) assembly weight:

23 kg (51 lb)
3. Attach a nylon sling onto the muffler (37) assembly.

46
Hoist and align the muffler (37) assembly with the
mounting hole on pump device (20). Install 44 43 20 WCEB-02-04-002
bracket (44) to pump device (20) with bolts (43) (3

used).
: 17 mm
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)
38, 39, 40
4. Align clamp (42) with the center between exhaust

pipe (41) and the muffler (37) pipe part. Secure
37
exhaust pipe (41) and muffler (37) with bolts (40)
(2 used), spring washers (39) (2 used) and nuts
(38) (2 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 41
42
WCEB-02-04-002
W2-4-5
34 35 20
5. Install the bracket (36) assembly to pump device
(20) with sems bolts (34) (2 used) and plate (35).
: 17 mm
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)
36
WCEB-02-04-008
6. Connect suction pipe (21) to pump device (20) 20 21 22

with socket bolts (22) (4 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
7. Connect hose (16) to suction pipe (21).

: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
21
16 WCEB-02-04-009
8. Connect hoses (33) (2 used) to pump device (20)

with split flanges (31) (4 used) and socket bolts
20
(32) (8 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
31
32
33
9. Connect hoses (28) (3 used) to pilot pump (30).

: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
WCEB-02-04-009
28
30
WCEB-02-04-006
W2-4-6
10. Install the cover (9) assembly to cover (3) and 9
support (5) with sems bolts (29) (6 used).
: 17 mm 29
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
3
11. Connect hoses (18) (2 used) to pump device (20) 5
(15) (8 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 18
15
WCEB-02-04-006
29 19 20 19
12. Connect hoses (24) (2 used) to regulators (23) (2 23

used).
: 19 mm
24
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
13. Connect connectors (17) (7 used) to pump device

(20).
17
WCEB-02-04-007
20
14. Connect hoses (13) (7 used) to filters (14) (2 10, 11 12 13 14

used).
: 17 mm 9
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 13
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
15. Install clip (11) to hoses (13) (2 used). Secure clip

(11) to cover (9) with sems bolt (10).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) WCEB-02-04-006
16. Connect connector (12).
W2-4-7
6 7 8
17. Install cover (7) to main frame (8) with sems bolts
(6) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-04-001
18. Install cover (2) to cover (3) and support (5) with 2, 3
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-04-020
19. Shut cover (1). 1
WCEB-02-04-005
W2-4-8
(Blank)
W2-4-9
DISASSEMBLY OF PUMP DEVICE 4
1 2 3 5
18
15 16 17
6 14
13
12
58 11
7 10
9 14
57
15 16 17
56
55
54 19
8
53 12
20
11
51 10
9
21
52 22
23 28
51 50 24
21
22
27
26
49 25
37
29
30 38
26 35 39
40
31 36
48 34
47
32
33
41
42
43
44
46 45
44 WCEB-02-04-014
W2-4-10
72
71
70 73
69
68
67 74
66 71
65
75
60 62
63
64 69
63
62 68
60 60
61 62 78
82 63 76
59 81
60 63 77
62
60
83 61 79
82
60 80
59 60
72
83
WCEB-02-04-011
1 - Socket Bolt (4 Used) 22 - Plug (2 Used) 43 - Retaining Ring 64 - Right Valve Plate
2 - Right Regulator 23 - O-Ring 44 - Ball Bearing (2 Used) 65 - Backup Ring
3 - Socket Bolt (2 Used) 24 - Stopper 45 - Gear 66 - O-Ring
4 - Socket Bolt (2 Used) 25 - Plug 46 - Gear Shaft 67 - Spring Pin (2 Used)
5 - Socket Bolt (2 Used) 26 - Retaining Ring (2 Used) 47 - Retaining Ring 68 - Pressure Sensor (2 Used)
6 - Left Regulator 27 - Gear 48 - Oil Seal 69 - O-Ring (2 Used)
7 - O-Ring (4 Used) 28 - Gasket 49 - Gear Casing 70 - Selector Head
8 - O-Ring (6 Used) 29 - Gear 50 - Spring Pin (2 Used) 71 - O-Ring (4 Used)
9 - Bearing Nut (2 Used) 30 - Plug 51 - Oil Seal (2 Used) 72 - Socket Bolt (16 Used)
10 - Bearing (2 Used) 31 - Elbow 52 - Retaining Ring (2 Used) 73 - Stopper S (2 Used)
11 - Ring (2 Used) 32 - Plug 53 - Pump Casing 74 - O-Ring (2 Used)
12 - Bearing (2 Used) 33 - O-Ring 54 - Spring Washer (6 Used) 75 - Socket Bolt (12 Used)
13 - Shaft 34 - Gasket 55 - Bolt (6 Used) 76 - Set Screw (2 Used)
14 - Pin (2 Used) 35 - Socket Bolt (2 Used) 56 - Spring Pin (2 Used) 77 - Servo Piston (2 Used)
15 - Center Shaft (2 Used) 36 - Pipe 57 - O-Ring (2 Used) 78 - Pin (2 Used)
16 - Spring (2 Used) 37 - Level Gauge 58 - O-Ring (2 Used) 79 - O-Ring (2 Used)
17 - Plunger (14 Used) 38 - Socket Bolt (2 Used) 59 - Pin (2 Used) 80 - Stopper (2 Used)
18 - Rotor (2 Used) 39 - Spring Washer (2 Used) 60 - Retaining Ring (12 Used) 81 - Left Valve Plate
19 - Shaft 40 - Washer (2 Used) 61 - Pin (2 Used) 82 - Pin (4 Used)
20 - Slide Ring 41 - Pilot Pump 62 - Lever (4 Used) 83 - Link (2 Used)
21 - O-Ring (2 Used) 42 - Retaining Ring 63 - Pin (4 Used)
W2-4-11
4
1 2 3 5
70
58
7
57
53
49
25
37
30 38
35 39
40
31 36
34
32
41
WCEB-02-04-013
W2-4-12
Disassembly of Pump Device 7. Hoist the pump casing (53) assembly. Place the
pump casing (53) assembly with gear casing (49)
1. Remove plug (25) from gear casing (49). facing downward. Place the wooden block (80
: 17 mm mm ( 3.1 in) or more square) under gear casing
(49).
2. Remove plug (32) from gear casing (49). Drain off
gear oil from gear casing (49). (Approx. 1.0 L, 0.3 8. Remove socket bolts (35) (2 used) from pipe (36).
US gal) Remove level gauge (37), pipe (36) and gasket
: 22 mm (34) from gear casing (49).
: 6 mm
3. Remove socket bolts (1) (4 used) from right
regulator (2). Raise right regulator (2) to the 9. Remove socket bolts (38) (2 used), spring
direction of selector head (70). Remove right washers (39) (2 used) and washers (40) (2 used)
regulator (2) from pump casing (53). from pilot pump (41). Tap the flange of pilot pump
: 8 mm (41) by using a plastic hammer and remove pilot
pump (41) from gear casing (49).
4. Remove socket bolts (3) (2 used) and socket bolts : 8 mm
(5) (2 used) from left regulator (6). Raise left NOTE: THREEBOND has been applied onto the
regulator (6) to the direction of selector head (70). mounting surface of pilot pump (41).
Remove left regulator (6) from pump casing (53).
Do not remove socket bolt (4). 10. Remove plug (30) and elbow (31) from gear
: 8 mm casing (49).
: 30 mm
5. Remove O-rings (7) (4 used) and O-rings (57, 58)
(2 used for each) from pump casing (53).
CAUTION: The pump casing (53) assembly

weight: 160 kg (360 lb)
CAUTION: When hoisting the pump casing

(53) assembly, turn to the gear
casing (49) side and do not take
pump casing (53) off the ground.

the thread hole for socket bolts (1, 3) of pump
casing (53). Attach a nylon sling onto eyebolts (2
used).
W2-4-13
16
8 16
53
72
71 73
70
69 74
68
71
66
65 75
69
68
79
80
72
WCEB-02-04-012
W2-4-14
11. Remove the pressure sensors (68) (2 used) 15. Record the clearance between pump casing (53)
assembly from selector head (70). and selector head (70). Remove socket bolts (75)
: 27 mm (12 used) from selector head (70).
: 10 mm
12. Remove socket bolts (72) (16 used) from stoppers NOTE: While loosening socket bolt (75), selector
S (73) (2 used) and stoppers L (80) (2 used). head (70) will push out due to the force of
Remove stoppers S (73) (2 used) and stoppers L spring (16).
(80) (2 used) from selector head (70).
: 6 mm
NOTE: O-rings (74, 79) are installed to stopper S CAUTION: Selector head (70) weight: 28 kg
(73) and stopper L (80). If it is difficult to (62 lb)
remove the stopper, tap the outer periphery
of the stopper. Turn the stopper until about 16. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
half of the hole for the mounting bolt can be the bolt hole on the upper surface of selector
seen. Insert a screwdriver into the head (70). Hoist and remove selector head (70)
mounting bolt hole. Remove the stopper by from pump casing (53). O-ring (66) may be
using a screwdriver. removed with the lower surface of selector head
(70) attached. Check O-ring (66).
17. Remove O-rings (8) (6 used), O-ring (66) and

Stopper backup ring (65) from pump casing (53).
W178-02-11-082
13. Remove O-rings (71) (4 used) from selector head

(70).
14. Remove O-rings (74, 79) (2 used for each) from

stoppers S (73) (2 used) and stoppers L (80) (2
used).
W2-4-15
18
15 16 17
13
15 16 17
55
54 19
53
50
28
27
49 70
29 75
60 62
63
64
63
62
60 60
61 62 78
82 63 76
59 81
60 63 77
62
60
83 61
82
60
59 60
83
WCEB-02-04-012
W2-4-16
18. Warm up set screws (76) (2 used) by using a drier.
Remove set screws (76) (2 used) from servo CAUTION: Pump casing (53) weight: 105 kg
pistons (77) (2 used). Remove pins (78) (2 used) (240 lb)
from servo pistons (77) (2 used).
: 6 mm 24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (75) hole on pump casing (53).
19. Remove servo pistons (77) (2 used) from selector Hoist and remove pump casing (53) from gear
head (70). casing (49). Shafts (13, 19) and gears (27, 29) are
removed with pump casing (53) together.
20. Both right valve plate (64) and left valve plate (81) Place pump casing (53) with the mounting surface
are very similar and their installing directions are for the regulator facing upward.
determined. Record the position and the direction
of right valve plate (64) and left valve plate (81) 25. Remove spring pins (50) (2 used) and gasket (28)
before removing. Remove retaining rings (60) (4 from gear casing (49).
used) from pins (63) (4 used). Remove right valve
plate (64) and left valve plate (81) from links (83)
(2 used). Do not remove pins (63) (4 used) unless
necessary.
21. Remove rotor (18), spring (16), the center shaft

(15) assembly and plungers (17) (7 used) from
pump casing (53) in this order. (Both right and left
pumps)
NOTE: When removing plunger (17), turn plunger
(17) inside and remove plunger (7).
IMPORTANT: As the pump performance may be

changed, do not deform link (83).
22. Remove the link (83) assemblies (2 used)from
pump casing (53). Do not disassemble the link
(83) assembly unless necessary.
NOTE: If it is difficult to remove the link (83)
assembly, use a screwdriver.
23. Remove bolts (55) (6 used) and spring washer

(54) from pump casing (53).
: 24 mm
W2-4-17
13
12
10
19
53 12
10
21
22
23
24
21
22
27
26
70
29
26
WCEB-02-04-012
W2-4-18
26. Put the matching marks on the meshed position
of splines on shafts (13, 19) and gears (27, 29). CAUTION: Pump casing (53) weight: 70 kg
Put the matching marks on the meshed position (160 lb)
of gears (27, 29).
31. Attach a nylon sling onto pump casing (53). Hoist
27 29 and place pump casing (53) on the wooden
blocks with the pump transmission side facing
downward. Use the wooden block: 100 mm (3.9
in) or more square.
32. Remove shafts (13, 19) from pump casing (53) by

19
using special tools (ST 1470, ST 1471). Bearings
13
(10, 12) are removed with shafts (13, 19) together.
W137-02-04-007 ST 1470
27. Remove retaining rings (26) (2 used) from shafts ST 1471

(13, 19). Remove gears (27, 29) from shafts (13,
19).
13
CAUTION: Pump casing (53) weight: 70 kg 19

(160 lb)
28. Attach a nylon sling onto pump casing (53). Hoist 53

and place pump casing (53) with the mounting
side for selector head (70) facing downward.
29. Remove stoppers (24) (2 used) from pump casing W178-02-04-054

(53). Remove O-rings (23) (2 used) from stoppers
(24) (2 used).
: 19 mm
30. Remove plugs (22) (2 used) from pump casing

(53). Remove O-rings (21) (2 used) from plugs
(22) (2 used).
: 8 mm
W2-4-19
13
12
11
10
19
53 12
20
11
51 10
9
52
51
49
48
47
42
43
44
46 45
44 WCEB-02-04-014
W2-4-20
33. Remove slide ring (20) from pump casing (53). 39. Remove ball bearing (44) and gear shaft (46)
from the upper side of gear casing (49) by using
34. Remove bearing nuts (9) (2 used) from shafts (13, special tool (ST 1393).
19) by using special tool (ST 3058).
ST 3058
9
46
44
W137-02-04-023
W178-02-11-085
35. Remove bearings (10, 12) (2 used for each) and

rings (11) (2 used) from shafts (13, 19) by using a 40. Remove gear (45) and ball bearing (44) from gear
press. casing (49).
41. Install a shackle to the bolt hole on the periphery

CAUTION: Pump casing (53) weight: 42 kg of gear casing (49). Hoist and turn over gear
(93 lb) casing (49) by using a nylon sling.
36. Attach a nylon sling onto pump casing (53). Hoist 42. Remove retaining ring (47) and oil seal (48) from
and place pump casing (53) with the mounting gear casing (49).
surface for the regulator facing upward.
37. Remove retaining rings (52) (2 used) and oil seals

(51) (2 used) from pump casing (53).
38. Remove retaining ring (42) from gear casing (49).

Remove retaining ring (43) from gear shaft (46).
W2-4-21
ASSEMBLY OF PUMP DEVICE
81 66 65 18 16 15 17 12 20 11 10 9 51 29
26
19
52
13
26
27
64 60, 63 62 18 82 16 15 17 12 11 10 9 51
72 73 71 74 8 7 56 57 61 60 59 58 53
70
79
76
78
79
W178-02-11-086
72 67 22 21 83 14 24 23
80
W2-4-22
38, 39, 40 41 34, 35, 36 43 42 45 44
32, 33 31 30 6 5 4 3 37
46
25
47
48
50
49
WCEB-02-04-004
68 75 2 1 55 54 28
1- Socket Bolt (4 Used) 22 - Plug (2 Used) 43 - Retaining Ring 64 - Right Valve Plate
2- Right Regulator 23 - O-Ring 44 - Ball Bearing (2 Used) 65 - Backup Ring
3- Socket Bolt (2 Used) 24 - Stopper 45 - Gear 66 - O-Ring
4- Socket Bolt (2 Used) 25 - Plug 46 - Gear Shaft 67 - Spring Pin (2 Used)
5- Socket Bolt (2 Used) 26 - Retaining Ring (2 Used) 47 - Retaining Ring 68 - Pressure Sensor (2 Used)
6- Left Regulator 27 - Gear 48 - Oil Seal 69 - O-Ring (2 Used)
7- O-Ring (4 Used) 28 - Gasket 49 - Gear Casing 70 - Selector Head
8- O-Ring (6 Used) 29 - Gear 50 - Spring Pin (2 Used) 71 - O-Ring (4 Used)
9- Bearing Nut (2 Used) 30 - Plug 51 - Oil Seal (2 Used) 72 - Socket Bolt (16 Used)
10 - Bearing (2 Used) 31 - Elbow 52 - Retaining Ring (2 Used) 73 - Stopper S (2 Used)
11 - Ring (2 Used) 32 - Plug 53 - Pump Casing 74 - O-Ring (2 Used)
12 - Bearing (2 Used) 33 - O-Ring 54 - Spring Washer (6 Used) 75 - Socket Bolt (12 Used)
13 - Shaft 34 - Gasket 55 - Bolt (6 Used) 76 - Set Screw (2 Used)
14 - Pin (2 Used) 35 - Socket Bolt (2 Used) 56 - Spring Pin (2 Used) 77 - Servo Piston (2 Used)
15 - Center Shaft (2 Used) 36 - Pipe 57 - O-Ring (2 Used) 78 - Pin (2 Used)
16 - Spring (2 Used) 37 - Level Gauge 58 - O-Ring (2 Used) 79 - O-Ring (2 Used)
17 - Plunger (14 Used) 38 - Socket Bolt (2 Used) 59 - Pin (2 Used) 80 - Stopper L (2 Used)
18 - Rotor (2 Used) 39 - Spring Washer (2 Used) 60 - Retaining Ring (12 Used) 81 - Left Valve Plate
19 - Shaft 40 - Washer (2 Used) 61 - Pin (2 Used) 82 - Pin (4 Used)
20 - Slide Ring 41 - Pilot Pump 62 - Lever (4 Used) 83 - Link (2 Used)
21 - O-Ring (2 Used) 42 - Retaining Ring 63 - Pin (4 Used)
W2-4-23
43 42 44 45 44
32, 33
49
WCEB-02-04-004
12 11 10
19
13
12 11 10 W178-02-11-089
W2-4-24
Assembly of Pump Device
1. Tap and install ball bearing (44) into gear casing

CAUTION: Be careful as bearing (10) is too
(49) with the stamped mark facing inside by using
a bar and hammer. Tap and listen to ring in order hot.
to check that ball bearing (44) is installed
completely. 9. Apply hydraulic oil onto the inside of bearings (10)
(2 used). Install bearings (10) (2 used) to shafts
2. Place gear (45) on ball bearing (44). Insert gear (13, 19) by using a press.
shaft (46) while aligning with the spline.
3. Tap and install ball bearing (44) into gear shaft

(46) with the stamped mark facing outside by
using a bar and hammer. Tap and listen to ring in
order to check that ball bearing (44) is installed
completely.
4. Install retaining ring (42) to gear casing (49).

Install retaining ring (43) to gear shaft (46).
5. Install O-ring (33) to plug (32). Install plug (32) to

gear casing (49).
: 22 mm
: 70 N⋅m (7 kgf⋅m, 52 lbf⋅ft)
6. Warm up bearings (10, 12) (2 used for each) to 50

to 80 °C (122 to 176 °F).
CAUTION: Be careful as bearing (12) is too

hot.
7. Apply hydraulic oil onto the inside of bearings (12)

(2 used). Install bearings (12) (2 used) to shafts
(13, 19) by using a press.
8. Install rings (11) (2 used) to shafts (13, 19).
W2-4-25
WCEB-02-04-004
53 12 20 10 9
19
13
12 10 9 W178-02-11-089
W2-4-26
10. Set the pre-loads of bearings (10, 12) installed on
shaft (13) according to the following procedures.
• Apply hydraulic oil onto the thread part of bearing
nut (9). Tighten bearing nut (9) until bearing nut
(9) comes in contact with bearing (10) by using
special tool (ST 3058).
ST 3058
9
10
W178-02-11-090
• Install special tool (ST 3070) to bearing (10).

Rotate 2 to 3 turns and measure the starting
torque.
ST 3070
10
W178-02-11-091
• Adjust bearing nut (9) until the starting torque

reaches specification.
: 1.96±0.49 N⋅m
(0.20±0.05 kgf⋅m, 1.45±0.36 lbf⋅ft)
NOTE: If the starting torque is higher than the limit
of specified torque, loosen bearing nut (9).
Tap the shaft end and release the load of
bearing (10).
11. Set the pre-loads of bearings (10, 12) installed on

shaft (19) in the same way as step 10.
12. Install slide ring (20) to the side to insert shaft (19)
in pump casing (53).
W2-4-27
53 12 10 51
19
52
13
51
Regulator Mounting Surface 53
W178-02-11-092
24 23
W2-4-28
13. Warm up pump casing (53) to 50 to 80 °C (122 to 19. Install special tools (ST 2649, ST 2650) over the
176 °F). spline parts of shafts (13, 19).
NOTE: If special tools are not available, wind the
14. Apply hydraulic oil onto the outside of bearings vinyl tape over the spline part of the shaft in
(10, 12) installed on shaft (19). Install shaft (19) to order not to damage oil seal (51).
pump casing (53) by using special tool.
If it is difficult to insert shaft (19), tap shaft (19) by
using a bar.
Special Tool
ST 2650
51
M8, Pitch 1.25 mm
53
19
W178-02-11-094
ST 2649
Wooden Block
Wooden Block 20. Apply grease onto the inside of oil seals (51) (2
used). Evenly tap and install oil seals (51) (2
W178-02-11-093
used) to shafts (13, 19).
15. Install shaft (13) to pump casing (53) in the same 21. Remove special tools (ST 2649, ST 2650) from
way as step 14. shafts (13, 19).
16. Wait for pump casing (53) in order to cool down to 22. Install retaining rings (52) (2 used) to pump casing
the temperature lower than 40 °C (104 °F). (53).
17. Install O-ring (23) to stopper (24). Install stopper

(24) to pump casing (53).
: 19 mm
: 34.5 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
CAUTION: Pump casing (53) weight: 65 kg

(150 lb)
18. Attach a nylon sling onto pump casing (53). Hoist

and place pump casing (53) with the mounting
surface for the regulator facing upward.
W2-4-29
45
50
49
WCEB-02-04-004
75 53 55 54 28
53 29
26
19
13
26
17 27 W178-02-11-096
W2-4-30
23. Align the matching marks and install gears (27,
CAUTION: Pump casing (53) weight: 70 kg
29) to shafts (13, 19). Install retaining rings (26) (2
used) to shafts (13, 19). (160 lb)
When replacing the shaft and the gear, install the
gear according to the following procedure. 25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
• Secure special tool (ST 7934) to the plunger (17) the socket bolt (75) hole on pump casing (53).
mounting side of shafts (13, 19). Hoist pump casing (53).
While engaging gear (45) with gear (29), install
19 pump casing (53) to gear casing (49) with bolts
(55) and spring washers (54) (6 used for each).
ST 7934 13 : 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
M8, Pitch 1.25 mm W178-02-11-097
• Turn shafts (13, 19) clockwise, viewed from the

mounting side for gears (27, 29), until shafts (13,
19) come into contact with special tool. (Remove
a play in periphery direction.)
• Install gear (27) and retaining ring (26) to the
spline of shaft (13).
• Insert gear (29) into the spline of shaft (19) and
engage with gear (27). If gear (29) does not
engage, turn and adjust shaft (19) in a play range
of special tool.
• Install retaining ring (26) to the spline of shaft
(19).
• Remove special tool (ST 7934).
24. Install spring pins (50) (2 used) to gear casing

(49). Install gasket (28).
W2-4-31
34, 35, 36
38, 39, 40 41 41 38 39, 40
49
WCEB-02-04-004
62 83 15 14 17 53
70
19
13
W178-02-11-096
62 59, 61 83 15 14 17
W2-4-32
26. Apply THREEBOND #1215 onto the mounting 30. Insert plungers (17) (7 used for each) into shafts
surface of pilot pump (41). Install pilot pump (41) (13, 19).
to gear casing (49) with socket bolts (38), spring
washers (39) and washers (40) (2 used for each). 31. Apply grease onto pins (14) (2 used). Install pin
: 8 mm (14) to center shafts (15) (2 used).
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
32. Apply grease onto the spherical surface of center
27. Install gasket (34) and pipe (36) to gear casing shafts (15) (2 used). Install center shafts (15) (2
(49) with socket bolts (35) (2 used). used) to shafts (13, 19).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
IMPORTANT: As the pump performance may be

changed, do not deform link (83).
28. Align with the groove for pin (59) on pump casing
(53) and install the link (83) assemblies (2 used),
with lever (62) facing to the selector head (70)
side.
NOTE: Both surfaces of pin (59) are parallel to
each other. Align the parallel surface with
the groove.
59
83
61
53
Parallel Parallel W178-02-11-098
Surface Surface
29. Apply hydraulic oil onto the plunger (17) mounting
surface of shafts (13, 19).
W2-4-33
60 62 16 79 18 15 14 17 53
63
81
64 60, 63 62 18 83 16 15 14 17 W178-02-11-099
8 65 18 53
70 19
W178-02-04-016
67 14
W2-4-34
33. Install springs (16) (2 used) to center shafts (15) 38. Install backup ring (65), O-ring (66) and O-rings
(2 used). (8) (6 used) to pump casing (53).
34. Insert center shafts (15) (2 used) and plungers 39. Install spring pins (67) (2 used) to pump casing
(17) (14 used) into rotors (18) (2 used). (53).
35. Insert the round file into the center hole on center
shaft (15). While rotating center shaft (15) by
using the round file, insert pin (14) into the groove
of rotor (18). (Both right and left pumps)
NOTE: If pin (14) does not enter into the groove on
rotor (18), selector head (70) cannot be
installed to pump casing (53).
36. Insert pins (63) (2 used) of right valve plate (64)

into the hole on levers (62) (2 used) for right
regulator (2). Install retaining rings (60) (2 used).
Check the direction to install right valve plate (64).
81 64
Upward
W178-02-11-100
37. Insert pins (63) (2 used) of left valve plate (81)

into the hole on levers (62) (2 used) for left
regulator (6). Install retaining rings (60) (2 used).
Check the direction to install left valve plate (81).
W2-4-35
Eyebolt
Mounting Hole
75
WCEB-02-04-004
70 75
72 71 73 74 18 53
70
77
76
78
Mounting Surface for

Suction Pipe
W178-02-04-016
79 72 64, 81 80 67 14
W2-4-36
40. Apply hydraulic oil onto servo pistons (77) (2 45. Install O-rings (74) (2 used) to stoppers S (73) (2
used). Insert servo pistons (77) (2 used) into used). Apply grease onto O-rings (74) (2 used).
selector head (70). Install stoppers S (73) (2 used) to selector head
(70) with socket bolts (72) (8 used).
41. Apply LOCTITE LI829 onto the thread part of set : 6 mm
screws (76) (2 used). Install pins (78) (2 used) to : 19.5 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
servo pistons (77) (2 used) with set screws (76) (2
used). 46. Install O-rings (79) (2 used) to stoppers L (80) (2
: 6 mm used). Apply grease onto O-rings (79) (2 used).
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) Install stoppers L (80) (2 used) to selector head
: 6 mm
CAUTION: Selector head (70) weight: 29 kg : 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
(64 lb)
42. Install eyebolts (M12, Pitch 1.75 mm) (2 used)

into the thread hole for the suction pipe on
selector head (70). Attach a nylon sling onto
eyebolts (2 used). Hoist selector head (70).
Place selector head (70) on pump casing (53)
while aligning selector head (70) with spring pin
(67).
NOTE: Check the clearance between selector
head (70) and pump casing (53) in order to
compare with the clearance before
disassembling. If the clearance is larger,
pin (14) may not be inserted into the groove
on rotor (18), or pin (78) may not be
inserted into the holes on valve plates (64,
81).
43. Install selector head (70) to pump casing (53) with

socket bolts (75) (12 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
44. Install O-rings (71) (4 used) to selector head (70).
W2-4-37
47
19
48
49
WCEB-02-04-004
53 7 56 57 61 58
5 6 3
83 2 1
WCEB-02-04-015
W2-4-38
47. Install O-rings (58) (2 used), O-rings (57) (2 used),
O-rings (7) (4 used) and spring pins (56) (2 used) CAUTION: Pump device weight: 160 kg (360
to pump casing (53). lb)
48. Install right regulator (2) to pump casing (53) 50. Hoist and place selector head (70) with the
according to the following procedure. regulator mounting side facing upward.
• Adjust the sleeve position so that two grooves in
both sleeves on right regulator (2) are in a line. 51. Insert special tool (ST 2650) to shaft (19). Apply
• Place right regulator (2) on pump casing (53). grease onto oil seal (48). Install oil seal (48) to
Insert pin (61) for link (83) into two grooves on the shaft (19).
sleeve. Remove special tool (ST 2650). Tap and install oil
• Move right regulator (2) so that spring pin (56) out seal (48).
of pump casing (53) can enter into right regulator NOTE: If special tool (ST 2650) is not available,
(2). wind the vinyl tape over the spline parts of
• Install right regulator (2) to pump casing (53) with shaft (19) in order to protect oil seal (48).
socket bolts (1) (4 used). Install oil seal (48).
: 8 mm ST 2650
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
61
2 Sleeve 48
53 W178-02-11-101
83 56
W178-02-11-103
49. Install left regulator (6) to pump casing (53) with
socket bolts (3) (2 used) and socket bolts (5) (2 52. Install retaining ring (47) to gear casing (49).
used) in the same way as step 48.
: 8 mm
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W2-4-39
31 30 37 36 25
49
WCEB-02-04-004
68
W178-02-04-016
W2-4-40
53. Wind the seal tape onto elbow (31). Install elbow
(31) to gear casing (49). Add engine oil (1.0 L, 0.3
US gal) through the elbow (31) hole.
54. Wind the seal tape onto plug (30). Install plug (30)
to elbow (31).
: 30 mm
: 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
49 30
31
W1V1-02-04-010
IMPORTANT: The breather hole of plug (25) is

located at the left side, viewed from
the front of gear casing (49).
55. Wind the seal tape onto plug (25). Install plug (25)
to gear casing (49).
: 17 mm
: 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
56. Insert level gauge (37) into pipe (36).
57. Install pressure sensors (68) (2 used) to selector

head (70).
: 27 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
W2-4-41
DISASSEMBLY OF REGULATOR
Left Regulator
Right Regulator 2 14
13
3 12
WCEB-02-04-016
11
10
9
4 15
16
17
5 6
7
8
18
19 28
20
23
24 21
22
31 32
25 30 33
29 34
26
35
27 36
37
28 38
39
40
41
WCEB-02-04-019
42
1- Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut

2- Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut
3- Solenoid Valve 14 - Piston 25 - Cover 35 - Cover
4- O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster
5- Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring
6- O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper
7- O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring
8- O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring
9- Piston 20 - Stopper 31 - Piston 41 - Spool
10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve
11 - Backup Ring 22 - Adjuster
W2-4-42
Disassembly of Regulator IMPORTANT: As the setting changes, do not turn
• The regulators are used for right pump and left lock nuts (33, 34).
pump. The inner structure in the regulator is fully 4. Remove socket bolts (28) (4 used) from cover
identical, and the difference is only in its (35). Remove cover (35) and piston (14) from
accessories. casing (32). The stopper (38) assembly is
Here the left regulator is explained. removed with cover (35) together.
: 6 mm
IMPORTANT: As the setting changes, do not
disassemble adjusting screws (23, 5. Remove springs (17, 18) from casing (32).
24, 26, 27, 33 and 34).
When adjusting screws (23, 24, 26, 6. Insert a round bar into the hole on casing (32).
27, 33 and 34) must be disassembled, Push the spool (16) end. Remove cylinder (12),
carry out adjustment according to sleeve (15) and spool (16) from casing (32).
the procedure of performance test Piston (9) is removed with cylinder (12) together.
after assembling.
7. Remove piston (9) from cylinder (12).
1. Clamp casing (32) in a vise. Remove pipe (1)
from casing (32). 8. Remove spring (40) from casing (32).
: 22 mm
9. Insert a round bar into the hole on casing (32).
2. Remove socket bolts (2) (2 used) from solenoid Push the spool (41) end. Remove cylinder (30),
valve (3). Remove the solenoid valve (3) sleeve (42) and spool (41) from casing (32).
assembly and O-rings (6, 7, 8) from casing (32). Piston (31) is removed with cylinder (30) together.
: 8 mm
10. Remove piston (31) from cylinder (30).
IMPORTANT: As the setting changes, do not turn
set bolt (26), lock nuts (23, 24 and
27).
3. Remove socket bolts (28) (4 used) from cover
(25). Remove cover (25) from casing (32). Set
bolt (26) and the stopper (20) assembly are
removed with cover (25) together.
: 6 mm
W2-4-43
ASSEMBLY OF REGULATOR
2 3, 6, 7, 8
4, 5
WCEB-02-04-016
24 23 22 19 21 20 18 17 15 16 32 9 10 11 12 13 14
35
26
38
27
28 WCEB-02-04-017
25 29 30 31 42 41 40 37 39 34 36 33
1 - Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut

2 - Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut
3 - Solenoid Valve 14 - Piston 25 - Cover 35 - Cover
4 - O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster
5 - Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring
6 - O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper
7 - O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring
8 - O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring
9 - Piston 20 - Stopper 31 - Piston 41 - Spool
10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve
11 - Backup Ring 22 - Adjuster
W2-4-44
Assembly of Regulator
IMPORTANT: Two holes for sleeves (15, 42) on 9. Install O-ring (37) and spring (40) to the stopper
casing (32) are the same bores. The (38) assembly with cover (35) attached. Install
shapes of various parts in casing cover (35) to casing (32) with socket bolts (28) (4
(32) are very similar. Check the used).
illustration and assemble the : 6 mm
regulator. : 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
1. Clean all parts and apply hydraulic oil. 10. Install O-ring (21) and springs (17, 18) to the
stopper (20) assembly with cover (25) attached.
2. Insert spool (41) into sleeve (42). Install sleeve Install cover (25) to casing (32) with socket bolts
(42) to the center of casing (32) by using a round (28) (4 used).
bar. Check the direction to install sleeve (42), : 6 mm
spool (41) and piston (31). : 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
3. Install O-ring (29) to cylinder (30). 11. Apply grease onto O-rings (6, 7 and 8). Install
O-rings (6, 7 and 8) to solenoid valve (3). Install
4. Insert piston (31) into cylinder (30). Install cylinder solenoid valve (3) to casing (32) with socket bolts
(30) to casing (32). (2) (2 used).
: 8 mm
5. Insert spool (16) into sleeve (15). Install sleeve : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
(15) to the center of casing (32) by using a round
bar. Check the direction to install sleeve (15) and 12. Apply grease onto the thread part of pipe (1).
spool (16). Install pipe (1) to casing (32).
: 22 mm
6. Install O-rings (10, 13) and backup ring (11) to : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
cylinder (12).
7. Insert piston (9) into cylinder (12). Install cylinder

(12) to casing (32).
8. Install piston (14) to cover (35) from the mounting

side for casing (32).
W2-4-45
STRUCTURE OF PILOT PUMP 9
8
6
1
2
3
7
6
5
4
3
2
1
10
11
13 12
6
1
2
3
7
6
14
3
2
1
15 WCEB-02-04-018
16
17
3 3 3 15
9
13
5
17
16
14
8 7 10 12 7
1 2 1 2 WCEB-02-04-010
W2-4-46

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Plate Seal 4
2 Backup Ring 4
3 Side Plate 4
4 Rear Drive Gear 1
5 Driven Gear 1
6 Knock Pin 8
7 Gear Plate 2
8 Cover 1
9 Socket Bolt 4
10 Coupling 1
11 Stabilizer 2
12 Center Plate 1
13 Driven Gear 1
14 Front Drive Gear 1
15 Flange 1
16 Oil Seal 1
17 Retaining Ring 1
W2-4-47
(Blank)
W2-4-48
UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF CON-
TROL VALVE

AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
WCEB-02-05-002
3 4
Remove cover (4) from cover (2), supports (5, 6)
2
and bracket (7).
: 17 mm
WCEB-02-05-001
5 6
WCEB-02-05-003
WCEB-02-05-004
W2-5-1
Remove cover (10) from cover (8). 9
: 17 mm 10
WCEB-02-05-008
2 11
Remove cover (8) from support (5) and cover (2).
: 17 mm
8
CAUTION: The cover (2) assembly weight: 27
kg (60 lb)
5. Attach a nylon sling onto cover (2). Hoist and hold

cover (2). Remove sems bolts (12) (2 used) from
cover (2). Remove the cover (2) assembly from
main frame (13).
WCEB-02-05-006
13 12
5 6
6. Remove sems bolts (14) (2 used) from support
(6).
: 17 mm 14
15
WCEB-02-05-003
7. Remove sems bolts (16) (4 used) from stay (15). 15

Remove stay (15) from bracket (17) and support
(6)
: 17 mm
WCEB-02-05-004
17 16
W2-5-2
8. Remove sems bolts (18) (5 used) from supports (5,
5 6
6). Remove supports (5, 6) from main frame (13).
: 17 mm, 19 mm
18 13 18 WCEB-02-05-003
9. Remove the bolts (13 used) from the clamps for

the pipings (26 used). Remove the clamps (13
used) from the pipings (26 used).
: 19 mm
10. Remove sems bolts (19) (3 used) from clamps

(20) (3 used).
: 17 mm
19
11. Remove sems bolts (25) (3 used) from clips (24) 20

(3 used).
: 17 mm 21
22
23 WCEB-02-05-010

(22). Remove bracket (22) from brackets (21, 31).
: 19 mm

clip (27) from bracket (30).
: 17 mm
24, 25
24, 25
(30). Remove the bracket (26) assembly from
bracket (30).
: 17 mm
22
26
WCEB-02-05-009
30 29 23 27, 28
W2-5-3
15. Remove bolts (36) (2 used) from coupling (2).
Remove the coupling (34) assembly from the pip- 31 32 33
ings and hydraulic oil tank (35).
: 13 mm
16. Remove socket bolts (31) (104 used) from split

flanges (32) (52 used). Remove split flanges (32)
(52 used) from the pipings (26 used). Disconnect
34
the pipings (26 used) from control valve (33). Cap
the open ends. Attach an identification tag onto 35
the disconnected the pipings for assembling.
: 6 mm, 8 mm 36
32
17. Disconnect the hoses (35 used) from control valve 3-Spool Solenoid
WCEB-02-05-010
(33). Cap the open ends. Attach an identification Valve Unit

: 19 mm, 22 mm
18. Remove the 3-spool solenoid valve unit from con-

trol valve (33). (Refer to REMOVAL AND IN-
STALLATION OF 3-SOOL SOLENOID VALVE
UNIT on W2-11-1.)
Hose
19. Disconnect the connectors (2 used) from control

valve (34).
20. Disconnect the connectors (4 used).
Eyebolt Mounting WCEB-02-05-009

Hole
CAUTION: The control valve (33) assembly
weight: 155 kg (342 lb) 33

control valve (33). Attach a nylon sling onto eye-
bolts. Hoist and hold control valve (33).
Eyebolt Mounting
Hole
WCEB-02-05-012
W2-5-4


used) from brackets (21, 31). Hoist and remove
the control valve (34) assembly from main frame
(13). 33
: 24 mm
CAUTION: Control valve (33) weight: 136 kg

(300lb)
23. While holding the control valve (33) assembly, 21, 39, 40
remove bolts (39) (6 used) and washers (40) (6
used) from brackets (21, 30). Remove brackets
(21, 30) from control valve (33).
: 22 mm
13
37, 38 WCEB-02-05-010
33
30
39, 40
13
37, 38 WCEB-02-05-009
W2-5-5
Installation Eyebolt Mounting
Hole
CAUTION: Control valve (33) weight: 136 kg 33

(300 lb)

control valve (33). Attach a nylon sling onto eye-
bolts. Hoist and hold control valve (33).
Eyebolt Mounting
Hole
WCEB-02-05-012
2. Install brackets (21, 30) to control valve (33) with

bolts (39) (6 used) and washers (40) (6 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 10 lbf⋅ft) 33

30
39, 40
3. Hoist and align the control valve (33) assembly
with the mounting hole on main frame (13). Install
the control valve (33) assembly to main frame (13)
with bolts (37) (4 used) and washers (38) (4
used). 13
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
37, 38 WCEB-02-05-009
33
21, 39, 40
13
37, 38
WCEB-02-05-010
W2-5-6
4. Connect the pipings (26 used) to control valve 31 32 33
(33) with split flanges (32) (52 used) and socket
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
: 8 mm
34
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
35
5. Connect the piping and hydraulic oil tank (35) with 36

the coupling (34) assembly. Secure coupling (34)
with bolts (36) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
32
6. Connect the hoses (35 used) to control valve (33).
: 19 mm 3-Spool Solenoid
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) Valve Unit WCEB-02-05-010
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
7. Connect the connectors (2 used) to control valve

(33).
8. Connect the connectors (4 used). Hose
9. Install the 3-spool solenoid valve unit to control

valve (33). (Refer to REMOVAL AND INSTALLA-
TION OF 3-SPOOL SOLENOID VALVE UNIT on
W2-11-1.)
10. Secure harness (41) to bracket (30) with clip (27) WCEB-02-05-009
and sems bolt (28).

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
11. Install the bracket (26) assembly to bracket (30)

with sems bolts (29) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
26
WCEB-02-05-009
30 29 27, 28, 41
W2-5-7
12. Install bracket (22) to brackets (21, 30) with sems
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
13. Secure the pilot hose to bracket (21) with clamps

(20) (3 used) and sems bolts (19) (3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
19
20
21
22
23 WCEB-02-05-010
14. Secure the pilot hose to brackets (22, 30) with

clips (24) (3 used) and sems bolts (25) (3 used).
: 7 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
24, 25
24, 25
22
WCEB-02-05-009
30 23
5 6
15. Install supports (5, 6) to main frame (13) with

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
18 13 18 WCEB-02-05-003
W2-5-8
16. Install stay (15) to support (6) with sems bolts (14)
6
(2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
14
15
WCEB-02-05-003
17. Install stay (15) to bracket (17) with sems bolts 15

(16) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-05-004
17 16
2
kg (60 lb)
18. Attach a nylon sling onto the cover (2) assembly.

Hoist and align the cover (2) assembly with the
mounting hole on main frame (13). Install the
cover (2) assembly to main frame (13) with sems
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-05-006
13 12
W2-5-9
19. Install covers (2, 8) to supports (5, 6) with sems 2 11
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
8
5 6 WCEB-02-05-006
WCEB-02-05-003
20. Install cover (10) to support (5) with sems bolts (9) 9
10
(3 used).
: 17 mm 8
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-05-008
21. Install covers (2, 4) to supports (5, 6) and bracket 3 4
: 17 mm
2
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-05-001
WCEB-02-05-004
W2-5-10
22. Shut cover (1).
WCEB-02-05-002
W2-5-11
DISASSEMBLY OF CONTROL VALVE
4-SPOOL SIDE
X
1
2 47
3 29
23 48
4
5 30
6 49
24
7 31 41
8 50
25
9
Arm 32 42
10 Regenerative 26 51
Valve
(Switch Valve) 33
Boom 43
Anti-Drift 11 27
19 46
Valve
12 36
20 34 44 52 55
13
21 37 37
14 56
15 45
28 35 57
16 22 58
38
17 38 53
39 39 59
18 54
40
40
W
64 71
62
65
63 66
67 72
73 W
70
60 68
61 69
X 74 WCEB-02-05-013
1- O-Ring 20 - Washer 39 - O-Ring (2 Used) 57 - O-Ring
2- Screw 21 - O-Ring 40 - Plug (2 Used) 58 - Spring
3- Backup Ring 22 - Spool 41 - O-Ring 59 - Poppet
4- O-Ring 23 - O-Ring 42 - Bolt 60 - Cap
5- O-Ring 24 - Bolt 43 - Spring Seat 61 - Nut
6- O-Ring 25 - Spring Seat 44 - Spring 62 - Plug
7- Backup Ring 26 - Spring 45 - Spring Seat 63 - O-Ring
8- Backup Ring 27 - Spring Seat 46 - Main Spool 64 - Cap
9- O-Ring 28 - Main Spool 47 - O-Ring 65 - Retaining Ring
10 - Sleeve 29 - O-Ring 48 - Bolt 66 - Shim
11 - Spool 30 - Screw 49 - Spring Seat 67 - Nut
12 - Washer 31 - O-Ring 50 - Spring 68 - Pilot Housing
13 - Spring 32 - Bolt 51 - Spring Seat 69 - Socket Bolt (11 Used)
14 - Backup Ring 33 - Spring Seat 52 - Main Spool 70 - Overload Relief Valve
15 - O-Ring 34 - Spring 53 - O-Ring 71 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Plug 72 - Backup Ring
17 - Spring 36 - Main Spool 55 - Plug 73 - O-Ring
18 - Poppet 37 - Poppet (2 Used) 56 - Backup Ring 74 - Housing
19 - Spring 38 - Spring (2 Used)
W2-5-12
Disassembly of control valve 4-Spool side (Up- IMPORTANT: Remove main spool assemblies (28,
per) 36, 46, 52) by turning. If they stick
• Attach an identification tag which specifies the even a little, try again instead of
location of spool in the housing for each spool in pulling roughly.
order to assemble correctly. 7. Remove the main spool (28, 36, 46, 52) assem-
blies and O-rings (23, 31, 41, 47) from housing
1. Remove socket bolts (69) (11 used) from pilot (74).
housing (68). Remove pilot housing (68) from
housing (74). IMPORTANT: Put the matching marks on main
: 6 mm spools (28, 36, 46, 52) and housing
(74).
2. Remove boom anti-drift valve assembly (5 to 16), 8. Clamp main spools (28, 36, 46, 52) in a vise by
O-ring (4) and backup ring (3) from pilot housing using wooden pieces. Remove bolts (24, 32, 42,
(68). 48), spring seats (25, 33, 43, 49), springs (26, 34,
NOTE: Remove the boom anti-drift valve assem- 44, 50) and spring seats (27, 35, 45, 51) from
bly from pilot housing (68) by prying by main spools (28, 36, 46, 52).
hand.
9. Remove plugs (40) (2 used), O-rings (39) (2
3. Remove plug (16), O-ring (15), backup ring (14), used), springs (38) (2 used) and poppets (37) (2
spring (13), washer (12) and spool (11) from used) from spools (36, 46).
sleeve (10).
10. Remove plug (54) and O-ring (53) from spool
4. Remove O-rings (5, 6, 9) and backup rings (7, 8) (52).
from sleeve (10).
11. Remove spring (17) and poppet (18) from hous-
5. Remove cap (64), retaining ring (65), shim (66) ing (74) by using a magnet.
and nut (67) from pilot housing (68).
Remove screw (30) from pilot valve (68). Re- 12. Remove spring (19), washer (20), O-ring (21) and
move O-ring (29) from screw (30). spool (22) from housing (74).
6. Remove cap (60) and nut (61) from pilot housing 13. Remove plug (55), backup ring (56), O-ring (57),
(68). spring (58) and poppet (59) from housing (74).
Remove screw (2) from pilot housing (68). Re-
move O-ring (1) from screw (2).
W2-5-13
W
71
72
73 W
70
X 74 WCEB-02-05-013
W2-5-14
IMPORTANT: Do not turn the lock nut as the set
pressure is changed.
14. Turn and remove the cartridges of overload relief
valves (70, 71) from housing (74).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
15. Remove backup ring (72) and O-ring (73) from

housing (74).
W2-5-15
74
80
79
81
78
87
86
85
84 91
77 83
76 82 90
Check Valve 89
75 Orifice Load Check
(Arm 2 88
(Arm 1 Parallel 102
Circuit) Tandem Circuit)
101
100
99
98
97 Bucket Flow Rate
96 Control Valve
95 (Poppet Valve)
94
93
103 92 117
116
112 115
114
113
107
104 105 108
106 109
110
WCEB-02-05-014
111
74 - Housing 85 - Spring 96 - O-Ring 107 -Spool

75 - Plug 86 - Poppet 97 - Spring 108 -Washer
76 - O-Ring 87 - Bushing 98 - Plug 109 -Spring
77 - Plug 88 - O-Ring 99 - O-Ring 110 -O-Ring
78 - O-Ring 89 - Backup Ring 100 - Spring 111 -Plug
79 - Spring 90 - Spring 101 - Poppet 112 -O-Ring (2 Used)
80 - Seat 91 - Poppet 102 - Valve Seat 113 -Plug
81 - Spool 92 - O-Ring 103 - Pilot Plate 114 -Backup Ring
82 - O-Ring 93 - Backup Ring 104 - Socket Bolt 115 -O-Ring
83 - Backup Ring 94 - Bushing 105 - Socket Bolt (5 Used) 116 -Spring
84 - Plug 95 - Backup Ring 106 - Socket Bolt (4 Used) 117 -Poppet
W2-5-16
Disassembly of Control Valve 4-Spool Side (Side) 22. Remove O-ring (82), backup ring (83), plug (84),
spring (85), poppet (86) and bushing (87) from
16. Remove plug (111) from pilot plate (103). Re- housing (74).
move spring (109), washer (108) and spool (107)
from pilot plate (103). 23. Remove plug (75) from plug (77). Remove O-ring
: 36 mm (76) from plug (75).
: 6 mm
17. Remove O-ring (110) from plug (111).
24. Remove plug (77), spring (79), seat (80) and
18. Remove socket bolt (104), socket bolts (105) (5 spool (81) from housing (74). Remove O-ring
used), socket bolts (106) (4 used) from pilot plate (78) from plug (77).
(103). Remove pilot plate (103) and O-ring (112)
from housing (74). 25. Remove plug (113), spring (116) and poppet
: 6 mm, 8 mm (117) from housing (74). Remove backup ring
(114) and O-ring (115) from plug (113).
19. Remove the bushing (94) assembly from pilot
plate (103). Remove O-rings (92, 96), backup
rings (93, 95) and spring (97) from bushing (94).
20. Remove plug (98) from housing (74).

Clamp the stepped part of plug (98) in a vise by
using wooden pieces. Remove valve seat (102),
poppet (101), spring (100) and O-ring (99) from
plug (98).
21. Remove O-ring (88), backup ring (89), spring

(90) and poppet (91) from housing (74). (2
places)
W2-5-17
74
123
118
124 127
125
119 126
120 Check Valve
121 (Flow Combiner Cir-
cuit)
128
114
122
Auxiliary Flow Rate
Control Valve
129
Auxiliary Flow Rate Control Valve
130
W1F1-02-05-005
74 - Housing 121 - Backup Ring 125 - O-Ring 128 - O-Ring (4 Used)

118 - Poppet 122 - Plug 126 - Plug 129 - Pilot Housing
119 - Spring 123 - Poppet 127 - Overload Relief Valve (2 Used) 130 - Socket Bolt (5 Used)
120 - O-Ring 124 - Spring
W2-5-18
Disassembly of Control Valve 4-Spool Side
(Lower)

26. Turn and remove the cartridge of overload relief
valves (127) (2 used) from housing (74).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
27. Remove socket bolts (130) (5 used) from pilot

housing (129). Remove pilot housing (129) and
O-ring (128) from housing (74).
: 6 mm
28. Remove plug (126), spring (124) and poppet

(123) from housing (74). Remove O-ring (125)
from plug (126).
29. Remove plug (122), spring (119) and poppet

(118) from housing (74). Remove backup ring
(121) and O-ring (120) from plug (122).
W2-5-19
DISASSEMBLY OF CONTROL VALVE
5-SPOOL SIDE 192
192
191 193
131 193
132
163
133
164
134 157
135 194
136 165
137 158
138 166
173
139 159
167
179
140
160
174
Arm Anti-Drift 142 185
Valve 143 141 180
161 168 175
144 151
145 181
149 176 186
146 156
162
182 187
147 177
148 169
183 188
150
170
171 178
152 189
172 184
190
195
WCEB-02-05-027
131 - Backup Ring 147 - Spring 166 - Spring 181 - Spring Seat
132 - O-Ring 148 - Poppet 167 - Spring Seat 182 - Spring
133 - Plug 149 - Backup Ring 168 - Main Spool 183 - Spring Seat
134 - O-Ring 150 - O-Ring 169 - Poppet 184 - Main Spool
135 - O-Ring 151 - Overload Relief Valve (3 Used) 170 - Spring 185 - O-Ring
136 - O-Ring 152 - O-Ring 171 - O-Ring 186 - Bolt
137 - Backup Ring 156 - Main Relief Valve 172 - Plug 187 - Spring Seat
138 - Backup Ring 157 - O-Ring 173 - O-Ring 188 - Spring
139 - O-Ring 158 - Bolt 174 - Bolt 189 - Spring Seat
140 - Sleeve 159 - Spring Seat 175 - Spring Seat 190 - Main Spool
141 - Spool 160 - Spring 176 - Spring 191 - Socket Bolt (10 Used)
142 - Washer 161 - Spring Seat 177 - Spring Seat 192 - Plug (2 Used)
143 - Spring 162 - Main Spool 178 - Main Spool 193 - O-Ring (2 Used)
144 - Backup Ring 163 - O-Ring 179 - O-Ring 194 - Pilot Housing
145 - O-Ring 164 - Bolt 180 - Bolt 195 - Housing
146 - Plug 165 - Spring Seat
W2-5-20
Disassembly of 5-Spool Side (Upper)
1. Remove socket bolts (191) (10 used) from pilot 7. Remove plug (172), spring (170) and poppet
housing (194). Remove pilot housing (194) from (169) from main spool (168). Remove O-ring
housing (195). (171) from plug (172).
: 6 mm
8. Remove spring (147), poppet (148), backup ring
2. Remove arm anti-drift valve assembly (133 to (149) and O-ring (150) from housing (195).
146), O-ring (132) and backup ring (131) from
pilot housing (194). IMPORTANT: Do not turn the lock nut as the set
NOTE: Remove the arm anti-drift valve assembly pressure is changed.
from pilot housing (194) by prying by hand. 9. Turn the cartridges of overload relief valves (151)
(3 used) and the cartridge of main relief valve
3. Remove plug (146), spring (143), washer (142) (156). Remove them from housing (195).
and spool (141) from sleeve (140). Remove : 27 mm
backup ring (144) and O-ring (145) from plug Lock Nut
(146). Cartridge
4. Remove plug (133), O-rings (134, 135, 136, 139)

and backup rings (137, 138) from sleeve (140).
5. Remove main spool assemblies (162, 168, 178, W176-02-06-017

184, 190) and O-rings (152, 157, 163, 173, 179,
185) from housing (195).
IMPORTANT: Put the matching marks on main

spools (162, 168, 178, 184, 190) and
housing (195).
6. Clamp main spools (162, 168, 178, 184, 190) in a
vise by using wooden pieces. Remove bolts (158,
164, 174, 180, 186), spring seats (159, 165, 175,
181, 187), springs (160, 166, 176, 182, 188) and
spring seats (161, 167, 177, 183, 189) from main
spools (162, 168, 178, 184, 190).
W2-5-21
Load Check 221 Load Check

Auxiliary Flow Rate 205 Valve (Arm 1 Valve (Arm 2
Control Valve Parallel Circuit) 222 Parallel Circuit)
206 223
(Poppet Valve) 207 216
217 224
208
209 218
Load Check 210 219
199 Valve 211 220
(Travel Parallel 201 212
200 Circuit) 202 213
203 214
204 215
196
197
198
195
231
232
230
233
Auxiliary Flow Rate 234
Control Valve
(Switch Valve) 229
228
227
226 WCAB-02-05-006
225
195 - Housing 205 - O-Ring 215 - Valve Seat 225 - Plug
196 - Socket Bolt 206 - Backup Ring 216 - O-Ring 226 - O-Ring
197 - Cover 207 - Bushing 217 - Backup Ring 227 - Spring
198 - O-Ring 208 - Backup Ring 218 - Plug 228 - Washer
199 - Socket Bolt (6 Used) 209 - O-Ring 219 - Spring 229 - Spool
200 - Pilot Plate 210 - Spring 220 - Poppet 230 - Socket Bolt (9 Used)
201 - O-Ring 211 - Plug 221 - O-Ring 231 - Socket Bolt
202 - Backup Ring 212 - O-Ring 222 - Backup Ring 232 - Pilot Plate
203 - Spring 213 - Spring 223 - Spring 233 - O-Ring
204 - Poppet 214 - Poppet 224 - Poppet 234 - O-Ring
W2-5-22
Disassembly of Control Valve 5-Spool Side (Side)
10. Remove plug (225) from pilot housing (232). 16. Remove socket bolts (199) (6 used) from pilot
Remove O-ring (226), spring (227), washer (228) plate (200). Remove pilot plate (200) from hous-
and spool (229) from pilot housing (232). ing (195).
: 36 mm : 6 mm
11. Remove socket bolts (230) (9 used) and Socket 17. Remove O-ring (216), backup ring (217), plug
Bolt (231) from pilot plate (232). Remove pilot (218), spring (219) and poppet (220) from the pi-
plate (232) and O-rings (233, 234) from housing lot plate (200) mounting surface of housing (195).
(195). (2 places)
: 6 mm, 8 mm
12. Remove bushing (207) from pilot plate (232). (223) and poppet (224) from the pilot plate (200)
Remove O-rings (205, 209), backup rings (206, mounting surface of housing (195).
208) and spring (210) from bushing (207).
13. Remove plug (211) from the pilot plate (232)

mounting surface of housing (195).
Clamp the stepped part of plug (211) in a vise by
using wooden pieces. Remove valve seat (215),
poppet (214), spring (213) and O-ring (212) from
plug (211).

(203) and poppet (204) from the pilot plate (232)
mounting surface of housing (195).

(223) and poppet (224) from the pilot plate (232)
mounting surface of housing (195). (3 places)
W2-5-23
195
249
243 250
244 248
251
235
245
236 252
237 246
238 253
247
239 259
240
241
242
Auxiliary Flow
Combiner
Valve 254 257
255 258
255 256
256 WCAB-02-05-007
195 - Housing 241 - Spring 248 - Overload Relief Valve 254 - Socket Bolt (9 Used)
235 - Plug 242 - Bolt 249 - O-Ring 255 - O-Ring (2 Used)
236 - Spring 243 - Plug 250 - Backup Ring 256 - Plug (2 Used)
237 - Poppet 244 - Spring 251 - O-Ring 257 - O-Ring
238 - Spool 245 - Poppet 252 - Plug 258 - Plug
239 - O-Ring 246 - Spool 253 - O-Ring (5 Used) 259 - Pilot Housing
240 - Washer 247 - O-Ring
W2-5-24
Disassembly of Control Valve 5-Spool Side
(Lower)

19. Turn and remove the cartridge of overload relief
valve (248) from housing (195).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
20. Remove socket bolts (254) (9 used) from pilot

housing (259). Remove pilot housing (259) and
O-rings (253) (5 used) from housing (195).
: 6 mm
21. Remove O-rings (239, 247), spool assembly (243

to 246) and auxiliary flow combiner valve assem-
bly (235 to 242) from housing (195).
IMPORTANT: Do not remove plug (235), spring

(236) and poppet (237) from spool
(238). When replacing these parts,
replace them as an assembly.
22. Clamp spool (238) in a vise by using wooden
pieces. Remove bolt (242), spring (241) and
washer (240) from spool (238).
IMPORTANT: Do not remove plug (243), spring

(244) and poppet (245) from spool
(246). When replacing these parts,
replace them as an assembly.
W2-5-25
ASSEMBLY AND DISASSEMBLY OF
4-SPOOL SIDE AND 5-SPOOL SIDE
195
267
266
261
262
264
263
74
265
268
269
260 270
271 272
273
274
275
276
280
277 279
278
WCEB-02-05-021
74 - Housing 264 - Backup Ring 270 - O-Ring 276 - O-Ring

195 - Housing 265 - O-Ring 271 - O-Ring 277 - O-Ring
260 - Socket Bolt (9 Used) 266 - O-Ring 272 - Backup Ring 278 - Backup Ring
261 - O-Ring 267 - Backup Ring 273 - O-Ring 279 - O-Ring
262 - O-Ring 268 - O-Ring 274 - O-Ring 280 - Backup Ring
263 - O-Ring 269 - Backup Ring 275 - O-Ring
W2-5-26
Disassemble Assemble
1. Install O-rings (261 to 263, 265, 266, 268, 270,

CAUTION: Housing (74) weight: 45 kg (100
271, 273 to 277, 279) and backup rings (264, 267,
Ib)
269, 272, 278, 280) to housing (195).
Housing (195) weight: 49 kg (110 lb)
1. Remove socket bolts (260) (9 used) from housing CAUTION: Housing (74) weight: 45 kg (100
(74). Divide housing (74) and housing (195). Ib)
Housing (195) weight: 49 kg (110 Ib)
2. Remove O-rings (261 to 263, 265, 266, 268, 270,
271, 273 to 277, 279) and backup rings (264, 267, 2. Connect housing (74) and housing (195) with
269, 272, 278, 280) from housing (195). socket bolts (260) (9 used).
: 12 mm
: 108+9.8 N·m (11+1 kgf·m 80+7 lbf·ft)
W2-5-27
ASSEMBLY OF CONTROL VALVE
4-SPOOL SIDE 48
A
23 63 62 31 41 47 49
24 32, 42
19 25 33, 43 50
20 55 34, 44
26 51
21
56, 57
22 58 27 35, 45
59
74
52
28 36, 46
37
38
Boom 1
WCEB-02-05-016 39 53
65, 66 40 54
64 Boom Anti-Drift Valve WCEB-02-05-015
67 5
68 29 10
60 6
30 11
61
7
1 8
2 14 9
12
Boom
15 13
Anti-Drift Valve
16
17
18
3 4 Section A W176-02-05-022 W176-02-05-025
1- O-Ring 20 - Washer 39 - O-Ring (2 Used) 57 - O-Ring

2- Screw 21 - O-Ring 40 - Plug (2 Used) 58 - Spring
3- Backup Ring 22 - Spool 41 - O-Ring 59 - Poppet
4- O-Ring 23 - O-Ring 42 - Bolt 60 - Cap
5- O-Ring 24 - Bolt 43 - Spring Seat 61 - Nut
6- O-Ring 25 - Spring Seat 44 - Spring 62 - Plug
7- Backup Ring 26 - Spring 45 - Spring Seat 63 - O-Ring
8- Backup Ring 27 - Spring Seat 46 - Main Spool 64 - Cap
9- O-Ring 28 - Main Spool 47 - O-Ring 65 - Retaining Ring
10 - Sleeve 29 - O-Ring 48 - Bolt 66 - Shim
11 - Spool 30 - Screw 49 - Spring Seat 67 - Nut
12 - Washer 31 - O-Ring 50 - Spring 68 - Pilot Housing
13 - Spring 32 - Bolt 51 - Spring Seat 69 - *Socket Bolt (8 Used)
14 - Backup Ring 33 - Spring Seat 52 - Main Spool 70 - *Overload Relief Valve
15 - O-Ring 34 - Spring 53 - O-Ring 71 - *Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Plug 72 - *Backup Ring
17 - Spring 36 - Main Spool 55 - Plug 73 - *O-Ring
18 - Poppet 37 - Poppet (2 Used) 56 - Backup Ring 74 - Housing
19 - Spring 38 - Spring (2 Used)
NOTE: * Refer to W2-5-12.
W2-5-28
Assembly of Control Valve 4-Spool Side (Upper)
1. Clamp main spools (36, 46) in a vise by using IMPORTANT: When sleeve (10) or spool (11) is re-
wooden pieces. Install poppets (37) (2 used), placed, replace both of them as an
springs (38) (2 used), O-rings (39) (2 used) and assembly.
plugs (40) (2 used). 6. Install O-ring (15), backup ring (14), spring (13),
: 17 mm washer (12) and spool (11) to plug (16). Install
: 25 N·m (2.5 kgf·m, 18 lbf·ft) the plug (16) assembly to sleeve (10).
NOTE: Install washer (12) with the chamfered side
2. Install spring seats (27, 35, 45, 51), springs (26, facing to the spring (13) side.
34, 44, 50), spring seats (25, 33, 43, 49) and
bolts (24, 32, 40, 42, 48) to spools (28, 36, 46, 7. Install boom anti-drift valve assembly (5 to 16) to
52). pilot housing (68).
: 17 mm
: 12 N·m (1.2 kgf·m, 9 lbf·ft) IMPORTANT: When housing (74) or poppet (18) is
replaced, tap poppet (18) by using a
3. Install screw (30) and O-ring (29) to pilot housing steel bar in order to make it fit.
(68). Install nut (67), shim (66), retaining ring (65) 8. Install poppet (18) and spring (17) to housing
and cap (64) to screw (30). (74).
: 17 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 9. Install spool (22), O-ring (21), washer (20) and
spring (19) to housing (74).
4. Install screw (2) and O-ring (1) to pilot housing
NOTE: Install washer (20) with the chamfered side
(68). Install nut (61) and cap (60) to screw (2).
facing to the spring (19) side.
: 17 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
10. Install poppet (59), spring (58), O-ring (57),
backup ring (56) and plug (55) to housing (74).
5. Install backup rings (7, 8) and O-rings (5, 6, 9) to
: 14 mm
sleeve (10).
: 118+20 N·m (12+2 kgf·m, 87+15 lbf·ft)
NOTE: Check the mounting positions of backup
rings (7, 8) and O-rings (6, 9). 11. Install main spool assemblies (28, 36, 46, 52),
10 9 8 7 6 O-rings (23, 31, 41, 47, 73) and backup ring (3,
72) to housing (74).
W176-02-05-023
W2-5-29
B Arm 2 Arm 1
C
70
68 71
69
Load Check Valve
(Arm 2 Tandem
71 Circuit)
90 91
74
103
84 85 86 87
104 105 106 74 WCEB-02-05-020 Check Valve Orifice
(Arm 1 Pallarel Curcit)
Section B
T176-03-03-006
Boom 1
Boom 2
111 110 109 108 107
Bucket Flow Rate
Control Valve
(Switch Valve)
98
92
97
93
88, 89
94 99
95 100
96
101
102 90
Bucket Flow Rate 91
Control Valve (Pop- Load Check Valve
pet Valve) (Boom 1 Pallarel
Section D Curcit)
W176-02-05-026
Section C
T176-03-03-005
68 - Pilot Housing 87 - Bushing 95 - Backup Ring 103 - Pilot Plate

69 - Socket Bolt (8 Used) 88 - O-Ring 96 - O-Ring 107 - Spool
70 - Overload Relief Valve 89 - Backup Ring 97 - Spring 108 - Washer
71 - Overload Relief Valve 90 - Spring 98 - Plug 109 - Spring
74 - Housing 91 - Poppet 99 - O-Ring 110 - O-Ring
84 - Plug 92 - O-Ring 100 - Spring 111 - Plug
85 - Spring 93 - Backup Ring 101 - Poppet 112 - *O-Ring
86 - Poppet 94 - Bushing 102 - Valve Seat
W2-5-30
IMPORTANT: Do not turn the lock nut of the relief 14. Install poppet (101), spring (100), O-ring (99) and
valve as the set pressure is plug (98) to valve seat (102).
changed.
12. Install pilot housing (68) to housing (74) with 15. Install O-rings (92, 96) and backup rings (93, 95)
socket bolts (69) (8 used). to bushing (94).
Turn and install the cartridges of overload relief
valves (70, 71) to housing (74). 16. Install the valve seat (102) assembly, spring (97)
: 6 mm and bushing (94) to housing (74).
: 25 N·m (2.5 kgf·m, 18 lbf·ft)
: 27 mm 17. Install poppet (91), spring (90), O-ring (88) and
: 78+3 N·m (8+0.3 kgf·m, 58+3 lbf·ft) backup ring (89) to housing (74). (2 places)
Lock Nut
18. Install bushing (87), poppet (86), spring (85) and
Cartridge
plug (84) to housing (74).
W176-02-06-017
NOTE: Apply grease onto O-rings of overload re-

lief valves (70, 71). (This prevents the
O-ring from being cut)
Assembly of Control Valve 4-Spool Side (Side)
13. Install spool (107), washer (108), spring (109)

and O-ring (110) to pilot plate (103). Temporarily
install plug (111) to pilot plate (103).
: 36 mm
110
103
111
Groove on the
outer surface
W1F3-02-05-006
NOTE: Tighten plug (111) after installing pilot plate

(103) to housing (74). There is a groove on
the outer surface of plug (111), but not of
plug (225).
W2-5-31
A
E
74
105
103,
112
104 111 106 WCEB-02-05-020
Swing
74
117
116
77
76 113
75
114, 115
78 79 80 81
Bypass Shut-Out Valve Section A T176-03-03-007
Section E
WCEB-02-05-022
74 - Housing 79 - Spring 105 - Socket Bolt (5 Used) 114 - Backup Ring

75 - Plug 80 - Seat 106 - Socket Bolt (4 Used) 115 - O-Ring
76 - O-Ring 81 - Spool 111 - Plug 116 - Spring
77 - Plug 103 - Pilot Plate 112 - O-Ring 117 - Poppet
78 - O-Ring 104 - Socket Bolt 113 - Plug
W2-5-32
19. Install O-ring (115) and backup ring (114) to plug
(113).
20. Install spring (116) and the plug (113) assembly

to housing (74) and poppet (117).
21. Install O-rings (112) (2 used) to housing (74). In-

stall pilot plate (103) to housing (74) with socket
bolts (105) (5 used), socket bolts (106) (4 used)
and socket bolt (104).
: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 8 mm
: 49+5 N⋅m (5+0.5 kgf⋅m, 36+4 lbf⋅ft)
22. Completely tighten plug (111) which was tempo-

rarily tightened in step 13.
: 36 mm
: 177 N⋅m (18 kgf⋅m, 131 lbf⋅ft)
23. Install O-ring (76) and plug (75) to plug (77).

: 6 mm
: 29+9.8 N⋅m (3+1 kgf⋅m, 21+7 lbf⋅ft)
24. Install spool (81), seat (80), spring (79), O-ring

(78) and plug (77) to housing (74).
: 27 mm
: 177+29 N⋅m (18+3 kgf⋅m, 131+21 lbf⋅ft)
NOTE: Install seat (80) with the chamfered side
facing to the spring (79) side.
W2-5-33
74
127
129
130
A B WCEB-02-05-016
WCEB-02-05-019
128 128 128 128
Section A
123
118
119
120, 121
122 125 126 124 WCEB-02-05-017
Section B
Auxiliary Flow Rate Control Valve
74 - Housing 121 - Backup Ring 125 - O-Ring 128 - O-Ring (4 Used)

118 - Poppet 122 - Plug 126 - Plug 129 - Pilot Housing
119 - Spring 123 - Poppet 127 - Overload Relief Valve (4 Used) 130 - Socket Bolt (5 Used)
120 - O-Ring 124 - Spring
W2-5-34
Assembly of Control Valve 4-Spool Side (Lower)
25. Install O-rings (128) (4 used) to housing (74). In-

stall pilot housing (129) to housing (74) with
: 6 mm
: 25+5 N·m (2.5+0.5 kgf·m, 18+4 lbf·ft)
26. Install poppet (123), spring (124), O-ring (125)

and plug (126) to housing (74).
: 14 mm
: 118+20 N·m (12+2 kgf·m, 87+15 lbf·ft)
27. Install poppet (118), spring (119), O-ring (120),

backup ring (121) and plug (122) to housing (74).
: 14 mm
: 118+20 N·m (12+2 kgf·m, 87+15 lbf·ft)
IMPORTANT: Do not turn the lock nut of the relief

valve as the set pressure is
changed.
28. Turn and install the cartridge of overload relief
valve (127) to housing (74).
: 27 mm
: 177+29 N·m (18+2.9 kgf·m, 131+21 lbf·ft)
Lock Nut
Cartridge
W176-02-06-017
NOTE: Apply grease onto O-rings of overload re-

lief valve (127). (This prevents O-ring from
being cut.)
W2-5-35
ASSEMBLY OF CONTROL VALVE
Main Spool Main Spool
5-SPOOL SIDE (154, 170, 176, 182) (160)
185 179 173 163 157 159, 175,
181, 187 165
160, 176, 166

182, 188
164
158, 174,
180, 186
167
161, 177,
183, 189 168
162, 178,
184, 190
169
170
171
172
Section A
190 184 178 168 162
WCEB-02-05-023
192,
Anti-Drift Valve 193 W176-02-05-024
B Arm Anti-Drift Valve
194
140 133
A
156 151 135
134
136
137
141
195 138
139
191
144
142
145
143
146
147
148
Section B W176-02-05-027
WCEB-02-05-020
131 - *Backup Ring 147 - Spring 166 - Spring 181 - Spring Seat
132 - *O-Ring 148 - Poppet 167 - Spring Seat 182 - Spring
133 - Plug 149 - *Backup Ring 168 - Main Spool 183 - Spring Seat
134 - O-Ring 150 - *O-Ring 169 - Poppet 184 - Main Spool
135 - O-Ring 151 - Overload Relief Valve (3 Used) 170 - Spring 185 - O-Ring
136 - O-Ring 152 - *O-Ring 171 - O-Ring 186 - Bolt
137 - Backup Ring 156 - Main Relief Valve 172 - Plug 187 - Spring Seat
138 - Backup Ring 157 - O-Ring 173 - O-Ring 188 - Spring
139 - O-Ring 158 - Bolt 174 - Bolt 189 - Spring Seat
140 - Sleeve 159 - Spring Seat 175 - Spring Seat 190 - Main Spool
141 - Spool 160 - Spring 176 - Spring 191 - Socket Bolt (10 Used)
142 - Washer 161 - Spring Seat 177 - Spring Seat 192 - Plug
143 - Spring 162 - Main Spool 178 - Main Spool 193 - O-Ring
144 - Backup Ring 163 - O-Ring 179 - O-Ring 194 - Pilot Housing
145 - O-Ring 164 - Bolt 180 - Bolt 195 - Housing
146 - Plug 165 - Spring Seat
W2-5-36
Assembly of Control Valve 5-Spool Side (Upper)
1. Clamp main spool (168) by using wooden pieces 5. Install arm anti-drift valve assembly (133 to 146)
in a vise. Install poppet (169), spring (170), O-ring to pilot housing (194).
(171) and plug (172) to main spool (168).
: 17 mm IMPORTANT: When housing (195) or poppet (148)
: 25+5 N⋅m (2.5+0.5 kgf⋅m 18+4 lbf⋅ft) is replaced, tap poppet (148) by us-
ing a steel bar in order to make it fit.
2. Install spring seats (161, 167, 177, 183, 189), 6. Install poppet (148), spring (147), O-ring (150)
springs (160, 166, 176, 182, 188), spring seats and backup ring (149) to housing (195).
(159, 165, 175, 181, 187) and bolts (158, 164,
174, 180, 186) to main spools (162, 168, 178, 7. Install the main spool (162, 168, 178, 184, 190)
184, 178). assemblies, O-rings (132, 152, 157, 163, 173,
: 17 mm 179, 185) and backup ring (131) to housing (195).
: 12+3 N⋅m (1.2+0.3 kgf⋅m, 9+2 lbf⋅ft)
IMPORTANT: Do not turn the lock nut of the relief
3. Install O-rings (134, 135, 136, 139), backup rings valve as the set pressure is
(137, 138) and plug (133) to sleeve (140). changed.
NOTE: Check the mounting positions of backup 8. Install pilot housing (194) to housing (195) with
rings (137, 138) and O-rings (136, 139). socket bolts (191) (10 used).
Turn the cartridges of overload relief valves (151)
(3 used) and the cartridge of main relief valve
(156). Install them to housing (195).
139 138 137 136
: 17 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)
: 27 mm
: 177+29 N⋅m (18+2.9 kgf⋅m, 131+21 lbf⋅ft)
Lock Nut
Cartridge
W176-02-05-023
IMPORTANT: When sleeve (140) or spool (141) is

replaced, replace both of them as an W176-02-06-017
assembly.
4. Install O-ring (145), backup ring (144), spring
(143), washer (142) and spool (141) to plug (146).
Install the plug (146) assembly to sleeve (140).
NOTE: Install washer (142) with the chamfered
side facing to the spring (143) side.
W2-5-37
Blade/Outrigger Boom 2
199
195
200
231
230 Load Check Valve
(Tandem Circuit)
232,
233,
234
F E
D
224 224
C
B
A 223 223
Auxiliary
Flow Rate
201, 221,
Control
Valve 225 202 222
226 227 228 229 WCEB-02-05-026
Auxiliary Flow Rate

Control Valve 203 Load
Check
(Switch Valve)
204 Valve
(Boom 2
Load Check
Pallarel
211 Valve
205 (Pallarel)
Circit)
210
206 Section C
Section B
207 212
WCEB-02-05-024
Swing
WCEB-02-05-025
Arm 1
208 213
209
214
215
Auxiliary Flow Rate Load

Control Valve Load Check
W176-02-05-026 Valve (Arm 1 Check
Section F (Poppet Valve)
Parallel Circuit) Valve
Main Releif Auxiliary (Swing
Flow Combiner Valve Circit)
224 224 224

223 223 223
216,
217 221,
221, 222 222
Check Valve 218
(Main Circuit)
218
216,
217
219
220
Load Check
Section A Valve
(Arm 1 Tandem
Section E
Circuit)
Section D W176-02-05-030
WCEB-02-05-018
195 - Housing 205 - O-Ring 215 - Valve Seat 225 - Plug

196 - Socket Bolt 206 - Backup Ring 216 - O-Ring 226 - O-Ring
197 - Cover 207 - Bushing 217 - Backup Ring 227 - Spring
198 - O-Ring 208 - Backup Ring 218 - Plug 228 - Washer
199 - Socket Bolt (6 Used) 209 - O-Ring 219 - Spring 229 - Spool
200 - Pilot Plate 210 - Spring 220 - Poppet 230 - Socket Bolt (9 Used)
201 - O-Ring 211 - Plug 221 - O-Ring 231 - Socket Bolt
202 - Backup Ring 212 - O-Ring 222 - Backup Ring 232 - Pilot Plate
203 - Spring 213 - Spring 223 - Spring 233 - O-Ring
204 - Poppet 214 - Poppet 224 - Poppet 234 - O-Ring
W2-5-38
Assembly of Control Valve 5-Spool Side (Side) 16. Completely tighten plug (225) which was tempo-
rarily tightened in step 9.
9. Install spool (229), washer (228), spring (227) : 36 mm
and O-ring (226) to pilot plate (232). Temporarily : 177+29 N⋅m (18+2.9 kgf⋅m, 131+21 lbf⋅ft)
install plug (225).
: 36 mm 17. Install poppet (220), spring (219), plug (218),
NOTE: Tighten plug (225) after installing pilot plate backup ring (217) and O-ring (216) to housing
(232) to housing (195). Plug (225) has no (195). (2 places)
groove on its outer surface.
18. Install poppet (224), spring (223), backup ring
10. Install poppet (214), spring (213), O-ring (212) (222) and O-ring (221) to housing (195).
and plug (211) to valve seat (215).
19. Install pilot plate (200) to housing (195) with
11. Install O-rings (205, 209) and backup rings (206, socket bolts (199) (6 used).
208) to bushing (207). : 6 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)
12. Install the valve seat (215) assembly, spring (210)
and bushing (207) to housing (195).
13. Install poppet (224), spring (223), O-ring (221)

and backup ring (222) to housing (195). (3
places)
14. Install poppet (204), spring (203), backup ring

(202) and O-ring (201) to housing (195).
15. Install O-rings (233, 234) to housing (195). Install

pilot plate (232) to housing (195) with socket bolts
(230) (9 used) and socket bolt (231).
: 6 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)
: 8 mm
: 49+5 N⋅m (4.9⋅0.5 kgf⋅m, 36+lbf⋅ft)
W2-5-39
195
252
254
259
A
248
WCEB-02-05-028 WCEB-02-05-023
253 253 253 253 253
Section B
235
243
244 236
245
237 Auxiliary Flow
Combiner
246 238 Valve
247 239, 240
241
242
Section A WCEB-02-05-018
195 - Housing 241 - Spring 248 - Overload Relief Valve 254 - Socket Bolt (9 Used)
235 - Plug 242 - Bolt 249 - *O-Ring 255 - *O-Ring (2 Used)
236 - Spring 243 - Plug 250 - *Backup Ring 256 - *Plug (2 Used)
237 - Poppet 244 - Spring 251 - *O-Ring 257 - *O-Ring
238 - Spool 245 - Poppet 252 - Plug 258 - *Plug
239 - O-Ring 246 - Spool 253 - O-Ring (5 Used) 259 - Pilot Housing
240 - Washer 247 - O-Ring
W2-5-40
Assembly of Control Valve 5-Spool Side (Lower)
IMPORTANT: If spool (238) is disassembled, or 22. Install O-rings (253) (5 used) to housing (195).
poppet (237), spring (236) and plug Install pilot housing (259) to housing (195) with
(235) are replaced, replace as an socket bolts (254) (9 used).
assembly as the external dimen- : 6 mm
sions of spool (238) are specified. : 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)
pieces. Install washer (240), spring (241) and bolt IMPORTANT: Do not turn the lock nut of the relief
(242) to spool (238). valve as the set pressure is
: 17 mm changed.
: 12+2 N⋅m (1.2+0.2 kgf⋅m, 9+1 lbf⋅ft) 23. Turn and install the cartridge of overload relief
NOTE: Install washer (240) with its chamfered valve (248) to housing (195).
side facing to the spring (241) side. : 27 mm
: 177+29 N⋅m (18+2.9 kgf⋅m, 131+21 lbf⋅ft)
IMPORTANT: If spool (246) is disassembled, or Lock Nut
poppet (245), spring (244) and plug Cartridge
(243) are replaced, replace as an
assembly as the external dimen-
sions of spool (246) are specified.
21. Install O-rings (239, 247), spool (246) assembly W176-02-06-017

(243 to 246) and auxiliary flow combiner valve NOTE: Apply grease onto O-rings of the overload
assembly (235 to 242) to housing (195). relief valve. (This prevents O-ring from be-
ing cut.)
W2-5-41
(Blank)
W2-5-42
POSITIONING CONTROL VALVE

AIR FROM HYDRAULIC OIL TANK.)
Removal
1. Disconnect hoses (1) (6 used) from valve (3).
1 2 3 4
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm, 27 mm
1
2. Remove sems bolts (2) (3 used) from valve (3).
Remove valve (3) from bracket (4).
: 17 mm
WCEB-02-05-011
Installation
1. Install valve (3) to bracket (4) with sems bolts (2)
(3 used).
: 17 mm 1 2 3 4
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (1) (6 used) to valve (3).

: 19 mm 1
: 29.5 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
WCEB-02-05-011
W2-5-43
DISASSEMBLY OF POSITIONING
CONTROL VALVE 19
10 20
21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1
37
38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11 44
56 45
55
54
53 46
52 47
51
48 62
61
60
50
49
59
58
57
W198-02-05-001
1- Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring (2 Used) 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring (2 Used) 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Rivet
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring (2 Used) 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring
W2-5-44
Disassembly of Positioning Control Valve
1. Remove socket bolts (45) (2 used) and socket 5. Remove sleeve assembly (37 to 42) from
bolts (48, 49) from covers (46, 50). Remove housing (62).
O-rings (47, 56) from covers (46, 50). : 36 mm
IMPORTANT: Turn and remove the spools. If they 6. Remove spring (43) and poppet (44) from
stick even a little, try again instead housing (62).
of pulling roughly.
7. Clamp seat (37) in a vise. Remove sleeve (41),
2. Remove spool assembly (51 to 59) from housing spring (40), valve (39) and O-rings (38, 42) from
(62). seat (37).
: 36 mm
pieces. Remove end spool (51), seat (52),
springs (53, 54) and seat (55) from spool (57).
: 8 mm
IMPORTANT: Do not disassemble overload relief

valve assemblies (1 to 18), (19 to 36)
as the set pressures is changed.
4. Remove overload relief valve assemblies (1 to
18), (19 to 36) from housing (62).
: 32 mm
NOTE: Each of overload relief valve assemblies (1
to 18), (19 to 36) has a different set
pressure. Thus they should be identified
for reassembling.
W2-5-45
ASSEMBLY OF POSITIONING CONTROL
VALVE
Section X-X 37 39 40 38
41
43
62
42
44 19 to 36
1 to 18 A1 B1
A1 B1
X X
W198-02-05-002 W198-02-05-003
57
Section W-W
54 53 55 56 62
50 51 52 47
48 45
W W
W198-02-05-004
49
57 59 58 46
W198-02-05-005
1- Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring (2 Used) 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring (2 Used) 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Rivet
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring (2 Used) 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring
W2-5-46
Assembly of Positioning Control Valve
1. Clamp seat (37) in a vise. Install O-ring (38), IMPORTANT: Install the spool (57) assembly to
valve (39), spring (40), sleeve (41) and O-ring housing (62) and check if it moves
(42) to seat (37). smoothly by hand.
: 36 mm 7. Insert spool (57) assembly (51 to 59) into
: 59 N⋅m (6 kgf⋅m) housing (62) from the port A1 side.
NOTE: If spool assembly (51 to 59) is not
2. Insert poppet (44) and spring (43) into housing straightly inserted, the inner surface of
(62). housing (62) or spool (57) may be
damaged and cannot be used. Insert it
3. Install the seat (37) assembly to housing (62). straight.
: 36 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft) 8. Install O-rings (47, 56) to covers (46, 50). Install
covers (46, 50) to housing (62) with socket bolts
IMPORTANT: Each of overload relief valve (45) (2 used) and socket bolts (48, 49).
assemblies (1 to 18), (19 to 36) has a : 6 mm
different set pressure. Do not install : 25.5 N⋅m (2.6 kgf⋅m, 19 lbf⋅ft)
at an incorrect position.
4. Install overload relief valve assemblies (1 to 18),
(19 to 36) to housing (62).
: 32 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
5. Install O-ring (58) to plug (59).

pieces. Install plug (59) to spool (57). Install seat
(55), springs (53, 54), seat (52) and end spool
(51) from the opposite side.
: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft)
: 8 mm
: 18.6 N⋅m (1.9 kgf⋅m, 14 lbf⋅ft)
W2-5-47
(Blank)
W2-5-48
UPPERSTRUCTURE / Swing Device
REMOVAL AND INSTALLATION OF SWING
DEVICE

tank before doing any work. (Refer to Bleed
Air from Hydraulic Oil Tank on W1-4-1.)
1 2 3 2 4
Removal
Remove cover (3) from hydraulic oil tank (1) and
cover (4).
: 17 mm
WCEB-02-06-006
2. Disconnect hoses (6) (2 used) from swing damp-

ener valve (5) and swing motor (12). Cap the open 5 6 7 8, 9
ends.
: 19 mm
10
3. Disconnect hoses (7, 8) from swing motor (8). Cap
the open ends. Remove O-ring (9) from swing
motor (12). 11
: 19 mm, 36 mm
4. Remove socket bolts (10) (8 used) and split 12

flanges (11) (4 used) from hoses (13) (2 used).
Disconnect hoses (13) (2 used) from swing motor
(12). Cap the open ends. 13
: 6 mm
WCEB-02-06-003
5. Disconnect connector (14) from pressure switch 14

(15).
15 WCEB-02-06-005
W2-6-1
CAUTION: Swing device (16) weight: 131 kg

(290 lb)
6. Attach a nylon sling onto the body of swing motor

(12). Hoist and hold swing motor (12).
Nylon sling (eye-type at both ends): 2 used
12
7. Remove bolts (17) (10 used) and washers (18)
(10 used) from swing device (16). Remove swing
16
device (16) from main frame (19).
: 30 mm
NOTE: The number of hoses around the swing 17, 18
device is different according to specification
on the front attachment. When swing de-
vice is removed, check them.
WCEB-02-06-003
NOTE: When hoisting the swing device, the swing 19
device may be contacted with the hose.
Hoist the swing device slowly.
12
8. Remove pressure switch (15) from swing motor
(12).
: 24 mm
15 WCEB-02-06-005
9. Remove socket bolts (21) (4 used) from swing 20 5

dampener valve (5). Remove swing dampener
valve (5) from bracket (20).
: 6 mm
21 WCEB-02-06-003
W2-6-2
Installation 20 5
1. Install swing dampener valve (5) to bracket (20)
: 6 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
21 WCEB-02-06-003
2. Install pressure switch (15) to swing motor (12). 12

: 24 mm
: 16 N⋅m (1.6 kgf⋅m, 12 lbf⋅ft)
15 WCEB-02-06-005
CAUTION: Swing device (16) weight: 131 kg

(290 lb)
IMPORTANT: Apply liquid packing onto the both

mounting surfaces on swing device
and frame.
3. Attach a nylon sling onto the body of swing motor
(12). Hoist swing motor (12). Align swing motor 12
(12) with the mounting hole on main frame (19).
4. Install swing device (16) to main frame (19) with 16

: 30 mm
: 500 N⋅m (50 kgf⋅m, 369 lbf⋅ft) 17, 18
WCEB-02-06-003
19
W2-6-3
5. Connect hoses (13) (2 used) to swing motor (12)
(10) (8 used).
: 6 mm 10
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
11
12
13
6. Connect connector (14) to pressure switch (15).

WCEB-02-06-003
14
7. Install O-ring (9) to hose (8). Apply grease onto

15 WCEB-02-06-005
O-ring (9).
8. Connect hoses (7, 8) to swing motor (12). 5 6 7 8, 9

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
9. Connect hoses (6) (2 used) to swing dampener 12

valve (5) and swing motor (12).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
IMPORTANT: After completing the work, fill hy-

draulic oil from the drain port of
swing motor (12). Start the engine
and check for any oil leaks.
10. Fill hydraulic oil in swing motor (12).
WCEB-02-06-003
W2-6-4
11. Install cover (3) to hydraulic oil tank (1) and cover 1 2 3 2 4
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-06-006
W2-6-5
DISASSEMBLY OF SWING DEVICE
22 1
23
24
3
25
32
21 4
31 5
20 6
26 7
19 8
27
18 9
28 10
17
11
29 16
12
15
13
30
14 11
WCEB-02-06-004
1- Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-6
Disassembly of Swing Device 3. Remove drain plug (31) from pipe (32). Drain off
oil from the swing device.
: 8 mm
CAUTION: Swing device weight: 131 kg (290
lb) 4. Remove pipe (32) from housing (25).
: 18 mm
1. Wind a nylon sling onto the body of swing motor
(1). Hoist swing motor (1). 5. Put the matching marks at the jointed part be-
Nylon Sling
tween swing motor (1) and ring gear (24), be-
tween ring gear (24) and housing (25).
CAUTION: Swing motor (1) weight: 34 kg (75

lb)
6. Remove socket bolts (22) (7 used) from swing

motor (1). Remove swing motor (1) from ring gear
(24).
: 8 mm
NOTE: THREEBOND has been applied onto the
jointed surface. Insert a screwdriver into the
notch between jointed parts and separate
the surfaces in order to remove easily.
W176-02-06-002 7. Remove first stage sun gear (2) from first stage
carrier (21).
2. Place the swing device on bracket (ST 5098).
Secure the swing device on bracket (ST 5098) 8. Remove the first stage carrier (21) assembly from
with the bolts (M20) (2 used). At this time, insert ring gear (24).
the stopper at the bottom of bracket into the
clearance between teeth of the pinion gear. Se-
cure the bracket on a workbench in order to re-
duce the reaction force.
: 30 mm
Swing Device
ST 5098
Stopper
W178-02-06-012
W2-6-7
23
24
3
25
21 4
20 6
18 9
10
17
11
16
12
15
13
30
11
WCEB-02-06-004
W2-6-8
9. Remove socket bolts (23) (2 used) from ring gear 16. Remove thrust plate (3) from first stage carrier
(24). (21).
: 12 mm
IMPORTANT: Do not damage the rotating surface
for the needle bearing of pin (4) ex-
CAUTION: Ring gear (24) weight: 13 kg (30 lb)
cept for the both ends.
17. Clamp the end of pin (4) opposite the spring pin
the swing motor (1) mounting thread part on ring
(5) hole in a vise. Tap and remove spring pins (5)
gear (24). Hoist and remove ring gear (24) from
(3 used) from first stage carrier (21) by using spe-
housing (25).
cial tool (ST 1462).
NOTE: THREEBOND has been applied on the
jointed surface. Insert a screwdriver into the 18. Disassemble the second stage carrier (18) as-
notch between jointed parts and separate sembly in the same way as the first stage carrier
the surfaces in order to remove easily. (21) assembly. Check a difference in the number of
thrust plates (11) (6 used).
11. Remove second stage sun gear (20) from second
stage carrier (18). 19. Remove bolts (17) (2 used) from lock plate (16).
Remove lock plate (16) from bearing nut (15).
12. Remove the second stage carrier (18) assembly : 17 mm
from shaft (30).
20. Remove bearing nut (15) from shaft (30) by using
IMPORTANT: The hole for spring pin (5) located on special tool (ST 2927).
first stage carrier (21) is not a ST 2927
through one. Check the tapping-in 15
distance of spring pin (5).
13. Tap spring pin (5) on first stage carrier (21) as-
sembly into pin (4) by using special tool (ST 1462).
Stop tapping when spring pin (5) reaches the
middle of the hole of first stage carrier (21) and do
not tap spring pin (5) to the end.
14. Remove pin (4), planetary gear (7), needle bear-

ing (6) and thrust plate (8) from first stage carrier W178-02-06-008
(21).
CAUTION: The housing (25) assembly
15. Remove other two sets of pin (4), planetary gear weight: 63 kg (140 lb)
(7), needle bearing (6) and thrust plate (8) from
first stage carrier (21) in the same orders as steps 21. Install eyebolts (M14, Pitch 2.0 mm) (2 used) into
13 and 14. the bolt (23) hole on housing (25). Hoist and hold
housing (25). Remove bracket (ST 5098) from
housing (25).
: 30 mm
W2-6-9
25
26
28
30
14
WCEB-02-06-004
W2-6-10
23. Set special tool to the shaft (30) assembly.
CAUTION: If pushing shaft (30) by using a
press, provide a protection cover (outer di- NOTE: Use the following parts as special tool when
ameter: 290 mm (11.4 in), inner diameter: 90 removing roller bearing (26).
mm (3.5 in), thickness: 25 to 30 mm (1.0 to 1.2 Shaft or bolt: Length: 200 mm (7.9 in), Di-
in)). Cover housing (25) with the protection ameter: 19 mm (0.7 in) 8 used. All should
cover. be identical in length with no wear and de-
When housing (25) and/or roller bearing (14) formation on both ends.
are broken and flown off without the protec- Material: S35C
tion cover, the metal fragments may result in Hose clamp: Standard diameter: 8-1/2 in,
personal injury. (Tightening range: 185 to 215 mm (7.3 to
Press at 30 ton or less. 8.5 in)) 2 used.
Degrease the housing (25) inside before Guide: Height: 160 mm (6.3 in), Outer di-
heating roller bearing (14). Failure to de- ameter: 230 mm (9.1 in), Inner diameter:
grease may cause a fire. 210 mm (8.3 in)
22. Press off shaft (30) from housing (25). The inner
race of roller bearing (26) and sleeve (28) are
removed with shaft (30) together. • Special tool when removing roller bearing
Hose Clamp Shaft
Press
30 14
25
Protection
Protection Cover
Cover
W157-02-06-012
W157-02-06-010 W157-02-06-011
30
26
28
Shaft
W157-02-06-013
Guide
CAUTION: Push the shaft of special tool in

the con cave part of pinion and secure by
using a hose clamp in order not to loosen the
shaft.
W2-6-11
25
26
27
28
29
30
14
WCEB-02-06-004
W2-6-12
CAUTION: Shaft (30) weight: 17 kg (37 lb) CAUTION: Housing (25) weight: 36 kg (80 lb)
27. Fasten the body of housing (25) by using a nylon

CAUTION: When pushing shaft (30) by using
sling. Hoist and turn over housing (25).
a press inside the guide.
28. Insert a screwdriver into the notch on housing (25)
Press where oil seal (27) is mounted. Remove oil seal
30
(27).
NOTE: THREEBOND has been applied onto the
26
periphery of oil seal (27). Oil seal (27) can-
28
not be reused.
29. Tap and remove the outer race of roller bearing

Guide
(14) from housing (25) by using a bar and ham-
mer.
W157-02-06-014
24. Push the spline side on shaft (30) by using a press.

Remove the inner race of roller bearing (26) and
sleeve (28) from shaft (30).
25. Remove O-ring (29) from sleeve (28).
26. Insert a round bar into the oil passage in housing

(25). Tap and remove the outer race of roller
bearing (26).
25
Oil Passage
26
W178-02-06-001
W2-6-13
ASSEMBLY OF SWING DEVICE
4 6 2
5
21
7
3
8
24
10 18
11 20
13 23
19
12
17
11 16
15
9
14
32
26 25
27
28
29
30
31
WCEB-02-06-001 WCEB-02-06-002
1- *Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - *Socket Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
NOTE: As for parts (1, 22), refer to W2-6-6.
W2-6-14
Assembly of Swing Device
1. Install O-ring (29) to sleeve (28). 5. Apply THREEBOND #1215 onto the outer surface
of oil seal (27). Place oil seal (27) flat on housing
(25) and push by hands in gently. Place special
CAUTION: Shaft (30) + sleeve (28) + outer
tool (ST 2928) on oil seal (27). Tap in special tool
race weight: 22 kg (50 lb)
by using a hammer straight.
2. Install sleeve (28) and the inner race of roller ST 2928
bearing (26) to shaft (30). Install sleeve (28) and 27
the inner race of roller bearing (26) by using spe-
cial tool (ST 2929) and a press.
NOTE: The press-in distance of inner race of roller
bearing (26) can be assured by using spe- 25
cial tool.
W176-02-06-006
Press
6. Apply grease to the inner surface of oil seal (27).

Apply grease to the outer surface of sleeve (28)
attached with shaft (30).
ST 2929
NOTE: Apply grease carefully when installing shaft
26
(30) in order not to curl the lip.
28
CAUTION: Housing (25) + roller bearing (14)
30 outer races weight: 37 kg (80 lb)
7. Wind nylon sling onto the body of housing (25).

Hoist and place housing (25) with the ring gear
W178-02-06-013
(24) mounting side facing upward.
8. Tap and install the outer race of roller bearing (14)

CAUTION: Housing (25) weight: 36 kg (80 lb) to housing (25) by using a bar and hammer. Tap
and listen to ring in order to check if the installa-
3. Fasten the body of housing (25) by using a nylon tion is completed.
sling. Hoist and place housing (25) with the
sleeve (28) mounting side facing upward.
4. Evenly tap and install the outer race of roller

bearing (26) to housing (25) by using a bar and
hammer. Tap and listen to ring in order to check if
the installation is completed.
W2-6-15
15
14
26 25
27
30
WCEB-02-06-001 WCEB-02-06-002
W2-6-16
14. Place special tool (ST 2930) on the inner race of
CAUTION: Housing (25) + outer races (2
roller bearing (14). Install the inner race of roller
used) of roller bearings (14, 26) weight:
bearing (14) by using a press.
39 kg (90 lb)
NOTE: The specified press-in distance of inner
9. Install eyebolts (M14, Pitch 2.0 mm) (2 used) into race can be assured by using special tool.
the bolt (23) holes on housing (25). Hoist and ST 2930
place housing (25) on shaft (30). Check and align
carefully in order not to curl the oil seal (28) lip.
14
10. Tap and install the inner race of roller bearing (14)
to shaft (30) by using a bar and hammer. Tap the
inner race until the upper end of inner race
reaches two threads for bearing nut (15) in shaft
(30).
NOTE: The fitting between the inner race of roller
bearing (14) and shaft (30) is tight. W178-02-06-011
11. Tighten bearing nut (15) to shaft (30) by hand. 15. Hoist and place the housing (25) assembly on
NOTE: Prevent shaft (30) from falling off when bracket (ST 5098). Install the housing (25) as-
hoisting housing (25). sembly with bolts (M14, Pitch 2.5 m) (2 used). At
this time, insert the stopper at the bottom of
bracket into the clearance between teeth of the
CAUTION: Housing (25) + shaft (30) + roller pinion gear. Secure the bracket on a workbench in
bearings (14, 26) weight: 60 kg (130 lb) order to reduce the reaction force.
: 30 mm
12. Hoist the housing (25) assembly by using eye- 25
bolts (M14, Pitch 2.0 mm) (2 used) installed in
step 9. Place the housing (25) assembly on the
press.
ST 5098
Stopper
13. Remove bearing nut (15) from shaft (30).
W178-02-06-012
W2-6-17
4 6
5
21
7
3
8
10 18
11
13
19
12
17
11 16
15
9
14
30
WCEB-02-06-001 WCEB-02-06-002
W2-6-18
IMPORTANT: Check the direction to install bearing IMPORTANT: Check the direction to install spring
nut (15). pin (10) and thrust plate (19).
IMPORTANT: Apply grease for keeping correct 18. Assemble second stage carrier (18) into an as-
tightening torque. sembly in the following way.
• Install needle bearing (12) to planetary gear (13).
16. Apply a film of grease onto the thread part of Clamp planetary gear (13) between thrust plates
bearing nut (15). Install bearing nut (15) to shaft (11) (2 used) and install them to second stage
(30) with the step part of bearing nut (15) facing to carrier (18).
the roller bearing (14) side. Tighten bearing but • Install pin (9) to the position where needle bearing
(15) by using special tool (ST 2927) to the speci- (12) has been installed with the spring pin (10)
fied torque. hole facing front. The spring pin (10) holes both in
: 390 N⋅m (40 kgf⋅m, 288 lbf⋅ft) second stage carrier (18) and pin (9) should be in
line.
• Install spring pin (10) to second stage carrier (18)
ST 2927
by using special tool (ST 1462). Face the slit of
15 spring pin (10) to the end of pin (9).
10
Slit
W178-02-06-002
W178-02-06-008 • Install thrust plate (19) to second stage carrier

(18) with the oil groove facing upward.
17. Install lock plate (16) to bearing nut (15) with bolts • Install needle bearings (12) (2 used), thrust plates
(17) (2 used). In case the spline of lock plate (16) (11) (4 used), pins (9) (2 used) and spring pins
and that of shaft (30) are not aligned, tighten (10) (2 used) to other hole (2 places) on the sec-
bearing nut (15) in tightening direction until both ond stage carrier (18) in the same way.
splines are aligned.
: 17 mm IMPORTANT: Check the position to install thrust
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) plate (8).
19. Assemble first stage carrier (21) into an assembly.
Install planetary gears (7) (3 used), needle bear-
ings (6) (3 used), thrust plates (8) (3 used), pins
(4) (3 used), spring pins (5) (3 used) and thrust
plate (3) in the same way as for second stage
carrier (18). Check that mounting position of
thrust plate (8) is located under needle bearing
(6).
W2-6-19
21
24
18
20
23
16
32
25
30
31
WCEB-02-06-001 WCEB-02-06-002
NOTE: As for parts (1, 22), refer to W2-6-6.
W2-6-20
IMPORTANT: Check the direction to install second 24. Install the first stage carrier (21) assembly to the
stage carrier (18). spline of second stage sun gear (20).
20. Install the second stage carrier (18) assembly to
the spline of shaft (30). Check that the concave IMPORTANT: Check the direction to install first
part of boss in bottom side of second stage carrier stage sun gear (2).
(18) comes in contact with lock plate (16) at this 25. Install first stage sun gear (2) to the first stage
time. carrier (21) assembly with the step side facing
downward.
Can cave Part 18
16 26. Wind the seal tape onto the thread part of pipe
30
(32). Install pipe (32) to housing (25) with pipe
(32) facing downward.
: 18 mm
27. Wind the seal tape onto drain plug (31). Install
drain plug (31) to pipe (32).
: 8 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W178-02-06-014
28. Add gear oil into ring gear (24) until gear oil
21. Install second stage sun gear (20) to the second
reaches the middle part of first stage sun gear (2).
stage carrier (18) assembly with the small di-
(Approx. 3.2 L, 0.8 US gal)
ameter part facing upward.
29. Apply THREEBOND #1215 onto the swing motor
22. Apply THREEBOND #1215 onto the ring gear
(1) mounting surface of ring gear (24). Clean off
(24) mounting surface of housing (25). Clean off
old adhesive in advance.
old adhesive in advance.
CAUTION: Swing motor (1) weight: 34 kg (70

CAUTION: Ring gear (24) weight: 13 kg (30 lb)
lb)
30. Fasten the body of swing motor (1) by using a
the motor mounting thread part on ring gear (24).
sling nylon. Hoist swings motor (1) and align the
Hoist and align ring gear (24) with the mounting
matching marks on ring gear (24). Install swing
hole on housing (25). Align the matching marks
motor (1) to ring gear (24) with socket bolts (22) (7
made when disassembling. Install ring gear (24)
used).
to housing (25) with socket bolts (23) (12 used).
: 8 mm
: 12 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
: 140 N⋅m (15 kgf⋅m, 103 lbf⋅ft)
W2-6-21
DISASSEMBLY OF SWING MOTOR
34 １
33 2
32 3
4
31
5
30
6
29
28 7
27
26
8
25
9
24
10
23
11
22
23 12
13
22
14
23
15
22
23
22 16
17
21 18
19
20
W176-02-06-008
1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring
W2-6-22
Disassembly of Swing Motor
6. Apply air through the parking brake port of casing

CAUTION: Swing motor weight: 34 kg (70 lb)
(20). Raise and remove piston (25).
1. Fasten the body of swing motor by using a nylon NOTE: If piston (25) is not raised, push in piston
sling. Hoist and place valve unit (32) with if facing (25) by using special tools (ST 2921 and ST
upward. As shaft (7) is out of casing (20), place 2922) and retry to raise piston (25). As for
the swing motor on the wooden block (50 mm (2.0 the operation of special tool, refer to the
in) or more square). assembly of the swing motor.
IMPORTANT: Do not drop valve plate (27).

2. Remove socket bolts (34) (4 used) from valve unit
(32). Remove valve unit (32) from casing (20). 20 Parking
Brake Port
: 14 mm
3. Wind the vinyl tape onto the tip of shaft (7). Pro-
tect shaft (7).
NOTE: The tip of shaft (7) is the rotating surface of
needle bearing (30).
W176-02-06-009
4. Remove needle bearing (30) from valve unit (32).

7. Remove rotor (1) from casing (20). At this time,
NOTE: Insert your finger in the back of needle
plates (23) (4 used) and friction plates (22) (4
bearing (30). Remove needle bearing (30)
used) are removed with rotor (1) together.
straight while rotating. If needle bearing
(30) cannot be removed, push in by using
8. Hold plungers (5) (2 used) at the opposite corner.
special tool (ST 2899) and pull up again. As
Remove plungers (5) (2 used) from casing (20).
for the assembly, refer to the assembly of
Disc spring (2), bushing (3) and retainer (4) are
the swing motor.
removed with plunger (5) together.
5. Remove disc spring (29) from casing (20).
9. Remove other plungers (5) (7 used) from casing
(20).
W2-6-23
30
6
10
11
12
14
15
16
17
19
20
W176-02-06-008
W2-6-24
10. Hang the claws of special tools (ST 1458) (2 IMPORTANT: When shaft (7) falls down from roller
used) to the inner diameter of swash plate (6). bearing (9), the rotating surface of
Remove swash plate (6) from casing (20). needle bearing (30) may be damaged.
Hold shaft (7) in order not to drop.
ST 1458 16. Secure special tool (ST 1459) in a vise. Insert
6 shaft (7) into special tool (ST 1459) with the spline
side facing upward. Tap the spline side and re-
20 move roller bearing (9) from shaft (7) by using a
plastic hammer.
W176-02-06-011 ST 1459
11. Remove retaining ring (8) from casing (20).
12. Place casing (20) horizontally.
13. Tap the head at the spline of shaft (7) by using a

plastic hammer and remove shaft (7) from casing
(20). At this time, roller bearing (9) are removed
with shaft (7) together.
W176-02-06-021
14. Tap and remove oil seal (11) by using a screw- 17. Remove plug (12) from casing (20). Remove
driver. As THREEBOND is applied to the outer spring (14) and poppet (15) from casing (20).
surface of oil seal (11), cannot be reused oil seal : 6 mm
(11).
IMPORTANT: Do not damage the oil seal (11) lip 18. Remove plug (19) from casing (20). Remove
surface of shaft (7). spring (17) and plunger (16) from casing (20).
15. Remove retaining ring (10) from shaft (7). : 6 mm
NOTE: Do not remove a reinforcing mesh and a

filter are set inside plunger (16) unless
necessary. If the reinforcing mesh and the
filter are removed, clamp plunger (16) in a
vise. Remove plug (19) by using a 3 mm
hexagonal wrench. Before assembling,
degrease plunger (16) and plug (19). Apply
LOCTITE #242 onto the thread part.
Tighten them to torque of 5.9 N·m (0.6
kgf·m).
W2-6-25
ASSEMBLY OF SWING MOTOR
34
32
33
30
28
29
27
16 17 18 19
15 31
14
25
13
26
12
24
23
22
5
Parking Brake Release Block
4
21
8
6
9
2
20
3
10 11 W176-02-06-012
7
1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring
W2-6-26
Assembly of Swing Motor
1. Place casing (20) with the mounting surface of IMPORTANT: Check the direction to install roller
valve unit (32) facing upward on the wooden bearing (9).
block (50 mm (2.0 in) or more square). 7. Install roller bearing (9) with all the stamped
marks on the outer race, inner race and inner ring
2. Install spring (17) to plunger (16). Install plunger plate facing outward.
(16) to the hole on the parking brake release
block of casing (20). Marked Surface on Marked Surface on
Outer Race Inner Race
3. Install O-ring (18) to plug (19). Install plug (19) to
the hole on the parking brake release block of
casing (20).
: 6 mm W176-02-06-014
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) Marked Surface on
Inner Ring Plate
4. Install spring (14) to poppet (15). Install poppet
(15) to the hole on the parking brake release IMPORTANT: Check the direction to install roller
block of casing (20). bearing (9).
8. Install the inner ring plate side of roller bearing (9)
5. Install O-ring (13) to plug (12). Install plug (12) to to the spline side of shaft (7) first. Push in roller
the hole on the parking brake release block of bearing (9) to the front end of the mating position
casing (20). with shaft (7). At this time, do not damage the seal
: 6 mm lip surface of shaft (9).
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
9. Insert the spline side of shaft (7) into special tool
6. Clean old adhesive on the mounting part of oil (ST 2896). Tap the opposite side of shaft (7) by
seal (11) on casing (20). using a plastic hammer and install roller bearing
Apply THREEBOND #1104 or #1215 onto the (9) to shaft (7).
outer surface of oil seal (11). Install oil seal (11) to
casing (20) by using special tools (ST 2897, ST
2898).
7
9
ST 2898
ST 2896
ST 2897
20
W176-02-06-018
10. Install retaining ring (10) to shaft (7). At this time,

11 W176-02-06-010 do not damage the seal lip surface of shaft (7).
W2-6-27
32
25
26
24
23
22
5
4
21
8
6
20
3
11 W176-02-06-012
7
W2-6-28
11. Apply grease onto the inner surface of oil seal (11) ▪ Place retainer (4) on bushing (3) with the
and the seal lip surface of shaft (7). chamfered surface facing downward.
4
12. Install shaft (7) to casing (20). Tap and install shaft
(7) to casing (20) by using a plastic hammer. Tap
and listen to ring in order to check if the installa-
tion is completed. Chamfered
Surface
13. Install retaining ring (8) to casing (20). 3 W176-02-06-016
14. Apply grease onto the chamfered surface and ▪ Align the plunger (5) hole of retainer (4) with
outer surface of swash plate (6). that of rotor (1). Install plungers (5) (9 used).
15. Install swash plate (6) to casing (20) with the 17. Place casing (20) horizontally with the drain plug
chamfered surface facing downward. (21) side facing downward.
NOTE: After installing swash plate (6), turn it. If
swash plate (6) does not turn, it may be 18. Install rotor (1) assembled in step 16 to casing
seizing. In that case, install swash plate (6) (20) while aligning with the spline of shaft (7).
again.
IMPORTANT: Shaft (7) is out of casing (20). Place
IMPORTANT: The flat surface of rotor (1) is a slid- casing (20) on the wooden block (50
ing surface with the valve plate. Do mm or more square).
not damage the sliding surface. 19. Place casing (20) vertically with the mounting
16. Assemble rotor (1) into an assembly. surface of valve unit (32) facing upward.
▪ Place rotor (1) with the flat surface facing
downward. IMPORTANT: Check the installation order of plate
▪ Assemble disc springs (2) (4 used) as the outer (23) and friction plate (22).
surface is matching with the outer surface and 20. Install plates (23) (4 used) and friction plates (22)
the inner surface is matching with the inner (4 used) to casing (20) alternately. Install friction
surface. Place them on the projection. Cover plate (22) with the mold attached first.
them with bushing (3). Check the direction of
disc spring (2). Refer to the following. 21. Install O-rings (24, 26) to piston (25).
2 3
W176-02-06-015
W2-6-29
34
32
33
30
28
29
27
31
25
20
W176-02-06-012
W2-6-30
22. Place piston (25) evenly on casing (20). Cover 25. Install O-ring (31) to valve unit (32).
special tools (ST 2921, ST 2922) on piston (25).
Tap piston (25) by using a hammer. 26. Apply grease onto the flat surface of valve plate
(27).
ST 2922
NOTE: Apply grease more in order not to drop
valve plate (27) when installing valve unit
(32) to casing (20).
ST 2921
IMPORTANT: Do not drop valve plate (27).

25 27. Install valve plate (27) while aligning with knock
20
pin (28) of valve unit (32). Turn over valve unit
(32). Place valve unit (32) on casing (20).
28. Install valve unit (32) to casing (20) with spring

washers (33) (4 used) and socket bolts (34) (4
used).
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
W176-02-06-020
IMPORTANT: Check the direction of disc spring

(29).
23. Install disc spring (29) to casing (20). At this time,
install disc spring (29) with the outer surface side
facing to the back.
24. Install needle bearing (30) to valve unit (32) by

using special tool (ST 2899).
ST 2899
30
32
W176-02-06-019
W2-6-31
DISASSEMBLY OF VALVE UNIT
7
6
1 2 3 4 5 9
10
11
12
4
3
2
1
13
14
15
16
W176-02-06-007
16
15
14
13
1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Spring Seat (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)
W2-6-32
Disassembly of Valve Unit 4. Remove plugs (13) (2 used) from valve housing
(5). Remove springs (15) (2 used) and poppets
▪ As for Removal/Installation of the valve unit (16) (2 used) from valve housing (5) by using a
from/to the swing motor, refer to Disassemble and magnet.
Assemble Swing Motor. : 12 mm
IMPORTANT: The lower surface of valve housing 5. Remove plugs (1) (2 used) from valve housing (5).
(5) is the contact surface of the valve Remove springs (3) (2 used) from valve housing
plate. Do not damage the contact (5).
surface. : 8 mm
1. Set the cloth on the workbench. Place valve
housing (5) on the cloth. IMPORTANT: Do not damage the inside of valve
housing (5).
IMPORTANT: As the set pressure changes, do not 6. Insert a round bar into valve housing (5). Remove
turn the lock nut. spool (12) to the opposite side. At this time, spring
2. Remove the relief valve (8) assemblies (2 used) seat (4) is removed with spool (12) together. If
from valve housing (5). spool (12) cannot be removed, push back spool
: 32 mm (12) and remove spool (12) again.
8 Lock Nut 7. Remove other spring seat (4) in valve housing (5)
by using a magnet.
W176-02-06-017
3. Remove backup rings (6, 10) (2 used for each)

and O-rings (7, 11, 9) (2 used for each) from relief
valves (8) (2 used).
W2-6-33
ASSEMBLY OF VALVE UNIT
8
10
11
13
14
15
16
2 3 4 12 4 3 2
Section E
1 1
W176-02-06-013
1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Spring Seat (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)
W2-6-34
Assembly of Valve Unit
1. Install O-rings (9) (2 used) to relief valves (8) (2 5. Install O-rings (14) (2 used) to plugs (13) (2 used).
used). Install plugs (13) (2 used) to valve housing (5).
: 12 mm
2. Install O-rings (7, 11) (2 used for each) and : 235 N⋅m (24 kgf⋅m, 173 lbf⋅ft)
backup rings (6, 10) (2 used for each) to relief
valves (8) (2 used). 6. Install spring seat (4) to spool (12) only at one
side. Install spring seat (4) to the center of valve
IMPORTANT: As the set pressure changes, do not housing (5) from the side without spool (12). At
turn the lock nut in relief valve (8). this time, do not drop spring seat (4) inside of
3. Install the relief valve (8) assemblies (2 used) to valve housing (5).
valve housing (5).
: 32 mm 7. Push spool (12) more until the position right be-
: 235 N⋅m (24 kgf⋅m, 173 lbf⋅ft) fore the spool (12) end comes out from the oppo-
site-side hole on valve housing (5). When pushed
Lock Nut too much, spring seat (4) inserted to spool (12)
8
falls inside of valve housing (5).
8. Install spring seat (4) and spring (3) to the end of

spool (12) coming out from valve housing (5).
Push spool (12) into valve housing (5) to the step
part of spool (12).
9. Push back spool (12) approximately half way of

W176-02-06-017
valve housing (5). Install spring (3) to spool (12)
from the opposite-side hole.
4. Install poppets (16) (2 used) and springs (15) (2
used) to valve housing (5). 10. Install O-rings (2) (2 used) to plugs (1) (2 used).
Install plugs (1) (2 used) to valve housing (5).
: 8 mm
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
W2-6-35
STRUCTURE OF SWING DAMPENER VALVE
1 2 3 4 5
WCEB-02-06-008

Item Part Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Relief Valve 2 : 24 69 (7) (51)
2 Backup Ring 2
3 O-Ring 2
4 Casing 1 1B P20
5 Plug 2 :4 9 (1) (7)
W2-6-36
MAINTENANCE STANDARD
Swing Motor Shoe
1. Clearance between plunger and shoe bottom

Unit: mm (in)
Standard Allowable Limit
0 0.2 (0.008)
ε
ε≤0.2 mm (0.008 in) Plunger
W105-02-06-130
D
2. Clearance between plunger outer diameter and Rotor
rotor cylinder inner bore
Unit: mm (in)
Standard Allowable Limit
0 0.05 (0.002)
D-d≤0.05 mm (0.002 in)
W105-02-06-134
Plunger Assembly
d
Rotor
W105-02-06-135
W2-6-37
Parking Brake
A
W176-02-06-022
C
Unit: mm
Part Name Standard Allowable Limit Remedy
A Friction Plate Thickness 2.4 2.35
B Disc Spring (Overall height) 6.8 6.7
C Piston Thickness 41.0 -
D Plate Thickness 1.4 1.35
Remarks No wear on the piston as it does not slide.
IMPORTANT: The piston thickness is shown as

the distance from the contact point
of disc spring to the contact point of
plate.
NOTE: 1 mm = 0.03937 in
Plunger
W155-03-02-007
Unit: mm
Standard Allowable Limit Remedy
A 5.5 5.3 Replace
NOTE: 1 mm = 0.03937 in
W2-6-38
UPPERSTRUCTURE / Pilot Valve
REMOVAL AND INSTALLATION OF PILOT
VALVE

Removal of Left Pilot Valve 1 2 3 4 5
1. Remove sems bolts (4) (2 used) from seat belts

(6) (2 used). Remove seat belt (6) from brackets 6
(5) (2 used).
: 16 mm
WCEB-02-01-001
6 4 5 2 3
WCEB-02-01-017
2. Remove socket bolts (3) (4 used) from seat (1).

Remove seat (1) from plate (2).
: 6 mm 3
WCEB-02-01-002
2
7
3. Remove screws (9) (4 used) from boot (7). Raise

boot (7) from bracket (8). 8
W1JB-02-07-002
W2-7-1
4. Remove screw (10) from covers (11, 12).
10
12
11
WCEB-02-07-001
5. Remove sems bolt (14) from cover (11). Remove

screws (13) (3 used) from covers (11, 12). Re-
move covers (11, 12) from bracket (8).
: 10 mm 12
11
13
14 WCEB-02-07-003
11
13
12
8 13 WCEB-02-07-004
W2-7-2
6. Remove clip bands (17) (2 used) from lever (15) 15 16 17
and harness (18). Disconnect a connector from
harness (18).
7. Loosen lock nut (16). Remove lever (15) assem-

bly from pilot valve (19).
: 19 mm, 22 mm 18
8. Disconnect hoses (20) (6 used) from pilot valve

tag onto the disconnected hoses for assembling. 19
: 19 mm
20
W1JB-02-07-005
9. Remove sems bolts (21) (4 used) from bracket (8). 21 8

Remove pilot valve (19) from bracket (8).
: 13 mm
19
W1JB-02-07-005
21
W2-7-3
Installation of Left Pilot Valve
21 8
1. Install pilot valve (19) to bracket (8) with sems
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
2. Connect hoses (20) (6 used) onto pilot valve (6).

: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
19
20
W1JB-02-07-005
21
15 16 17
3. Install lever (15) assembly to pilot valve (19). Se-
cure lever (15) assembly to pilot valve (19) with
lock nut (16).
: 22 mm
: 55 N·m (5.5 kgf·m, 41 lbf·ft)
18
4. Connect harness (18) connector.
5. Install harness (18) to bracket (8) of pilot valve

(19) with clip band (17).
8
19
W1JB-02-07-005
6. Install cover (11, 12) to bracket (8) with round

head screws (13) (3 used) and sems bolt (14).
: 10 mm
: 3.3 to 4.2 N·m 12
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)
11
13
14
WCEB-02-07-003
W2-7-4
7. Install cover (11, 12) to bracket (8) with round
head screw (10).
10 8
12
11 WCEB-02-07-001
7
8. Install boot (7) to bracket (8) with round head
screws (9) (4 used).
W1JB-02-07-002
1
9. Install seat (1) to plate (2) with socket bolts (3) (4

used).
3
: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
10. Install seat belt (6) (2 used) to bracket (5) (2 used)

: 16 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 2
WCEB-02-01-002
1 2 3 4 5
WCEB-02-01-001
W2-7-5
Removal of Right Pilot Valve
1. Remove the seat. (Refer to W2-7-1.)
2. Remove cap (3) (2 used) and round head screws 1 2

(1, 4) (1 each used) from cover (2). Remove cover 3, 4
(2) from bracket (7).
3. Remove sems bolt (6) from cover (5). 5

: 10 mm
4. Remove round head screw (9) from cover (8).

7 6
WCEB-02-07-006
8
3, 4
9
WCEB-02-07-005
5. Remove round head screws (11) (4 used) from 10

boot (10). Remove boot (10) from bracket (7).
7
11
W1JB-02-07-002
6. Remove round head screw (12) from cover (5, 8).

Remove covers (5, 8) from bracket (7). 12
8 5
W1JB-02-07-016
W2-7-6
7. Remove clip bands (15) (2 used) from lever (13)
and harness (16). Disconnect a connector from 13 14 15
harness (16).
8. Loosen lock nut (14). Remove lever (13) assem- 16

bly from pilot valve (17).
: 19 mm, 22 mm
17
W1JB-02-07-005
9. Remove sems bolts (19) (3 used) from bracket (7).

Remove bracket (7) assembly from stand (18).
Hoist bracket (7) assembly.
: 17 mm
19 18
WCEB-02-07-009
10. Disconnect hoses (20) (6 used) from pilot valve (6).

21 7
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm
11. Remove sems bolts (21) (4 used) from bracket (7). 17

Remove pilot valve (17) from bracket (7).
: 13 mm
20
W1JB-02-07-005
21
W2-7-7
Installation of Right Pilot Valve 21 7
1. Install pilot valve (17) to bracket (7) with sems

: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 17
2. Connect hoses (20) (6 used) onto pilot valve (6).

: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
20
W1JB-02-07-005
21
13 14 15
3. Install lever (13) assembly to pilot valve (17). Se-
cure lever (13) assembly to pilot valve (17) with
lock nut (14).
: 22 mm 16
: 56 N·m (5.5 kgf·m, 41 lbf·ft)
4. Connect harness (16) connector.

7
5. Install harness (16) to pilot valve (17) and bracket
(7) with clip band (15) (2 used).
17
W1JB-02-07-005
6. Install cover (5) to bracket (7) with sems bolts (6).

: 10 mm
: 3.3 to 4.2 N·m
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)
7 6
WCEB-02-07-006
W2-7-8
7. Install bracket (7) assembly to stand (18) with
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
8. Install cover (8) to bracket (7) with round head

screw (9).
9
19
18 8 WCEB-02-07-009
9. Install covers (5, 8) to bracket (7) with round head

screw (12). 12
8 5
W1JB-02-07-016
10
10. Install boot (10) to bracket (7) with round head
7
11
W1JB-02-07-002
11. Install cover (2) to bracket (7) with round head

screws (1, 4) (2 each used). Attach cap (3) (2
2
used) to cover (2).
1
3, 4
8
5
7 6
WCEB-02-07-006
W2-7-9
21
12. Install seat (21) to plate (23) with socket bolts (22)
(4 used).
22
: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
WCEB-02-01-002
23
13. Install seat belts (26) (2 used) to brackets (25) (2 21 23 22 24 25

used) with sems bolts (24) (2 used).
: 16 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
26
WCEB-02-01-001
26 24 25 23 22
WCEB-02-01-017
W2-7-10
TRAVEL PILOT VALVE

Removal
1. Remove mat (1) from cab (2) inside.
WCEB-02-01-003
2. Remove sems bolts (4) (2 used) from pedal (3).

Remove pedal (3) from bracket (5).
: 13 mm
WCEB-02-07-002
Auxiliary Brake Pedal
Pedal

Remove bracket (5) from travel pilot valve (6). 3
: 13 mm
4
7 6 WCEB-02-07-007
W2-7-11
4. Remove sems bolts (8) (6 used) from cover (9). 8 9 8
: 17 mm
10
WCEB-02-13-001
11 12 13
5. Disconnect hoses (11) (4 used) from travel pilot
valve (14). Cap the open ends. Attach an identifi-
cation tag onto the disconnected hoses for as-
14
sembling.
: 19 mm
6. Remove sems bolts (12) (2 used) from travel pilot

valve (14). Remove travel pilot valve (14) from
plate (13).
11
: 17 mm
WCEB-02-07-008
W2-7-12
Installation
1. Install travel pilot valve (14) to plate (13) with 11 12 13
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 14
2. Connect hoses (11) (4 used) onto travel pilot valve

(14).
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
11
WCEB-02-07-008
3. Install bracket (5) to travel pilot valve (6) with

sems bolts (7) (2 used). 3
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 4
4. Install pedal (3) to bracket (5) with sems bolts (4)

(2 used).
: 13 mm 5
: 20 N·m (2 kgf·m, 15 lbf·ft)
7 6 WCEB-02-07-007
WCEB-02-07-002
Auxiliary Brake Pedal
Pedal
5. Install mat (1) to the cab (2) inside.
WCEB-02-01-003
W2-7-13
6. Install cover (9) to main frame (10) with sems bolts 8 9 8
(8) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft) 10
WCEB-02-13-001
W2-7-14
(Blank)
W2-7-15
DISASSEMBLY OF FRONT/SWING PILOT VALVES
10
10
11
1
11 12
12
2 13
13
14
5
5
6 15
6
16
7
7
17
8
8
18
9
9
19
19
20
20
W1F3-02-07-001
1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)
W2-7-16
Disassembly of Front/Swing Pilot Valves 3. Install special tool (ST 7260) to universal joint (3).
• Spool (13) has been selected to match the hole of Remove universal joint (3) from casing (14) by
casing (14). Therefore, the parts cannot be returning.
placed individually. : 24 mm
• Indicate the port number of the removed in order
not to confuse parts. The port numbers are
stamped on the outer surface of casing (14).
1. Clamp the pilot valve in a vice. Secure the plot

valve with the port plate (18) facing downward. Section A-A
2. Put the matching marks on plate (4) and casing

(14). Secure cam (2) by using a spanner. Remove
screw joint (1) and cam (2) from universal joint ST 7260
(3).
: 32 mm
CAUTION: Springs (10) (4 used) are in the

compressed condition. Therefore, when A A
loosening universal joint (3), plate (4), bush-
ings (6) (4 used), and pushers (8) (4 used) are 3
raised at the same time. Do not fly out them.
W577-02-06-003
4. Remove plate (4) from casing (14).
IMPORTANT: When bushing (6) (4 used) are still in

casing (14), remove pusher (8) by
moving left and right. Do not dam-
age pusher (8).
IMPORTANT: Indicate the port numbers of the
spool (13) assembly and springs (10)
(4 used) in order not to confuse the
parts. Do not damage spool (13).
5. Remove the pusher (8) assembly, the spool (13)
assembly and springs (10) (4 used) from casing
(14).
6. Remove pushers (8) (4 used), O-rings (7) (4

used) and oil seals (5) (4 used) from bushings (6)
(4 used).
W2-7-17
11
11 12
12
13
13
14
15
16
17
18
9
9
20
W1F3-02-07-001
W2-7-18
IMPORTANT: Do not disassemble the spool (13)
assembly unless necessary.
IMPORTANT: When removing spring seats (9) (4
used) from spool (13), push in
spring seat (9) once and remove it
by moving to a larger hole of 2 holes
on spring seat (9). At this time, do
not push in spring seat (9) for more
than 6 mm (0.2 in).
13
WCEB-02-07-010
11 9
7. Remove spring seats (9) (4 used), springs (11) (4

used) and washers (12) (4 used) from spool (13).
8. Clamp the pilot valve in a vice. Secure the pilot

valve with port plate (18) facing upward.
9. Remove socket bolts (20) (2 used) and seal

washers (19) (2 used) from port plate (18).
10. Remove port plate (18), O-ring (15), bushing (16)

and spring pin (17) from casing (14).
W2-7-19
ASSEMBLY OF FRONT/SWING PILOT VALVES
1
3
8
5
4
6
11
10
12
13
14
16
15
17
18
19
20 W1F3-02-07-002
1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)
W2-7-20
Assembly of Front/Swing Pilot Valves IMPORTANT: Install spring (10) to the same posi-
• Replace the seals with the new ones. tion before disassembling.
4. Install springs (10) (4 used) to casing (14).
1. Install bushing (16) and O-ring (15) to casing (14).
IMPORTANT: Install the spool (13) assemblies (4
2. Install spring pin (17) to port plate (18). Install port used) to the same position as it was
plate (18) to casing (14) with socket bolts (20) (2 before disassembling.
used) and seal washers (19) (2 used). 5. Install the spool (13) assemblies (4 used) to cas-
: 20.5±2 N·m (2.1±0.2 kgf·m, 15±2 lbf·ft) ing (14).
IMPORTANT: When installing spring seats (9) (4 6. Install O-rings (7) (4 used) and oil seals (5) (4
used) to spool (13), insert spool (13) used) to bushings (6) (4 used).
from a larger hole of 2 holes on
spring seat (9) and move to a smaller IMPORTANT: Apply hydraulic oil onto the outer
hole direction. At this time, do not surface of pushers (8) (4 used).
push in spool (13) for more than 6 7. Install pushers (8) (4 used) to bushings (6) (4
mm (0.2 in). used).
IMPORTANT: If installing plate (4) is difficult due

to strong springs (10) (4 used), place
the bushing (6) assemblies (4 used)
13 on 4 holes of casing (14). Place plate
(4) on them. Temporarily secure the
bushing (6) assemblies (4 used).
While holding it with universal joint
WCEB-02-07-010 (3).
9
8. Install the bushing (6) assemblies (4 used) to
3. Install washers (12) (4 used), springs (11) (4 casing (14), by aligning the matching marks be-
used) and spring seats (9) (4 used) to spools (13) fore disassembly.
(4 used) in this order.
W2-7-21
1
3
14
W1F3-02-07-002
W2-7-22
9. Install universal joint (3) to casing (14) by using
special toll (ST 7260).
: 24 mm
: 47.1±2.9 N·m
(4.8±0.3 kgf·m, 35±2 lbf·ft)
10. Screw in universal joint (3) until pushers (8) (4

used) come in contact with cam (2) evenly.
IMPORTANT: When tightening screw joint (1), do

not move cam (2).
11. Secure cam (2) by using a spanner. Install screw
joint (1) to universal joint (3).
: 32 mm
: 68.6±4.9 N·m
(7.0±0.5 kgf·m, 51±4 lbf·ft)
12. Apply grease onto the rotating part of universal

joint (3) and the top of pusher (8).
W2-7-23
DISASSEMBLY OF TRAVEL AND AUXIL-
IARY/POSITIONING PILOT VALVES
20
7 20
8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15
15
4
11
14
14
3
3 12
13
2
2
21
1
1
W1LA-02-06-001
1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)
W2-7-24
Disassembly of Travel and Auxiliary/Positioning
Pilot Valves
• Spool (15) has been selected to match the hole of 7. Remove spring guides (19) (2 used), springs (18)
casing (21). Therefore, the parts cannot be re- (2 used), washers (16) (2 used) and shims (17) (2
placed individually. used) from the spool (15) assemblies (2 used).
• Indicate the port number of the removed in order
not to confuse. IMPORTANT: As the spool (15) assemblies (2
used) are adjusted by shim (17), do
IMPORTANT: Before disassembling, put the not disassemble the spool (15) as-
matching marks on cam (9), pin (10), sembly unless necessary. If the
cover (11) and casing (21). spool (15) assembly is disassem-
1. Secure the pilot valve in a vise. Remove boot (7) bled, record the quantity and thick-
from cover (11). ness of shim (17).
IMPORTANT: Do not remove bushing (4) from
2. Remove set screw (8) from cam (9). Remove pin cover (11) unless bushing (4) is
(10) from cover (11). Remove cam (9) from cover damaged.
(11). 8. Remove bushings (4) (2 used) from cover (11).
NOTE: LOCTITE is applied onto the set screw
part.
NOTE: Steel ball (5) cannot be disassembled from
cam (9).
3. Loosen and remove socket bolts (6) (2 used) from

cover (11) alternately. Remove cover (11) from
casing (21).
4. Remove the pusher (20) assemblies (2 used)

from casing (21).
5. Remove bushings (2) (2 used) from the pusher

(20) assembly. Remove O-rings (1) (2 used) and
packings (3) (2 used) from bushings (2) (2 used).
IMPORTANT: Indicate the port numbers in order

not to confuse the parts.
6. Remove the spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).
W2-7-25
ASSEMBLY OF TRAVEL AND AUXIL-
IARY/POSITIONING PILOT VALVES
7 8 10 9
20
11
19
18
14
17
16
12
13
15
W1LA-02-06-002
21
1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packin (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)
NOTE: *Refer to W2-7-24.
W2-7-26
Assembly of Travel and Auxiliary/Positioning Pi- 8. Apply LOCTITE #241 onto setscrew (8). Secure
lot Valve cam (9) to pin (10) with setscrew (8).
• Clean not to confuse the parts. Arrange the parts : 5 N·m (0.5 kgf·m, 41 lbf·ft)
by port in order.
9. Install boot (7) to cover (11).
1. Install bushings (4) (2 used) to cover (11).
IMPORTANT: Install shim (17) as its thickness

becomes same before disassem-
bling.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used) and spring guides (19) (2
used) to spools (15) (2 used) in this order.
IMPORTANT: Install the spool (15) assembly into

the same hole before disassembling.
3. Install spring (14) (2 used) to casing (21). Install
the spool (15) assemblies (2 used) to casing (21).
4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3
W585-02-06-005
Lip
5. Install pushers (20) (2 used) to the bushing (2)

assemblies (2 used). Install the pusher (20) as-
semblies (2 used) to casing (21).
6. Secure casing (21) in a vise. Install cover (11) to

casing (21) with socket bolts (6) (2 used).
: 23.5 N·m (2.4 kgf·m, 17 lbf·ft)
7. Install cam (9) to cover (11). Secure cam (9) to

cover (11) with pin (10).
W2-7-27
(Blank)
W2-7-28
UPPERSTRUCTURE / Electric Lever
ELECTRIC LEVER
Removal of Auxiliary/Positioning Electric Lever

1 2
Remove cover (1) from main frame (3). 3
: 17 mm
WCEB-02-13-001
WCEB-02-08-002
5
WCEB-02-01-003

Remove pedal (9) from bracket (10).
8
: 13 mm
5. Remove sems bolts (7) (2 used) from bracket (10). 7 9

Remove bracket (10) from electric lever (11).
: 13 mm
11 10
WCEB-02-08-001
W2-8-1
plate (14).
: 17 mm
WCEB-02-08-001
14 13 12
11
7. Remove sems bolts (15) (2 used) from electric
lever (11). Remove electric lever (11) from bracket
(12).
15
: 17 mm
WCEB-02-08-002
Installation of Auxiliary/Positioning Electric Lever
1. Install electric lever (11) to bracket (12) with sems 11

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
15
WCEB-02-08-002
2. Install the bracket (12) assembly to plate (14) with

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-08-001
14 13 12
W2-8-2
3. Install bracket (10) to electric lever (11) with sems
bolts (7) (2 used).
: 13 mm 8
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
4. Install pedal (9) to bracket (10) with sems bolts (8) 7 9

(2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
11 10
WCEB-02-08-001
5. Install mat (6) to the inside of cab (5). 5
WCEB-02-01-003
WCEB-02-08-002
1 2
(2) (6 used). 3
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-13-001
W2-8-3
Removal of Blade/Outrigger Electric Lever
1. Remove caps (4) (2 used) from cover (2). Remove

screws (5, 7) (2 used for each) from cover (2). 2
: 17 mm 3
1
2. Remove sems bolt (6) from cover (3).

: 10 mm 4, 5
8 7 6 WCEB-02-07-006
3. Remove screw (9) from cover (1).
9
WCEB-02-07-009
4. Remove screws (11) (4 used) from boot (10). 10

Raise boot (10) from bracket (8).
8
11
W1JB-02-07-002
5. Remove screw (12) from cover (1). Remove

covers (1, 3) from bracket (8).
12 10
W1JB-02-07-016
W2-8-4
WCEB-02-08-004
13
7. Remove socket bolts (18) (2 used) from lever (14). 14 15

Remove lever (14) from electric lever (17).
: 6 mm

bracket (8).
16
: 17 mm
WCEB-02-08-003
18 17 8
9. Remove sems bolts (19) (2 used) from electric

lever (17). Remove electric lever (17) from bracket
(15). 19
: 17 mm
15
17
WCEB-02-08-004
W2-8-5
Installation of Blade/Outrigger Electric Lever
1. Install electric lever (17) to bracket (15) with sems 19

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
15
17
WCEB-02-08-004
13
3. Install the bracket (15) assembly to bracket (8) 14 15

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
4. Install lever (14) to electric lever (17) with socket

: 6 mm 16
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
WCEB-02-08-003
18 17 8
5. Install covers (1, 3) to bracket (8) with screw (12). 12 10
3
1
6. Install boot (10) to bracket (8) with screws (11) (4 W1JB-02-07-016
used). 10
11
W1JB-02-07-002
W2-8-6
7. Install cover (1) to bracket (8) with screw (9).
1 WCEB-02-07-009
8. Install cover (3) to bracket (8) with sems bolt (6).

: 10 mm
: 3.3 to 4.2 N⋅m 2
3
(0.3 to 0.4 kgf⋅m, 2.4 to 3 lbf⋅ft)
9. Install cover (2) to bracket (8) with screws (5, 7) (2

used for each). 4, 5
10. Install caps (4) (2 used) to cover (2).
8 7 6 WCEB-02-07-006
W2-8-7
DISASSEMBLY OF ELECTRIC LEVER
10
8 11
7
12
6
5 13
14
15
16
17
4 18
3
2
1
19
20
W1MG-02-07-003
1- Screw (2 Used) 6- Bushing (2 Used) 11 - Cam 16 - Bushing (2 Used)

2- Plate 7- Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used)
3- Screw (2 Used) 8- Arm 13 - Holder 18 - Housing
4- Potentiometer 9- Boot 14 - O-Ring (2 Used) 19 - Clip
5- Pin 10 - Set Screw 15 - Bushing (2 Used) 20 - Screw
W2-8-8
Disassembly of Electric Lever
IMPORTANT: Housing (18) is made of aluminum. IMPORTANT: Keep the disassembled parts
As too strong a force may deform or carefully in order to install them to
damage it, handle it with care. their original ports.
1. Secure housing (18) in a vise. 10. Remove the pusher (16) assemblies (2 used) and
springs (17) (2 used) from housing (18).
2. Remove screws (1) (2 used) from plate (2).
Remove plate (2) from housing (18). IMPORTANT: Do not damage bushing (15).
3. Remove screws (20) from clip (19). Remove clip 11. Remove pushers (16) (2 used) and O-rings (14) (2
(19) from housing (18). used) from bushings (15) (2 used).
4. Remove screws (3) (2 used) from potentiometer IMPORTANT: Bushing (6) cannot be reused.
(4). Remove potentiometer (4) from housing (18).
12. Remove bushings (6) (2 used) from holder (13).
5. Remove boot (9) from holder (13).
6. Remove set screw (10) from cam (11).

: 2.5 mm
7. Remove pin (5) from holder (13). Remove cam

(11) from holder (13).
8. Remove screw (7) from arm (8). Remove arm (8)

from cam (11).
IMPORTANT: The pusher (16) assembly may fly

out by spring (17).
9. Remove socket bolts (12) (2 used) from holder

(13). Remove holder (13) from housing (18).
: 5 mm
W2-8-9
ASSEMBLY OF ELECTRIC LEVER
7 8 9
11
5, 6
16
14
12
15
3 13
17
4
18
T1MG-03-09-008
20 19
1- *Screw (2 Used) 6- Bushing (2 Used) 11 - Cam 16 - Pusher (2 Used)

2- *Plate 7- Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used)
3- Screw (2 Used) 8- Arm 13 - Holder 18 - Housing
4- Potentiometer 9- Boot 14 - O-Ring (2 Used) 19 - Clip
5- Pin 10 - *Set Screw 15 - Bushing (2 Used) 20 - Screw
NOTE: As for the item with mark*, refer to W2-7-8.
W2-8-10
Assembly of Electric Lever
1. Apply grease onto O-rings (14) (2 used). 13. Install pin (5) to holder (13). Secure pin (5) to cam
(11) with screw (10).
2. Install O-rings (14) (2 used) to bushings (15) (2 : 2.5 mm
used). : 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
3. Apply grease onto the inner surface of bushings 14. Apply grease to the gap between arm (8) and the
(15) (2 used). link part of potentiometer (4).
4. Install pushers (16) (2 used) to bushings (15) (2 15. Apply LOCTITE #262 onto screws (3) (2 used).
used).
IMPORTANT: Adjust the gap between arm (8) and
5. Install springs (17) (2 used) and the pusher (16) the link of potentiometer (4) to 0.4
assemblies (2 used) to housing (18). mm on one side.
6. Install bushings (6) (2 used) to holder (13). 16. Install potentiometer (4) to housing (18) with
7. Install holder (13) to housing (18) with socket bolts : 1.0 N⋅m (0.1 kgf⋅m, 0.7 lbf⋅ft)
(12) (2 used).
: 5 mm 17. Secure the harness of potentiometer (4) with clip
: 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft) (19).
8. Apply grease onto the end of pushers (16) (2 18. Apply LOCTITE #262 onto screw (20).
used).
19. Install clip (19) to housing (18) with screw (20).
9. Install arm (8) to cam (11) with screw (7). : 0.8 N⋅m (0.1 kgf⋅m, 0.6 lbf⋅ft)
: 3 N⋅m (0.3 kgf⋅m, 2 lbf⋅ft)
20. Apply THREEBOND #1104 onto the mating
10. Apply grease onto the mounting surfaces of holder surfaces of housing (18) and plate (2).
(13) and cam (11).
21. Install plate (2) to housing (18) with screws (1) (2
11. Install cam (11) to holder (13). used).
12. Apply LOCTITE #262 onto screw (10). 22. Install boot (9) to holder (13).
W2-8-11
(Blank)
W2-8-12
UPPERSTRUCTURE / Signal Control Valve
SIGNAL CONTROL VALVE

Removal
WCEB-02-05-002
3
Remove cover (4) from cover (2), supports (5) (2 4
2
used) and bracket (6).
: 17 mm
3
WCEB-02-05-001
5
WCEB-02-05-003
WCEB-02-05-004
W2-9-1
: 17 mm
2
7
kg (60 lb)
8
4. Attach a nylon sling onto cover (2). Hoist and hold
cover (2). Remove sems bolts (9) (2 used) from
cover (2). Remove the cover (2) assembly from
main frame (10).
: 17 mm
WCEB-02-05-006
10 9
11 12
5. Disconnect hoses (11) (32 used) from signal

control valve (12). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm 11
13 12 WCEB-02-09-001
6. Disconnect connectors (13) (2 used) from signal

control valve (12).
WCEB-02-05-005
12
7. Remove socket bolts (14) (4 used) from signal
control valve (12). Remove signal control valve
: 8 mm
14
15
WCEB-02-09-001
W2-9-2
Installation 11 12
1. Install signal control valve (12) to bracket (15) with
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
11
2. Connect hoses (11) (32 used) to signal control
valve (12).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
14
15
WCEB-02-09-001
13 12
3. Connect connectors (13) (2 used) to signal control
valve (12).
WCEB-02-05-005
CAUTION: The cover (2) assembly weight: 27 2

kg (60 lb) 7
4. Attach a nylon sling onto the cover (2) assembly.

Hoist and align the cover (2) assembly with the
mounting holes on main frame (10). 8

(9) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-05-006
10 9
5
6. Install cover (2) to support (5) and cover (7) with

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-05-003
W2-9-3
7. Install covers (2, 4) to supports (5) (2 used) and
3
bracket (6) with sems bolts (3) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 4
2
WCEB-02-05-001
WCEB-02-05-003
WCEB-02-05-004
8. Shut cover (1).
WCEB-02-05-002
W2-9-4
(Blank)
W2-9-5
STRUCTURE OF SIGNAL CONTROL VALVE
4 13
12
11
7
4
10
9
7 8
7 7
4
4
W1JB-02-10-002
W2-9-6
15
14 16
17
18
19
16 20
17
21
19
16 20
17
18
19
20
14
22
23
24
25
26
27
19
28
17
16
20 29
19
18 14
5 17
20 16
19
21
17
20 16
19
18
17
16 W1JB-02-10-003
Detail of Body 2 (5)
1- Bolt (3 Used) 9- Body 3 17 - O-Ring (7 Used) 25 - O-Ring

2- Body 1 10 - Gasket 18 - Spring (4 Used) 26 - Spring
3- Gasket 11 - Body 4 19 - Spring Guide (7 Used) 27 - Spool
4- Filter (17 Used) 12 - Gasket 20 - Spool (6 Used) 28 - Spring
5- Body 2 13 - Body 5 21 - Spring (2 Used) 29 - Plate
6- Gasket 14 - Socket Bolt (11 Used) 22 - Plate
7- Shuttle Valve (2 Used) 15 - Plate 23 - O-Ring
8- Spring (4 Used) 16 - Plug (7 Used) 24 - Shuttle Valve
W2-9-7
(Blank)
W2-9-8
UPPERSTRUCTURE / Shockless Valve
SHOCKLESS VALVE

Removal of Swing Shockless Valve
1. Open side cover (1).
WCEB-02-05-002

2
: 17 mm
4 WCEB-02-05-007
3. Disconnect hoses (5) (10 used) from swing

shockless valve (6). Cap the open ends. Attach an 5 6
assembling.
: 19 mm

Remove swing shockless valve (6) from bracket
(8). 5
: 17 mm
8 7 WCEB-02-10-002
W2-10-1
Installation of Swing Shockless Valve
5 6
1. Install swing shockless valve (6) to bracket (8)
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (5) (10 used) to swing shockless 5

valve (6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
8 7 WCEB-02-10-002

(3) (4 used).
: 17 mm 3
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
4 WCEB-02-05-007
4. Shut side cover (1).
WCEB-02-05-002
W2-10-2
Removal of Travel Shockless Valve
1 2
: 17 mm 3
WCEB-02-13-001
2. Disconnect connector (4) from pressure sensor 4 5 6 7

(5).
3. Disconnect connectors (6) (2 used).
4. Disconnect hoses (7) (6 used) from travel

shockless valve (8). Cap the open ends. Attach an
assembling.
: 19 mm
8
WCEB-02-10-003
7
10 9
Remove the travel shockless valve (8) assembly
from main frame (3).
: 17 mm
10
Remove travel shockless valve (8) from bracket
(9). 3
: 17 mm
8, 11
WCEB-02-10-003
W2-10-3
Installation of Travel Shockless Valve
10 9
1. Install travel shockless valve (8) to bracket (9) with
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
10
2. Install the bracket (9) assembly to main frame (3)
: 17 mm 3
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
8, 11
WCEB-02-10-003
3. Connect hoses (7) (6 used) to travel shockless 4 5 6 7

valve (8).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
4. Connect connector (4) to pressure sensor (5).
5. Connect connectors (6) (2 used).
WCEB-02-10-003
7
1 2
(1) (6 used).
: 17 mm 3
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-13-001
W2-10-4
(Blank)
W2-10-5
STRUCTURE OF SWING SHOCKLESS VALVE
Section D 1 2
B D
Section B
18 A
17
3
16
15
Orifice
4
14 5
C C
13 6
7
12
8
11 Section C 9
10
Section A
Orifice WCEB-02-10-001
W2-10-6
Tightening Torque
Part Name Q’ ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft)
1 Check Valve 1
2 Retaining Ring 1
3 Body 1
4 Steel Ball 2
5 O-Ring 2
6 Plug 2
7 Spring 2
8 O-Ring 2
9 Plug 2 9.8 (1) (7)
10 Plug 2 8.8 (0.9) (6)
11 Plug 2 48.5 (4.9) (36)
12 O-Ring 2
13 Spring 2
14 Plunger 2
15 Ring 2
16 Spring 2
17 O-Ring 2
18 Plug 2 48.5 (4.9) (36)
W2-10-7
STRUCTURE OF TRAVEL SHOCKLESS
VALVE
13
1
14
4
4
T1F3-03-08-004
T1F3-03-08-005
5
Section A
7
T1F3-03-08-006
8 9 10 11 12
Section B
W2-10-8
Tightening Torque
Part Name Q’ ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid 2
2 O-Ring 2 1B P14
3 Spool 2
4 Body 1
5 Spring 2
6 Plug 6
7 Orifice 2 1.6 to 2.0 (0.16 to 0.2) (1.2 to 1.5)
8 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13)
9 Steel Ball 2 9/32
10 Spring 2
11 O-Ring 4 1B P8
12 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13)
13 Nut 2 : 19 mm 4.9 (0.5) (3.6)
14 Tube 2 30 to 37 (3 to 4) (22 to 27)
W2-10-9
(Blank)
W2-10-10
UPPERSTRUCTURE / Solenoid Valve
3-SPOOL SOLENOID VALVE UNIT
CAUTION: Bleed air from hydraulic oil tank

before doing any work. (Refer to BLEED AIR
FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal 1
1. Open cover (1).
WCEB-02-05-002

Remove cover (4) from cover (2), supports (5) (2 3
used) and bracket (6).
: 17 mm
2
4
WCEB-02-05-001
WCEB-02-05-003
WCEB-02-05-004
W2-11-1
7 8
4. Disconnect hoses (8) (14 used) from 3-spool

solenoid valve unit (9). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 19 mm, 22 mm 9
5. Disconnect pipings (7) (3 used) from 3-spool

10, 11
solenoid valve unit (9).
: 19 mm
12
6. Remove socket bolts (10) (2 used) and washers
(11) (2 used) from 3-spool solenoid valve unit (9).
Remove 3-spool solenoid valve unit (9) from WCEB-02-11-012
13
control valve (12).
: 8 mm
Installation 7 8
1. Install 3-spool solenoid valve unit (9) to control
valve (12) with socket bolts (10) (2 used) and
washers (11) (2 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2. Connect pipings (7) (3 used) to 3-spool solenoid 9

valve unit (9).
: 19 mm 10, 11
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
12
3. Connect hoses (8) (14 used) to 3-spool solenoid
valve unit (9).
: 19 mm
WCEB-02-11-012
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 13
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
4. Connect connectors (13) (3 used).
W2-11-2
5. Install covers (2, 4) to supports (5) (2 used) and
3
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 2 4
WCEB-02-05-001
5
WCEB-02-05-003
WCEB-02-05-004
6. Shut cover (1).
WCEB-02-05-002
W2-11-3
(Blank)
W2-11-4
STRUCTURE OF 3-SPOOL SOLENOID VALVE UNIT
WCEB-02-11-008
WCEB-02-11-009
Filter Plug
Plug Filter
WCEB-02-11-011
View A Section B
WCEB-02-11-010
W2-11-5
DISASSEMBLY AND ASSEMBLY OF 3-SPOOL SOLENOID VALVE UNIT
1
2
3
4
5
7
8
9
12
13 14
10 15
11 16
17
18
19
W18G-02-08-012
4 2 3, 5 6 1 8 12 13 17 10 18
19
W18G-02-08-013
7 9 14 15 16 11
1- Socket Bolt (4 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Bolt 9- Diaphragm 14 - O-Ring 19 - Wave Spring
5- Spring 10 - Spool 15 - O-Ring
W2-11-6
Disassembly of 3-Spool Solenoid Valve Unit Assembly of 3-Spool Solenoid Valve Unit
IMPORTANT: Do not lose spring (7) in the hole of 1. Install wave spring (19) and plate (18) to the
solenoid (6) when removing housing.
solenoid (6).
Do not disassemble pressure IMPORTANT: When inserting sleeve (17) into the
adjusting lock nut (2) and adjusting housing, align the hole on sleeve
bolt (4). (17) with that on the housing.
1. Remove socket bolts (1) (2 used) from solenoid 2. Install O-rings (14, 15, 16) to sleeve (17). Insert
(6). Remove solenoid (6) and O-ring (8) from the sleeve (17) into the housing.
housing.
: 4 mm IMPORTANT: When inserting spool (10) into
sleeve (17), do not damage the edge
IMPORTANT: Do not remove orifice (11) from on sleeve (17).
spool (10). After inserting spool (10), try to push
it about 3 to 5 mm (0.1 to 0.2 in) by
2. Remove spool (10) from sleeve (17). Remove fingers. Check if spool (10) moves
diaphragm (9), washer (12) and spring (13) from smoothly.
spool (10).
3. Install diaphragm (9), washer (12) and spring (13)
3. Remove sleeve (17) from the housing. Remove to spool (10). Insert spool (10) into sleeve (17).
plate (18) and wave spring (19) from the housing
by using a magnet. IMPORTANT: When installing solenoid (6), prevent
spring (7) from falling off.
4. Remove O-rings (14, 15, 16) from sleeve (17).
4. Install spring (7) to solenoid (6). Install solenoid
(6) to the housing with socket bolts (1) (2 used).
: 4 mm
: 5+2−0 N⋅m (0.5+0.2−0 kgf⋅m, 4+1.5−0 lbf⋅ft)
W2-11-7
SOLENOID VALVE UNIT (FOR ELECTRIC
LEVER OPERATION)

1
Removal
1. Open cover (1).
WCEB-02-01-005
2. Disconnect connector (6) from washer tank (2).

2 3
3. Disconnect vinyl hose (7) from washer tank (2).
Cap the open ends.
4. Remove sems bolts (5) (4 used) from cover (4). 4

Remove cover (4) from cover (3).
: 17 mm
5
WCEB-02-11-001
7 6
5. Disconnect connector (9) from ECM (Engine

Controller) (8).
WCEB-02-11-003
9
W2-11-8
6. Remove sems bolts (10) (4 used) from cover (3). 10 3
Remove the cover (3) assembly from bracket
(11).
: 17 mm
WCEB-02-11-001
11 10
12
7. Disconnect connectors (12) (5 used) from
solenoid valve unit (13). 13
8. Disconnect hoses (14) (9 used) from solenoid

valve unit (13). Cap the open ends. Attach an
14
assembling.
: 19 mm
NOTE: The number of solenoid valve units, the
connectors and the hoses differ depending
on the front attachment specifications.
WCEB-02-11-004
12
9. Remove bolts (16) (4 used) and washers (17) (4 13

used) from bracket (15). Remove solenoid valve
unit (13) from bracket (15).
: 17 mm
16, 17 15 WCEB-02-11-004
W2-11-9
12
Installation
1. Install solenoid valve unit (13) to bracket (15) with
13
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (14) (9 used) to solenoid valve 14

unit (13).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
3. Connect connectors (12) (5 used) to solenoid

valve unit (13).
16, 17 15 12
WCEB-02-11-004
4. Install the cover (3) assembly to bracket (11) with

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
10 2 3
5. Connect connector (6) and vinyl hose (7) to
washer tank (2).
WCEB-02-11-001
11 7 6
6. Connect connector (9) to ECM (Engine

Controller) (8).
8
WCEB-02-11-003
9
W2-11-10
7. Install cover (4) to cover (3) with sems bolts (5) (4 3
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
4
WCEB-02-11-001
1
8. Shut cover (1).
WCEB-02-01-005
W2-11-11
STRUCTURE OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION)
2 3 4 5 6 7
A A
A A
A A
WCEB-02-11-006
Section A WCEB-02-11-007

1 Solenoid Valve Assembly 1
4 Socket Bolt 4 :6 19.5+5−0 (2+0.5−0) (14+4−0)
5 Washer 4
6 End Plate 1
7 Socket Bolt 18 4.9+5−0 (0.5+0.5−0) (4+4−0)
8 Lock Nut 8 4.9+5−0 (0.5+0.5−0) (4+4−0)
W2-11-12
1-SPOOL SOLENOID VALVE UNIT
CAUTION: Bleed air from hydraulic oil tank

before doing any work. (Refer to BLEED AIR
FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
1. Open cover (1).
WCEB-02-05-002

Remove cover (2) from main frame (3). 2 3
: 17 mm
WCEB-02-05-007

5 3
4. Disconnect hoses (6) (3 used) from 1-spool
solenoid valve unit (7). Cap the open ends. 6
: 17 mm
9
5. Remove sems bolts (8) (2 used) from 1-spool 7
solenoid valve unit (7). Remove 1-spool solenoid
valve unit (7) and clip (9) from main frame (3).
: 13 mm
8 6 WCEB-02-11-002
W2-11-13
Installation
5 3
1. Install 1-spool solenoid valve unit (7) and clip (9)
to main frame (3) with sems bolts (8) (2 used). 6
: 13 mm
9
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
7
2. Connect hoses (6) (3 used) to 1-spool solenoid
valve unit (7).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
8 6 WCEB-02-11-002
4. Install cover (2) to main frame (3) with sems bolts 2 3

(4) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 4
WCEB-02-05-007
5. Shut cover (1).
WCEB-02-05-002
W2-11-14
STRUCTURE OF 1-SPOOL SOLENOID VALVE UNIT
WCEB-02-11-005

(mm) N⋅m (kgf⋅m)
1 Solenoid 1
2 Socket Bolt 2 4.9 to 5.9 (0.5 to 0.6) (3.6 to 4.4)
3 O-Ring 1
4 Spool 1
5 Spring 1
6 Housing 1
7 O-Ring 1
8 Plug 1 13.2 to 17.6 (1.3 to 1.8) (9.8 to 13)
W2-11-15
(Blank)
W2-11-16
UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
REMOVAL AND INSTALLATION OF PILOT
SHUT-OFF SOLENOID VALVE

AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 1 2
Removal 3
: 17 mm
WCEB-02-13-001
2. Disconnect hoses (4) (9 used) from pilot shut-off

solenoid valve (5). Cap the open ends. Attach an 4 3 5 6
7
assembling.
: 17 mm, 19 mm
3. Disconnect connector (8). 8

Remove the bracket (7) assembly from main
frame (3).
: 17 mm
WCEB-02-12-001
5 7, 9
Remove bracket (7) from pilot shut-off solenoid
valve (5).
: 17 mm
WCEB-02-12-001
W2-12-1
3 5 7, 9
Installation 6
1. Install bracket (7) to pilot shut-off solenoid valve
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-12-001
3. Connect hoses (4) (9 used) to pilot shut-off

4 5
solenoid valve (5).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
8
WCEB-02-12-001
1 2
(1) (6 used). 3
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-13-001
W2-12-2
STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE
W1JB-02-08-001
3 4 5 6 7 8
W1JB-02-08-002

Item Part Name Q’ty Remarks
1 Plug 1 : 6 26.5 (2.7) (20)
2 O-Ring 1
3 Spring 1
4 Spool 1
5 Filter 1
6 Body 1
7 O-Ring 1
8 Solenoid 1
9 Socket Bolt 2 : 4 3.92 (0.4) (3)
W2-12-3
(Blank)
W2-12-4
UPPERSTRUCTURE / Steering Valve
STEERING VALVE

AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 2 3
Removal
1. Open door (4) and upper front glass (2).
2. Remove lower front glass (1) from cab (3).
WCEB-02-01-004

Remove pedal (7) from bracket (8). WCEB-02-01-003
: 13 mm
8 WCEB-02-08-001
W2-13-1
5. Remove caps (10) (5 used) from cover (9).
Remove screws (11) (5 used) from cover (9). 10, 11
Remove cover (9) from stand (15).
6. Remove caps (13) (3 used) from cover (12). 12, 13, 14

Remove screws (14) (5 used) from cover (12).
9
15
WCEB-02-13-002
7. Remove screws (17) (4 used) from cover (16).

16
15 17 WCEB-02-13-003
8. Remove sems bolts (18) (6 used) from cover (19). 18 19 18

: 19 mm 20
WCEB-02-13-001
9. Disconnect hoses (22) (5 used) from steering 21

valve (21). Cap the open ends. Attach an
assembling.
: 22 mm, 27 mm 22
WCEB-02-13-006
W2-13-2
10. Remove sems bolts (23) (4 used) from stand (15).
Remove the steering valve (21) assembly from
stand (15).
: 17 mm
23
15
WCEB-02-13-004
21
WCEB-02-13-006
24
11. Remove socket bolts (24) (2 used) from priority

valve (25). Remove priority valve (25) and O-rings 25, 26
(26) (5 used) from steering valve (21).
21
WCEB-02-13-005
W2-13-3
Installation 24
1. Install priority valve (25) to steering valve (21) with
O-rings (26) (5 used) and socket bolts (24) (2
used). 25, 26
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
21
WCEB-02-13-005
2. Install the steering valve (21) assembly to stand

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
23
15
WCEB-02-13-004
3. Connect hoses (22) (5 used) to steering valve 21

(21).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm 22
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
WCEB-02-13-006
18 19 18
4. Install cover (19) to main frame (20) with sems
bolts (18) (6 used). 20
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-13-001
W2-13-4
5. Install cover (16) to stand (15) with screws (17) (4
used).
16
15 17 WCEB-02-13-003
10, 11
used). Install caps (10) (5 used) to cover (9).
15
WCEB-02-13-002

used). Install caps (13) (3 used) to cover (12).
12, 13, 14
15
WCEB-02-13-002
6
8. Install pedal (7) to bracket (8) with sems bolts (6)
(2 used).
: 13 mm
7
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
8 WCEB-02-08-001
W2-13-5
3
WCEB-02-01-003
2 3
10. Install lower front glass (1) to cab (3).
11. Shut upper front glass (2) and door (4).
WCEB-02-01-004
W2-13-6
UPPERSTRUCTURE / Brake Valve
BRAKE VALVE

Removal
1. Remove mat (1) from the inside of cab (2). 1
WCEB-02-01-003
3 4 5
: 17 mm
WCEB-02-13-001
6, 7 8 9
10
4. Remove socket bolts (7) (2 used) from bracket (6).

Remove the bracket (6) assembly from bracket
(8).
: 6 mm
5. Disconnect hoses (9) (6 used) from brake valve

tag onto the disconnected hoses for assembling. 11 WCEB-02-14-005
: 17 mm, 22 mm, 27 mm
12 10 13
6. Remove rubber (14) from brake pedal (15).
7. Remove sems bolts (12) (4 used) from plate (13).

Remove the brake valve (10) assembly from plate
(13).
: 17 mm
14, 15 12
WCEB-02-14-006
W2-14-1
Installation 12 10 13
1. Align the brake valve (10) assembly with the
mounting hole on plate (13). Install the brake valve
(10) assembly to plate (13) with sems bolts (12) (4
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2. Install rubber (14) to brake pedal (15).
14, 15 12
WCEB-02-14-006
6, 7 8 9
3. Connect hoses (9) (6 used) to brake valve (10). 10
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m,58 lbf⋅ft)
4. Install the bracket (6) assembly to bracket (8) with

: 6 mm 11 WCEB-02-14-005
: 58.8 to 73.5 N⋅m

(6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)
3 4 5

(3) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-13-001

1
WCEB-02-01-003
W2-14-2
(Blank)
W2-14-3
DISASSEMBLY OF BRAKE VALVE
1
11
29 3
28
8
5 7
4
6 10
27
9
12
13
14
15
16
26
25
17
3
3
30 24 16
31
32 23
33 22
34 18
43
35
36
42 37 19
41
38
20
44 40 21
45
46
47 29
48
39
44
45
46
47
49
WCEB-02-14-004
48
W2-14-4
1- Rubber 14 - Bushing 26 - Bracket 38 - Push Rod

2- Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder
3- Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder
4- Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32)
5- Bushing 18 - Roller Assembly 30 - Rod 42 - Plug
6- Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used)
7- Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used)
8- Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used)
9- Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)
10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used)
11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used)
12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring
13 - Spring Pin
W2-14-5
11
29 3
28
4 5 7 8
6 10
27
9
12
13
14
15
16
26
25
17
3
3
30 24 16
31
32 23
33 22
34 18
43
35
36
42 37 19
41
38
20
44 40 21
45
46
47 29
48
39
44
45
46
47
49
WCEB-02-14-004
48
W2-14-6
Disassembly of Brake Valve IMPORTANT: The spool (48) assembly is also used
inside cylinder (39). Keep them in
IMPORTANT: Put the matching marks onto order not to confuse.
bracket (26), flange (28), cylinder 9. Remove plug (42), spring (44) and the spool (48)
(39) and cylinder (40) before disas- assembly from cylinder (40).
sembling.
1. Secure the brake valve in a vise with the cylinder 10. Remove plunger (47), retaining ring (45) and re-
(40) side facing downward. tainer (46) from the spool (48) assembly.
2. Remove socket bolts (21) (2 used) from bracket IMPORTANT: The reaction force of spring (44) acts
(19). Remove bracket (19) and brake switch (20) on socket bolt (43). While holding
from bracket (26). cylinder (40), slowly remove socket
: 6 mm bolt (43).
11. Remove socket bolts (43) (4 used) from cylinder
3. Remove split pins (3) (3 used) from pins (8, 10 (40).
and 16) except the roller assembly (18) part.
Remove pins (8, 10 and 16) from bracket (26) and 12. Remove cylinder (40) and the cylinder (39) as-
link (17). sembly from flange (28).
4. Remove spring pin (13) from yoke (15). Remove 13. Remove the spool (48) assembly from cylinder
pin (12) from yoke (15). (39).
5. Remove split pin (3) from pin (16). Remove pin 14. Remove plunger (47), spring (44), retaining ring
(16) and the roller (18) assembly from link (17). (45) and retainer (46) from the spool (48) assem-
bly.
6. Remove seat (22), stopper (23) and boot (24)
from flange (28). 15. Remove return spring (31), holder (32), rod (30),
balance spring (34), spring (33), retainers (35, 36),
7. Remove socket bolts (25) (4 used) from bracket pilot piston (37) and push rod (38) from flange
(26). Remove bracket (26) from flange (28). (28).
8. Secure the flange (28) part in a vise with the push 16. Remove oil seal (27) from flange (28).
rod (38) side facing downward.
17. Remove O-rings (29) (2 used) from flange (28)
and cylinder (39).
W2-14-7
ASSEMBLY OF BRAKE VALVE
1
12
2
11
8
15
14 26 28 39 43 40
16
10
A 42
21
17
19
16
18
20
22 23 31 30 29 48 49 47 45 46 44 WCEB-02-14-001
22 24 25
42
47
41
WCEB-02-14-002
38 27 37 36 35 33 34 32 46 29 48 45
13 5
12
7
15
3 8
9
26
17
10
21
3
16
3 18
19
View A WCEB-02-14-003
W2-14-8
1- Rubber 14 - Bushing 26 - Bracket 38 - Push Rod

2- Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder
3- Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder
4- * Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32)
5- Bushing 18 - Roller Assembly 30 - Rod 42 - Plug
6- * Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used)
7- Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used)
8- Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used)
9- Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)
10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used)
11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used)
12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring
13 - Spring Pin
NOTE: As for the item with mark *, refer to W2-14-4.
W2-14-9
1
12
2
11
8
15
14 26 28 39 43 40
16
10
A 42
21
17
19
16
18
20
22 22 23 24 25 31 30 29 48 49 47 45 46 44 WCEB-02-14-001
42
47
41
WCEB-02-14-002
38 27 37 36 35 33 34 32 46 29 48 45
13 5
12
7
15
3 8
9
26
17
10
21
3
16
3 18
19
WCEB-02-14-003
View A
W2-14-10
Assembly of Brake Valve
1. Install oil seal (27) to flange (28). 10. Install spring (49), plunger (47) and spring (44) to
cylinder (39).
2. Secure flange (28) in a vise with the oil seal (27)
side facing downward. 11. Align the matching marks and place cylinder (40)
onto cylinder (39).
3. Install O-ring (29) to flange (28).
12. Install retainer (46) and retaining ring (45) to spool
4. Apply hydraulic oil onto rod (30), pilot piston (37), (48).
push rod (38), plungers (47) (2 used) and spools
(48) (2 used). 13. Install the spool (48) assembly to cylinder (40).
5. Install push rod (38), pilot piston (37), retainer (36), 14. Install plunger (47), spring (44) and plug (42) to
retainer (35), return spring (31), balance spring cylinder (40).
(34), spring (33), holder (32) and rod (30) to flange : 130 to 180 N⋅m
(28) in this order. (13 to 18 kgf⋅m, 96 to 133 lbf⋅ft)
6. Install O-ring (29) to cylinder (39). 15. Connect flange (28), cylinder (39) and cylinder
7. Align the matching marks and place cylinder (39) : 60 to 75 N⋅m
onto the flange (28) assembly. (6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)
8. Install retainer (46) and retaining ring (45) to spool

(48).
9. Install the spool (48) assembly to cylinder (39).
W2-14-11
1
12
2
11
8
15
26 28 40
16
10
A
21
17
19
16
18
20
22 23 WCEB-02-14-001
22 24 25
WCEB-02-14-002
13
12
15
3 8
26
17
10
21
3
16
3 18
19
View A WCEB-02-14-003
W2-14-12
16. Secure the cylinder assembly in a vise with the 26. Secure stopper bolt (4) to link (17) with lock nut
cylinder (40) side facing downward. (6).
: 6.0 to 10 N⋅m (0.6 to 1 kgf⋅m, 4 to 7 lbf⋅ft)
17. Install flange (28) to bracket (26) with socket bolts
(25) (4 used). 27. Install rubber (1) to brake pedal (2).
: 60 to 75 N⋅m (6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)
28. Install brake switch (20) to bracket (19). Install the
18. Install boot (24), stopper (23) and seat (22) to bracket (19) assembly to bracket (26) with socket
flange (28). bolts (21) (2 used).
: 6 mm
19. Apply grease onto all pin holes on brake pedal (2), : 58.8 to 73.5 N⋅m
bracket (26), yoke (15) and link (17). (6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)
20. Install yoke (15) to brake pedal (2) with pin (12)
and spring pin (13).
21. Install roller assembly (18) to link (17) with pin (16).
Secure pin (16) to link (17) with split pin (3).
22. Install the link (17) assembly to bracket (26) with

pin (10). Secure pin (10) to bracket (26) with split
pin (3).
23. Install boot (11) to the brake pedal (2) assembly.

Install brake pedal (2) to bracket (26) with pin (8).
Secure pin (8) to bracket (26) with split pin (3).
24. Install yoke (15) to link (17) with pin (16). Secure
pin (16) to link (17) with split pin (3).
25. Adjust play of link (17) to 0 mm with stopper bolt

(4).
W2-14-13
(Blank)
W2-14-14
UPPERSTRUCTURE / Accumulator Charge Valve
REMOVAL AND INSTALLATION OF AC-
CUMULATOR CHARGE VALVE

1 2 3
Removal
: 17 mm
WCEB-02-13-001
2. Disconnect hoses (4) (8 used) from accumulator

4 5, 6 7
charge valve (5). Cap the open ends. Attach an
assembling. 8
: 17 mm, 22 mm, 27 mm

Remove the bracket (8) assembly from main frame
(3).
: 17 mm

Remove accumulator charge valve (5) from 3 WCEB-02-15-001
bracket (8).
: 17 mm
W2-15-1
Installation
1. Install accumulator charge valve (5) to bracket (8)
with sems bolts (6) (4 used). 4 5, 6 7
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 8

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
3. Connect hoses (4) (8 used) to accumulator charge

valve (5).
: 17 mm 3 WCEB-02-15-001
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
1 2 3
(7) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-13-001
W2-15-2
(Blank)
W2-15-3
STRUCTURE OF ACCUMULATOR CHARGE VALVE
1, 2 3, 4 5, 6 1, 2
3, 4
5, 6
WCEB-02-15-002
8 8
9 9
10 10
11 11
1 6
Section A 2 Section B
18 19 20 5 6
26
15 16 17 21 22 23 24 6 9
14 5
27
13
25 28
12 29
37
36
WCEB-02-15-003
35 34 33 32 31 1 2 30 3 4
Section C
Section D
W2-15-4

No. Part Name Q’ty Remark
1 Plug 4 4.9 (0.5) (4)
2 O-Ring 4
3 Plug 3 26.5 (3) (20)
4 O-Ring 3
5 Plug 5 9.8 (1) (7)
6 O-Ring 5
7 Body 1
8 Plug 2 12 (1.2) (9)
9 O-Ring 3
10 Spring 2
11 Plunger 2
12 Plug 1 58.8 (6) (43)
13 Screw 1
14 Lock Nut 1
15 O-Ring 1
16 Spring 1
17 Needle Valve 1
18 O-Ring 1
19 Backup Ring 1
20 O-Ring 1
21 O-Ring 1
22 Backup Ring 1
23 Sleeve 1
24 Piston 1
25 Orifice 1 9.8 (1) (7)
26 Plug 1 12 (1.2) (9)
27 Spring 1
28 Plunger 1
29 Sleeve 1
30 Plunger 1
31 O-Ring 1
32 Washer 1
33 Spring 1
34 Spring 1
35 Plug 1 48.5 (5) (36)
36 O-Ring 1
37 Plug 1 48.5 (5) (36)
NOTE: Tools : 22 mm, 24 mm, 32 mm
: 1/8, 4 mm, 5 mm, 6 mm
W2-15-5
(Blank)
W2-15-6
MEMO
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SECTION 3
UNDERCARRIAGE
―CONTENTS―
Group 1 Swing Bearing Group 6 Axle Lock Cylinder
Removal and Installation of Removal and Installation of
Swing Bearing ......................................W3-1-1 Axle Lock Cylinder .............................. W3-6-1
Disassembly of Swing Bearing ................W3-1-4 Disassembly and Assembly of
Assembly of Swing Bearing.....................W3-1-6 Axle Lock Cylinder .............................. W3-6-4
Group 2 Travel Motor Group 7 Operate Check Valve

Removal and Installation of Removal and Installation of Operate Check
Travel Motor .........................................W3-2-1 Valve (for Axle Lock Cylinder) .................W3-7-1
Disassembly of Travel Motor...................W3-2-4 Structure of Operate Check Valve
Assembly of Travel Motor ..................... W3-2-12 (For Axle Lock Cylinder)..........................W3-7-2
Disassembly of Brake Valve.................. W3-2-20
Assembly of Brake Valve ...................... W3-2-22
Group 3 Center Joint Outrigger/BladeSolenoid Valve Unit......W3-8-1
Removal and Installation of Structure of Solenoid Valve Unit ...............W3-8-3
Cebter Joint ..........................................W3-3-1
Disassembly of Center Joint....................W3-3-6 Group 9 Transmission Changeover
Assembly of Center Joint ......................W3-3-8
Solenoid Valve
Removal and Installation of Transmission
Maintenance Standard ........................... W3-3-11
Changeover Solenoid Valve..................W3-9-1
Removal and Installation of Group 10 Propeller Shaft
Transmission.........................................W3-4-1 Removal and Installation of
Disassembly of Transmission ..................W3-4-6 Propeller Shaft.....................................W3-10-1
Assembly of Transmission..................... W3-4-18
Group 5 Axle
Removal and Installation of Axle .............W3-5-1
Disassembly of Front Axle .................... W3-5-10
Assembly of Front Axle......................... W3-5-20
Disassembly of Rear Axle ..................... W3-5-30
Assembly of Rear Axle ......................... W3-5-36
Disassembly of Differential ................... W3-5-44
Assembly of Differential........................ W3-5-50
CEBW-3-1
(Blank)
CEBW-3-2
UNDERCARRIAGE / Swing Bearing
SWING BEARING
Before removing and installing the swing bearing, the

upperstructure must be removed first. For removal
and installation of the upperstructure, refer to the
REMOVAL AND INSTALLATION OF MAIN FRAME on
W2-3-1.
The procedure starts on the premise that the upper- Matching Mark 1 2
structure has already been removed.
Removal
1. Put the matching marks on inner race (1) of the
swing bearing and track frame (2).
WCEB-03-01-001
2. Remove knock pin (3) from outer race (4) of the 3 4 5 1

swing bearing.
3. Remove bolts (5) (36 used) from inner race (1) of

the swing bearing.
: 24 mm
WCEB-03-01-001
CAUTION: Swing bearing weight: 157 kg

(350 lb)
2
4. Install special tools (ST 0050) (3 used) to the
swing bearing. Attach a wire rope onto special
tool. Hoist and remove the swing bearing from
track frame (2).
ST 0050
Swing Bearing
WCEB-03-01-002
W3-1-1
Installation
Clean the mounting surfaces of track frame (2) and
the swing bearing.
1. Apply THREEBOND #1102 onto the swing bear-

ing mounting surface of track frame (2).
2
Swing Bearing
WCEB-03-01-002
CAUTION: Swing bearing weight: 157 kg Machine

Front
(350 lb)
Position for
IMPORTANT: If the matching mark do not align, Grease Fitting
the soft zone position of the inner ”S” (Soft Zone)
Marking Position
race will be dislocated.
2. Hoist and align swing bearing with the mounting 6°
holes on track frame (2). Position for
Plug
0.2
10°
21°
Position for
Position for
Knock Pin
Grease Fitting
WCEB-03-01-003
3 4 5 1 2
3. Install inner race (1) of the swing bearing to track
fame (2) with bolts (5) (36 used).
: 24 mm
: 270 N⋅m (27 kgf⋅m, 200 lbf⋅ft)
4. Install knock pin (3) to outer race (4) of the swing

bearing.
WCEB-03-01-001
W3-1-2
5. After installing the swing bearing, add grease
Swing Bearing Grease Level Pinion
(Shell Alvania EP2 or equivalent) up to 19 mm
(0.75 in) height from the bottom of the grease
bath.
19 mm (0.75 in)
Grease Bath WCEB-03-01-004
W3-1-3
DISASSEMBLY OF SWING BEARING
1 2 3
9 7 6 5 W155-03-01-001
6
9
W105-03-01-011
1- Outer Race 4- Plug 6- Ball (99 Used) 8- Grease Fitting (2 Used)

2- Seal 5- Seal 7- Inner Race 9- Support (99 Used)
3- Pin
W3-1-4
Disassembly of Swing Bearing
1. Tap and remove pin (3) of plug (4) upward from CAUTION: Swing bearing weight: 157 kg
the bottom side. (350 lb)
NOTE: After installing pin (3), pin (3) was crimped. 3. Place inner race (7) of the swing bearing onto a
Grind off the crimped part. wooden block by using special tool (ST 0050).
Hoist and hold outer race (1) slightly.
3 4. Remove balls (6) (99 used) and supports (9) (99

used) from the plug hole while rotating outer race
(1).
Use magnet (A) when removing ball (6). Use wire
(B) and remove support (9).
4
1
2
A
W105-03-01-007 7
2. Remove plug (4) from outer race (1).

NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5 mm) of plug (4). Tap or pull the
bolt from the inner side. 6 5
W105-03-01-009
B
4
W105-03-01-010
W105-03-01-008 9
5. Separate outer race (1) from inner race (7).
6. Remove seals (2, 5) from outer race (1) and in-

ner race (7) respectively by using a scrapper.
W3-1-5
ASSEMBLY OF SWING BEARING
1 2 3
9 7 6 5 W155-03-01-001
6
9
W105-03-01-011
1- Outer Race 4- Plug 6- Ball (99 Used) 8- Grease Fitting (2 Used)

2- Seal 5- Seal 7- Inner Race 9- Support (99 Used)
3- Pin
W3-1-6
Assembly of Swing Bearing
IMPORTANT: Apply grease onto balls (6) (99 2. Tap and install plug (4) into outer race (1). Secure
used) and supports (9) (99 used) plug (4) to outer race (1) with pin (3). Crimp the
head of pin (3) by using a punch.
CAUTION: Swing bearing weight: 157 kg
(350 lb) 3
1. Hoist outer race (1) horizontally and align outer
race (1) with inner race (7) coaxially.
While rotating outer race (1), insert balls (6) and 1
supports (9) into the plug hole by using a round
bar.
2
W142-03-01-007
3. Install lifting tool (ST 0050) to outer race (1).

Hoist outer race (1). Thoroughly degrease the
slots for seals (2, 5). Apply THREEBOND #1745
to seal (2) and #1735 onto seal (5). Install seals
6
(2, 5) onto outer race (1) and inner race (7).
5 W142-03-01-005
4. Add grease 0.3 L (0.1 US gal.) (Alvania EP2

grease or equivalent) to the swing bearing
1 through grease fitting (8). At this time, rotate
outer race (1) and add grease.
W142-03-01-006
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Motor
TRAVEL MOTOR

Before removing and installing travel motor (7), the

propeller shaft must be removed first. For removal and
installation of the propeller shaft, refer to REMOVAL
AND INSTALLATION OF PROPELLER SHAFT on
W3-10-1.
Therefore, in this section, the procedure starts from the
premise that the propeller shaft has already been
removed.
Removal
2
IMPORTANT: Attach an identification tag onto the
disconnected hoses for assembling. 3
1. Disconnect hoses (1) (7 used) and connector (3) 1
from travel motor (2). Cap the disconnected
hoses.
: 19 mm, 22 mm, 27 mm 4
CAUTION: Travel motor (2) weight: 80 kg

(180 lb) WCGB-03-05-030
5
2. Loosen socket bolts (4) (4 used) of travel motor
(2). While holding the lower side of travel motor
(2) by using a forklift, remove socket bolts (4) (4
used).
: 14 mm
3. Remove travel motor (2) from transmission (5).
W3-2-1
Installation
2
CAUTION: Travel motor (2) weight: 80 kg
(180 lb)
3
1. Install travel motor (2) to transmission (5) with 1
: 14 mm
: 270 N·m (27.5 kgf·m, 200 lbf·ft) 4
2. Connect hoses (1) (7 used) and connector (3) to

travel motor (2).
: 19 mm WCGB-03-05-030
: 29.5 N·m (3 kgf·m, 22 lbf·ft) 5

: 22 mm
: 39 N·m (4 kgf·m, 29 lbf·ft)
: 27 mm
: 64 N·m (6.5 kgf·m, 47 lbf·ft)
: 12 mm
: 180 N·m (18 kgf·m, 133 lbf·ft)
3. Install the propeller shaft to transmission (5).

PROPELLER SHAFT on W3-10-1.)
IMPORTANT: After installing the travel motor (2),

fill hydraulic oil into the travel motor
(2). Perform break-in operation after
installing the travel motor (2) in order
to prevent the travel motor (2) and/or
travel reduction gear from seizuring.
Condition 1.Engine control dial: Slow idle
2.Travel speed mode switch: Slow
speed
3.Operation duration: Over 2 minutes
W3-2-2
(Blank)
W3-2-3
DISASSEMBLY OF TRAVEL MOTOR
47 1 2 3 4 5 6 7 8 9 10 11 12 13
46
45
44
14
43
42 15
41
40
39
16
37, 38
17
36
18
35
19
34
20
WCGB-03-02-004
33 32 31 30 29 28 27 26 25 24 23 22 21
A
48 37, 38 37, 38
View A
56
28, 53, 54
49 4, 55 49
52
50 50
51 WCGB-03-02-001
WCGB-03-02-002
51 8
W3-2-4
1- Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar

2- Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring
3- Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston
4- Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve
5- O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring
6- Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used)
7- Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used)
8- Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used)
9- Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)
10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used)
11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring
12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring
13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used)
14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)
W3-2-5
47 1 2 3 4 5
46
45
44
43
42
41
40
39
37, 38
36
35
20
WCGB-03-02-004
28
48 37, 38 37, 38
View A
56
28, 53, 54
49 4, 55 49
52
50 50
WCGB-03-02-001
WCGB-03-02-002
W3-2-6
Disassembly of Travel Motor
CAUTION: Travel motor weight: 80 kg (180 6. Remove the bushing (41) assembly, spring (39),
lb) collar (40) and spring (35) from head cover (36)
in this order.
1. Set the travel motor onto a wooden block
(100×500 mm, 3.9×19.7 in) with the drive shaft 7. Remove spring collar (43) and spring (42) from
(20) side facing downward. the bushing (41) assembly.
NOTE: When the workbench is used.
Workbench: ST 5092 8. Remove O-ring (5), O-rings (55) (4 used),
Upper Plate: ST 7333 adjusting screw (1), lock nut (2) and pin (3) from
solenoid valve (4).
2. Remove socket bolts (48) (2 used). Remove
brake valve (37) and O-rings (38) (2 used). 9. Remove retaining ring (44) from solenoid valve
: 5 mm (4). Remove the sleeve (46) assembly.
IMPORTANT: Do not disassemble relief valves 10. Remove control piston (45) from sleeve (46).
(49) (2 used). Remove retaining ring (47) from control piston
3. Remove relief valves (49) (2 used) and plugs (45).
(50) (2 used) from head cover (36).
: 27 mm, 32 mm 11. Remove socket bolts (52) (4 used). Remove
cover (28) and O-rings (53, 54) from head cover
4. Before removing, record the dimension of part A. (36).
: 6 mm
1 2
W1GL-03-02-006
5. Remove socket bolts (56) (4 used). Remove

solenoid valve (4) from head cover (36).
When removing solenoid valve (4), prevent
spring (39) from flying out.
: 6 mm
W3-2-7
6 7 8 9
14
15
16
36
20
WCGB-03-02-004
26 25 24 23 21
View A
51 WCGB-03-02-001
WCGB-03-02-002
51 8
W3-2-8
12. Before removing, record the dimensions of part B 16. Secure rotor (23), center shaft (21) and plungers
and part C. (9) (7 used) by using a screw bar (M8, Pitch 1.25
mm, Length 120 mm). Remove adjusting screw
B (25) from housing (8).
Screw Bar
23
Lock Nut
C Washer
9 21
26 25
9
7 6
8
W1GL-03-02-003
W1GL-03-02-005
13. Loosen lock nuts (7, 24). Remove adjusting 17. Remove retaining ring (16) and shim (15) from
screws (6, 25) from housing (8). housing (8).
14. Install adjusting screw (25) (M12, Pitch 1.75 mm, 18. Set the housing (8) assembly in a vise with the
Length 100 mm) to adjusting screw (6) mounting rotor (23) side facing downward. Remove the
part, so that the angle of center shaft (21) should drive shaft (20) assembly from housing (8).
be zero.
19. Remove oil seal (14) from housing (8).
25
W1GL-03-02-004
21
15. Put the matching marks on the contacting surface
of head cover (36) and housing (8). Remove
socket bolts (51) (8 used). Remove head cover
(36) from housing (8).
W3-2-9
36
34
WCGB-03-02-004
33 32 31 30 29 27
View A
WCGB-03-02-001
WCGB-03-02-002
W3-2-10
20. Set head cover (36) in a vise with the valve plate
(34) side facing upward.
21. Remove socket bolt (29) and piston (27) from

servo piston (31).
22. Remove rings (30) (2 used) from piston (27).
CAUTION: Warm up lock pin (32). Take care

not to burn yourself.
23. Warm up the mounting part of lock pin (32) by

using a torch.
NOTE: Adhesive has been applied onto lock pin
(32). Warm up the adhesive by using slow
fire.
24. Remove pin (33) from servo piston (31).
25. Remove servo piston (31) from head cover (36).
W3-2-11
ASSEMBLY OF TRAVEL MOTOR
47 1 2 3 4 5 6 7 8 9 10 11 12 13
46
45
44
14
43
42 15
41
40
39
16
37, 38
17
36
18
35
19
34
20
WCGB-03-02-004
33 32 31 30 29 28 27 26 25 24 23 22 21
A
48 37, 38 37, 38
View A
56
28, 53, 54
49 4, 55 49
52
50 50
51 WCGB-03-02-001
WCGB-03-02-002
51 8
W3-2-12
1 - Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar

2 - Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring
3 - Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston
4 - Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve
5 - O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring
6 - Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used)
7 - Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used)
8 - Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used)
9 - Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)
10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used)
11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring
12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring
13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used)
14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)
W3-2-13
47 1 2 3 4 5
46
45
44
43
42
41
40
39
36
35
34
WCGB-03-02-004
33 32 31 30 29 28 27
View A
56
28, 53, 54
4, 55
52
WCGB-03-02-001
WCGB-03-02-002
W3-2-14
Assembly of Travel Motor
1. Set head cover (36) in a vise with the valve plate 7. Install retaining rings (47, 44) to control piston
(34) side facing upward. (45) and sleeve (46).
2. Apply hydraulic oil onto servo piston (31). Insert 8. Apply hydraulic oil onto solenoid valve (4), control
servo piston (31) into head cover (36). Install pin piston (45) and sleeve (46).
(33).
9. Install O-ring (5) to solenoid valve (4).
3. Apply LOCTITE #241 onto lock pin (32). Insert
lock pin (32) into servo piston (31). Secure pin 10. Install control piston (45) to sleeve (46). Insert the
(33). sleeve (46) assembly and pin (3) into solenoid
valve (4).
4. Install rings (30) (2 used) to piston (27). Install
piston (27) to servo piston (31) with socket bolt 11. Install spring collar (43) and spring (42) to the
(29). solenoid valve (4) assembly.
5. Install O-rings (53, 45) and cover (28) to head 12. Install O-rings (55) (4 used) to the mounting
cover (36). Install cover (28) to head cover (36) surface of head cover (36) and solenoid valve (4).
: 6 mm 13. Install springs (35, 39), collar (40) and bushing
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) (41) to the large chamber side of head cover
(36).
6. Install adjusting screw (1) and lock nut (2) to
solenoid valve (4) with the dimension of part A 14. Install the solenoid valve (4) assembly to head
recorded before disassembling. cover (36) with socket bolts (56) (4 used).
1 2
W1GL-03-02-006
W3-2-15
6 7 8
14
15
16
36
20
WCGB-03-02-004
25 24 23 21
View A
51 WCGB-03-02-001
WCGB-03-02-002
51 8
W3-2-16
19. Temporarily install adjusting screw (25) (M12,
CAUTION: After warming up housing (8), Pitch 1.75 mm, Length 100 mm) to the adjusting
start the work. screw (6) mounting part, so that the angle of
center shaft (21) should be zero.
15. Warm up housing (8) to 50 to 80 °C (122 to
176 °F). Install the drive shaft (20) assembly to
housing (8). If the drive shaft (20) assembly
cannot be inserted, insert it by using a bar.
21
16. Face the rotor (23) side in housing (8) downward.
Install oil seal (14), shim (15) and retaining ring
25
(16) to housing (8).
17. Set the travel motor onto a wooden block

(100×500 mm, 3.9×19.7 in) with the drive shaft
(20) side facing downward. W1GL-03-02-008
NOTE: When the workbench is used.

Workbench: ST 5092 20. Align the matching marks. Install head cover (36)
Upper Plate: ST 7333 to housing (8) with socket bolts (51) (8 used).
18. Remove the screw bar, the lock nut and the 21. Remove temporarily installed adjusting screw
washer from rotor (23). (25) from housing (8).
22. Install adjusting screw (25), lock nut (24),

23 Screw Bar adjusting screw (6) and lock nut (7) to housing
Lock Nut (8) so that the dimensions of part B and part C
Washer
should be the same dimensions before
disassembling.
B
W1GL-03-02-003
25 24
8 7 6
W1GL-03-02-005
W3-2-17
37, 38
36
WCGB-03-02-004
48 37, 38 37, 38
View A
49 49
50 50
WCGB-03-02-001
WCGB-03-02-002
W3-2-18
23. Install relief valves (49) (2 used) and plugs (50)
(2 used) to head cover (36).
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)
24. Install brake valve (37) and O-rings (38) (2 used)

to head cover (36) with socket bolts (48) (2
used).
: 5mm
W3-2-19
DISASSEMBLY OF BRAKE VALVE
A
View A
B
Brake Valve
7
Brake Valve
5, 6
WCGB-03-02-001
WCGB-03-02-002
2 3 4 8 9
10
Section C
11
12
13
17 16 15 14
7
Section B
WCGB-03-02-005
1- Cover 6- Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used)

2- Socket Bolt (4 Used) 7- Plug 11 - Plug 15 - O-Ring
3- Valve Casing 8- O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve
4- Counterbalance Valve 9- Cover 13 - Check Valve 17 - Check Valve (2 Used)
5- Plug
W3-2-20
Disassembly of Brake Valve 7. Remove shuttle valve (16) from valve casing (3)
by using a socket wrench.
1. Remove socket bolts (2) (4 used). Remove cover : 4 mm
(1) and O-ring (8) from valve casing (3).
: 10 mm 8. Remove plug (5) from valve casing (3).
2. Remove socket bolts (10) (4 used). Remove 9. Remove orifice (6) from valve casing (3).
cover (9) and O-ring (8) from valve casing (3). : 3 mm
: 10 mm
IMPORTANT: When removing counterbalance

valve (4), remove counterbalance
valve (4) by turning in order to
prevent it from bounding.
3. Slowly remove counterbalance valve (4) from
valve casing (3) by turning.
CAUTION: When removing plug (11), prevent

spring (12) from flying out.
4. Remove plugs (11) (2 used), O-rings (14) (2

used), springs (12) (2 used) and check valve
(13).
: 36 mm
5. Remove check valve (17) from valve casing (3)

by using a socket wrench.
6. Remove plug (7) and O-ring (15) from valve

casing (3).
W3-2-21
ASSEMBLY OF BRAKE VALVE
A
View A
B Brake Valve
Brake Valve
5, 6
WCGB-03-02-001
WCGB-03-02-002
2 3 4 8 9
10
Section C
11
12
13
17 16 15 14
7
Section B
WCGB-03-02-005
1- Cover 6- Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used)

2- Socket Bolt (4 Used) 7- Plug 11 - Plug 15 - O-Ring
3- Valve Casing 8- O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve
4- Counterbalance Valve 9- Cover 13 - Check Valve 17 - Check Valve (2 Used)
5- Plug
W3-2-22
Assembly of Brake Valve
1. Install orifice (6) and plug (5) to valve casing (3).

: 3 mm
2. Install shuttle valve (16) and plug (7) to valve

casing (3).
3. Install check valves (17) (2 used) to valve casing

(3).
4. Install check valve (13) to check valve (17).
5. Install springs (12) (2 used) to plugs (11) (2 used).

Install the plug (11) assemblies (2 used) and
O-rings (14) (2 used) to valve casing (3).
: 36 mm
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)
IMPORTANT: Slowly insert counterbalance valve

(4) into valve casing (3) by turning.
Check if counterbalance valve (4)
moves smoothly.
6. Insert counterbalance valve (4) into valve casing
(3).
7. Install cover (1) and O-ring (8) to valve casing (3)

: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
8. Install cover (9) and O-ring (8) to valve casing (3)

: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
W3-2-23
(Blank)
W3-2-24
UNDERCARRIAGE / Center Joint
REMOVAL AND INSTALLATION OF CEN-
TER JOINT
Removal
NOTE: If disconnecting the hoses (5 used) for the
front attachment, the center joint can be 1
removed easily. The number of hoses dif-
fers depending on the front attachment
specifications. 2, 3
1. Disconnect connectors (4, 6).

4
2. Remove bolt (2) and washer (3) from clips (5) (2
used). Remove clips (5) (2 used) from center joint
(1). 5
: 10 mm
WCEB-03-03-002
6
7 8 9
4. Remove bolt (11) and washer (12) from clip (10).

Remove clip (10) from stopper (13). 10
: 17 mm
5. Remove sems bolts (8) (3 used) from slip ring (7).

11, 12
Remove the slip ring (7) assembly from stopper
(13). (Length: approx. 670 mm (26.4 in))
: 10 mm
13 WCEB-03-03-001
W3-3-1
14 15, 16
used) from stopper (13). Remove stopper (13)
from center joint (1).
: 24 mm
7. Disconnect hoses (14) (13 used) from center joint

(1). Cap the open ends. Attach an identification 14
: 19 mm, 22 mm, 27 mm, 36 mm
13
1 14 WCEB-03-03-001
17 1
8. Disconnect hoses (17) (22 used) from center joint
: 19 mm, 22 mm, 27 mm, 41 mm

the hole on bolt (15). Attach a nylon sling onto
17
eyebolts. Hoist and hold center joint (1).
CAUTION: The center joint (1) assembly

WCEB-03-03-002
IMPORTANT: The propeller shaft and the travel

transmission are located under cen-
ter joint (1). When hoisting and re-
moving center joint (1), do not hit
them.
used) from center joint (1). Hoist and remove the
center joint (1) assembly from track frame (18).
: 22 mm
18 19, 20 1 WCEB-03-03-002
W3-3-2
Installation
CAUTION: The center joint (1) assembly

IMPORTANT: The propeller shaft and the travel

transmission are located under the
center joint (1). Hoist center joint (1)
in order not to hit them.
1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to 17 1
center joint (1). Attach a nylon sling onto eyebolt.
Hoist and align center joint (1) with the mounting
hole on track frame (18).
2. Apply LOCTITE #262 onto bolts (19) (4 used). In-

stall center joint (1) to track frame (18) with bolts
(19) (4 used) and washers (20) (4 used). 17
: 22 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
3. Connect hoses (17) (22 used) to center joint (1).

: 19 mm
18 19, 20 1 WCEB-03-03-002
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
W3-3-3
4. Connect hoses (14) (13 used) to center joint (1).
14 15, 16
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 14
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
13
5. Apply LOCTITE #262 onto bolts (15) (5 used). In-
stall stopper (13) to center joint (1) with bolts (15)
(5 used) and washers (16) (5 used).
: 24 mm 1 WCEB-03-03-001
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
7 8 9
6. Install the slip ring (7) assembly to center joint (1).
Install slip ring (7) to stopper (13) with sems bolts
(8) (3 used).
: 10 mm 10
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft) 11, 12
7. Install clip (10) to stopper (13) with bolt (11) and

13
washer (12).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
1 WCEB-03-03-001
W3-3-4
9. Install clips (5) (2 used) to center joint (1) with bolt
(2) and washer (3).
: 10 mm
2, 3
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft)
4
10. Connect connectors (4, 6).
WCEB-03-03-002
1 6
W3-3-5
DISASSEMBLY OF CENTER JOINT
2
3
12 3
11
6
10 T1F3-03-10-001
9
8 7
1- Spindle 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate

2- O-Ring 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring
3- Bushing (2 Used) 7- O-Ring 10 - Cover
4- Body
W3-3-6
Disassembly of Center Joint
CAUTION: Body (4) weight: 39 kg (86 lb)
CAUTION: Center joint weight: 90 kg (198 lb) IMPORTANT: For easy removal, use the pins (2
used).
1. Remove bolts (6) (2 used) on cover (10) diago- Do not damage the seal groove by
nally. Install eyebolts (M10, Pitch 1.5 mm) (2 the pins.
used) to the hole for bolt (6). Attach a nylon sling 5. Remove oil seals (5) (15 used) from body (4).
onto eyebolt. Hoist and secure the center joint on
workbench (ST 5103).
: 17 mm
IMPORTANT: Put the matching marks on body (4)

and spindle (1).
2. Remove bolts (6) (4 used) from cover (10). Re-
move cover (10) and O-rings (7, 9) from body (4).
: 17 mm
3
3. Remove bolts (8) (4 used) from plate (11). Re-
move plate (11) from spindle (1). 4, 5
: 17 mm
IMPORTANT: Do not damage the seal sliding sur-

face of spindle (1). W105-03-03-015
4. Set the puller onto body (4). Remove body (4)
from spindle (1).
NOTE: There is a hole for the harness at the cen- 6. Remove bushings (3) (2 used) and O-rings (2, 12)
ter of spindle (1). Place a plate in order to from body (4).
cover the hole on spindle (1).
Puller
W202-03-03-011
W3-3-7
ASSEMBLY OF CENTER JOINT
2
3
12 3
11
6
10 T1F3-03-10-001
9
8 7
1- Spindle 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate

2- O-Ring 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring
3- Bushing (2 Used) 7- O-Ring 10 - Cover
4- Body
W3-3-8
Assembly of Center Joint 5. Install plate (11) to spindle (1) with bolts (8) (4
used).
: 17 mm
CAUTION: Body (4) weight: 39 kg (86 lb) : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
1. Install O-rings (2, 12) to body (4). 6. Install O-rings (7,9) to body (4) and spindle (1)
respectively.
NOTE: If removing bushing (3) from body (4), in-
7. Install cover (10) to body (4) with bolts (6) (6
stall bushing (3) first. (Refer to the following
used).
page.)
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Install oil seals (5) (15 used) to body (4).
IMPORTANT: After installing the seals, apply

grease onto the inner surface of
body (4), the inner surface of the
circuit and the seals.
CAUTION: Spindle (1) weight: 51 kg (112 lb)
3. Place spindle (1) onto a workbench. Install body

(4) to spindle (1) and align the matching marks
made when disassembling.
IMPORTANT: There is almost no clearance be-

tween body (4) and spindle (1). In-
sert body (4) along the axis straight
and slowly.
Install body (4) so that part A (the plate (11) mounting

part) is flat.
A 1
4
W800-03-03-002
4. Lightly tap body (4) by using a plastic hammer.

Insert body (4) until body (4) comes in contact
with the flange of spindle (1).
W3-3-9
When replacing body (4) with the new one, the fol-
lowing procedures are required.
1
Install bushings (3) (2 used) to body (4).
1. Clean body (4) and bushing (3).
4
2. Install bushing (3) to body (4) by using a press.
Pushing Force: 0.5 to 1.5 t (1100 to 3300 lb)
Pushing Tool (1): ST 7331
3
W105-03-03-029
W3-3-10
Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Seizure, abnormal wear Replace
3. Uneven wear within 180° Replace
Wear Area within
Half Range
Bushing
T157-01-01-040
Sliding surface with Heavily damaged one by seizure or foreign Replace

seals matter
1) Excessively worn one by seizure or for- Replace
Sliding surface between eign matter, or one having the score or
body and spindle other 0.1 mm (0.004 in) or more
than sliding surfaces 2) One having the score of less than 0.1 Replace the sur-
with seals mm (0.004 in) face smooth by
using an oil stone
Body Spindle
1) One that has worn 0.5 mm (0.02 in) or Replace
more, or excessively worn
2) One that has worn 0.5 mm (0.02 in) or Repair the surface
Sliding surface with less smooth
plate 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less smooth
than the allowable wear limit 0.5 mm
(0.02 in) and is repairable
1) One that has worn 0.5 mm (0.02 in) or Replace
more
2) One that has worn less than 0.5 mm Repair the surface
Sliding surface with (0.02 in) smooth
Cover
plate 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less smooth
than the allowable wear limit 0.5 mm
(0.02 in) and is repairable
W3-3-11
(Blank)
W3-3-12
UNDERCARRIAGE / Transmission
TRANSMISSION

When removing and installing the transmission, the

propeller shaft and the pipings of travel motor should
be removed first.
Refer to REMOVAL AND INSTALLATION OF TRAVEL
MOTOR on W3-2-1.
IMPORTANT: When removing and installing the

transmission, bleed air from the oil
pressure port and the brake before
doing any work.
Refer to TROUBLESHOOTING / T5-7
Troubleshooting B in Technical Man-
ual.
Removal
IMPORTANT: Remove the transmission with the

1
travel motor together in order to
keep the balance of weight.
1. Raise the machine until tire (1) at the rear axle
side is raised. Place a stand under frame (2).
2
2. Remove plugs (4) (2 used). Drain oil from the 1 W1GL-03-05-003
transmission.
: 14 mm Transmission 3
IMPORTANT: Attach an identification tag onto the
disconnected hoses for assembling.
3. Disconnect hoses (3) (9 used) and the connectors Travel
Motor
(2 used) from the transmission and the travel
motor. Cap the open ends of the disconnected
hoses.
: 17 mm, 22 mm, 27 mm
: 12 mm 4 WCEB-03-05-022
3
Transmission
WCEB-03-05-023
Travel
Motor
W3-4-1
CAUTION: Propeller shaft (6) weight: 30 kg Transmission

(70 lb)
Travel
4. Remove nuts (7) (8 used) from propeller shaft (6) Motor
in the front side. Insert a pry bar between the
transmission and propeller shaft (6). Pry them Front Side
toward the front side. Lower propeller shaft (6)
onto the ground.
: 14 mm
WCEB-03-05-022
7 6
CAUTION: Propeller shaft (10) weight: 30 kg

(70 lb) 8 9 2
5. Remove nuts (11) (8 used) from propeller shaft

(10) in the rear side. Insert a pry bar between the
transmission and propeller shaft (10). Pry them 10
toward the rear side. Lower propeller shaft (10)
onto the ground. 11
: 14 mm
Rear Side
CAUTION: Transmission assembly weight:

12
260 kg (573 lb)
6. Loosen bolts (12) (3 used) of plate (8). While Transmission

holding the lower side of the transmission by using W1F3-03-04-001
a forklift, remove bolts (12) (3 used).

: 30 mm
CAUTION: Plate (8) weight: 35 kg (80 lb)
7. Remove bolts (9) (3 used). Remove plate (8) from

the transmission.
: 30 mm
Transmission
CAUTION: Travel motor weight: 80 kg (180 lb)
8. Remove socket bolts (5) (4 used). Hoist and re- Travel

Motor
move the travel motor from the transmission.
: 14 mm Front Side
WCEB-03-05-022
5
W3-4-2
Installation
Transmission
CAUTION: Travel motor weight: 80 kg (180 lb)
1. Hoist the travel motor. Install the travel motor to Travel

Motor
the transmission with socket bolts (5) (4 used).
: 14 mm
: 270 N⋅m (27 kgf⋅m, 199 lbf⋅ft)
WCEB-03-05-022
5
CAUTION: Plate (8) weight: 35 kg (80 lb)
2. Install plate (8) to the transmission with bolts (9) (3 8 9 2

used).
: 30 mm
: 540 N⋅m (55 kgf⋅m, 398 lbf⋅ft)
10
CAUTION: Transmission assembly weight: 11
260 kg (573 lb)
3. Install the transmission assembly to frame (2) with

12
: 30 mm
: 540 N⋅m (55 kgf⋅m, 398 lbf⋅ft)
Transmission
W1F3-03-04-001

(70 lb)
4. Install propeller shaft (10) to the transmission with

nuts (11) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
W3-4-3
3
5. Connect hoses (3) (9 used) and the connectors (2
used) to the travel motor and the transmission.
: 19 mm 3
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) Transmission
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m 58 lbf⋅ft)
: 12 mm WCEB-03-05-023
Travel
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft) Motor
CAUTION: Propeller shaft (6) weight: 30 kg Transmission 3

(70 lb)
6. Install propeller shaft (6) to the transmission with Travel

nuts (7) (8 used). Motor
7
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
7. Add oil to the transmission. Install plugs (4) (2 4 6 WCEB-03-05-022

used).
: 14 mm
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
NOTE: Gear Oil 3.0 L (0.8 US gal)
W3-4-4
(Blank)
W3-4-5
DISASSEMBLY OF TRANSMISSION
Part A
WCGB-03-04-001
Part A
3 4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22 23

2 24
1 25
26
54
27, 28
52, 53
51
50
27, 28
49
29
48
30, 31
47
WCGB-03-04-002
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32
W3-4-6
Part B WCEB-03-04-001
Part B
57 58 59 60 61 62 63 64 65
66
67
68
55, 56 69
55, 56
75 70
71
72
WCEB-03-04-002
74 73
W3-4-7
1- Cover 21 - Bearing 41 - Friction Plate (10 Used) 61 - Bearing

2- Bolt (5 Used) 22 - Housing 42 - O-Ring 62 - Final Gear
3- O-Ring (5 Used) 23 - Bearing 43 - Ring 63 - Cover
4- Oil Seal 24 - O-Ring (2 Used) 44 - Ring 64 - Bolt (5 Used)
5- Pin (2 Used) 25 - Bolt (4 Used) 45 - Brake Piston 65 - Bearing
6- Oil Seal 26 - Shift Interlock Controller 46 - Disc Spring 66 - Cover
7- Oil Seal 27 - Socket Bolt (5 Used) 47 - Clutch Piston 67 - Shaft Seal
8- Seal Ring 28 - Washer (5 Used) 48 - Oil Seal 68 - Plate
9- O-Ring (2 Used) 29 - Plate 49 - Shaft 69 - Plate
10 - Gasket 30 - Bearing 50 - Spring 70 - O-Ring
11 - Plate (7 Used) 31 - Washer (2 Used) 51 - Holder 71 - Flange
12 - Friction Plate (6 Used) 32 - Planetary Carrier 52 - Bearing 72 - Retaining Ring
13 - Disc Plate 33 - Slot Pin (6 Used) 53 - Plate (2 Used) 73 - O-Ring (2 Used)
14 - Retaining Ring 34 - Ring Gear 54 - Disc Spring 74 - Screen Sheet
15 - Shim 35 - Retaining Ring 55 - Bolt (4 Used) 75 - O-Ring
16 - Planetary Gear (3 Used) 36 - Retaining Ring 56 - Washer (4 Used)
17 - Retaining Ring (3 Used) 37 - Bearing 57 - Plate
18 - Washer (3 Used) 38 - Collar 58 - Flange
19 - Bearing 39 - Disc Plate 59 - Plate
20 - Retaining Ring 40 - Plate (9 Used) 60 - Shaft Seal
W3-4-8
(Blank)
W3-4-9
Part A
WCGB-03-04-001
Part A
22 24
26
27, 28
27, 28
WCGB-03-04-002
W3-4-10
Disassembly of Transmission
3. Remove plugs (81) (2 used) and seal rings (82) (2

CAUTION: Transmission
used) from housing (22).
weight: 135 kg (300 lb) : 8 mm
1. Attach a nylon sling onto the transmission. Hoist 81, 82
the transmission. Lower the transmission onto a
workbench.
2. Remove bolts (76, 78) (2 used for each) and seal

rings (77, 79) (2 used for each) from the trans-
mission. Disconnect pipings (80) (2 used) from the
transmission.
: 22 mm, 24 mm
22
76, 77 78, 79 80
WCGB-03-04-006
4. Remove socket bolts (27) (5 used) and washers

(28) (5 used). Remove shift interlock controller
(26) and O-rings (24) (2 used) from the transmis-
sion.
: 6 mm
5. Remove socket bolt (84). Remove travel N sensor

(83) and O-rings (85) (2 used) from housing (22).
: 6 mm
84, 85
WCEB-03-04-006
83
22
WCGB-03-04-006
W3-4-11
Part A
WCGB-03-04-001
Part A
3 4 5 7 22
54
47
46 45
WCGB-03-04-002
W3-4-12
6. Remove bleeder (86) and plug (93) from housing 10. Remove spring (91), O-ring (92) and piston (93)
(22). from housing (22).
: 27 mm 22
: 8 mm
86, 87 22 91, 92, 93
WCGB-03-04-014
11. Remove disc springs (46, 54) from housing (22).

Remove clutch piston (47).
WCEB-03-04-006
12. Remove pins (5) (2 used) from housing (22).
7. Remove plugs (88, 89) from housing (22).
: 8 mm
13. Apply air to the hole of bleeder valve (90) on
88 89 22 housing (22). Remove brake piston (45). Remove
fitting (94) from housing (22).
: 17 mm
WCEB-03-04-005
8. Remove bleeder valve (90) from housing (22).

: 17 mm
22
94 90 WCEB-03-04-006
14. Remove oil seals (4, 7) from housing (22).
90 WCEB-03-04-006
9. Remove bolts (2) (5 used). Remove cover (1) and

O-ring (3) from housing (22).
: 19 mm
W3-4-13
Part A
WCGB-03-04-001
Part A
6 8 9 10 11 12 13 14, 15 16, 17, 18, 19 20 21 22
23
25
52, 53
51
50
49
29
48
30, 31
45 44 43 42 41 40 39 38 37 36 35 34 33 32
WCGB-03-04-002
W3-4-14
15. Remove oil seals (6, 48) from brake piston (45). 26. Remove retaining ring (20) from shaft (49). Re-
move collar (38).
IMPORTANT: Do not remove bearing (52) unless
necessary. IMPORTANT: Do not remove bearing (37) unless
16. Remove bearing (52) and plales (53) (2 used) necessary.
from shaft (49). 27. Remove retaining rings (35, 36) from ring gear
(34). Remove bearing (37).
17. Remove holder (51) and spring (50) from shaft
(49). 28. Remove bearing (30) and washers (31) (2 used)
from planetary carrier (32).
18. Remove the ring (44) assembly from housing (22).
29. Remove bolts (25) (4 used). Remove plate (29)
19. Remove ring (43), seal ring (8), O-rings (9) (2 from housing (22).
used), O-ring (42) and gasket (10) from the ring : 17 mm
(44) assembly.
30. Remove planetary carrier (32) from housing (22).
20. Remove friction plates (12) (6 used), plates (11) (7
used) and disc plate (13) from housing (22). IMPORTANT: Do not remove bearings (21, 23)
unless necessary.
21. Remove retaining ring (14) and shim (15) from 31. Remove the inner races of bearings (21, 23) from
housing (22). planetary carrier (32).
22. Remove friction plates (41) (10 used) and plates IMPORTANT: Do not remove bearings (21, 23)
(40) (9 used) from housing (22). unless necessary.
32. Remove the outer races of bearings (21, 23) from
23. Remove disc plate (39) from housing (22). housing (22).
24. Remove the shaft (49) assembly from housing IMPORTANT: Do not remove bearing (19) unless
(22). necessary.
33. Remove retaining rings (17) (3 used), washers
25. Remove shaft (49) from ring gear (34). (18) (3 used) and bearings (19) (3 used) from
planetary gears (16) (3 used).
34. Remove slot pins (33) (6 used) from planetary

gear (16).
W3-4-15
Part B
57 58 59 60 61 62 63 64 65
66
67
68
55, 56 69
55, 56
75 70
71
72
WCEB-03-04-002
22
74 73
W3-4-16
35. Remove bleeder valves (95) (2 used) from hous- 39. Remove bolts (64) (5 used). Install eyebolt (M10,
ing (22). Pitch 4.0 mm) to the bolt (55) hole. Remove with
: 17 mm cover (66) and final gear (62) from housing (22).
95 : 19 mm
22
40. Remove final gear (62) and cover (63) from cover
(66).

necessary.
41. Remove retaining ring (72) from cover (66). Re-
move bearing (65).
42. Remove O-rings (73) (2 used) from cover (66).
43. Remove screen sheet (74) from housing (22).
WCEB-03-04-005 IMPORTANT: Do not remove bearing (61) unless

necessary.
36. Remove bolts (55) (4 used) and washers (56) (4 44. Remove bearing (61) from housing (22).
used) from both sides of housing (22). Remove
plates (57, 69) and O-rings (70, 75) from housing
(22).
: 17 mm
37. Remove flanges (58, 71), plates (59, 68) and shaft
seals (60, 67) from housing (22).
38. Hoist the transmission with the rear axle mounting

side facing upward.
W3-4-17
ASSEMBLY OF TRANSMISSION
Part A
WCGB-03-04-001
Part A
4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22

3 23
24
2
25
1
26
54
27, 28
52, 53
51
50
27, 28
49
29
48
30, 31
47
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32
WCGB-03-04-002
W3-4-18
Part B
57 58 59 60 61 62 63 64 65
66
67
68
55, 56 69
55, 56
75 70
71
72
WCEB-03-04-002
74 73
W3-4-19
1- Cover 21 - Bearing 41 - Friction Plate (10 Used) 61 - Bearing

2- Bolt (5 Used) 22 - Housing 42 - O-Ring 62 - Final Gear
3- O-Ring (5 Used) 23 - Bearing 43 - Ring 63 - Cover
4- Oil Seal 24 - O-Ring (2 Used) 44 - Ring 64 - Bolt (5 Used)
5- Pin (2 Used) 25 - Bolt (4 Used) 45 - Brake Piston 65 - Bearing
6- Oil Seal 26 - Shift Interlock Controller 46 - Disc Spring 66 - Cover
7- Oil Seal 27 - Socket Bolt (5 Used) 47 - Clutch Piston 67 - Shaft Seal
8- Seal Ring 28 - Washer (5 Used) 48 - Oil Seal 68 - Plate
9- O-Ring (2 Used) 29 - Plate 49 - Shaft 69 - Plate
10 - Gasket 30 - Bearing 50 - Spring 70 - O-Ring
11 - Plate (7 Used) 31 - Washer (2 Used) 51 - Holder 71 - Flange
12 - Friction Plate (6 Used) 32 - Planetary Carrier 52 - Bearing 72 - Retaining Ring
13 - Disc Plate 33 - Slot Pin (6 Used) 53 - Plate (2 Used) 73 - O-Ring (2 Used)
14 - Retaining Ring 34 - Ring Gear 54 - Disc Spring 74 - Screen Sheet
15 - Shim 35 - Retaining Ring 55 - Bolt (4 Used) 75 - O-Ring
16 - Planetary Gear (3 Used) 36 - Retaining Ring 56 - Washer (4 Used)
17 - Retaining Ring (3 Used) 37 - Bearing 57 - Plate
18 - Washer (3 Used) 38 - Collar 58 - Flange
19 - Bearing 39 - Disc Plate 59 - Plate
20 - Retaining Ring 40 - Plate (9 Used) 60 - Shaft Seal
W3-4-20
(Blank)
W3-4-21
Part B
57 58 59 60 61 62 63 64 65
66
67
68
55, 56 69
55, 56
75 70
71
72
WCEB-03-04-002
74 73
22
W3-4-22
Assembly of Transmission
1. Hoist and set housing (22) with the front axle IMPORTANT: Install cover (63) so that the convex
mounting side facing upward. part of the cover (63) back side can
enter into the groove of cover (66).
2. Install bearing (61) to housing (22). 6. Install cover (63) to cover (66).
3. Install screen sheet (74) to housing (22). At this 63

time, pass the slot pin through the hole on screen
sheet (74). 66
WCEB-03-04-003
22
7. Install final gear (62) to cover (66).
8. Hoist and set the housing (22) assembly with the

rear axle mounting side facing upward.
WCGB-03-04-009
Slot Pin
9. Warm bearing (61) by using a drier. Install the fi-
4. Install bearing (65) and retaining ring (72) to cover nal gear (62) assembly to housing (22).
(66).
10. Install cover (66) to housing (22) with bolts (64) (5
5. Apply hydraulic oil onto O-ring (73). Install O-rings used).
(73) (2 used) to cover (66). : 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)
W3-4-23
Part B
57 58 59 60
67
68
55, 56 69
75 70
71
WCEB-03-04-002
22
W3-4-24
IMPORTANT: Apply grease onto the seal and the
dust lip of shaft seal (67).
11. Apply alcohol to the outer surface of shaft seal
(67). Install shaft seal (67) to cover (66).
NOTE: Dimension A: 27.5+0.3 mm (1.1+0.01 in)
Dimension B: 17.6-0.5 mm (0.7-0.02 in)
71 68 67 66
A B
WCEB-03-04-004
IMPORTANT: Apply grease onto the seal and the

dust lip of shaft seal (60).
12. Apply alcohol to the outer surface of shaft seal
(60). Install shaft seal (60) to housing (22).
13. Install plates (59, 68) to flanges (58, 71).
14. Install flanges (58, 71) and O-rings (70, 75) to

housing (22).
15. Install plates (57, 69) to flanges (58, 71) with bolts
(55) (2 used) and washers (56) (2 used).
: 17 mm
: 46 N⋅m (4.7 kgf⋅m, 34 blf⋅ft)
W3-4-25
Part A
WCGB-03-04-001
Part A
13 14, 15 16, 17, 18, 19 20 21 22

23
25
49
29
30, 31
39 38 37 36 35 34 33 32
WCGB-03-04-002
W3-4-26
16. Install the outer race of bearing (23) to housing 24. Hoist and set housing (22) with the rear axle
(22). mounting side facing upward.
17. Hoist and set housing (22) with the rear axle 25. Install the inner race of bearing (23) to housing
mounting side facing downward. (22).
18. Install the outer race of bearing (21) to housing 26. Install plate (29) to housing (22) with bolts (25) (4
(22). used). At this time, rotate planetary carrier (32)
clockwise and counterclockwise several times.
19. Apply grease onto slot pin (33). Install slot pins : 17 mm
(33) (6 used) to planetary carrier (32). : 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)
NOTE: Dimension C: 28-1.0 mm (1.1-0.03 in)
33
27. Install collar (38) to shaft (49) and secure them
32
with retaining ring (20).
C
28. Secure bearing (37) to ring gear (34) with retain-
ing rings (36) (2 used).
29. Install shaft (49) to ring gear (34) and secure them
with retaining ring (35).
30. Hoist and set housing (22) with the rear axle
mounting side facing downward.
WCGB-03-04-017 31. Install bearing (30) and washers (31) (3 used) to

planetary carrier (32).
20. Install planetary gears (16) (3 used), bearings
(19) (3 used) and washers (18) (3 used) to 32. Install the shaft (49) assembly to housing (22).
planetary carrier (32) with retaining rings (17) (3
used). 33. Secure the shaft (49) assembly to housing (22)
with retaining ring (14) and shim (15).
21. Install the inner race of bearing (21) to planetary
carrier (32). 34. Install disc plates (13, 39) to housing (22).
22. Install planetary carrier (32) to housing (22).
23. Tighten planetary carrier (32) to housing (22) by

using special tool (ZF number: 5870 654 049).
W3-4-27
Part A
WCGB-03-04-001
Part A
11 12 22
54
52, 53
51
49
47
46 45
41 40
WCGB-03-04-002
W3-4-28
35. Install friction plates (12) (6 used) and plates (11) 42. Measure dimension F between housing (22) and
(7 used) to housing (22). clutch piston (47).
NOTE: Dimension F: 22.5 mm (0.9 in)
36. Remove friction plates (41) (10 used) and plates
(40) (9 used) from housing (22).
37. Apply hydraulic oil onto plate (53). Install holder

(51), bearing (52) and plates (53) (2 used) to shaft
(49). F
38. Install brake piston (45) without the seals to

housing (22). 47
22
39. Install clutch piston (47) without the seals to
housing (22). WCGB-03-04-018
43. Measure dimension G between housing (22) and

40. Install disc springs (46, 54) to housing (22).
brake piston (45).
41. Install special tool (ZF number: 5870 200 131) to NOTE: Dimension G: 11.9 mm (0.5 in)
housing (22) with the bolts (2 used). Measure
dimensions D and E of disc springs (46, 54).
: 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)
NOTE: Dimension D: 2.4+0.3 mm (0.09+0.01 in) G
Dimension E: 1.8+0.3 mm (0.07+0.01 in)
45
54 46
22
WCGB-03-04-018
E 44. Remove the bolts (2 used). Remove special tool

D (ZF number: 5870 200 131) and disc springs (46,
54) from housing (22).
: 19 mm
22
45. Remove brake piston (45), clutch piston (47),
WCGB-03-04-018
holder (51), bearing (52) and plates (53) (2 used)
from housing (22).
W3-4-29
Part A
WCGB-03-04-001
Part A
3 4 5 6 7 8 9 10 9 22
54
52, 53
51
50
49
48
47
46 45 44 43 42
WCGB-03-04-002
W3-4-30
46. Apply hydraulic oil onto the seal surface of ring 56. Install clutch piston (47) to housing (22). Push
(43) and O-ring (9). Install O-ring (9) to ring (43). clutch piston (47) toward the shaft. Install plugs
(81) (2 used) and seal rings (82) (2 used) to
47. Install ring (43) to housing (22) by using a plastic housing (22).
hammer. : 8 mm
: 25 N⋅m (2.5 kgf⋅ft, 18 lbf⋅ft)
48. Apply hydraulic oil onto the seal surface of ring
81,82
(44) and O-rings (9, 42). Install O-rings (9, 42), oil
seal (8) and gasket (10) to ring (44).
49. Install ring (44) to housing (22) by using a plastic

hammer.
50. Install spring (50) and holder (51) to shaft (49).
51. Apply hydraulic oil onto bearing (52). Install

bearing (52) and plates (53) (2 used) to shaft (49). 22
52. Apply hydraulic oil onto the seal surface of hous- WCGB-03-04-006
ing (22). Install oil seals (4, 7) to housing (22).

57. Install disc springs (46, 54) to housing (22).
53. Apply hydraulic oil onto the seal surface of brake
piston (45). Install oil seals (6, 48) to brake piston 58. Install piston (93), spring (91) and O-ring (92) to
(45). housing (22).
22
54. Install brake piston (45) to housing (22) by using a
plastic hammer.
91, 92, 93
55. Install pins (5) (2 used) to brake piston (45).
WCGB-03-04-014
59. Apply hydraulic oil onto O-ring (3). Install O-ring

(3) to cover (1).
60. Install cover (1) to housing (22) with bolts (2) (5

used).
: 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)
W3-4-31
Part A
WCGB-03-04-001
Part A
2 22
WCGB-03-04-002
W3-4-32
61. Install plug (87) and bleeder (86) to housing (22). 63. Install bleeder valve (90), fitting (94) and plugs
Bleeder (86) (88, 89) to housing (22).
: 27 mm Bleeder Valve (90)
: 22 N⋅m (2.2 kgf⋅ft, 16 lbf⋅ft) : 17 mm
Plug (87) : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
: 8 mm Fitting (94)
: 24 N⋅m (2.4 kgf⋅m, 59 lbf⋅ft) : 17 mm
: 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
86, 87 22 Plugs (88, 89)
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
22
WCEB-03-04-006
62. Install bleeder valves (95) (2 used), to housing

(22). 94 90
Bleeder Valve (95) WCEB-03-04-006
: 17 mm
: 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft) 88 89 22
95 22
WCEB-03-04-005
WCEB-03-04-005
W3-4-33
Part A
WCGB-03-04-001
Part A
22
26
27, 28
27, 28
WCGB-03-04-002
W3-4-34
64. Install travel N sensor (83), socket bolt (84) and 67. Add gear oil to the transmission. Install plug (76)
O-ring (85) to housing (22). and O-ring (77) to the transmission.
: 6 mm : 14 mm
: 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft) : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
84, 85
83
22
WCGB-03-04-006
65. Install shift interlock controller (26) to housing (22)

with socket bolts (27) (5 used) and washers (28)
(5 used).
: 6 mm
: 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft)
66. Connect pipings (80) (2 used) to the transmission

with bolts (76, 78) (2 used for each) and seal rings
(77, 79) (2 used for each).
: 22 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 24 mm
: 45 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)
76, 77 78, 79 80
WCEB-03-04-006
W3-4-35
(Blank)
W3-4-36
UNDERCARRIAGE / Axle
REMOVAL AND INSTALLATION OF AXLE
Removal of Front Axle

3 2 3 3 2 3 4
1. Loosen nuts (1) (20 used) for tires (3) (4 used)
and tire rings (2) (2 used).
: 30 mm
2. Swing the machine by 90º. Raise the front axle 1

side of frame (4) until tire (3) is raised. Place a
stand under frame (4).
W1GL-03-05-003
CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb) 5 Steering Cylinder Front Axle
3. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used) from frame (4).
: 30 mm
4. Disconnect brake hoses (5) (2 used) from the

right and left sides of the front axle.
: 22 mm
WCEB-03-05-021
W3-5-1
5. Disconnect grease hose (6) from pin (7).
: 17 mm
6 7
6. Disconnect steering hoses (8) (2 used) from the
steering cylinder.
: 22 mm

(70 lb)
WCEB-03-05-026
7. Place the wooden block under propeller shaft (11).

Remove bolts (10) (8 used) and nuts (9) (8 used). 4 7 8
Remove propeller shaft (11) from the front axle.
: 14 mm
Steering Cylinder WCGB-03-05-025
Front Axle
8. Remove nuts (12) (2 used). Remove bolt (13)
from pin (7). 11
: 24 mm
9, 10
9. Hold the lower side of the front axle by using a
forklift.
CAUTION: Front axle weight: 630 kg (1390

lb)
CAUTION: Pin (7) weight: 14 kg (31 lb) (outer WCGB-03-05-028
diameter 70 mm (2.8 in))

4 13
10. Remove pin (7) from the front axle. Remove the
front axle from frame (4).
12
WCGB-03-05-027
W3-5-2
Installation of Front Axle
4 13
CAUTION: Front axle weight: 630 kg (1390

lb) 6
7
CAUTION: Pin (7) weight: 14 kg (31 lb) (outer
diameter 70 mm (2.8 in))
1. Hold the front axle by using a forklift. Install the 12

front axle to frame (4) with pin (7).
WCEB-03-05-026
2. Secure pin (7) with bolt (13) and nuts (12) (2

used). 4 7 8
: 24 mm
: 270 N·m (27.5·kgfm, 199 lbf·ft)
3. Connect steering hoses (8) (2 used) to the steer-

ing cylinder.
: 22 mm
: 39 N·m (4.0 kgf·m, 29 lbf·ft)
Steering Cylinder WCGB-03-05-025
4. Connect brake hoses (5) (2 used) to the right and

left sides of the front axle. Steering Cylinder Front Axle
: 22 mm 5
: 39 N·m (4.0 kgf·m, 29 lbf·ft)
5. Connect grease hose (6) to pin (7).

: 17 mm
: 24.5 N·m (2.5 kgf·m, 18 lbf·ft)
CAUTION: Propeller shaft (11) weight：30 kg WCEB-03-05-021

(70 lb)
6. Install propeller shaft (11) to the front axle with
Front Axle
bolts (10) (8 used) and nuts (9) (8 used). 11
: 14 mm
: 108 N·m (11 kgf·m, 80 lbf·ft) 9, 10
WCGB-03-05-028
W3-5-3

Tire ring (2) weight: 25 kg (60 lb) 3 2 3 3 2 3 4
7. Install tire (3), tire ring (2) and tire (3) to the front
axle in this order and tighten them with nuts (1)
(10 used) temporarily.
: 30 mm
8. Install tire ring (2) and tires (3) (2 used) to the

other side of the front axle in the same way as
step 7. 1
9. Remove the stand from frame (4).

W1GL-03-05-003
10. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used).
: 30 mm
: 600 N·m (61 kgf·m, 443 lbf·ft)
W3-5-4
Removal of Rear Axle
1. Loosen nuts (1) (20 used) for tires (3) (4 used) 4

and tire rings (2) (2 used). 3
: 30 mm
2. Swing the machine by 90º. Raise the rear axle

side of frame (4) until tire (3) is raised. Place a
stand under frame (4).
2
Tire ring (2) weight: 25 kg (60 lb) 1 3 W1GL-03-05-003
3. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used) from frame (4).
: 30 mm
CAUTION: Propeller shaft (7) weight: 30 kg Rear Axle

(70 lb)
7
4. Place a wooden block under propeller shaft (7).
5, 6
Remove bolts (6) (8 used) and nuts (5) (8 used).
Remove propeller shaft (7) from the rear axle.
: 14 mm
WCGB-03-05-028
W3-5-5
7. Disconnect brake pipings (8) (2 used) from the 4 8
right and left sides of the rear axle.
: 19 mm
CAUTION: Rear axle weight: 550 kg (1220 lb)
8. Hold the lower side of the rear axle by using a

forklift.
9. Remove nuts (10) (8 used) from the right and left WCGB-03-05-023
sides of the rear axle. Remove bolts (9) (8 used) 9

from frame (4).
10
: 30 mm
10. Remove the rear axle from frame (4). 4
WCGB-03-05-022
W1GL-03-05-003
W3-5-6
Installation of Rear Axle 4 8
1. Hold the rear axle by using a forklift. Install the

rear axle to frame (4) with bolts (9) (8 used) and
nuts (10) (8 used).
: 30 mm
: 560 N·m (57 kgf·m, 413 lbf·ft)
WCGB-03-05-023
2. Connect brake pipings (8) (2 used) to the right 9

and left sides of the rear axle.
: 19 mm 10
: 29.5 N·m (3.0 kgf·m, 22 lbf·ft)
CAUTION: Propeller shaft (7) weight: 30 kg WCGB-03-05-022

(70 lb)
Rear Axle
3. Install propeller shaft (7) to the rear axle with nuts 7

(5) (8 used) and bolts (6) (8 used). 5, 6
: 14 mm
: 108 N·m (11 kgf·m, 80 lbf·ft)

Tire ring (2) weight: 25 kg (60 lb)
WCGB-03-05-028
4. Install tire (3), tire ring (2) and tire (3) to the rear
axle in this order and tighten them with nuts (1)
(10 used) temporarily.
: 30 mm
5. Install tire ring (2) and tires (3) (2 used) to the 3

other side of the rear axle in the same way as
step 4.
1 3 W1GL-03-05-003
W3-5-7
6. Remove the stand from frame (4).
7. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used). 4
: 30 mm 3
: 600 N·m (61 kgf·m, 443 lbf·ft)
1 3 W1GL-03-05-003
W3-5-8
(Blank)
W3-5-9
DISASSEMBLY OF FRONT AXLE
1
2
3
4
5
6
7
8
9
10
11
16 12
17 18 13
19
20
14
21 22 15
23
24
25
26
27
28
40
39
38 36 29
37 30
31
32
41
42
35
43 34
33
44
45
46
47
48
49
50
51
52
56
WCEB-03-05-001
55
54 53
W3-5-10
1- Drive Housing 15 - Bushing 29 - Friction Plate (4 Used) 43 - Hub Carrier

2- Plug 16 - Plug 30 - Plate (5 Used) 44 - O-Ring
3- Axle Casing 17 - Pin 31 - Cover (4 Used) 45 - Bearing
4- Washer (16 Used) 18 - Socket Bolt (6 Used) 32 - Socket Bolt (16 Used) 46 - Snap Ring
5- Bolt (16 Used) 19 - Shim 33 - Bolt (3 Used) 47 - Ring Gear
6- Nut 20 - Seal Ring 34 - Spring (3 Used) 48 - Support
7- Lock Bolt 21 - Bushing 35 - Socket Bolt (3 Used) 49 - Retaining Ring (3 Used)
8- Retaining Ring (2 Used) 22 - Knuckle 36 - Pin 50 - Planetary Gear (3 Used)
9- Bearing 23 - O-Ring 37 - Bolt (6 Used) 51 - Roller Bearing (3 Used)
10 - Seal Ring 24 - O-Ring 38 - Seal Ring 52 - Planetary Carrier
11 - Bushing 25 - Backup Ring 39 - Ball Bushing 53 - Plug
12 - O-Ring 26 - O-Ring 40 - Plug 54 - Plug
13 - Double Joint Shaft 27 - Backup Ring 41 - Seal Ring 55 - Plate
14 - Shaft Seal 28 - Piston 42 - Bearing 56 - Nut (8 Used)
W3-5-11
2
3
16
22
40
52
WCEB-03-05-001
53
W3-5-12
Disassembly of Front Axle
CAUTION: Front axle weight: 630 kg (1390 lb) 5. Remove socket bolts (62) (5 used). Tap and re-
move steering cylinder (61) from drive housing (1)
1. Hoist the front axle. Lower the front axle on a by using a plastic hammer.
workbench. : 12 mm
62 1
2. Remove nut (58) from the right and left sides of
the front axle. Remove tie rods (57) (2 used) from
knuckle (22) in the right and left sides. 61
: 41 mm
57 58 22
3
WCEB-03-05-017
6. Remove O-rings (63) (2 used) from drive housing

(1).
WCEB-03-05-015
1 63
3. Warm the connection part of piston rod (59) and

tie rod (57) by using a drier. Attach a spanner onto
the connection part of the right and left sides of
the front axle. Remove tie rods (57) (2 used) from
piston rod (59).
: 55 mm
1
Connection Part
59 57
WCEB-03-05-019
7. Remove plugs (2, 16, 40 and 53) from the right

and left sides of the front axle. Drain gear oil from
the front axle.
60 Plug (2)
: 8 mm
WCEB-03-05-016 Plugs (16, 40, 53)
: 10 mm
4. Remove elbows (60) (2 used) from drive housing
(1).
W3-5-13
22
23
29
30
31
32
41
42
43
44
45
46
47
48
49
50
51
52
56
WCEB-03-05-001
54
W3-5-14
8. Remove nuts (64) (10 used), washers (65) (20 IMPORTANT: Do not remove bearing (45) unless
used) and plug (54) from planetary carrier (52). necessary.
: 30 mm 15. Pry the clearance between cover (31) and hub
: 8 mm carrier (43) by using a pry bar. Remove hub carrier
52 64, 65 (43) and the inner race of bearing (45) from cover
(31). At this time, do not drop the inner race of
bearing (45).
IMPORTANT: Do not remove bearings (42, 45)

unless necessary.
hub carrier (43).
17. Remove socket bolts (32) (16 used) from cover

WCEB-03-05-010 (31).
: 8 mm
9. Attach a nylon sling onto planetary carrier (52).
Pry the clearance between hub carrier (43) and IMPORTANT: When removing cover (31), do not
planetary carrier (52) by using a pry bar. Hoist and drop plate (30) and friction plate (29).
remove planetary carrier (52) from the front axle. 18. Put the matching marks on cover (31) and knuckle
(22). Pry the clearance between cover (31) and
10. Remove retaining rings (49) (3 used) from plane- knuckle (22) by using a pry bar. Hoist and remove
tary gears (50) (3 used). Remove planetary gears cover (31) from knuckle (22).
(50) (3 used) and roller bearings (51) (3 used)
from planetary carrier (52). 19. Remove plates (30) (5 used) and friction plates
(29) (4 used) from cover (31).
11. Remove O-ring (44) from hub carrier (43).
20. Remove seal ring (41) from cover (31).
12. Remove nuts (56) (8 used). Remove plate (55)
from the ring gear (47) assembly. 21. Remove O-ring (23) from knuckle (22).
: 27 mm
13. Remove the ring gear (47) assembly from hub

carrier (43).
14. Remove snap ring (46) from the ring gear (47)
assembly. Remove support (48).
W3-5-15
6
7
17 18
19
20
21 22
14
24 15
25
26
27
28
39
38 36
37
42
35
34
33
WCEB-03-05-001
W3-5-16
IMPORTANT: Do not remove bearing (42) unless 27. Remove ball cover (68) from pin (36).
necessary.
22. Remove the inner race of bearing (42) from 68
knuckle (22). 36
IMPORTANT: Before removing bolt (33), record the

dimension of bolt (33) extended from
piston (28).
23. Remove bolts (33) (3 used), socket bolts (35) (3
used) and springs (34) (3 used) from piston (28).
WCEB-03-05-004
: 11 mm
: 5 mm
28. Hoist and hold knuckle (22). Remove bolts (18) (6
used) from the upper side of knuckle (22). Pry the
IMPORTANT: Do not fly out piston (28).
clearance between knuckle (22) and pin (17).
24. Remove cap (66) and plug (67) from knuckle (22).
Remove pin (17), shims (19) (3 used) and seal
Apply pressure air through the plug (67) hole and
ring (20) from knuckle (22).
remove piston (28) from knuckle (22).
: 10 mm
29. Hoist and hold knuckle (22). Remove knuckle (22)
22 from axle casing (3).
28
30. Remove seal ring (14) and bushing (15) from
knuckle (22).
66, 67
31. Remove bushing (21) and ball bushing (39) from
the upper and lower pins (17, 36) holes of knuckle
(22) by using a gear puller.
32. Remove nut (6) and lock bolt (7) from axle casing
(3).
WCEB-03-05-011 : 19 mm
: 6 mm
25. Remove O-rings (24, 26) and backup rings (25,
27) from piston (28).
26. Remove bolts (37) (6 used) from the lower side of

knuckle (22). Pry the clearance between knuckle
(22) and pin (36) by using a pry bar. Remove pin
(36) and seal ring (38) from knuckle (22).
W3-5-17
3
4
5
8
9
10
11
12
13
WCEB-03-05-001
W3-5-18
33. Attach a nylon sling onto axle casing (3). Remove
Remove axle casing (3) with double joint shaft
(13) together from drive housing (1).
: 19 mm
34. Remove double joint shaft (13) from axle casing

(3) by using a plastic hammer.
35. Remove retaining rings (8) (2 used) from the

bushing (11) assembly.
36. Remove the bushing (11) assembly from double

joint shaft (13).

necessary.
37. Remove bearing (9), seal ring (10) and O-ring (12)
from the bushing (11) assembly by using a gear
puller.
38. Remove the parts at the opposite side of the front

axle in the same way as steps 8 to 37.
39. Remove the differential from drive housing (1).

(Refer to Disassemble Differential on W3-5-44.)
W3-5-19
ASSEMBLY OF FRONT AXLE
Detail of Drive Housing Inside

1
Planetary Carrier
WCEB-03-05-008
Detail of Planetary Carrier Inside

18 17 24, 25 26, 27 22 23 31 41 44 42 43 49
20 47
21 50
19 51
52
6
49
7
Drive Housing 13
9
10 56
WCEB-03-05-006
11 12 3 37 36 39 38 40 28 29 32 30 14 15 45 48 55
W3-5-20
1- Drive Housing 15 - Bushing 29 - Friction Plate (4 Used) 43 - Hub Carrier

2- *Plug 16 - *Plug 30 - Plate (5 Used) 44 - O-Ring
3- Axle Casing 17 - Pin 31 - Cover (4 Used) 45 - Bearing
4- *Washer (16 Used) 18 - Socket Bolt (6 Used) 32 - Bolt (16 Used) 46 - *Snap Ring
5- *Bolt (16 Used) 19 - Shim 33 - *Bolt (3 Used) 47 - Ring Gear
6- Nut 20 - Seal Ring 34 - *Spring (3 Used) 48 - Support
7- Lock Bolt 21 - Bushing 35 - *Socket Bolt (3 Used) 49 - Retaining Ring (3 Used)
8- *Retaining Ring (2 Used) 22 - Knuckle 36 - Pin 50 - Planetary Gear (3 Used)
9- Bearing 23 - O-Ring 37 - Bolt (6 Used) 51 - Roller Bearing (3 Used)
10 - Seal Ring 24 - O-Ring 38 - Seal Ring 52 - Planetary Carrier
11 - Bushing 25 - Backup Ring 39 - Ball Bushing 53 - *Plug
12 - O-Ring 26 - O-Ring 40 - Plug 54 - *Plug
13 - Double Joint Shaft 27 - Backup Ring 41 - Seal Ring 55 - Plate
14 - Shaft Seal 28 - Piston 42 - Bearing 56 - Nut (8 Used)
W3-5-21
Planetary Carrier
WCEB-03-05-008
18 17 22
20
21
19
7
13
Drive Housing 9
10
WCEB-03-05-006
11 12 3 36 39 38 14 15
W3-5-22
Assembly of Front Axle
1. Apply LOCTITE #242 onto bolt (5). Hoist axle 7. Install ball cover (68) to pin (36).
casing (3). Install axle casing (3) to drive housing
(1) with bolts (5) (16 used) and washers (4) (16 68
used). 36
: 19 mm
: 283 to 312 N·m
(29 to 32 kgf·m, 209 to 230 lbf⋅ft)
2. Install O-ring (12), seal ring (10), bearing (9) and

retaining ring (8) to bushing (11).
WCEB-03-05-004
3. Install the bushing (11) assembly and retaining

8. Install seal rings (20, 38) to pins (17, 36).
ring (8) to double joint shaft (13).
9. Apply grease onto bushing (15) and seal ring (14).
4. Install double joint shaft (13) to axle casing (3).
Install bushing (15) and seal ring (14) to knuckle
(22).
5. Apply LOCTITE #242 onto nut (6) and lock bolt (7).
Install nut (6) and lock bolt (7) to axle casing (3).
IMPORTANT: When installing double joint shaft
: 19 mm
(13) to knuckle (22), do not damage
: 60 to 70 N⋅m
bushing (15) and seal ring (14).
(6 to 7 kgf⋅m, 44 to 52 lbf⋅ft)
10. Apply grease onto double joint shaft (13). Hoist
: 6 mm
and install knuckle (22) to axle casing (3).
: 15 to 20 N⋅m
(1.5 to 2 kgf⋅m, 11 to 15 lbf⋅ft)
11. Apply grease onto pin (17). Install shims (19) (3
used) and pin (17) to the upper side of knuckle
6. Apply grease onto bushing (21) and ball bushing
(22) and secure them with bolts (18) (6 used).
(39). Install bushing (21) and ball bushing (39) to
axle casing (3). NOTE: Adjust the thickness of shim (19) from 1.5
to 2.0 mm (0.06 to 0.08 in).
: 15 mm
: 116 to 128 N⋅m
(12 to 13 kgf⋅m, 86 to 94 lbf⋅ft)
W3-5-23
Planetary Carrier
WCEB-03-05-008
17 24, 25 26, 27 22 23 31 41 44 42 43
19
Drive Housing
WCEB-03-05-006
37 36 28 29 32 30
W3-5-24
12. Apply grease onto pin (36). Install pin (36) the 18. Install plug (67) and cap (66) to knuckle (22).
lower side of to knuckle (22) and secure them with : 10 mm 22
bolts (37) (6 used). 28
: 15 mm
: 116 to 128 N⋅m
(12 to 13 kgf⋅m, 86 to 94 lbf⋅ft)
66, 67
13. Insert a pry bar between the pin (17) side of
knuckle (22) and axle casing (3). Move knuckle
(22) up and down. Measure the clearance be-
tween pin (17) and shim (19). In case the correct
dimension can not be obtained, adjust with shim
(19).
WCEB-03-05-011
NOTE: Correct dimension: 0.5 mm (0.02 in)
19. Install O-ring (23) and the inner race of bearing
14. Measure the torque of pin (17). (42) to knuckle (22).
NOTE: Correct torque: 40 to 80 Nm (4 to 8 kgfm,
30 to 59 lbf⋅ft) 20. Install seal ring (41) to cover (31).
15. Install O-rings (24, 26) and backup rings (25, 27) 21. Install the outer race of bearing (42) to hub carrier
to piston (28). (43).
IMPORTANT: When installing piston (28), do not 22. Install hub carrier (43) to cover (31).
damage O-rings (24, 26) and backup
rings (25, 27). 23. Apply grease onto O-ring (44). Install O-ring (44)
16. Apply LOCTITE #270 onto socket bolt (35). Install to hub carrier (43).
piston (28) to knuckle (22) with socket bolts (35)
(3 used) by using a plastic hammer. 24. Apply grease onto plate (30) and friction plate (29).
: 5 mm Install plates (30) (5 used) and friction plates (29)
: 5 to 7 N⋅m (4 used) to the cover (31) assembly alternately. At
(0.5 to 0.7 kgf⋅m, 4 to 5 lbf⋅ft) this time, align the claws of friction plate (29).
17. Apply LOCTITE #242 onto bolt (33). Install bolts 30

(33) (3 used) and springs (34) (3 used) to piston
(28).
: 11 mm 29
: 10 to 15 N⋅m
(1 to 1.5 kgf⋅m, 7 to 11 lbf⋅ft) 31
Claw
WCEB-03-05-005
W3-5-25
Planetary Carrier
WCEB-03-05-008
22 31 43
47
50
51
52
49
Drive Housing
56
WCEB-03-05-006
29 32 30 45 48 55
W3-5-26
IMPORTANT: When hoisting the cover (31) as- 33. Hoist planetary carrier (52). Install planetary car-
sembly, do not drop plate (30) and rier (52) to hub carrier (43).
friction plate (29).
25. Hoist the cover (31) assembly and align the 34. Install plug (54) to planetary carrier (52).
matching marks on knuckle (22) and cover (31). : 8 mm
Install the cover (31) assembly to knuckle (22) : 35 to 50 N⋅m
with bolts (32) (16 used) temporarily. (3.6 to 5 kgf⋅m, 26 to 37 lbf⋅ft)
: 22 mm
35. Install nuts (64) (16 used) and washers (65) (20
26. Install the inner race of bearing (45) to hub carrier used) to planetary carrier (52).
(43) by using a plastic hammer. : 30 mm
: 400 N⋅m (40 kgf⋅m, 295 lbf⋅ft)
27. Install support (48) and snap ring (46) to ring gear
(47). 52 64, 65
28. Hoist the ring gear (47) assembly. Install the ring
gear (47) assembly to hub carrier (43).
IMPORTANT: Apply LOCTITE #242 onto nut (56).

29. Apply grease to plate (55). Install plate (55) to ring
gear (47) with nuts (56) (8 used) temporarily.
: 27 mm
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)
WCEB-03-05-010
30. Tighten bolts (32) (16 used).

: 22 mm 36. Install the parts at the opposite side of the front
: 182 to 202 N⋅m axle in the same way as steps 1 to 35.
(19 to 21 kgf⋅m, 134 to 149 lbf⋅ft)
37. Apply grease onto O-ring (63). Install O-rings (63)
31. Tighten nuts (56) (8 used). (2 used) to drive housing (1).
: 22 mm
: 255 to 285 N⋅m 1 63
(26 to 29 kgf⋅m, 188 to 210 lbf⋅ft)
32. Install planetary gears (50) (3 used), roller bear-

ings (51) (3 used) and retaining rings (49) (3 used)
to planetary carrier (52).
WCEB-03-05-019
W3-5-27
Planetary Carrier
WCEB-03-05-008
22
Drive Housing
WCEB-03-05-006
3 40
W3-5-28
38. Apply LOCTITE #242 onto socket bolt (62). Install 41. Install tie rod (57) to the left and right sides of
steering cylinder (61) to drive housing (1) and knuckle (22). Install nut (58) to the pin of tie rod
secure if with socket bolts (62) (5 used). (57).
: 12 mm : 41 mm
: 180 to 200 N⋅m : 350 to 390 N⋅m
(18 to 20 kgf⋅m, 133 to 148 lbf⋅ft) (36 to 40 kgf⋅m, 258 to 288 lbf⋅ft)
62 1 57 58 22
61
3
WCEB-03-05-015
WCEB-03-05-017
42. Add gear oil to the left and right sides of the front
39. Install elbows (60) (2 used) to drive housing (1). axle. Install plugs (2, 16, 40 and 53).
Plug (2)
40. Apply LOCTITE #242 onto the connection part of
: 8 mm
piston rod (59) and tie rod (57). Install tie rods (57)
: 35 to 50 N⋅m
(2 used) to the left and right sides of piston rod
(3.6 to 5 kgf⋅m, 26 to 37 lbf⋅ft)
(59).
Plugs (16, 40, 53)
: 55 mm
: 10 mm
: 430 to 470 N⋅m
: 35 to 50 N⋅m
(43 to 47 kgf⋅m, 317 to 347 lbf⋅ft)
(3.6 to 5 kgf⋅m, 26 to 37 lbf⋅ft)
1
Connection Part
59 57
60
WCEB-03-05-016
W3-5-29
DISASSEMBLY OF REAR AXLE
1
2
3
4
5
6
7
8
10 9
11
12
13
14
15
16
17
28 18
19
20
27
21
22
23
29
30
31 26
32 25
24
33
34
35
36
37
38
39
40
41
42
46
45 43 WCEB-03-05-002
44
W3-5-30
1- Drive Housing 13 - Cover 25 - Spring (3 Used) 37 - Ring Gear

2- Plug 14 - O-Ring 26 - Bolt (3 Used) 38 - Support
3- Plug 15 - O-Ring 27 - Bolt (20 Used) 39 - Retaining Ring (3 Used)
4- Axle Casing 16 - Backup Ring 28 - Plug 40 - Planetary Gear (3 Used)
5- Bolt (16 Used) 17 - O-Ring 29 - Seal Ring 41 - Roller Bearing (3 Used)
6- O-Ring 18 - Backup Ring 30 - Bearing 42 - Planetary Carrier
7- Seal Ring 19 - Piston 31 - Hub Carrier 43 - Plug
8- Guide Ring 20 - Friction Plate (5 Used) 32 - Washer (20 Used) 44 - Plug
9- Shaft 21 - Plate (6 Used) 33 - Nut (10 Used) 45 - Plate
10 - Plug 22 - Cover 34 - O-Ring 46 - Nut (8 Used)
11 - Cap 23 - Socket Bolt (16 Used) 35 - Bearing
12 - Plug 24 - Bolt (3 Used) 36 - Snap Ring
W3-5-31
2
3
4
7
8
10 9
28
20
21
22
30
31
32
33
34
35
36
37
38
39
40
41
42
46
45 43 WCEB-03-05-002
44
W3-5-32
Disassembly of Rear Axle

8. Remove nuts (46) (8 used). Remove plate (45)
from ring gear (37).
1. Hoist the rear axle. Lower the rear axle on a : 27 mm
workbench.
9. Pry the clearance between hub carrier (31) and
2. Remove plugs (2, 3, 10 and 43) from the left and ring gear (37) by using a pry bar. Remove the ring
right sides of the rear axle. Drain gear oil from the gear (37) assembly from hub carrier (31).
rear axle.
Plug (2) 10. Remove snap ring (36) from the ring gear (37)
: 8 mm assembly. Remove support (38).
Plugs (3, 10, 43)
: 10 mm
11. Remove guide ring (8) and seal ring (7) from axle
casing (4).
3. Remove plug (44) from planetary carrier (42).
: 8 mm
necessary.
4. Remove nuts (33) (10 used) and washers (32) (20
12. Pry the clearance between cover (22) and hub
used). Pry the clearance between planetary car-
carrier (31) by using a pry bar. Remove hub carrier
rier (42) and hub carrier (31) by using a pry bar.
(31) and the inner race of bearing (35) from cover
Remove planetary carrier (42) from the rear axle.
(22). At this time, do not drop the inner race of
: 30 mm
bearing (35).
5. Remove retaining rings (39) (3 used) from plane-
13. Remove the inner race of bearing (30) from axle
tary gears (40) (3 used). Remove planetary gears
casing (4).
(40) (3 used) and roller bearings (41) (3 used)
from planetary carrier (42).
hub carrier (31).
6. Remove O-ring (34) from hub carrier (31).
15. Remove plug (28) from axle casing (4).
7. Remove shaft (9) from the rear axle. : 10 mm
W3-5-33
4
5
10
11
12
13
14
15
16
17
18
19
20
27
21
22
23
29
31 26
25
24
WCEB-03-05-002
W3-5-34
16. Remove socket bolts (23) (16 used) from cover 24. Put the matching marks on axle casing (4) and
(22). cover (12). Remove bolts (27) (20 used). Remove
: 8 mm cover (12) from the rear axle.
: 22 mm
IMPORTANT: When removing cover (22), do not
drop plate (21) and friction plate (20). 25. Remove O-ring (6) from axle casing (4).
17. Put the matching marks on cover (22) and cover
(13). Pry the clearance between cover (22) and 26. Hoist and hold axle casing (4). Remove bolts (5)
cover (13) by using a pry bar. Hoist and remove (16 used). Hoist and remove axle casing (4) from
cover (22) from cover (13). drive housing (1).
: 19 mm
18. Remove plates (21) (6 used) and friction plates
(20) (5 used) from cover (22). 27. Remove the parts at the opposite side of the rear
19. Remove seal ring (29) from hub carrier (31).
20. Remove O-ring (14) from cover (13).
IMPORTANT: Before removing bolt (24), record the

dimension of bolt (24) extended from
piston (19).
21. Remove bolts (24) (3 used), socket bolts (26) (3
used) and springs (25) (3 used) from piston (19).
: 11 mm
: 5 mm
IMPORTANT: Do not fly out piston (19).

22. Remove cap (11) and plug (12) from cover (13).
Apply pressure air through the plug (12) hole and
remove piston (19) from cover (13).
: 10 mm
23. Remove O-rings (15, 17) and backup rings (16,

18) from piston (19).
W3-5-35
ASSEMBLY OF REAR AXLE
Detail of Drive Housing Inside
1
Planetary Carrier
WCEB-03-05-009
Detail of Planetary Carrier Inside

15, 16 17, 18 14 20 21 23 29 34 30 35 36
13
37
11, 12 40
39
4
41
42
Drive Housing
46
7
45
27
38
6
28
WCEB-03-05-007
19 22 31 8
W3-5-36
1 - Drive Housing 13 - Cover 25 - *Spring (3 Used) 37 - Ring Gear

2 - *Plug 14 - O-Ring 26 - *Bolt (3 Used) 38 - Support
3 - *Plug 15 - O-Ring 27 - Bolt (20 Used) 39 - Retaining Ring (3 Used)
4 - Axle Casing 16 - Backup Ring 28 - Plug 40 - Planetary Gear (3 Used)
5 - *Bolt (16 Used) 17 - O-Ring 29 - Seal Ring 41 - Roller Bearing (3 Used)
6 - O-Ring 18 - Backup Ring 30 - Bearing 42 - Planetary Carrier
7 - Seal Ring 19 - Piston 31 - Hub Carrier 43 - *Plug
8 - Guide Ring 20 - Friction Plate (5 Used) 32 - *Washer (20 Used) 44 - *Plug
9 - Shaft 21 - Plate (6 Used) 33 - *Nut (10 Used) 45 - Plate
10 - *Plug 22 - Cover 34 - O-Ring 46 - Nut (8 Used)
11 - Cap 23 - Socket Bolt (16 Used) 35 - Bearing
12 - Plug 24 - *Bolt (3 Used) 36 - Snap Ring
W3-5-37
Planetary Carrier
WCEB-03-05-009
15, 16 17, 18 29 30
13
11, 12
Drive Housing
WCEB-03-05-007
19 22 31 8
W3-5-38
Assembly of Rear Axle
1. Hoist axle casing (4). Install axle casing (4) to 6. Apply LOCTITE #270 onto socket bolt (26). Install
drive housing (1) with bolts (5) (16 used). socket bolts (26) (3 used) to piston (19).
: 19 mm : 5 mm
: 283 to 312 N⋅m : 5 to 7 N⋅m
(29 to 32 kgf⋅m, 209 to 230 lbf⋅ft) (0.5 to 0.7 kgf⋅m, 4 to 5 lbf⋅ft)
2. Install O-ring (6) to axle casing (4). 7. Apply LOCTITE #242 onto bolt (24). Install bolts
(24) (3 used) and springs (25) (3 used) to piston
3. Apply LOCTITE #242 onto bolt (27). Install cover (19).
(13) to axle casing (4). Install bolts (27) (20 used) : 11 mm
to cover (13). : 10 to 15 N⋅m
: 22 mm (1 to 1.5 kgf⋅m, 7 to 11 lbf⋅ft)
: 283 to 312 N⋅m
(29 to 32 kgf⋅m, 209 to 230 lbf⋅ft) 8. Install plug (12) and cap (11) to cover (13).
: 10 mm
4. Install O-rings (15, 17) and backup rings (16, 18)
to piston (19). 9. Install O-ring (6), seal ring (7) and guide ring (8) to
axle casing (4).
IMPORTANT: When installing piston (19), do not
damage O-rings (15, 17) and backup 10. Install the inner race of bearing (30) to axle casing
rings (16, 18). (4).
5. Install piston (19) to cover (13) by using a plastic
hammer. 11. Install seal ring (29) to cover (22).
12. Install the outer race of bearing (30) to hub carrier

(31).
13. Install cover (22) to hub carrier (31).
W3-5-39
Planetary Carrier
WCEB-03-05-009
20 21 23 34 35 36
13 37
40
39
41
42
Drive Housing
46
45
38
WCEB-03-05-007
22 31
W3-5-40
14. Apply grease onto plate (21) and friction plate (20). IMPORTANT: Apply LOCTITE #242 onto nut (46).
Install plates (21) (6 used) and friction plates (20) 19. Apply grease onto plate (45). Install plate (45) to
(5 used) to hub carrier (31) alternately. At this time, ring gear (37) with nuts (46) (8 used) temporarily.
align the claws of friction plate (20). : 27 mm
21 20. Tighten socket bolts (23) (16 used).

: 8 mm
: 182 to 202 N⋅m
20 (19 to 21 kgf⋅m, 134 to 149 lbf⋅ft)
31
21. Tighten nuts (46) (8 used).
Claw : 27 mm
: 255 to 285 N⋅m
WCEB-03-05-005
(26 to 29 kgf⋅m, 188 to 210 lbf⋅ft)
IMPORTANT: When installing cover (22), do not 22. Install planetary gears (40) (3 used), roller bear-
drop plate (21) and friction plate (20). ings (41) (3 used) and retaining rings (39) (3 used)
15. Hoist the cover (22) assembly and align the to planetary carrier (42).
matching marks on cover (13) and cover (22). In-
stall the cover (22) assembly to cover (13) with 23. Apply grease onto O-ring (34). Install O-ring (34)
bolts (23) (16 used) temporarily. to hub carrier (31).
: 8 mm
24. Hoist planetary carrier (42). Install planetary car-
16. Install the inner race of bearing (35) to hub carrier rier (42) to hub carrier (31).
(31) by using a plastic hammer.
17. Install support (38) and snap ring (36) to ring gear
(37).
18. Hoist ring gear (37). Install ring gear (37) to hub
carrier (31).
W3-5-41
Planetary Carrier
WCEB-03-05-009
42
Drive Housing
WCEB-03-05-007
W3-5-42
25. Install plug (44) to planetary carrier (42).
: 10 mm
: 40 to 50 N⋅m
(4 to 5 kgf⋅m, 30 to 37 lbf⋅ft)
26. Install the parts at the opposite side of the rear

27. Add gear oil to the left and right sides of the rear
axle. Install plugs (2, 3, 10 and 43).
Plug (2)
: 8 mm
: 35 to 50 N⋅m
(3.6 to 5 kgf⋅m, 22 to 37 lbf⋅ft)
Plugs (3, 10, 43)
: 10 mm
: 35 to 50 N⋅m
(3.6 to 5 kgf⋅m, 22 to 37 lbf⋅ft)
W3-5-43
DISASSEMBLY OF DIFFERENTIAL
NOTE: Disassembly of the differential is common

to the front axle and the rear axle.
The illustration shows the front axle.
1 2 3 4 5 6 7 8 9 10
11
11
10 12
9
13
14
20
15
19
16
18
A 17 WCEB-03-05-008
21 22 23 24 25 26 27
Section A
28
29
30
31
32 1
WCEB-03-05-012
W3-5-44
1- Drive Housing 9- O-Ring 17 - Differential Case 25 - Bearing

2- Differential Case 10 - Cover 18 - Washer 26 - Seal Ring
3- Retaining Ring 11 - O-Ring 19 - Bearing 27 - Guard
4- Cover 12 - Bearing 20 - Side Gear 28 - Flange
5- Spider (2 Used) 13 - Bearing Nut 21 - Pinion 29 - O-Ring
6- Washer (4 Used) 14 - Washer 22 - Bearing 30 - Nut
7- Pinion Gear (4 Used) 15 - Side Gear 23 - Shim 31 - Dust Seal
8- Bevel Gear 16 - Bolt (16 Used) 24 - Bushing 32 - Shim
W3-5-45
1 2 3 4 9 10
11
11
10 12
9
13
WCEB-03-05-008
21 25 26 27
28
29
30
31
1
WCEB-03-05-012
W3-5-46
Disassembly of Differential
1. Remove the axle casing from drive housing (1). 5. Remove the differential from drive housing (1).
(Refer to Disassemble Front Axle on W3-5-10 and
Disassemble Rear Axle on W3-5-30.)
1
Differential
2. Remove socket bolt (33). Remove bearing nut
(13) from cover (10) by using special tool (DANA
Special tool No.：T6 2379).
: 6 mm
33 13
10
WCEB-03-05-013
6. Remove retaining ring (3) from drive housing (1).

Remove cover (4).
WCEB-03-05-014 7. Remove nut (30) and O-ring (29) from drive

housing (1).
3. Remove socket bolts (34) (4 used). Remove cover : 36 mm
(10) from drive housing (1).
: 10 mm 8. Remove flange (28) and guard (27) from drive
housing (1).
34 1
9. Remove dust seal (31) from flange (28).
10. Remove seal ring (26) from drive housing (1).

10
necessary.
11. Remove pinion (21) from drive housing (1) by us-
ing a plastic hammer. At this time, do not drop the
inner race of bearing (25).
WCEB-03-05-019
4. Remove the outer race of bearing (12) and

O-rings (9, 11) from cover (10).
W3-5-47
1 2 5 6 7 8 10
12
14
20
15
19
16
18
17 WCEB-03-05-008
21 22 23 24 25
32 1
WCEB-03-05-012
W3-5-48
IMPORTANT: Do not remove bearing (22) unless 17. Remove washers (6) (2 used), (14, 18), pinion
necessary. gears (7) (4 used), side gears (15, 20) and spiders
12. Remove bushing (24), shim (32) and the inner (5) (2 used) from differential case (17).
race of bearing (22) from pinion (21).
18. Remove other cover (10) from drive housing (1) in
IMPORTANT: Do not remove bearings (22, 25) the same way as steps 2 to 4.
unless necessary. NOTE: Cover (10) is installed on only one side of
13. Remove the outer races of bearings (22, 25) and drive housing (1) of the rear axle.
shim (23) from drive housing (1).
14. Secure the differential in a vise. Remove the inner

race of bearings (12, 19) from the differential.
15. Remove bolts (16) (16 used) from bevel gear (8).
: 17 mm
16
WCEB-03-05-018
16. Remove socket bolts (35) (15 used) from differen-

tial case (2). Remove differential case (2) from
differential case (17).
: 8 mm 17
2
35
WCEB-03-05-020
W3-5-49
ASSEMBLY OF DIFFERENTIAL
NOTE: Assembly of the differential is common to

the front axle and the rear axle.
The illustration shows the front axle.
11 2 3 4 5 6 7 8 9 10
15
14
13 12
9
1
14
20
2
19
7
18
A 9 WCEB-03-05-008
21 22 23 24 25 26 27
Section A
28
29
30
31
32 1
WCEB-03-05-012
W3-5-50
1- Drive Housing 9- O-Ring 17 - Differential Case 25 - Bearing

2- Differential Case 10 - Cover 18 - Washer 26 - Seal Ring
3- Retaining Ring 11 - O-Ring 19 - Bearing 27 - Guard
4- Cover 12 - Bearing 20 - Side Gear 28 - Flange
5- Spider (2 Used) 13 - Bearing Nut 21 - Pinion 29 - O-Ring
6- Washer (4 Used) 14 - Washer 22 - Bearing 30 - Nut
7- Pinion Gear (4 Used) 15 - Side Gear 23 - Shim 31 - Dust Seal
8- Bevel Gear 16 - Bolt (16 Used) 24 - Bushing 32 - Shim
W3-5-51
1 2 3 4 5 6 7 8
12
14
20
15
19
16
18
17 WCEB-03-05-008
21 22 23 24 25 26 27
28
30
31
32 1
WCEB-03-05-012
W3-5-52
Assembly of Differential
1. Install washers (6) (2 used), (14, 18), pinion gears 5. Install the outer races of bearings (22, 25) and
(7) (4 used), side gears (15, 20) and spiders (5) (2 shim (23) to drive housing (1).
used) to differential case (17).
6. Apply hydraulic oil onto bearing (25). Install the
2. Apply LOCTITE #270 onto socket bolt (35). Install inner race of bearing (25) to drive housing (1).
differential case (2) to the differential case (17)
assembly with socket bolts (35) (15 used). 7. Apply hydraulic oil onto bearing (22). Install the
: 8 mm inner race of bearing (22), shim (32) and bushing
: 78 to 86 N⋅m (24) to pinion (21).
(8 to 9 kgf⋅m, 58 to 63 lbf⋅ft) NOTE: Shim (32) thickness: 1.33 to 1.35 mm (0.05
17 to 0.05 in)
2
8. Install the pinion (21) assembly and flange (28) to
drive housing (1).
35
9. Apply LOCTITE #242 onto nut (30). Install nut (30)
to pinion (21).
: 36 mm
WCEB-03-05-020
: 800 to 1000 N⋅m (80 to 100 kgf⋅m, 590 to
738 lbf⋅ft)
3. Install bevel gear (8) to the differential case (17)
assembly with socket bolts (16) (16 used). 10. Measure the torque of pinion (21).
: 17 mm
: 128 to 142 N⋅m NOTE: Correct torque: 120 to 180 N⋅m (12 to 18
(13 to 14.5 kgf⋅m, 94 to 105 lbf⋅ft) kgf⋅m, 89 to 1.33 lbf⋅ft)
16 11. Remove nut (30) and flange (28) from drive

housing (1).
8 : 36 mm
12. Install seal ring (26) to drive housing (1).
13. Install dust seal (31) to flange (28).
WCEB-03-05-018 14. Install guard (27) and flange (28) to drive housing
(1).
4. Install the inner races of bearings (12, 19) to the
differential.
W3-5-53
1 3 4 9 10
11
11
10 12
9
13
WCEB-03-05-008
21
29
30
1
WCEB-03-05-012
W3-5-54
15. Apply LOCTITE #242 onto nut (30). Install O-ring 19. Install bearing nut (13) to cover (10) by using
(29) and nut (30) to pinion (21). special tool (DANA Special tool No.：T6 2379).
: 36 mm Install socket bolt (33) to cover (10).
: 800 to 1000 N⋅m : 6 mm
(80 to 100 kgf⋅m, 590 to 738 lbf⋅ft) : 24 to 26 N⋅m
(2.4 to 2.7 kgf⋅m, 18 to 19 lbf⋅ft)
16. Install the differential to drive housing (1).
33 13
1 10
Differential
WCEB-03-05-014
20. Install cover (4) and retaining ring (3) to drive

housing (1).
WCEB-03-05-013
17. Apply grease onto O-rings (9, 11). Install O-rings 21. Install the axle casing to drive housing (1). (Refer
(9, 11) and the outer race of bearing (12) to cover to Assemble Front Axle on W3-5-20 and Assem-
(10). ble Rear Axle on W3-5-36.)
18. Apply LOCTITE #242 onto socket bolt (34). Install

cover (10) to drive housing (1). Secure cover (10)
: 10 mm
: 116 to 128 N⋅m
(12 to 13 kgf⋅m, 86 to 94 lbf⋅ft)
34 1
10
WCEB-03-05-019
W3-5-55
(Blank)
W3-5-56
UNDERCARRIAGE / Axle Lock Cylinder
REMOVAL AND INSTALLATION OF AXLE
LOCK CYLINDER

The procedure starts on the premise that the front axle

has already been removed.
Removal 1 2 3
1. Disconnect hoses (1) (2 used) from operate check
valve (3). Cap the open ends.
: 19 mm
IMPORTANT: Do not remove operate check valve

(3). If removing operate check valve
(3), rod (4) may come off due to the
entering air.
2. Remove socket bolts (2) (2 used) from operate
check valve (3). Install eyebolts (M8, Pitch 1.25
mm) (2 used) into the hole. Attach a nylon sling
onto eyebolts. Hoist and hold operate check valve
(3).
: 6 mm
4 WCEB-03-06-001
WCEB-03-06-003
CAUTION: Axle lock cylinder (5) weight: 38
kg (84 lb)
5
3. Remove socket bolts (6) (3 used), washers (7) (3
used), bolt (8) and spacer (9) from axle lock Pulling-Out Hole
cylinder (5).
: 17 mm 6, 7
: 32 mm
9
Pulling-Out Hole
8
WCEB-03-06-001
W3-6-1
10
CAUTION: Axle lock cylinder (5) weight: 38
kg (84 lb)
4. Install the bolts (M12, Pitch 1.75 mm) (2 used) into 5

the pulling-out hole on axle lock cylinder (5). Pulling-Out Hole
Tighten the bolts (2 used) alternately. Remove axle
lock cylinder (5) from track frame (10).
: 19 mm
Pulling-Out Hole
WCEB-03-06-001
W3-6-2
Installation
CAUTION: Axle lock cylinder (5) weight: 38 10

kg (84 lb)
1. Apply LOCTITE #262 onto socket bolts (6) (3

used) and bolt (8). 5
2. Hoist and align axle lock cylinder (5) with the

mounting hole on track frame (10). Install axle lock
6, 7
cylinder (5) to track frame (10) with socket bolts (6) 9
(3 used), washers (7) (3 used), bolt (8) and spacer
(9).
: 17 mm
: 750 N⋅m (76.5 kgf⋅m, 553 lbf⋅ft)
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 553 lbf⋅ft)
8 WCEB-03-06-001
3. Remove eyebolts (2 used) from axle lock cylinder 2 3 5

(5).
4. Install operate check valve (3) to axle lock cylinder

: 6 mm
: 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)
WCEB-03-06-003
1 3
5. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
WCEB-03-06-001
W3-6-3
DISASSEMBLY AND ASSEMBLY OF AXLE
LOCK CYLINDER
8, 9 10
8, 9 10 7
2 View A WCEB-03-06-003
1 WCEB-03-06-002
1- Retaining Ring 4- Dust Seal 7- Housing 9 - O-Ring

2- Dust Seal 5- Seal Ring 8- Operate Check Valve 10 - Socket Bolt (4 Used)
3- Air Ring (4 Used) 6- Rod
W3-6-4
Disassembly of Axle Lock Cylinder Assembly of Axle Lock Cylinder
1. Install seal ring (5), dust seal (4) and air rings (3)
CAUTION: Axle lock cylinder weight: 38 kg
(4 used) to housing (7).
(84 lb)
2. Install dust seal (2) and retaining ring (1) to
1. Place the axle lock cylinder onto the workbench
housing (7).
horizontally.
IMPORTANT: Apply hydraulic oil onto the inner
surface of housing (7), dust seals (2,
check valve (8). Remove operate check valve (8)
4), seal ring (5) and air ring (3).
and O-ring (9) from housing (7).
3. Install rod (6) to housing (7).
3. Apply air to the port hole on housing (7) and
remove rod (6). CAUTION: Axle lock cylinder weight: 38 kg
(84 lb)
4. Remove retaining ring (1) and dust seal (2) from
housing (7). 4. Install operate check valve (8) to housing (7) with
socket bolts (10) (4 used) and O-ring (9).
5. Remove air rings (3) (4 used), dust seal (4) and : 6 mm
seal ring (5) from housing (7). : 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)
W3-6-5
(Blank)
W3-6-6
UNDERCARRIAGE / Operate Check Valve
OPERATE CHECK VALVE (FOR AXEL
LOCK CYLINDER)

1 2
Removal 3, 4
: 19 mm
5
check valve (3). Remove operate check valve (3)
and O-ring (4) from axle lock cylinder (5). Cap the
open ends.
: 6 mm
WCEB-03-06-001
Installation 1 2 3, 4
1. Apply grease onto O-ring (4). Install O-ring (4) to
operate check valve (3).
2. Install operate check valve (3) to axle lock cylinder

5
: 6 mm
: 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)
3. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
WCEB-03-06-001
W3-7-1
UNDERCARRIAGE / Operate Check Valve
STRUCTURE OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER)
1 2 3 4 5 6 7 8 9 10 11 12 13
WCEB-03-06-004

1 Plug 1 : 6.2 2±0.5 (0.2±0.05) (1.5±0.4)
2 O-Ring 1 1A P11
3 Plug 1 : 27 120±12 (12±1.2) (89±9)
4 O-Ring 1 1B P18
5 Piston 1
6 Body 1
7 Poppet 1
8 Sleeve 1
9 Spring 1
10 O-Ring 1 1B P11
11 Plug 1 : 36 500±50 (51±5) (369±37)
12 O-Ring 1 1B P26
13 Plug 1 :6 34.3±3.4 (3.5±0.3) (25±2.5)
W3-7-2
UNDERCARRIAGE / Solenoid Valve
OUTRIGGER / BLADE SOLENOID VALVE
UNIT

AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Solenoid Valve Unit
IMPORTANT: One side of the solenoid valve unit Solenoid Valve Unit
cannot be removed. Remove the
plate (2) assembly.
Removal
1. Disconnect hoses (3) (8 used) from solenoid valve
units (4) (2 used). Cap the open ends. Attach an
assembling.
: 19 mm, 22 mm
2. Disconnect connectors (1) (4 used) from solenoid

W1F3-04-04-004
valve units (4) (2 used).

Remove the plate (2) assembly from track frame 1 Solenoid Valve Unit 2 3 Solenoid Valve Unit
(6).
: 17 mm

Remove solenoid valve units (4) (2 used) from 1
plate (2).
: 17 mm
3
7 3 6 4, 5 WCEB-03-08-001
W3-8-1
Installation
1. Install solenoid valve units (4) (2 used) to plate (2)
with sems bolts (5) (4 used). Solenoid Valve Unit
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) Solenoid Valve Unit
2. Install the plate (2) assembly to track frame (6)

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
3. Connect hoses (3) (8 used) to solenoid valve units

(4) (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) W1F3-04-04-004
4. Connect connectors (1) (4 used) to solenoid valve

units (4) (2 used).
1 Solenoid Valve Unit 2 3
Solenoid Valve Unit
7 3 6 4, 5 WCEB-03-08-001
W3-8-2
STRUCTURE OF SOLENOID VALVE UNIT
T1F3-03-08-001
5

No. Part Name Q’ty Remarks
(mm) N·m (kgf·m) (lbf·ft)
1 Solenoid 2
2 Piston 2
3 O-Ring 2 1B P14
4 Body 1
5 Spool 2
6 Spring 2
W3-8-3
(Blank)
W3-8-4
UPPERSTRUCTURE / Transmission Changeover Solenoid Valve
REMOVEAL AND INSTALLATION OF
TRANSMISSION CHANGEOVER
SOLENOID VALVE

1 2
Removal
2. Disconnect hoses (2) (4 used) from transmission

changeover solenoid valve (3). Cap the open ends.
Attach an identification tag onto the disconnected
hoses for assembling.
: 19 mm
3. Remove socket bolts (4) (3 used) from WCEB-03-09-001

transmission changeover solenoid valve (3). 5 4 3
Remove transmission changeover solenoid valve
: 6 mm
Installation 1 2
1. Install transmission changeover solenoid valve (3)
to bracket (5) with socket bolts (4) (3 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
2. Connect hoses (2) (4 used) to transmission

changeover solenoid valve (3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
3. Connect connectors (1) (2 used) to transmission 5 4 3

WCEB-03-09-001
changeover solenoid valve (3).
W3-9-1
UPPERSTRUCTURE / Transmission Changeover Solenoid Valve
(Blank)
W3-9-2
UNDERCARRIAGE / Propeller Shaft
PROPELLER SHAFT
Preparation
1. Park the machine on a solid, level surface. Lower
the front attachment onto the ground.
2. Lower the blade and the outrigger onto the ground.
3. Place the blocks in front of and behind the axle in

order to secure the machine.
WCEB-03-10-006
Removal
1. Remove grease fitting (3) from propeller shaft (1).
: 10 mm
A
B
IMPORTANT: Propeller shaft (1) cannot be C
removed individually. If removing
propeller shaft (1) individually, spline
seal (2) is damaged. Remove the WCEB-03-10-001
propeller shaft (1) assembly. 1
2 3 WCEB-03-10-007
Detail B
1 4 5
2. Remove nuts (4) (8 used) from flange (5).

: 14 mm
6
3. Insert a screwdriver between flange (5) and shaft
(6). Remove the propeller shaft (1) assembly from
shaft (6). Lower one side of the propeller shaft (1)
assembly onto the ground.
Detail C WCEB-03-10-003
W3-10-1
7 8 9 1
: 14 mm

(7). Remove the propeller shaft (1) assembly from
shaft (7).
Detail A WCEB-03-10-002
6. Remove grease fitting (10) from propeller shaft

(12).
: 10 mm
IMPORTANT: Propeller shaft (12) cannot be

removed individually. If removing
A
propeller shaft (12) individually,
spline seal (11) is damaged. Remove D
the propeller shaft (12) assembly. E
WCEB-03-10-001
10 11 12
Detail E
WCEB-03-10-008

: 14 mm
13 14 15 12
(13). Remove the propeller shaft (12) assembly
from shaft (13). Lower one side of the propeller
shaft (12) assembly onto the ground.
Detail D WCEB-03-10-004
W3-10-2
: 14 mm

(18). Remove the propeller shaft (12) assembly
from shaft (18).
F
WCEB-03-10-001
12 16 17 18
Details F WCEB-03-10-005
Installation
1. Align flange (17) of the propeller shaft (12)
assembly with the mounting part of shaft (18).
Secure flange (17) to shaft (18) with nuts (16) (8
used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
D
F
WCEB-03-10-001
12 16 17 18
Details F WCEB-03-10-005
13 14 15 12
2. Align flange (14) of the propeller shaft (12)
assembly with the mounting part of shaft (13).
Secure flange (14) to shaft (13) with nuts (15) (8
used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
Details D WCEB-03-10-004
W3-10-3
3. Align flange (5) of the propeller shaft (1) assembly
with the mounting part of shaft (6). Secure flange
(5) to shaft (6) with nuts (4) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
A
C
WCEB-03-10-001
1 4 5
WCEB-03-10-003
Detail C
4. Align flange (8) of the propeller shaft (1) assembly 7 8 9 1

with the mounting part of shaft (7). Secure flange
(8) to shaft (7) with nuts (9) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
Detail A WCEB-03-10-002
5. Install grease fittings (3, 10) to propeller shafts (1,

12). Apply grease.
： 10 mm
3 WCEB-03-10-007
10 12
WCEB-03-10-008
W3-10-4
MEMO
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SECTION 4
FRONT ATTACHMENT
— CONTENTS —
Group 1 Front Attachment Group 3 Hose Rupture Valve
Hydraulic Circuit Pressure Hydraulic Circuit Pressure
Release Procedure .............................. W4-1-1 Release Procedure ...............................W4-3-1
Removal and Installation of Removal and Installation of Hose
Front Attachment (Monoblock Boom) .. W4-1-2 Rupture Valve for Arm Cylinder ............W4-3-2
Removal and Installation of Removal and Installation of Hose Rupture
Front Attachment (2-Piece Boom)...... W4-1-11 Valve for Positioning Cylinder ...............W4-3-3
Maintenance Standard ......................... W4-1-20 Removal and Installation of Hose
Standard Dimensions for Rupture Valve for Boom Cylinder .........W4-3-5
Arm and Bucket Connection .............. W4-1-23 Structure of Hose Rupture Valve
Standard Dimensions for for Arm Cylinder ....................................W4-3-8
Arm and Boom Connection ................ W4-1-24 Structure of Hose Rupture Valves
for Boom and Positioning Cylinders ...W4-3-12
Group 2 Cylinder
Hydraulic Circuit Pressure Group 4 Operate Check Valve
Release Procedure .............................. W4-2-1 Remove and Install Operate Check
Removal and Installation of Cylinder ..... W4-2-2 Valve (for Blade and Outrigger) ............W4-4-1
Disassembly of Boom, Arm and Structure of Operate Check Valve ..........W4-4-3
Bucket Cylinders ................................ W4-2-26
Assembly of Boom, Arm and
Bucket Cylinders ................................ W4-2-32
Disassembly of Positioning Cylinder.... W4-2-38
Assembly of Positioning Cylinder ........ W4-2-42
Disassembly of Outrigger and
Blade Cylinders .................................. W4-2-46
Assembly of Outrigger and
Blade Cylinder .................................... W4-2-48
Maintenance Standard ......................... W4-2-54
CEBW-4-1
(Blank)
CEBW-4-2
FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
NOTE: Operate the pilot pump by using the power

from the battery without starting the engine
and deliver the pilot pressure to the spool
of the control valve.
1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.
2. Turn the engine stop switch ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.
IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, oper- WCEB-02-01-002
Engine Stop Switch
ate the lever 4 to 5 times in order to release any
pressure in the hydraulic circuit.
4. Return the pilot shut-off lever to the LOCK posi-

tion.
5. Turn the engine stop switch OFF.
W4-1-1
FRONT ATTACHMENT (MONOBLOCK
BOOM)
Removal 1 1
1. As for the lubrication hoses to the front attach-
ment, disconnect hoses (1) (2 used) to the boss
at the boom cylinder (3) rod side from the
adapter.
: 17 mm
WCGB-04-01-001
2. Remove nuts (7) (4 used) from bolts (4) (2 used).

Remove bolts (4) (2 used) and stoppers (5) (2
1 2 3 4
used) from pin (6).
: 24 mm
5
CAUTION: Boom cylinder (3) weight: 110 kg
(243 lb) 6
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec- 7
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
WCGB-04-01-002
3. Attach a nylon sling onto the end of the boom
cylinder (3) tube. Hoist and hold the boom cylin-
der (3) tube. By using a bar and a hammer, tap
pin (6) into the position where thrust plate (2) can
be removed. Remove thrust plate (2).
NOTE: When pin (6) cannot be removed, start the
engine and operate the boom lever. Adjust
the rod pin hole on the boom cylinder.
W4-1-2
4. Place the tube end of boom cylinder (3) on a
stand of 1 m (39 in) height.
Start the engine. Operate the boom lever and re- Stand
tract boom cylinder (3). In order not to extend the
rod, pass a wire through the rod hole and secure
the rod to the cylinder tube.
Stop the engine.
3
Wire
5. Remove boom cylinder (3) from the boom.
Refer to Removal of Boom Cylinder on W4-2-10.
6. Remove other boom cylinder (3) in the same way

as steps 3, 4 and 5.
W554-02-03-007
CAUTION: Do not stand toward the removal 2 3

direction of the pins as the pins may come
off suddenly.
7. Slowly tap and remove pin (6) by using a bar and

a hammer. Remove thrust plate (2).
6
8. After stopping the engine, push the air bleed
valve. Bleed air from the hydraulic oil tank and
remove the cap.
Release the pressure in the hydraulic circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE WCGB-04-01-002
RRLEASE PROCEDURE on W4-1-1. Air Bleed Valve
Cap
Hydraulic
Oil Tank
9. Disconnect hoses (8, 9) (2 used for each) from WCEB-04-01-002
the bucket cylinder and the arm cylinder. Cap the

disconnected hoses and pipes.
: 36 mm
NOTE: The number of the hoses may differ de-

pending on the front attachment specifica-
tions.
W1F3-04-01-010
8 9
W4-1-3
10
WCEB-02-05-002

Remove cover (13) from cover (11), support (18)
and bracket (14).
: 17 mm 13
11
Remove cover (15) from cover (16).
: 17 mm
15
WCEB-02-05-001
17 16
18
WCEB-02-05-003
14
WCEB-02-05-004
W4-1-4
CAUTION: Boom foot pin (21) weight: 23 kg 19

(51 lb)
20
13. Remove nuts (22) (2 used) from bolt (19). Re-
move bolt (19) from main frame (20). 21
: 30 mm
22
WCEB-04-01-001
CAUTION: Front attachment weight: 2000 kg Boom

(4410 lb)
14. Attach a wire rope onto the boom. Hoist and hold
the boom.
CAUTION: Boom foot pin (21) weight: 23 kg

(51 lb) WCEB-02-03-001
15. Install the bolt (M20, Pitch 2.5 mm) to boom foot
pin (21). Attach a pry bar onto the bolt head. Pull
out boom foot pin (21).
: 30 mm
20
16. While turning the bolt gradually by hand, remove
boom foot pin (21) from main frame (20). 21
NOTE: When boom foot pin (21) cannot be re-
moved, adjust the position by using a lifting
rope for the front attachment.
WCEB-04-01-001
17. Hoist the front attachment assembly and move
the machine backward.
18. Place a wooden block. Lower the front attach-

ment assembly onto the wooden block.
W4-1-5
Installation
Boom
CAUTION: Front attachment weight: 2000 kg
(4410 lb)

the machine forward. Align the boom foot with the
mounting hole on main frame (20).
Insert a thrust plate into the left and right sides of
the boom. Adjust the clearance between the plate
and main frame (20) within 1 mm (0.04 in).
(Adjust the position by using a lifting rope for the
front attachment.)
WCEB-02-03-001

to prevent personal injury. 20
(51 lb) 21
2. Align the lock holes on foot pin (21) and the collar 22
hole on main frame (20). Install boom foot pin
(21). Secure boom foot pin (21) to main frame
(20) with bolt (19) and nuts (22) (2 used). WCEB-04-01-001
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)
17
15
3. Install cover (15) to cover (16) with sems bolts

(17) (3 used).
: 17 mm 16 WCEB-02-05-008
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W4-1-6
4. Install cover (13) to cover (11), support (18) and
12
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
13
11
14
WCEB-02-05-001
18
WCEB-02-05-003
14
WCEB-02-05-004
5. Shut cover (10).
10
WCEB-02-05-002
W4-1-7
6. Remove the caps from the hoses and the pipes.
Connect hoses (8, 9) (3 used for each) to the
bucket cylinder and the arm cylinder.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
W1F3-04-01-010
8 9

(243 lb)
7. Install boom cylinder (3).

Refer to Installation of Boom Cylinder on
W4-2-12.
Wire

a hammer is used. Wear necessary protec-
8. Remove the wire from boom cylinder (3). Attach a

nylon sling onto the end of the boom cylinder (3)
WCEB-04-01-003
tube. Hoist and align the boom cylinder (3) tube
with the mounting hole on the boom.
6 2
9. Insert thrust plate (2) between the boom and
boom cylinder (3), and between boom cylinder
(3) and collar (5). Install pin (6). Install boom cyl-
3
inder (3) to the both sides.
4
10. Install stoppers (5) (2 used) to pin (6). Secure
stoppers (5) (2 used) to pin (6) with bolts (4) (2
used) and nuts (7) (4 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
5
7
W178-04-01-004
W4-1-8
11. Connect lubrication hoses (1) (2 used) to the
boom cylinder (3) rod side. 1 1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
3 3
WCGB-04-01-001
Left Boom Cylinder Arm Cylinder Right Boom

Rod Side Bottom Side Cylinder
Boom Foot Side Rod Side
12. Apply grease onto the boom cylinder (3) rod side,
the bottom side and the boom foot side.
WCGB-04-01-004
W4-1-9
IMPORTANT: When removing the arm from the
boom, perform the following steps
when installing the arm.
13. Install thrust plates (23) to the left and right sides
of the arm. Adjust total clearance of left and right
within 1.5 mm (0.06 in). Boom
14. After installing the arm, apply grease onto grease Arm
fitting (24) in the boom connecting boss of the
arm.
IMPORTANT: For handling of HN bushing for the

front attachment, check the follow-
ings.
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged.
Use a press. WCEB-02-03-001
Precautions when reinforcing the arm

The heat when welding in order to reinforce the arm
may cause oil leakage from HN bushing and decrease
lubrication performance.
When the welding heat causes the oil leakage of the
bushing, replace the bushing.
Use the special tool when removing or installing the

bushing.
Special tool: ST 1454 23 23
24 24
M157-07-157
W4-1-10
FRONT ATTACHMENT (2-PIECE BOOM)
1 1
Removal
1. As for the lubrication hoses to the front attach-
ment, disconnect hoses (1) (2 used) of to the
boss at the boom cylinder (3) rod side from the
adapter.
: 17 mm
WCGB-04-01-001
1 2 3 4
2. Remove nuts (7) (4 used) from bolts (4) (2 used).
Remove bolts (4) (2 used) and stoppers (5) (2
used) from pin (6).
5
: 24 mm
6
(290 lb)
7
WCGB-04-01-002
3. Attach a nylon sling onto the end of the boom
cylinder (3) tube. Hoist and hold the boom cylin-
der (3) tube. By using a bar and a hammer, tap
pin (6) into the position where thrust plate (2) can 2, 6 4, 5 1
be removed. Remove thrust plate (2).
NOTE: When pin (6) can not be removed, start the
engine and operate the boom lever. Adjust
the rod pin hole on the boom cylinder.
7 3
WCEB-04-01-004
W4-1-11
4. Place the tube end of boom cylinder (3) on a
stand of 1 m (39 in) height.
Start the engine. Operate the boom lever and re- Stand
tract boom cylinder (3). In order not to extend the
rod, pass a wire through the rod hole and secure
the rod to the cylinder tube.
Stop the engine.
3
Wire
5. Remove boom cylinder (3) from the boom.
Refer to Removal of Boom Cylinder on W4-2-10.
6. Remove other boom cylinder (3) in the same way

as steps 3, 4 and 5.
W554-02-03-007
CAUTION: Do not stand toward the removal

direction of the pins as the pins may come 2 3
off suddenly.
7. Slowly tap and remove pin (6) by using a bar and

a hammer. Remove thrust plate (2).
6
8. After stopping the engine, push the air bleed val-
ve. Bleed air from the hydraulic oil tank and re-
move the cap.
Release the pressure in the hydraulic circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE WCGB-04-01-002
RRLEASE PROCEDURE on W4-1-1. Air Bleed Valve
9. Disconnect hoses (8) (4 used) and hoses (9) (3

used) from the bucket cylinder, the arm cylinder
Cap
and the positioning cylinder. Cap the discon-
nected hoses.
: 36 mm
NOTE: The number of the hoses may differ de-
pending on the front attachment specifica- Hydraulic
tions. Oil Tank
WCEB-04-01-002
8 8
9 9 WCGB-04-01-003
W4-1-12
10
WCEB-02-05-002

12
Remove cover (13) from cover (11), support (18)
and bracket (14).
: 17 mm
11 13

Remove cover (15) from cover (16). 14
: 17 mm
15
WCEB-02-05-001
17 16
18
WCEB-02-05-003
14
WCEB-02-05-004
W4-1-13

(51 lb)
20
13. Remove nuts (22) (2 used) from bolt (19). Re-
move bolt (19) from main frame (20).
21
: 30 mm
22
WCEB-04-01-001

Boom
(5324 lb)
14. Attach a wire rope onto the boom. Hoist and hold
the boom.
WCEB-02-03-002

(51 lb)
15. Install the bolt (M20, Pitch 2.5 mm) to boom foot
20
pin (21). Attach a pry bar onto the bolt head. Pull
out boom foot pin (21).
: 30 mm 21
16. While turning the bolt gradually by hand, remove

boom foot pin (21) from main frame (20).
NOTE: When boom foot pin (21) cannot be re- WCEB-04-01-001
moved, adjust the position by using a lifting

rope for the front attachment.

the machine backward.
18. Place a wooden block. Lower the front attach-

ment assembly onto the wooden block.
W4-1-14
Installation
Boom
(5324 lb)

the machine forward. Align the boom foot with the
mounting hole on main frame (20).
Insert a thrust plate into the left and right sides of
the boom. Adjust the clearance between the plate
and main frame (20) within 1 mm (0.04 in).
(Adjust the position by using a lifting rope for the
front attachment.)
WCEB-02-03-002


(51 lb)
22
2. Align the lock holes on foot pin (21) and the collar
hole on main frame (20). Install boom foot pin
(21). Secure boom foot pin (21) to main frame WCEB-04-01-001
(20) with bolt (19) and nuts (22) (2 used).

: 30 mm 17
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)
15
3. Install cover (15) to cover (16) with sems bolts
(17) (3 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
16 WCEB-02-05-008
W4-1-15
4. Install cover (13) to cover (11), support (18) and 12
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 11 13
14
WCEB-02-05-001
18
WCEB-02-05-003
14
WCEB-02-05-004
5. Shut cover (10).
10
WCEB-02-05-002
W4-1-16
6. Remove the caps from the hoses and the pipes. 8 8
Connect hoses (8) (4 used) and hoses (9) (3
used) to the bucket cylinder and the arm cylinder.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
9 9 WCGB-04-01-003

(290 lb)
7. Install boom cylinder (3).

Refer to Installation of Boom Cylinder on Wire
W4-2-12.
CAUTION: Metal fragments may fly off when 3

WCEB-04-01-003
2 3 4
8. Remove the wire from boom cylinder (3). Attach a
nylon sling onto the end of the boom cylinder (3)
tube. Hoist and align the boom cylinder (3) tube 5
with the mounting hole on the boom.
6
9. Insert thrust plate (2) between the boom and
boom cylinder (3), and between boom cylinder 7
(3) and collar (5). Install pin (6). Install boom cyl-
inder (3) to the both sides.
10. Install stoppers (5) (2 used) to pin (6). Secure WCGB-04-01-002
stoppers (5) (2 used) to pin (6) with bolts (4) (2

used) and nuts (7) (4 used). 2, 6 4, 5
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)
7 3
WCEB-04-01-004
W4-1-17
11. Connect lubrication hoses (1) (2 used) to the 1
boom cylinder (3) rod side.
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
WCEB-04-01-004
1 3
WCGB-04-01-002
12. Apply grease onto the boom cylinder (3) rod side,
the bottom side and the boom foot side.
Second Boom Foot Right

Second Boom Foot Left
Arm Cylinder Bottom Side
Boom Cylinder Rod Side
Left Boom Foot Side
Right Boom Foot Side
WCEB-04-01-007
W4-1-18
IMPORTANT: When removing the arm from the
boom, perform the following steps
when installing the arm.
13. Install thrust plates (23) to the left and right sides Boom
of the arm. Adjust total clearance of left and right
within 1.5 mm (0.06 in). Arm
14. After installing the arm, apply grease onto grease

fitting (24) in the boom connecting boss of the
arm.
IMPORTANT: For handling of HN bushing for the

front attachment, check the follow-
ings.
Precautions when installing the bushing WCEB-02-03-002
If a hammer is used, the bushing may be damaged.
Use a press.
Unit: mm (in)
+1.0 +0.04
Precautions when reinforcing the arm 268 -0 (10.6 -0 )
The heat when welding in order to reinforce the arm
may cause oil leakage from HN bushing and decrease
lubrication performance.
When the welding heat causes the oil leakage of the
bushing, replace the bushing.
Use the special tool when removing or installing the

bushing.
Special tool: ST 1454
23 23
W1GL-04-01-012
24
W1GL-04-01-011
W4-1-19
Pin and Bushing
F
N
C
A
L M
E
B
D
G I K
J
H WCEB-02-03-001
WCEB-02-03-002
Unit: mm (in)
Pin 71 (2.8) 70.0 (2.8)
A
Bushing 71 (2.8) 72.5 (2.9)
Pin 80 (3.1) 79.0 (3.1)
B Boss (Main Frame) 80 (3.1) 81.5 (3.2)
Bushing (Boom Cylinder) 80 (3.1) 81.5 (3.2)
Pin 71 (2.8) 70.0 (2.8)
C Bushing (Boom Cylinder) 71 (2.8) 72.5 (2.9)
Boss (Boom) 71 (2.8) 72.5 (2.9)
Replace
Pin 71 (2.8) 70.0 (2.8)
D
Bushing 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
E Boss (Arm) 71 (2.8) 72.5 (2.9)
Bushing (Arm Cylinder) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
F Boss (Boom) 71 (2.8) 72.5 (2.9)
Bushing (Arm Cylinder) 71 (2.8) 72.5 (2.9)
W4-1-20
Unit: mm (in)
Pin 60 (2.4) 59.0 (2.3)
G Boss (Arm) 60 (2.4) 61.5 (2.4)
Bushing (Bucket Cylinder) 60 (2.4) 61.5 (2.4)
Pin 65 (2.6) 64.0 (2.5)
H Bushing 65 (2.6) 66.5 (2.6)
Bushing (Bucket Cylinder) 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64.0 (2.5)
I
Bushing 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64.0 (2.5)
J Replace
Bushing 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64.0 (2.5)
K
Bushing 65 (2.6) 66.5 (2.6)
Pin 80 (3.1) 79.0 (3.1)
L
Bushing 80 (3.1) 81.5 (3.2)
Pin 80 (3.1) 79.0 (3.1)
M
Bushing 80 (3.1) 81.5 (3.2)
Pin 71 (2.8) 70.0 (2.8)
N
Bushing 71 (2.8) 72.5 (2.9)
IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a
press and special tool (ST 1454).
W4-1-21
Point
B C
W105-04-01-020
Unit: mm (in)
A 178.5 (7) 90 (3.5)
B 79 (3.1) -
Replace
C 95 (3.7) -
D 81 (3.2) -
Side Cutter
C
D
W155-04-01-002
Unit: mm (in)
A 229 (9) 149 (5.9)
B 245 (9.6) -
Replace
C 330 (13) -
D 135 (5.3) -
W4-1-22
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
Section B
Section A
W1CF-04-01-007
Unit: mm (in)
a 352 (1.9)
b 10 (0.4)
c 505 (7.9)
d 460 (6.1)
e -
f 1230 (48)
g 377 (19)
h 255 (10)
i 65 (2.6)
j 362 (14)
k 70 (2.8)
l 377 (19)
m 255 (14)
n 65 (2.6)
o 90°
p 30°
q 398 (16)
W4-1-23
STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION
WCEB-04-01-005
WCEB-04-01-006
Section C
W1GL-04-01-010
Unit: mm (in)
s 71 (2.8)
t 268 (10.6)
u 428 (17)
W4-1-24
FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE

and deliver the pilot pressure to the spool
of the control valve.
1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.


3. With the key switch in the START position, oper- WCEB-02-01-002
Engine Stop Switch
ate the lever 4 to 5 times in order to release any
pressure in the hydraulic circuit.
4. Return the pilot shut-off lever to the LOCK posi-

tion.
W4-2-1
REMOVAL AND INSTALLATION OF CYL-
INDER
1
Removal of Bucket Cylinder
1. Insert wooden block (3) between the ground and

the end of arm (2), and between arm (2) and
bucket cylinder (1). 3
2. Stop the engine. Push the air bleed button and 2

bleed air from the hydraulic oil tank. Remove the 3
cap.
Release the pressure in the bucket circuit. W554-04-02-006
Refer to HYDRAULIC CIRCUIT PRESSURE

RELEASE PROCEDURE on W4-2-1.
CAUTION: Before removing pin (7), fasten

the link by using a wire in order not to fall
off.
CAUTION: Metal fragments may fly off when 4 5
3. Remove nuts (6) (2 used) and bolt (4). Remove

pin (7) by tapping. Remove thrust plates (5) (4
used).
: 24 mm
4. In order not to extend rod (8) of bucket cylinder

7 6
(1), pass wire (9) through the cylinder rod hole
and secure to the bucket cylinder (1) tube. W158-04-02-006
8 1
9 W102-04-02-005
W4-2-2
5. Disconnect bucket cylinder hoses (12) (2 used)
10
at the bottom of bucket cylinder (1). Cap the open
ends
: 27 mm
CAUTION: Bucket cylinder (1) weight: 100

kg (220 lb) 15
tion, such as goggles, hard hats, etc in order 13
6. Hoist and hold bucket cylinder (1). Remove nuts

(13) (2 used) and bolt (15). Remove pin (11) by
tapping. Remove thrust plates (10) (2 used). 1
: 24 mm
7. Remove bucket cylinder (1).
12 W187-04-02-004
W4-2-3
Installation of Bucket Cylinder
10
IMPORTANT: If a hammer is used when installing
the bushing, the bushing may be
damaged. Use a press.
CAUTION: Bucket cylinder (1) weight: 100 15

kg (220 lb)
14
a hammer is used when installing pin (11). 13
Wear necessary protection, such as goggles,
hard hats, etc in order to prevent personal
injury.
1. Hoist bucket cylinder (1). Align the hole on the 1

Arm
cylinder tube side with the cylinder mounting hole
on the arm. Install thrust plates (10) (2 used) and
pin (11).
2. Install stopper (14) and pin (11) to the arm. Se- 12 W187-04-02-004
cure with bolt (15) and nuts (13) (2 used).

: 24 mm
: 180 N⋅m (18.5 kgf⋅m, 133 lbf·ft) 8 1
3. Connect bucket cylinder hoses (12) (2 used).

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf·ft)
4. Remove wire (9) from rod (8) of bucket cylinder

(1).
9 W102-04-02-005
W4-2-4

a hammer is used. Wear necessary protec- 16 4 17 5
5. Start the engine. Operate the lever and align the

hole on the bucket cylinder (1) rod side with
those on links (16, 18). Install thrust plates (5) (4
used) and pin (7).
6. Secure stopper (17) and pin (7) with bolt (4) and
7 18 6
nuts (6) (2 used).
: 24 mm W158-04-02-006
: 270 N⋅m (27 kgf⋅m, 200 lbf·ft)
IMPORTANT: In case link (18) has been removed

19 19
from the arm, insert thrust plate (19)
when installing link (18).
IMPORTANT: After completing the work, add hy-
draulic oil to the specified level.
Operate bucket cylinder (1) fully to
the stroke end several times and
bleed air from the circuit.
At the same time, check each con- W157-04-01-015
18 18
nection of the hoses for any oil
leaks.
W4-2-5
Removal of Arm Cylinder
1
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).
2. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank. Remove the
2
cap.
Release the pressure in the arm circuit.
3 W187-04-02-005
3. Remove nuts (8) (2 used) and bolt (10) from pin 10 4 5

(5) at the rod side in arm cylinder (1).
: 30 mm
1

4. Remove pin (5) by tapping. Remove thrust plates

(4) (4 used).
8
W187-04-02-006
6 1
5. In order not to extend rod (6) of arm cylinder (1),
pass wire (7) through the cylinder rod hole and
secure to the arm cylinder (1) tube.
7 W187-04-02-010
W4-2-6
6. Disconnect pipings (11) (2 used) at the bottom of
1
arm cylinder (1). Cap the open ends. (When a
hose rupture valve is provided, refer to RE-
MOVAL AND INSTALLATION OF HOSE RUP- 11
TURE VALVE on W4-3-1.)
: 36 mm
7. Disconnect lubrication hose (12) from arm cylin-

der (1).
: 19 mm 12
CAUTION: Arm cylinder (1) weight: 160 kg

(360 lb)
WCGB-04-01-001
8. Attach a nylon sling at the center of gravity of arm
cylinder (1). Hoist and hold arm cylinder (1).
1

9. Remove nuts (15) (2 used) and bolt (17) from the

tube side in arm cylinder (1). Remove pin (14).
Remove thrust plate (13). Hoist and remove arm
cylinder (1).
: 30 mm W102-04-02-016
17 13 14
15
W187-04-02-007
W4-2-7
Installation of Arm Cylinder
17 13 14
the bushing, the bushing may be 1
CAUTION: Arm cylinder (1) weight: 160 kg
(360 lb)
16
15
1. Attach a nylon sling at the center of gravity of arm
cylinder (1). Hoist arm cylinder (1). Align the hole
on the cylinder tube side hole with the cylinder
mounting hole on the boom.
W187-04-02-007
1
tion, such as goggles, hard hats, etc in order 11
2. Install thrust plate (13) and pin (14). Secure pin

(14) and stopper (16) with bolt (17) and nuts (15)
(2 used).
12
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)
3. Connect lubrication hose (12) and pipings (11) (2

used) of arm cylinder (1).
: 19 mm WCGB-04-01-001
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)

: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf·ft)
IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for
any oil leaks at the hose connec-
tions.
W4-2-8
4. Remove wire (7) from rod (6) of arm cylinder (1).
6 1
Hold arm cylinder (1) and start the engine. Oper-
ate the lever and align the hole at the rod (6) side
with the mounting hole on arm (18).
1
3
5. Install thrust plate (4) and pin (5). Secure pin (5) W187-04-02-010
and stopper (9) with bolt (10) and nuts (8) (2 9 10 4 5

used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)
IMPORTANT: When completing the work, operate

arm cylinder (1) to the stroke end 18
several times and bleed air from the
circuit.
W187-04-02-006
W4-2-9
Removal of Boom Cylinder
1
1. Disconnect lubrication hose (1) from boom cylin-
der (2).
: 19 mm
CAUTION: Boom cylinder (2) weight:

2
2. Attach a wire rope onto boom cylinder (2). Hoist
Boom
and hold boom cylinder (2). WCGB-04-01-002

3. Remove nuts (5) (2 used), bolt (7) and stopper

(6) from the boom cylinder (2) rod side. Remove
pin (4) by tapping. Remove thrust plates (3) (2 7
used).
: 24 mm
4. Place the rod side of boom cylinder (2) on a

stand. Remove other boom cylinder (2) in the
same way.
6
5. Operate the lever and retract boom cylinder (2). 5 3 4 3 2
In order not to extend the rod, pass a wire W158-04-02-013
through the rod hole and secure to the cylinder
tube.
6. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank.
Release the pressure in the circuit.
2
Stand
W105-04-02-035
W4-2-10
7. Disconnect hoses (12) (4 used) at the bottom of
boom cylinder (2). Attach a plug onto the open
end of the hose. Cap the open end of boom cyl-
inder (2). (When a hose rupture valve is provided,
refer to REMOVEAL AND INSTALLATION OF
HOSE RUPTURE VALVE on W4-3-1.)
Plug 1 3/16-12UN
: 36 mm

tion, such as goggles, hard hats, etc in order W105-04-02-036
2 8
11
8. Remove nuts (10) (2 used) and bolt (8) from the
cylinder bottom side of the main frame.
Remove pin (9) by tapping. Remove thrust plate
(11).
(Monoblock boom)
: 24 mm
(2-piece boom) 9
: 30 mm
9 10
CAUTION: Boom cylinder (2) weight: 12 10

Monoblock boom: 110 kg (250 lb) W178-04-02-009
9. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist and remove boom cyl-
inder (2).
Remove other boom cylinder (2) in the same
way.
W105-04-02-040
W4-2-11
Installation of Boom Cylinder
CAUTION: Boom cylinder (2) weight:


the bushing, the bushing may be
1. Attach a wire rope at the center of gravity of
boom cylinder (2). Hoist boom cylinder (2). Align
the hole at the boom cylinder tube side with the
mounting hole on the main frame.

W105-04-02-040
2 8
2. Install thrust plate (11) and pin (9). Secure with 11
bolt (8) and nuts (10) (2 used).
(Monoblock boom)
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft)
(2-piece boom)
: 30 mm
: 550 N⋅m (56 kgf⋅m, 406 lbf·ft) 9
3. Install other boom cylinder (2) in the same way. 9 10
4. Connect hoses (12) (4 used) to boom cylinders 12 10

W178-04-02-009
(2) (2 used).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf·ft)

tions.
W4-2-12
5. Hoist boom cylinder (2). Start the engine. Oper-
ate the lever and align the hole at the cylinder rod
side with the mounting hole on the boom.
7
6. Insert thrust plate (3) and install pin (4).

6
7. Secure pin (4) and stopper (6) with bolt (7) and 5 3 4 3 2
nut (5). W158-04-02-013
: 24 mm
: 270 N⋅m (27 kgf⋅m, 200 lbf·ft)
1 7
8. Connect lubrication hose (1).
: 19 mm 4
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
6
9. Install other boom cylinder (2) in the same way.
5
boom cylinder (2) to the stroke end
2
circuit.
Boom WCGB-04-01-002
W4-2-13
Removal of Positioning Cylinder
(2-Piece Boom Only)
1. Disconnect lubrication hose (1) from positioning

cylinder (2).
: 19 mm
CAUTION: Positioning cylinder (2) weight:

185 kg (410 lb)
2 1
WCCB-04-01-009
2. Attach a nylon sling onto positioning cylinder (2).
Hoist and hold positioning cylinder (2).

3. Remove nuts (6) (2 used) and bolt (5) from stop-

4
per (3) of the second boom.
: 30 mm
4. Remove pin (4).

5, 6
W1F3-04-04-003
W4-2-14
5. Disconnect hoses (7) (2 used) and hoses (8) (3
used) from positioning cylinder (2). Cap the open 7
ends of the disconnected hoses.
: 19 mm, 36 mm 2
W1F3-04-03-001
6. Remove nuts (12) (2 used) and bolt (13) from

stopper (11) of the first boom.
Remove pin (9) and thrust plate (10) by using a
hammer and a bar.
: 30 mm

185 kg (410 lb)
7. Hoist and remove positioning cylinder (2).
12, 13 2
9, 10
11
W1F3-04-04-003
W4-2-15
Installation of Positioning Cylinder
(2-Piece Boom Only)

185 kg (410 lb)
1. Hoist positioning cylinder (2). Align the pin holes

at the bottom side with those of the first boom.
Insert thrust plate (10) and install pin (9) by tap-
ping.
2. Align the pin holes of stopper (11) and pin (9). In- 12, 13 2
stall and secure with bolt (13) and nuts (12) (2
used).
: 30 mm 11 9, 10
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)
W1F3-04-04-003
W4-2-16
tions. 3
3. Connect hoses (7) (2 used) and hoses (8) (3
used) to positioning cylinder (2).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 36 mm 4
: 175 N⋅m (18 kgf⋅m, 130 lbf·ft)
4. Start the engine and extend positioning cylinder

(2). Align the rod hole of positioning cylinder (2) 5, 6
with the hole of the second boom. Insert thrust
plate (10) and install pin (4) by tapping. 2
5. Align the pin holes of stopper (3) and pin (4). In-
stall bolt (5) and nuts (6) (2 used). 9, 10
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)
W1F3-04-04-003
W1F3-04-03-001
6. Connect lubrication hose (1) to positioning cylin-

der (2).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

positioning cylinder (2) to the stroke
end several times and bleed air from
the circuit.
WCCB-04-01-009
2 1
W4-2-17
Removal of Blade Cylinder
IMPORTANT: Before starting the work, lower the

blade onto the ground.

a hammer is used. Wear necessary protection,
such as goggles, hard hats, etc in order to
prevent personal injury.
Removal 1 2, 3
4
used) from cover (4). Remove cover (4) from
bracket (1).
: 19 mm
WCEB-04-02-001
5 6 7 8 9
2. Disconnect hoses (5) (4 used) from blade cylinder
10
: 19 mm, 27 mm 11
CAUTION: Blade cylinder (6) weight: 50 kg

(110 lb)
3. Attach a nylon sling onto blade cylinder (6). Hoist

and hold blade cylinder (6).
4. Remove nuts (10) (4 used) from bolts (8) (2 used). WCEB-04-02-002

Remove bolts (8) (2 used) from pins (9, 13). Re-
move pins (9, 13) from bracket (11) and link (12).
: 24 mm
6
5. Remove thrust plates (7) (6 used) between the
bottom part and bracket (11) and between the rod
part and link (12) in blade cylinder (6).
8
7
12
13 10 WCEB-04-02-001
W4-2-18
CAUTION: Blade cylinder (6) weight: 50 kg 6 11

(110 lb)
6. Remove blade cylinder (6) from bracket (11) and

link (12).
12
WCEB-04-02-002
6 7 8 9
Installation of Blade Cylinder 10
CAUTION: Blade cylinder (6) weight: 50 kg 11

(110 lb)
1. Attach a nylon sling onto blade cylinder (6). Hoist

blade cylinder (6). Align the bottom and rod parts
of blade cylinder (6) with the mounting holes on
bracket (11) and link (12).
2. Install thrust plates (7) (6 used) to the bottom and

rod parts of blade cylinder (6). Install blade cylin- WCEB-04-02-002
der (6) to bracket (11) and link (12) with pins (9,
13).
6
3. Secure pins (9, 13) to bracket (11) and link (12)
with bolts (8) (2 used) and nuts (10) (4 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft) 8
7
12
13 10 WCEB-04-02-001
5 6
4. Connect hoses (5) (4 used) to blade cylinder (6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf·ft)
WCEB-04-02-002
W4-2-19
5. Install cover (4) to bracket (1) with bolts (2) (4 2, 3
1
: 19 mm 4
: 90 N⋅m (9.2 kgf⋅m, 66 lbf·ft)

the blade cylinder to the stroke end
circuit.
WCEB-04-02-001
W4-2-20
Removal of Outrigger Cylinder

a hammer is used. Wear necessary protection,
such as goggles, hard hats, etc in order to
prevent personal injury.
1. Remove sems bolts (4) (3 used), washers (5) (2

used) and collars (6) (2 used) from cover (3).
Remove cover (3) from outrigger cylinder (2).
: 17 mm 1 2 3 4, 5, 6 4
2. Disconnect hoses (1) (4 used) from outrigger cyl-

inder (2). Cap the open ends. Attach an identifica-
tion tag onto the disconnected hoses for assem-
bling.
: 19 mm, 27 mm
3. Remove operate check valve (9) from outrigger

cylinder (2). (Refer to REMOVAL AND INSTAL-
9 7, 8 WCEB-04-02-004
LATION OF OPERATE CHECK VALVE on
W4-4-1.)
4. Disconnect piping (7) from outrigger cylinder (2).

Remove O-ring (8) from piping (7).
: 6 mm
2
CAUTION: Outrigger cylinder (2) weight: 70
kg (160 lb)
5. Attach a nylon sling onto the rod side of the out-

rigger cylinder (2) tube. Hoist and hold outrigger
cylinder (2).
WCEB-04-02-003
W4-2-21

kg (160 lb) 2 10, 11

used) from pin (13). Remove pin (13) and thrust
plates (14) (3 used) from outrigger (12). 12
: 19 mm
13, 14
7. Hoist outrigger cylinder (2) a little. Insert a wooden
block under outriger cylinder (2). Lower outrigger 15, 16
cylinder (2).
CAUTION: The outrigger (12) assembly 17 WCEB-04-02-003
8. Attach a nylon sling onto outrigger (12). Hoist and 17 10, 11

hold outrigger (12). Remove lock pin (11) from pin
(10). Remove pin (10) from outrigger beam (17).
Lower the outrigger (12) assembly.
Wooden Block
12
W1GL-04-02-006
CAUTION: Outrigger cylinder (2) weight: 70 18 17

kg (160 lb)
9. Attach a nylon sling onto outrigger cylinder (2).

Hoist and hold outrigger cylinder (2).
10. Remove ring (18) from pin (19). Remove lock pin
(20) from pin (19). Remove pin (19) and thrust
plates (21) (3 used) from outrigger beam (17).
11. Remove outrigger cylinder (2) from outrigger

beam (17).
19, 20, 21 2 WCEB-04-02-003
W4-2-22
Installation of Outrigger Cylinder

kg (160 lb) 18 17
1. Attach a nylon sling onto outrigger cylinder (2).

Hoist and align the hole on the bottom side with
the outrigger beam (17) mounting hole. Install
outrigger cylinder (2) to outrigger beam (17) with
thrust plates (21) (3 used) and pin (19).
2. Secure pin (19) to outrigger beam (17) with lock

pin (20) and ring (18).
19, 20, 21 2 WCEB-04-02-003
3. Install O-ring (8) to piping (7). Connect piping (7)

1 2
to outrigger cylinder (2).
: 6 mm
: 78±19 N⋅m (8±2 kgf⋅m, 58±6 lbf·ft)
4. Install operate check valve (9) to outrigger cylin-

der (2). (Refer to REMOVAL AND INSTALLATION
OF OPERATE CHECK VALVE on W4-4-1.)
5. Connect hoses (1) (4 used) to operate check

valve (9). 9 7, 8 WCEB-04-02-004
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf·ft)
2 3 4, 5, 6 4
6. Install cover (3) to outrigger cylinder (2) with sems
bolts (4) (3 used), washers (5) (2 used) and col-
lars (6) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft)
WCEB-04-02-004
W4-2-23
IMPORTANT: After the hose is connected, operate 17 10, 11
the outrigger cylinder to the stroke
end several times and bleed air from
the circuit.
7. Extend the rod of outrigger cylinder (2) and align
with the mounting hole on outrigger (12). Install
the rod part of outrigger cylinder (2) to outrigger
(12) with thrust plates (14) (3 used) and pin (13). 13, 14
2
8. Install pin (13) to outrigger (12) with bolts (15) (3 15, 16
: 19 mm Wooden Block
: 90 N⋅m (9 kgf⋅m, 66 lbf·ft) 12
W1GL-04-02-006
9. Remove the wooden block from the inside of out-

rigger beam (17).
17 10, 11
10. Operate outrigger cylinder (2) and align the
mounting hole on outrigger (12) with that on out-
rigger beam (17). Secure outrigger (12) to outrig-
ger beam (17) with pin (10) and lock pin (11). 12
2 WCEB-04-02-003
W4-2-24
(Blank)
W4-2-25
DISASSEMBLY OF BOOM, ARM AND
BUCKET CYLINDERS
Boom Cylinder
1 2 3 4 5 6 7 8 9 10 11
22 20 19 12
23
W1V1-04-02-007
26 25 17 18 24 19 21 18 17
Arm Cylinder 1 2 3 4 5 6 7 8 9 10 11
20 19 16 15 14 13 12
22
23
W1V1-04-02-008
26 25 17 18 24 19 21 18 17
W4-2-26
Bucket Cylinder
1 2 3 4 5 6 7 8 9 10 11
19 18 12
22
23
W1V1-04-02-009
17 18 24 19 21 20 17
1- Piston Rod 8- Bushing 15 - Cushion Seal 21 - Seal Ring

2- Wiper Ring 9- Snap Ring 16 - Snap Ring 22 - Set Screw
3- Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball
4- U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut
5- Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing
6- Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal
7- Cylinder Head 14 - Cushion Bearing
W4-2-27
1 6 7
14 12
W1V1-04-02-008
24
W4-2-28
Disassembly of Boom, Arm and Bucket Cylinders IMPORTANT: Pull out piston rod (1) straight in
• The disassembling procedure starts on the order not to damage the sliding
premise that the hydraulic pipings and the bands surface.
securing the pipings have been removed. 3. Tap and remove cylinder head (7) with piston rod
NOTE: The procedure for the arm cylinder is ex- (1) together from cylinder tube (12) by using a
plained. plastic hammer.
4. Secure piston rod (1) to special tool (ST 5908).

CAUTION: Boom cylinder weight: Put the matching marks on piston rod (1) and the
Monoblock boom: 110 kg (250 lb) end of piston (24) (Arm cylinder: cushion bearing
2-piece boom: 125 kg (280 lb) (14)).
Arm cylinder weight: 160 kg (360 lb)
Bucket cylinder weight: 100 kg (220 lb)
1. Hoist the cylinder. Secure the cylinder horizontally

on a workbench. Drain hydraulic oil from the cyl-
inder.
Special Tool: ST 5908

W158-04-02-022
W102-04-02-027
2. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Remove
socket bolts (6) (12 used) from cylinder head (7).
Boom and bucket cylinders:
: 12 mm
Arm cylinder:
: 14 mm
W4-2-29
1 2 3 4 5 6 7 8 9 10 11
20 19 16 15 14 13
22
23
W1V1-04-02-008
26 25 17 18 24 19 21 18 17
W4-2-30
5. Cut away the crimped part by using a hand drill 7. Remove slide rings (17) (2 used), slide rings (18)
and remove set screw (22). Remove steel ball (2 used), backup rings (19) (2 used), O-ring (20)
(23). and seal ring (21) from piston nut (24).
NOTE: Set screw (22) has been crimped by using
a punch at 2 places after installing. 8. Remove cylinder head (7) from piston rod (1).
: 6 mm 9. Remove O-ring (11) and backup rings (10, 3) from
Arm cylinder: cylinder head (7). Remove wiper ring (2), U-ring
: 8 mm (4), buffer ring (5), snap ring (9) and bushing (8)
by using the special tool.
6. Remove piston nut (24) by using special tool (ST Special tool (rod outer diameter):
5908) and the special tool. Boom and bucket cylinders: (ST 8017: 70 mm)
Remove cushion bearing (25) and cushion seal Arm cylinder: (ST 8019: 80 mm)
(26) from piston rod (1).
(Cushion bearing (25) is not equipped for the 10. (Arm cylinder only)
bucket cylinder. Cushion seal (26) is not equipped Remove stoppers (13) (2 used) from piston rod
for the bucket cylinder.) (1) by using a screwdriver. Remove cushion
Special tool (outer diameter at nut part): bearing (14), cushion seal (15) and snap ring (16).
Bucket cylinder: (ST 3271: 75 mm)
Boom cylinder: (ST 3242: 80 mm)
Arm cylinder: (ST 3263: 90 mm)
Special Tool: ST 5908

W158-04-02-022
W4-2-31
ASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS
Boom Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22
3 8 9 10, 11 26 24 20, 21 23 W1V1-04-02-005
Arm Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22 14
3 8 9 10, 11 26 24 20, 21 23 16 15 W1V1-04-02-003
Bucket Cylinder
1 2 4 5 6 7 12 17 18 19 18 17
22
3 8 9 10, 11 20, 21 23
W1V1-04-02-001
W4-2-32
1- Piston Rod 8- Bushing 15 - Cushion Seal 21 - Seal Ring

2- Wiper Ring 9- Snap Ring 16 - Snap Ring 22 - Set Screw
3- Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball
4- U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut
5- Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing
6- Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal
7- Cylinder Head 14 - Cushion Bearing
W4-2-33
1 2 4 5 7 17 18 19 18 17 14
13
3 8 9 10, 11 24 20, 21 16 15 W1V1-04-02-003
NOTE: The illustration shows the arm cylinder.
W4-2-34
Assembly of Boom, Arm and Bucket Cylinders
NOTE: The procedure for the arm cylinder is ex- 5. Install O-ring (20) and seal ring (21) to piston nut
plained. (24) by using special tool A.
After installing seal ring (21), adjust seal ring (21)
1. Install bushing (8) to cylinder head (7) by using by using special tool B.
the special tool. Special tools A and B (tube inner diameter):
Special tool (rod outer diameter): Bucket cylinder: (ST 2181, 2205: 100 mm)
Boom and bucket cylinders: (ST 8017: 70 mm) Boom cylinder: (ST 2977, 2332: 105 mm)
Arm cylinder: (ST 8019: 80 mm) Arm cylinder: (ST 2183, 2207: 115 mm)
IMPORTANT: Check the direction to install. 6. Install backup rings (19) (2 used), slide rings (17)
2. Install U-ring (4), backup ring (3), buffer ring (5) (2 used) and slide rings (18) (2 used) to piston nut
and snap ring (9) to cylinder head (7). (24).
3. Install wiper ring (2) to cylinder head (7) by using 7. Install the cylinder head (7) assembly to piston
the special tool and a plastic hammer. rod (1) by using the special tool.
Special tool (rod outer diameter): Special tool (rod outer diameter):
Boom and bucket cylinders: (ST 8017: 70 mm) Boom and bucket cylinders: (ST 8017: 70 mm)
Arm cylinder: (ST 8019: 80 mm) Arm cylinder: (ST 8019: 80 mm)
4. Install O-ring (11) and backup ring (10) to cylinder IMPORTANT: Face the slit in cushion seal (15) to
head (7). the piston nut (24) side. Check the
direction of the oil groove in cushion
bearing (14).
8. (Arm cylinder only)
Install snap ring (16) and cushion seal (15) to
piston rod (1). Install cushion bearing (14) and
stoppers (13) (2 used).
W4-2-35
1 6 7 12 25 22
26 24 23 W1V1-04-02-003
NOTE: The illustration shows the arm cylinder.
W4-2-36
IMPORTANT: Face the slit in cushion seal (26) to 11. Install steel ball (23) to piston rod (1). Tighten with
the piston nut (24) side. Check the set screw (22). Crimp set screw (22) by using a
direction of the oil groove in cushion punch at 2 places.
bearing (25). Boom and bucket cylinders:
9. Install cushion seal (26) and cushion bearing (25) : 6 mm
to piston rod (1). : 31.5±5.9 N⋅m (3.2±0.6 kgf⋅m, 23±4 lbf·ft)
(Cushion bearing (25) and cushion seal (26) are Arm cylinder:
not equipped for the bucket cylinder.) : 8 mm
: 57±11 N⋅m (5.8±1.1 kgf⋅m, 42±7 lbf·ft)
10. Align the matching marks and tighten piston nut
(24) by using special tool (ST 5908) and the spe-
CAUTION: Align the piston rod (1) assembly
cial tool.
with the center of cylinder tube (12) and in-
Special tool (outer diameter at nut part):
sert straight in order not to damage the rings.
Bucket cylinder: (ST 3271: 75 mm)
: 3540 N⋅m (359 kgf⋅m, 2620 lbf·ft)
Boom cylinder: (ST 3242: 80 mm) 12. Secure cylinder tube (12) horizontally on a work-
: 3140 N⋅m (320 kgf⋅m, 2320 lbf·ft) bench. Insert the piston rod (1) assembly into
Arm cylinder: (ST 3263: 90 mm) cylinder tube (12).
: 4320 N⋅m (441 kgf⋅m, 3190 lbf·ft)
13. Install cylinder head (7) to cylinder tube (12) with
: 12 mm
: 170 N⋅m (17 kgf⋅m, 126 lbf·ft)
Arm cylinder:
: 14 mm
: 267 N⋅m (27 kgf⋅m, 197 lbf·ft)
Special Tool: ST 5908 W158-04-02-022
W4-2-37
DISASSEMBLY OF POSITIONING CYLINDER
1
2 3 4
5
6 7
8 9
10
11
12
13
14 15
16
17
18
19 20 21
22
WCGB-04-02-010
1- Piston Rod 7- U-Ring 13 - Backup Ring 18 - O-Ring

2- Socket Bolt (14 Used) 8- Buffer Ring 14 - Piston 19 - Backup Ring (2 Used)
3- Cylinder Head 9- Bushing 15 - Slide Ring (2 Used) 20 - Set Screw
4- Retaining Ring 10 - Retaining Ring 16 - Wear Ring (2 Used) 21 - Piston Nut
5- Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring
W4-2-38
Disassembly of Positioning Cylinder
CAUTION: Do not drop piston rod (1) by tilt-
ing.
NOTE: The disassembling procedure starts on the
premise that the hydraulic pipings and the IMPORTANT: Pull out piston rod (1) straight in
bands securing the pipings have been re- order not to damage the sliding
moved. surface.
4. Slowly remove piston rod (1) from cylinder tube
CAUTION: Positioning cylinder weight: 185 (22). At this time, cylinder head (3) is removed
kg (410 lb) with piston rod (1) together. Set a cloth onto a
wooden block. Place piston rod (1) horizontally on
1. Hoist the cylinder. Secure the cylinder horizontally the wooden block.
on a workbench. Drain hydraulic oil from the cyl-
inder.
W102-04-02-027

onto piston rod (1). Hold piston rod (1). Remove
socket bolts (2) (14 used) from cylinder head (3).
: 14 mm
3. Remove cylinder head (3) from cylinder tube (22)

by using a pry bar.
W4-2-39
1
2 3 4
5
6 7
8 9
10
11
12
13
14 15
16
17
18
19 20 21
22
WCGB-04-02-010
W4-2-40
5. Cut away the crimped part by using a hand drill 9. Remove bushing (9) from cylinder head (3) by
and remove set screw (20) from piston nut (21). using special tool (ST 2613). Remove O-rings (11,
NOTE: Set screw (20) has been crimped by using 12), backup rings (6, 13), dust seal (5), U-ring (7),
a punch at 2 places after installing. buffer ring (8) and retaining rings (4, 10) from
: 4 mm bushing (9).
6. Remove piston nut (21) from piston rod (1) by

using special tool (ST 3335). Remove piston (14)
from piston rod (1) by using special tool (ST
3338).
7. Remove seal ring (17), slide ring (15), wear ring

(16), O-ring (18), retaining rings (19) (2 used) and
backup rings (17) (2 used) from piston (14).
8. Remove cylinder head (3) from piston rod (1).
W4-2-41
ASSEMBLY OF POSITIONING CYLINDER
6, 7 8 2 11 12, 13 16 17 18, 19
1 4, 5 9, 10 3 22 14 15 21 20
WCEB-04-02-010
1- Piston Rod 7- U-Ring 13 - Backup Ring 18 - O-Ring

2- Socket Bolt (14 Used) 8- Buffer Ring 14 - Piston 19 - Backup Ring (2 Used)
3- Cylinder Head 9- Bushing 15 - Slide Ring (2 Used) 20 - Set Screw
4- Retaining Ring 10 - Retaining Ring 16 - Wear Ring 21 - Piston Nut
5- Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring
W4-2-42
Assembly of Positioning Cylinder
1. Install bushing (9) to cylinder head (3) by using 5. Install O-ring (18), backup rings (19) (2 used),
special tool (ST 2613). Install retaining ring (10). seal ring (17), slide rings (15) (2 used) and wear
ring (16) to piston (14) by using special tool (ST
2. Tap and install dust seal (5) to cylinder head (3) 2589).
by using special tool (ST 2614) and a plastic
hammer. 6. Install the cylinder head (3) assembly to piston
rod (1) by using special tool (ST 2675).
IMPORTANT: Check the installing direction.
3. Install U-ring (7), backup ring (2), buffer ring (8)
and retaining ring (4) to cylinder head (3).
4. Install O-rings (11, 12) and backup ring (13) to

cylinder head (3).
W4-2-43
1 2 3 22 14 21 20
WCEB-04-02-010
W4-2-44
6. Apply hydraulic oil onto the inner surface of piston IMPORTANT: Align the piston rod (1) assembly
(14). Install piston (14) to piston rod (1) by using with the center of cylinder tube (22)
special tool (ST 3338). and insert straight in order not to
: 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf·ft) damage the rings.
10. Apply hydraulic oil onto the outer surface of piston
7. Apply hydraulic oil onto piston nut (21). Install (14). Hoist cylinder tube (22). Secure cylinder
piston nut (21) to piston rod (1) by using special tube (22) horizontally on a workbench. Insert the
tool (ST 3335). piston rod (1) assembly into cylinder tube (22).
: 1860±185 N⋅m
(190±19 kgf⋅m, 1380±137 lbf·ft) 11. Install cylinder head (3) to cylinder tube (22) by
using special tool (ST 2675). Tighten cylinder
8. Apply LOCTITE #242 onto two to three threads of head (3) with socket bolts (2) (14 used).
set screw (20). Install set screw (20) to piston nut : 14 mm
(21). After tightening set screw (20), crimp set : 470 to 490 N⋅m
screw (20) by using a punch at 2 places. (48 to 50 kgf⋅m, 345 to 360 lbf·ft)
: 4 mm
: 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)
W4-2-45
DISASSEMBLY OF OUTRIGGER AND BLADE CYLINDERS
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16 17
18
19
20
WCGB-04-02-002
1- Piston Rod 6- Seal 11 - O-Ring 16 - O-Ring

2- Cylinder Head 7- Bushing 12 - Piston 17 - Set Screw
3- Retaining Ring 8- Retaining Ring 13 - Seal Ring 18 - Piston Nut
4- Dust Seal 9- O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used)
5- U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube
W4-2-46
Disassembly of Outrigger and Blade Cylinders 4. Cut away the crimped part by using a hand drill
and remove set screw (17) from piston nut (18).
NOTE: The disassembling procedure starts on the NOTE: Set screw (17) has been crimped by using
premise that the hydraulic pipings and the a punch at 2 places after installing.
bands securing the pipings have been re- : 4 mm
moved.
5. Remove piston nut (18) by using special tool (ST
3333). Remove piston (12) from piston rod (1) by
CAUTION: Outrigger cylinder weight: 70 kg
using special tool (ST 3337).
(160 lb)
Blade cylinder weight: 50 kg (110 lb) 6. Remove cylinder head (2) from piston rod (1).
1. Hoist the cylinder. Secure the cylinder horizontally IMPORTANT: When removing the seals, do not
on a workbench. Drain hydraulic oil from the cyl- damage the parts.
inder. 7. Remove seal ring (13), wear ring (14), dust ring
(15) and O-ring (16) from piston (12).
8. Remove retaining rings (3, 8), U-ring (5), dust seal

(4) and backup ring (10) from the inside of cylin-
der head (2). Remove bushing (7) by using spe-
cial tool (ST 2684).
9. Remove O-rings (9, 11) and backup ring (10) from

W102-04-02-027
the outside of cylinder head (2).
2. Raise a detent (a part of cylinder tube (20)) in the
groove on cylinder head (2). Pry and remove cyl-
inder head (2) from cylinder tube (20).
R wrench: (ST 3221)
CAUTION: Do not drop piston rod (1) by tilt-

ing.
IMPORTANT: Remove piston rod (1) straight in

order not to damage the rod surface.
onto piston rod (1). Hold piston rod (1). Slowly
remove piston rod (1) from cylinder tube (20). Set
a cloth onto a wooden block. Place piston rod (1)
horizontally on the wooden block.
W4-2-47
ASSEMBLY OF OUTRIGGER AND BLADE CYLINDER
Outrigger Cylinder
1 3, 4 5 9 6 7, 8 2 10, 11 20 12 13 14 15 16, 19 18 17
WCEB-04-02-012
Blade Cylinder
1 3, 4 5 9 6 7, 8 2 10, 11 20 12 13 14 15 16, 19 18 17
WCEB-04-02-011
W4-2-48
1- Piston Rod 6- Seal 11 - O-Ring 16 - O-Ring

2- Cylinder Head 7- Bushing 12 - Piston 17 - Set Screw
3- Retaining Ring 8- Retaining Ring 13 - Seal Ring 18 - Piston Nut
4- Dust Seal 9- O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used)
5- U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube
W4-2-49
1 3, 4 5 9 6 7, 8 2 10, 11 12 13 14 15 16, 19 18 17
WCEB-04-02-012
NOTE: The illustration shows the outrigger cylinder.
W4-2-50
Assembly of Outrigger and Blade Cylinders IMPORTANT: After installing O-ring (16), check
that O-ring (16) is not twisted.
1. Install bushing (7) to cylinder head (2) by using 6. Install O-ring (16), backup rings (19) (2 used),
special tool (ST 2684). Install retaining ring (8). seal ring (13), wear ring (14) and dust ring (15) to
piston (12).
IMPORTANT: Install U-ring (5) with its lip part fac-
ing to the bushing (7) side. 7. Apply hydraulic oil onto the inner surface of piston
Install seal (6) with its projection part (12). Install piston (12) to piston rod (1) by using
and slit part facing to the bushing (7) special tool (ST 3337).
side. : 490±49 N⋅m (50±5 kgf⋅m, 360±36 lbf·ft)
2. Install U-ring (5) and seal (6) to cylinder head (2).
8. Apply hydraulic oil onto the threads of piston nut
3. Install dust seal (4) and retaining ring (3) to cyl- (18). Install piston nut (18) to piston rod (1) by
inder head (2) by using special tool (ST 2688). using special tool (ST 3333).
: 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf·ft)
IMPORTANT: Install backup ring (10) to the pin
hole side on piston rod (1). 9. Apply LOCTITE #242 onto set screw (17). Install
4. Install O-rings (9, 11) and backup ring (10) to cyl- set screw (17). After tightening set screw (17),
inder head (2). crimp set screw (17) by using a punch at 2 places.
: 4 mm
5. Install the cylinder head (2) assembly to piston : 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)
rod (1) by using special tool (ST 2692).
W4-2-51
2 20
1
WCEB-04-02-012
NOTE: The illustration shows the outrigger cylinder.
W4-2-52
IMPORTANT: Align the piston rod (1) assembly
with the center of cylinder tube (20)
straight in order not to damage the
rings.
10. Secure cylinder tube (20) horizontally on a work-

bench. Insert the piston rod (1) assembly into
cylinder tube (20).
11. Apply hydraulic oil onto the threads of cylinder

head (2). Install cylinder head (2) to cylinder tube
(20). Bend the detent and secure cylinder head
(2).
R wrench: (ST 3221)
: 490 to 690 N⋅m
(50 to 70 kgf⋅m, 360 to 510 lbf·ft)
W4-2-53
Piston Rod Rod Bend and Run Out of Piston Rod

A Dial Gauge
Piston Rod
W105-04-02-094 W166-04-02-022
1m
V Block
Unit: mm (in) Unit: mm (in)
Recommended Size After Bend Run Out Remedy
Cylinder Name
Re-Manufacturing (A)
+0.023 +0.001 0.5 (0.02) 1.0 (0.04) Repair
Boom 70 (2.8 )
-0.053 -0.002
+0.023 +0.001 1.0 (0.04) 2.0 (0.08) Replace
Arm 80 (3.1 )
-0.057 -0.002
+0.023 +0.001
Bucket 70 (2.8 )
-0.053 -0.002
+0.027 +0.001
Positioning 95 (3.7 )
-0.057 -0.002
+0.023 +0.001
Blade 60 (2.4 )
-0.043 -0.002
+0.023 +0.001
Outrigger 60 (2.4 )
-0.043 -0.002
W4-2-54
FRONT ATTACHMENT / Hose Rupture Valve
HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE

and deliver the pilot pressure to the spool of
the control valve.
1. Turn the pilot shut-off lever to the UNLOCK

position.


3. With the key switch in the START position, WCEB-02-01-002
Engine Stop Switch
operate the lever 4 to 5 times in order to release
any pressure in the hydraulic circuit.
4. Return the pilot shut-off lever to the LOCK

position.
W4-3-1
REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR ARM CYLINDER
CAUTION: Loosen the relief valve of hose 5

1 2 3, 4
rupture valve (3) slowly and release the
pressure.
Removal
1. Disconnect hoses (1) (2 used) from hose rupture
valve (3). Cap the open ends. 6
: 19 mm
2. Remove socket bolts (6) (4 used) from piping (5).

: 8 mm
3. Remove socket bolts (2) (4 used) from hose

rupture valve (3). Remove hose rupture valve (3) 7
and O-ring (4) from arm cylinder (7).
: 8 mm WCEB-04-03-003
1 2 3, 4 5
Installation
hose rupture valve (3).
2. Align hose rupture valve (3) with the mounting

holes on arm cylinder (7) and piping (5). Install
hose rupture valve (3) to arm cylinder (7) and 6
piping (5) with socket bolts (2, 6) (4 used for
each).
: 8 mm
: 52±10 N⋅m (5.2±1 kgf⋅m, 38±7 lbf⋅ft)
3. Connect hoses (1) (2 used) to hose rupture valve

7
(3).
: 19 mm WCEB-04-03-003
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
W4-3-2
RUPTURE VALVE FOR POSITIONING
CYLINDER
CAUTION: Loosen the relief valve of hose

rupture valve (7) slowly and release the 1 2 3 4
pressure.
Removal
1. Remove bolts (1) (2 used) from clamp (2).
Remove clamp (2) from bracket (3).
: 22 mm 5
2. Disconnect hoses (5) (3 used) from hose rupture

valve (7). Cap the open ends. Attach an 6
assembling.
: 19 mm 7, 8

Disconnect piping (4) from positioning cylinder (9).
WCEB-04-03-004
Remove hose rupture valve (7) and O-ring (8) 9
from positioning cylinder (9). Cap the open ends.
: 10 mm
W4-3-3
Installation
1. Apply grease onto O-ring (8). Install O-ring (8) to 1 2 3 4
2. Install hose rupture valve (7) and piping (4) to

positioning cylinder (9) with socket bolts (6) (4
used).
: 10 mm
: 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft) 5

(7). 6
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
7, 8
4. Secure piping (4) to bracket (3) with clamp (2) and
bolts (1) (2 used).
: 22 mm WCEB-04-03-004
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 9
W4-3-4
RUPTURE VALVE FOR BOOM CYLINDER
CAUTION: Loosen the relief valve of hose

1 2 3 4 5
rupture valve (8) slowly and release the
pressure.
Removal
1. Remove bolt (4) from clamps (3) (2 used).
Remove clamps (3) (2 used) from bracket (2) and
piping (5).
: 19 mm
2. Disconnect hoses (6) (6 used) from hose rupture 6

valve (8). Cap the open ends. Attach an
assembling.
: 17 mm, 19 mm, 27 mm

Disconnect piping (5) from boom cylinder (1).
Remove hose rupture valve (8) and O-ring (9) 8, 9 6 7 WCEB-04-03-002
from boom cylinder (1). Cap the open ends.

: 10 mm
W4-3-5
Installation 1 2 3 4 5
2. Install hose rupture valve (8) and piping (5) to

boom cylinder (1) with socket bolts (7) (4 used).
: 10 mm
: 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft)

(8). 6
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
8, 9 6 7 WCEB-04-03-002
4. Secure piping (5) to bracket (2) with clamps (3) (2

used) and bolt (4).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W4-3-6
(Blank)
W4-3-7
STRUCTURE OF HOSE RUPTURE VALVE FOR ARM CYLINDER
9 10 11 12 13 14 15 16
3 4 5 6 7 8
2
17
1 18
19
47
20
21
46
22
45
23
44
24
43
25
42
26
41
27
40 28
29
39
30
38 31
37
32
36
35
33
34 WCEB-04-03-006
W4-3-8

1 Spacer 1
2 Plug 3 :5
3 O-Ring 3
4 Backup Ring 1
5 O-Ring 1
6 Orifice 2
7 Backup Ring 2
8 O-Ring 1
9 Lock Nut 1 : 17
10 Poppet 1
11 Set Screw 1 :6
12 Spring 1
13 O-Ring 1
14 Washer 1
15 Adapter 1 : 24
16 O-Ring 1
17 Backup Ring 1
18 O-Ring 1
19 Casing 1
20 O-Ring 1
21 Plug 1 : 32
22 Stopper 1
23 Spool 1
24 Sleeve 1
25 Backup Ring 1
26 O-Ring 1
27 O-Ring 3
28 Plug 1
W4-3-9
47
46
45
44
43
42
41
40
29
39
30
38 31
37
32
36
35
33
34 WCEB-04-03-006
W4-3-10

29 Backup Ring 1
30 Spring 1
31 Holding Valve 1
32 Orifice 2
33 Body 1
34 O-Ring 1
35 O-Ring 1
36 Backup Ring 1
37 O-Ring 1
38 Backup Ring 1
39 Spring Seat 1
40 O-Ring 1
41 Piston 1
42 O-Ring 1
43 Cover 1 : 32
44 Stopper 1
45 Set Screw 1 :3
46 Lock Nut 1 : 10
47 Spring 1
Casing (19) and body (33)
4 :8
mounting socket bolt
W4-3-11
STRUCTURE OF HOSE RUPTURE VALVES
FOR BOOM CYLINDER AND POSITIONING
CYLINDER
9 10 11 12 13 14 15 16
17
3 4 5 6 7 8
2
18
1
19
47
20
46
21
45 22
23
44 24
25
43 26
27
42
28
41 29
40
30
39
38 31
37
32
36
35
33
34
W1V1-04-03-001
W4-3-12

1 Spacer 1
2 Plug 3 :5
3 O-Ring 3
4 Backup Ring 1
5 O-Ring 1
6 Orifice 2
7 Backup Ring 2
8 O-Ring 1
9 Lock Nut 1 : 17
10 Poppet 1
11 Set Screw 1 :6
12 Spring 1
13 O-Ring 1
14 Washer 1
15 Adapter 1 : 24
16 O-Ring 1
17 Backup Ring 1
18 O-Ring 1
19 Casing 1
20 O-Ring 1
21 Plug 1 : 32
22 Stopper 1
23 Spool 1
24 Sleeve 1
25 Backup Ring 1
26 O-Ring 1
27 O-Ring 3
28 Plug 1
W4-3-13
47
46
45
44
43
42
41 29
40
30
39
38 31
37
32
36
35
33
34
W1V1-04-03-001
W4-3-14

29 Backup Ring 1
30 Spring 1
31 Holding Valve 1
32 Orifice 2
33 Body 1
34 O-Ring 1
35 O-Ring 1
36 Backup Ring 1
37 O-Ring 1
38 Backup Ring 1
39 Spring Seat 1
40 O-Ring 1
41 Piston 1
42 O-Ring 1
43 Cover 1 : 32
44 Stopper 1
45 Set Screw 1 :3
46 Lock Nut 1 : 10
47 Spring 1
Casing (19) and body (33)
4 :8
mounting socket bolt
W4-3-15
(Blank)
W4-3-16
FRONT ATTACHMENT / Operate Check Valve
REMOVE AND INSTALL OPERATE CHECK Outrigger Beam Lock Pin Float
VALVE (FOR BLADE AND OUTRIGGER)
Removal
CAUTION: Lower the blade onto the ground
before doing any work.
Outrigger
CAUTION: Secure the outrigger beam and
the outrigger by using the lock pin before
doing any work.
WCEB-04-04-002
used) from guard cover (3). Remove guard cover
(3) from brackets (4) (2 used). 1, 2
: 19 mm
3
WCEB-04-02-001
5 6
: 19 mm, 27 mm
7, 8

: 6 mm 9

check valve (7). Remove operate check valve (7) 10
and O-rings (8) (2 used) from cylinder (11). Cap
the open ends.
11
: 6 mm 5
WCEB-04-02-002
10
11
6 7, 8 WCEB-04-04-001
W4-4-1
Installation
1. Apply grease onto O-rings (8) (2 used). 5 6
2. Install O-rings (8) (2 used) to operate check valve

(7).
7, 8
3. Install operate check valve (7) to cylinder (11) with
: 6 mm 9
: 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft)
4. Connect piping (9) to operate check valve (7) with 10

: 6 mm
11
: 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft) 5
WCEB-04-02-002
5. Connect hoses (5) (4 used) to operate check 9

valve (7).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm 10
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
6. Install guard cover (3) to brackets (4) (2 used) with

: 19 mm 11
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
6 7, 8 WCEB-04-04-001
1, 2
WCEB-04-02-001
Outrigger Beam Lock Pin Float
11
Outrigger
WCEB-04-04-002
W4-4-2
STRUCTURE OF OPERATE CHECK VALVE
1 2 3 4 5 6 7 8 9 10
11
12
13
WCEB-04-03-001

1 Plug 2 : 6 mm 34.3±3.4 (3.5±0.3) (25±3)
2 O-Ring 2 1B P11
3 Plug 2 : 36 mm 500±50 (51±5) (369±37)
4 O-Ring 2 1B P26
5 Spring 2
6 Sleeve 2
7 Poppet 2
8 Piston 2
9 O-Ring 1 1B P18
10 Plug 1 : 36 mm 240±24 (24±2.4) (18±2)
11 Casing 1
12 Plug 1 : 36 mm 240±24 (24±2.4) (18±2)
13 O-Ring 1B P18
W4-4-3
(Blank)
W4-4-4
MEMO
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Fax: 81-29-831-1162

PUBLICATION NO.:
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
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ZX140W-3 Full Service Manual

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ZX140W-3 Full Service Manual

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INTRODUCTION

• Please refer to the other materials (operator’s

• Each page has a number, located on the center

Consecutive Page Number for Each Group

In this manual, the following safety alert symbol and • CAUTION:

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Standard Chassis, Rear Blade)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Standard Chassis, Rear Outrigger)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Standard Chassis, Rear Outrigger)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Front Blade Rear Outrigger)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Front Blade Rear Outrigger)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Front Outrigger Rear Blade)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Front Outrigger Rear Blade)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Front Outrigger Rear Outrigger)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

ZX140W-3 (Front Outrigger Rear Outrigger)

Type of Front-End Attachment Monoblock Boom 2-Piece Boom

Type of Front-End Attachment Monoblock Boom

Type of Front-End Attachment Monoblock Boom

Type of Front-End Attachment 2-Piece Boom

Type of Front-End Attachment 2-Piece Boom

Main Component Layout

1- Blade Cylinder 3- 2-Spool Solenoid Valve Unit 5- Front Axle 8- Transmission

1- Blade Cylinder 3- 2-Spool Solenoid Valve Unit 5- Front Axle 8- Transmission

Electrical System (Overview)

Pump Device (Refer to T1-2-14.) Filter (Refer to T1-2-16.)

Travel Shockless Valve (Refer to T1-2-16.)

Swing Device (Refer to T1-2-14.)

Electrical System (Monitors and Switches)

Steering Column Monitor

Electrical System (Controllers and Relays)

1- MC (Main Controller) 3- Fuse Box 5- Option Controller

Dr.ZX Connector Fuse Box TCJB-01-02-010

fNOTE: OP: Optional

Swing Device Signal Control Valve

Control Valve Brake Valve

Travel Shockless Valve Transmission Changeover Solenoid Valve

Travel Device Filter

Diameter 650 mm (25.6 in), 5 Blades, Synthetic Resin, Intake

Performance (New Engine)

Engine Performance Curve (4JJ1XYSA)

Engine Speed min-1 (rpm) TCEB-01-03-001

Type In-line Type

Radiator Oil Cooler Intercooler

Core Size (Height × Width ×

Type 2-Stage Planetary Gear Reduction

· SC: For Arm Regenerative Control

Front: Steering Drive Axle with Hub Reduction

BATTERY RELAY Voltage and Current 24 V·100 A

• MC: Main Controller

Satellite Terminal Dr. ZX

CAN Bus Line

Steering Column ECM

NOTE: CAN (CAN Bus Line)

CAN bus line consists of two wires, CAN High and

Satellite Terminal Dr. ZX