CX210C Crawler Excavator Tier 4

CX210C
Tier 4
Crawler Excavator
SERVICE MANUAL
Printed in U.S.A. Part number 84551720B

English
Copyright © 2012 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. October 2012
Racine Wisconsin 53404 U.S.A. Replaces part number 84551720
Section
1001
Safety, general information and standard torque data
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ROPS Judgment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84551720B NA - August 2012 Copyright © 2011 CNH FRANCE

1001-1 PRINTED IN FRANCE
GENERAL INFORMATION
CLEANING
Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning.
Do not use caustic soda for steam cleaning.
After cleaning, dry and put oil on all parts.
Clean oil passages with compressed air.
Clean bearings in a suitable cleaning solvent,
dry the bearings completely and put oil on the bearings.
INSPECTION
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage.
Small scoring or grooves can be removed with a hone or crocus cloth.
Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early
failures.
BEARINGS
Check bearings for easy action.
If bearings have a loose fit or rough action replace the bearing.
Wash bearings with a suitable cleaning solvent and permit to air dry.
DO NOT DRY BEARINGS WITH COMPRESSED AIR.
NEEDLE BEARINGS
Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore.
Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.
GEARS
Check all gears for wear and damage.
Replace gears that have wear or damage.
Oil seals, O-rings and gaskets.
Always install new oil seals, O-rings and gaskets.
Put petroleum jelly on seals and O-rings.
SHAFTS
Check all shafts that have wear or damage.
Check the bearing and oil seal surfaces of the shafts for damage.
SERVICE PARTS
Always install genuine Case service parts.
When ordering refer to the
Parts Catalogue for the correct part number of the genuine Case replacement items.
Failures due to the use of other than genuine Case replacement parts are not covered by warranty.
LUBRICATION
Only use the oils and lubricants specified in the Operator’s or Service Manuals.
Failures due to the use of non-specified oils and lubricants are not covered by warranty.
84551720B NA - August 2012

1001-3
Safety
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

The message that follows the symbol contains important information about safety.
Carefully read the message.
Make sure you fully understand the causes of possible injury or death.
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the key switch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags are available from your service parts supplier.
WARNING
Read the operator's manual to familiarize yourself with the correct control functions.
WARNING
Operate the machine and equipment controls from the seat position only.
Any other method could result in serious injury.
WARNING
This is a one man machine, no riders allowed.
WARNING
Before starting engine, study Operator’s Manual safety messages.
Read all safety signs on machine.
Clear the area of other persons.
Learn and practice safe use of controls before operating.
It is your responsibility to understand and follow manufacturers instructions on machine operation, ser-
vice and to observe pertinent laws and regulations.
Operator's and Service Manuals may be obtained from your CASE dealer.
WARNING
If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can
be injured.
Always wear clothing that will not catch on objects.
Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face
protection, heavy gloves and reflector clothing.
WARNING
When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and
use extreme caution.
WARNING
When doing checks and tests on the equipment hydraulics, follow the procedures as they are written.
DO NOT change the procedure.
WARNING
When putting the hydraulic cylinders on this machine through the necessary cycles to check operation
or to remove air from a circuit, make sure all people are out of the way.
WARNING
Use insulated gloves or mittens when working with hot parts.
84551720B NA - August 2012

1001-4
WARNING
Lower all attachments to the ground or use stands to safely support the attachments before you do any
maintenance or service.
WARNING
Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious
infection.
If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately.
Maintain all hoses and tubes in good condition.
Make sure all connections are tight.
Make a replacement of any tube or hose that is damaged or thought to be damaged.
DO NOT use your hand to check for leaks, use a piece of cardboard or wood.
WARNING
When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze)
hammer or use a driver made from brass or bronze and a steel head hammer.
WARNING
When using a hammer to remove and install pivot pins or separate parts using compressed air or using
a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved
eye protectors).
WARNING
Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor.
Always block machine in place with suitable safety stands.
WARNING
When servicing or repairing the machine, keep the shop floor and operator's compartment and steps
free of oil, water, grease, tools, etc.
Use an oil absorbing material and/or shop cloths as required.
Use safe practices at all times.
WARNING
Some components of this machine are very heavy.
Use suitable lifting equipment or additional help as instructed in this Service Manual.
WARNING
Engine exhaust fumes can cause death.
If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an
exhaust pipe extension.
Open the doors and get outside air into the area.
WARNING
When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2),
you try to jump start and run the engine.
To prevent the battery electrolyte from freezing, try to keep the battery at full charge.
If you do not follow these instructions, you or others in the area can be injured.
84551720B NA - August 2012

1001-5
ROPS Judgment Method

1. Purpose
Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not.
The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not.
The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of
selectable options are mounted (as of 2009).
However, depending on the derivative machinery or the order details, the weight and boom position may differ
from the assumed weight or position.
2. Criteria for judging whether a machine satisfies the ROPS criteria
1) Weight
The weight must not be over the weight shown below for each class.
If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or
sustain a serious injury when the machine falls over.
If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria.
• Weight (X3 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)
Machine body total weight Class

SH75X-6
16000 kg (35274.146 lb) or less
SH125X-6
SH120-6
20500 kg (45195.000 lb) or less
SH150-6
28000 kg (61729.756 lb) or less SH235X-6
SH200-6
SH240-6
31000 kg (68343.658 lb) or less
SH240-6 LR
SH290-6
40000 kg (88185.365 lb) or less SH330-6
50000 kg (110231.707 lb) or less SH470-6
* The ROPS test assumes that the SH470-6 has a cage guard (alone).

CX75C
16000 kg (35274.146 lb) or less
CX145C
CX130C
20500 kg (45195.000 lb) or less CX160C
CX180C
28000 kg (61729.756 lb) or less CX235C
CX210C
CX250C
31000 kg (68343.658 lb) or less
CX250C LR
CX300C
40000 kg (88185.365 lb) or less CX370C
50000 kg (110231.707 lb) or less CX470C
* The ROPS test assumes that the CX470C has a cage guard (alone).

CX75C
16000 kg (35274.146 lb) or less
CX145C
CX130C
20500 kg (45195.000 lb) or less
CX160C
28000 kg (61729.756 lb) or less CX235C
CX210C
CX250C
31000 kg (68343.658 lb) or less
CX250C LR
CX300C
50000 kg (110231.707 lb) or less CX470C
84551720B NA - August 2012
1001-6
* The ROPS test assumes that the CX470C has a cage guard (alone).
• Weight (X2 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)

SH120-5
SH150-5
26600 kg (58643.268 lb) or less
SH200-5
SH240-5

CX130B
CX160B
26600 kg (58643.268 lb) or less CX180B
CX210B
CX240B
2) Boom position
WARNING
• If the machine has been modified so that the boom position has been lowered, the machine
will not satisfy the ROPS criteria.
• It is necessary to consult with our company if it is possible that the boom's position has been
lowered by modification.
• The extent to which a boom position has moved cannot be determined in the same way for
all machines.
a Ground point
With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the
diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard
machine (standard arm), the machine will not satisfy the ROPS criteria.
Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a
24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the
same.
3. Prohibited items
• Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or
modifications that reduce the functionality of the anchoring part at the left-rear of the cab)
• Modifications that effect the strength of the ROPS of a cab.
A forbidden all
All modifications (grinding, welding, drilling holes, removing, etc.) are prohib-
modifications
ited.
(red part)
Allow under spec- Removal of parts is prohibited.
ified conditions Bar welding and making holes [up to diameter 20 mm (0.787 in.)] by drilling
(gray part) are possible.
84551720B NA - August 2012
1001-7
[X3 Cab (SH120-6/SH150-6)]

[X3 Cab (CX130C/CX160C/CX180C)]
[X3 Cab (CX130C/CX160C)]
[X3 Cab (SH200-6/SH240-6/SH290-6)]

[X3 Cab (CX210C/CX240C/CX290C)]
84551720B NA - August 2012

1001-8
[X2 Cab (SH200-5/SH240-5/SH290-5)]

[X2 Cab (CX210B/CX240B/CX290B)]
• In general, high cabs do not satisfy the ROPS criteria. (It is necessary to consult with our company to check if
the high cab model satisfies the ROPS criteria.)
84551720B NA - August 2012

1001-9
Bolt and Nut Tightening

• Tighten alternating between left and right and top and bottom so that uniform tightening force is applied.
• If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the
old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to the thread section of the bolt.
Torque table
Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
mm 10 13 17 19 22 24 27 30
Wrench (in.) (0.394) (0.512) (0.669) (0.748) (0.866) (0.945) (1.063) (1.181)
Hexagon
19.6 39.2 58.8 98.1 156.9 196.1 294.2
bolt Tightening N・m 6.9
(14.459 (28.917 (43.376 (72.367 (115.74 (144.66 (217.02
torque (lbf・ft.) (5.090)
) ) ) ) 3) 1) 8)
mm 5 6 8 10 12 14 14 17
Wrench (in.)
Hexagon (0.197) (0.236) (0.315) (0.394) (0.472) (0.551) (0.551) (0.669)
socket 21.6 42.1 78.5 117.7 176.5 245.2 343.2
Tightening N・m 8.8
head bolt (15.934 (217.02 (57.909 (86.826 (130.20 (180.88 (253.17
torque (lbf・ft.) (6.492)
) 8) ) ) 2) 1) 5)
84551720B NA - August 2012

1001-10
Section
1002A
Specifications
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CX210C NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CX210C LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1002A-1 PRINTED IN FRANCE
Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Specifications
CX210C
Main Data
Operating weight 21700 kg (47840.56 lb)
Engine output 119.3 kW/1800 min-1 (159.98 HP/1800 rpm)
Heaped 0.9 m3
Bucket capacity
Leveled 0.61 m3
Performance
Standard weight 13.5 kN (3035.440 lbf)
Swing speed 11.8 min-1 (11.8 rpm)
Low speed 3.4 km/h (2.113 mile/h)
Travel speed
High speed 5.6 km/h (3.480 mile/h)
Maximum pulling force 188 kN (42271.32 lbf)
Grade ability 70 ％ (35°)
49 kPa (7.11 psi) [600 mm (23.622 in) 43 kPa (6.24 psi) [700 mm (27.559 in)
grouser shoe] grouser shoe]
Ground pressure
38 kPa (5.51 psi) [800 mm (31.496 in)
grouser shoe]
Main Unit Dimensions

Main unit length 4960 mm (195.276 in)
Main unit width 3190 mm (125.591 in)
Upper swing body width 2770 mm (109.055 in)
Cab width 1000 mm (39.307 in)
Main unit height 2960 mm (116.535 in)
Swing radius (rear end) 2750 mm (108.268 in)
Swing body rear end distance 2750 mm (108.268 in)
Swing body rear section bottom
1040 mm (40.945 in)
height
Distance between tumblers 3660 mm (144.094 in)
Overall track length 4470 mm (175.984 in)
Overall track width 3190 mm (125.590 in)
Distance between tracks 2390 mm (94.094 in)
Track shoe width 800 mm (31.496 in)[options 600 mm (23.622 in), 700 mm (27.559 in)]
Minimum ground clearance 440 mm (17.323 in)(to bottom of lower frame)
Engine
Name Isuzu 4HK1X diesel engine
4-cycle, water-cooled, overhead camshaft type, common rail system (elec-
Model tronic control), cooled EGR, with turbocharger (variable displacement type),
DPD system
No. of cylinders - bore x stroke 4 - D115 mm (4.528 in) x 125 mm (4.921 in)
Total stroke volume 5.193 L (1.37188 gal)
Maximum torque 621 N·m/1500 min-1 (458.10 lbf・ft/1500 rpm)
Starter 24 V 5.0 kW reduction type
Charging generator 24 V 50 A AC type
Battery 12 V 92 Ah/5 HR x 2
Cooling System
Fan type D650 mm (25.591 in), 7 blades, suction
Radiator
Fin type Wavy
Fin pitch 1.75 mm (0.06890 in)
84551720B NA - August 2012
1002A-3
Specifications
Oil cooler
Fin type Wavy
Intercooler
Fin type Triangular straight
Fuel cooler
Fin type Wavy
Upper Side Work System

Model Backhoe attachment
Components, dimensions, working dimensions
Standard bucket capacity Heaped 0.9 m3 (Leveled 0.61 m3)
Bucket width 1130 mm (44.488 in)
Bucket width with side cutter 1230 mm (48.425 in)
Bucket weight with side cutter 685 kg (1510.174 lb)
Boom length 5700 mm (224.409 in)
Standard (STD/HD) Short (STD/HD) Ultra Short (STD)
Arm type
[2.94 m (9.6457 ft)] [2.40 m (7.8740 ft)] [1.91 m (6.2664 ft)]
2940 mm (115.748
Arm length 2400 mm (94.488 in) 1910 mm (75.197 in)
in)
Bucket radius 1450 mm (57.087 in)
Bucket wrist angle 177°
9900 mm (389.764 9420 mm (370.866 8960 mm (352.756
Maximum digging radius
in) in) in)
9730 mm (383.071 9240 mm (363.780 8770 mm (345.276
Maximum digging radius at ground line
in) in) in)
6650 mm (261.811 6100 mm (240.157 5610 mm (220.866
Maximum digging depth
in) in) in)
5960 mm (234.646 5480 mm (215.748 5000 mm (196.850
Maximum vertical straight wall digging depth
in) in) in)
9610 mm (378.346 9390 mm (369.685 9140 mm (359.843
Maximum digging height
in) in) in)
6810 mm (268.110 6590 mm (259.449 6330 mm (249.213
Maximum dump height
in) in) in)
3660 mm (144.094 3600 mm (141.732 3580 mm (140.945
Minimum swing radius at front
in) in) in)
7640 mm (300.787 7700 mm (303.150 7700 mm (303.150
Height for minimum swing radius at front
in) in) in)
Operating Device
Operator's seat
Position Left side
Adjustable forward and back and up and down, reclining mechanism,
Structure
with seat suspension
Cab Sealed steel type, all reinforced glass
Levers and pedals
For travel use Lever and pedal type (hydraulic pilot type) x 2
For operating machine use Lever type (hydraulic pilot type) x 2
Instruments and switches
Work mode switchover 3 modes (SP/H/A)
Travel mode switchover Low-speed/high-speed switch type
One-touch idle Knob switch type
Engine emergency stop Switch type
Monitor device
Machine status display (full color liquid
crystal)
84551720B NA - August 2012
1002A-4
Specifications
Work mode select status SP/H/A

Instruments (full color liquid crystal)
Fuel gauge Bar graph and indicator
Engine coolant temperature gauge Bar graph and indicator
Hydraulic oil temperature gauge Bar graph and indicator
Hour meter Digital type
Machine status and warnings (full color liquid crystal and warning alarm) * has warning alarm
Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*) Engine oil pressure (*) Refill coolant
(*) Engine pre-heat Auto warm up Air cleaner (*) Anti-theft device triggered Engine system abnormality (*) Engine
emergency stop (*)
Illumination equipment
Tank front surface 24 V 70 W x 1
Working light Cab top 24 V 70 W x 2
Boom up 24 V 70 W x 1
Interior light 24 V 10 W x 1
Horn Electric horn x 2
Wiper with intermittent function, window washer, air conditioner, clock,
Other
rear view mirrors (left and right, total of 5)
Swing Units
Swing circle Swing bearing type (with inner gear)
Swing hydraulic motor Fixed displacement piston motor x 1
Reduction gear Planetary gear 2-stage reduction gear
Swing parking brake Mechanical lock (operational lever linkage type)
Travel Lower Body

Travel hydraulic motor Variable displacement piston motor x 2
Travel brake Hydraulic lock
Parking brake Mechanical lock (travel lever linkage type)
Track shoe
Model Assembly-type triple grouser shoe
No. of shoes (per side) 49
Shoe width 800 mm (31.496 in) [options 600 mm (23.622 in), 700 mm (27.559 in)]
Grouser height 26 mm (1.027 in)
Link pitch 190 mm (7.480 in)
Roller
No. of upper rollers (per side) 2
No. of lower rollers (per side) 8
Track belt tension adjuster Grease cylinder type (with cushion spring)
Hydraulic Equipment
Hydraulic Device
Hydraulic pump drive type Direct engine link (no transmission)

Hydraulic pump
Model Double variable displacement piston pump x 1
Gear pump x 1
Discharge volume Piston pump 2 x 211 L/min (55.742 gpm)
Gear pump 18 L/min (4.755 gpm)
Pump control method Simultaneous output full-horsepower control
Set pressure of main relief valve 34.3 MPa (4975.126 psi) [36.8 MPa (5337.975 psi) for pressure boost]
29.4 MPa (4264.578 psi) (boom down)
Set pressure of overload relief valve
38.7 MPa (5613.577 psi) (other)
84551720B NA - August 2012
1002A-5
Specifications
Control Valve and Cylinder
Control valve
Quadruple spool
Model One-piece type x 1
Quintuple spool
Operating method Hydraulic pilot type: travel, swing, and operating machine
Cylinder No. of cylinders x tube bore - rod diameter - stroke
Boom cylinder 2 x D120 mm (D4.724 in) - D85 mm (D3.346 in) - 1255 mm (49.409 in)
Arm cylinder 1 x D140mm (D5.512 in) - D100 mm (D3.937 in) - 1460 mm (57.480 in)
Bucket cylinder 1 x D120 mm (D4.724 in) - D85 mm (D3.346 in) - 1010 mm (39.764 in)
Capacities, Filters
Coolant and Oil Capacities
Coolant 28.7 L (7.582 gal)

Fuel 410 L (108.31 gal)
Engine lubricating oil 23.1 L (6.103 gal)
Travel reduction gear lubricating oil (one side) 5 L (1.32 gal)
Swing reduction gear lubricating oil 5 L (1.32 gal)
Hydraulic oil 240 L (63.40 gal)
Hydraulic oil tank regulation amount 147 L (38.83 gal)
Hydraulic Oil Filters
Suction filter (inside tank) 105 μm

Return filter (inside tank) 6 μm
Pilot line filter (inside housing) 8 μm
Fuel Filter
Main filter 2 μm
Pre-filter 5.5 μm
84551720B NA - August 2012

1002A-6
Specifications
CX210C NLC
Main Data
Heaped 0.9 m3
Bucket capacity
Leveled 0.61 m3
Performance
Travel speed
Grade ability 70 ％ (35°)
Ground pressure
38 kPa (5.51 psi) [800 mm (31.496 in)
grouser shoe]

Swing body rear section bottom
1040 mm (40.945 in)
height
Track shoe width 800 mm (31.496 in)[options 600 mm (23.622 in), 700 mm (27.559 in)]
Minimum ground clearance 440 mm (17.323 in)(to bottom of lower frame)
Engine
DPD system
Cooling System
Radiator
Fin type Wavy
84551720B NA - August 2012
1002A-7
Specifications
Oil cooler
Fin type Wavy
Intercooler
Fuel cooler
Fin type Wavy

Standard (STD/HD) Short (STD/HD) Ultra Short (STD)
Arm type
[2.94 m (9.6457 ft)] [2.40 m (7.8740 ft)] [1.91 m (6.2664 ft)]
2940 mm (115.748
Arm length 2400 mm (94.488 in) 1910 mm (75.197 in)
in)
9900 mm (389.764 9420 mm (370.866 8960 mm (352.756
Maximum digging radius
in) in) in)
9730 mm (383.071 9240 mm (363.780 8770 mm (345.276
Maximum digging radius at ground line
in) in) in)
6650 mm (261.811 6100 mm (240.157 5610 mm (220.866
Maximum digging depth
in) in) in)
5960 mm (234.646 5480 mm (215.748 5000 mm (196.850
Maximum vertical straight wall digging depth
in) in) in)
9610 mm (378.346 9390 mm (369.685 9140 mm (359.843
Maximum digging height
in) in) in)
6810 mm (268.110 6590 mm (259.449 6330 mm (249.213
Maximum dump height
in) in) in)
3660 mm (144.094 3600 mm (141.732 3580 mm (140.945
Minimum swing radius at front
in) in) in)
7640 mm (300.787 7700 mm (303.150 7700 mm (303.150
Height for minimum swing radius at front
in) in) in)
Operating Device
Operator's seat
Position Left side
Structure
Levers and pedals
Monitor device
crystal)
84551720B NA - August 2012
1002A-8
Specifications

emergency stop (*)
Other
Swing Units
Travel Lower Body

Track shoe
Shoe width 800 mm (31.496 in) [options 600 mm (23.622 in), 700 mm (27.559 in)]
Roller
Hydraulic Equipment
Hydraulic Device

Hydraulic pump
Gear pump x 1
38.7 MPa (5613.577 psi) (other)
84551720B NA - August 2012
1002A-9
Specifications
Control valve
Quadruple spool
Quintuple spool
Arm cylinder 1 x D140mm (D5.512 in) - D100 mm (D3.937 in) - 1460 mm (57.480 in)
Capacities, Filters

Fuel 410 L (108.31 gal)

Fuel Filter
Main filter 2 μm
Pre-filter 5.5 μm
84551720B NA - August 2012

1002A-10
Specifications
CX210C LR
Main Data
Heaped 0.37 m3
Bucket capacity
Leveled 0.31 m3

Heaped 0.37 m3
Bucket capacity
Leveled 0.31 m3
Performance
Travel speed
Grade ability 70 ％ (35゜)
36 kPa (5.22 psi) [800 mm (31.496 in) grouser shoe]
Ground pressure
32 kPa (4.64 psi) [900 mm (35.433 in) grouser shoe]

Travel speed
Grade ability 70 ％ (35゜)
Ground pressure
48 kPa (6.96 psi) [600 mm (23.622 in)
grouser shoe]

Swing body rear section bottom height 1040 mm (40.945 in)
Track shoe width 800 mm (31.496 in) [options 900 mm (35.433 in)]
Minimum ground clearance 440 mm (17.323 in) (to bottom of lower frame)

84551720B NA - August 2012
1002A-11
Specifications

Swing body rear section bottom height 1040 mm (40.945 in)
Track shoe width 800 mm (31.496 in) [options 600 mm (23.622 in), 700 mm (27.559 in)]
Minimum ground clearance 440 mm (17.323 in) (to bottom of lower frame)
Engine
DPD system
Cooling System
Radiator
Fin type Wavy
Oil cooler
Fin type Wavy
Intercooler
Fuel cooler
Fin type Wavy

Arm type Standard (LR) [6.40 m (20.9973 ft)]
Arm length 6400 mm (251.968 in)
Maximum digging radius 15600 mm (614.173 in)
Maximum digging radius at ground line 15490 mm (609.843 in)
Maximum digging depth 12010 mm (472.835 in)
Maximum vertical straight wall digging depth 10270 mm (404.331 in)
Maximum digging height 12970 mm (510.630 in)
Maximum dump height 10730 mm (422.441 in)
84551720B NA - August 2012
1002A-12
Specifications
Minimum swing radius at front 5190 mm (204.331 in)

Height for minimum swing radius at front 10390 mm (409.055 in)
Operating Device
Operator's seat
Position Left side
Structure
Levers and pedals
Monitor device
crystal)
emergency stop (*)
Other
Swing Units
Travel Lower Body

Track shoe
Shoe width 800 mm (31.496 in) [options 900 mm (35.433 in)]
84551720B NA - August 2012
1002A-13
Specifications
Roller

Track shoe
Shoe width 800 mm (31.496 in) [options 600 mm (23.622 in)、700 mm (27.559 in)]
Roller
Hydraulic Equipment
Hydraulic Device

Hydraulic pump
Gear pump x 1
38.7 MPa (5613.577 psi) (other)
Control valve
Quadruple spool
Quintuple spool
Arm cylinder 1 x D145 mm (D5.709 in) - D105 mm (D4.134 in) - 1627 mm (64.055 in)
Capacities, Filters

Fuel 410 L (108.31 gal)
84551720B NA - August 2012
1002A-14
Specifications

Fuel Filter
Main filter 2 μm
Pre-filter 5.5 μm
84551720B NA - August 2012

1002A-15
Specifications
84551720B NA - August 2012

1002A-16
Section
1002B
Main Equipment Table
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lower Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recoil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upper Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Cleaner (double element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Solenoid Valve (5 stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve for Left/Right Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve for Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remote Control Valve Characteristic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation Remote Control Valve Control Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Travel Remote Control Valve Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cushion Valve (heat circuit, with shuttle valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Selector Valve (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CX210C NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lower Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recoil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Upper Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air Cleaner (double element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1002B-1 PRINTED IN FRANCE
Control-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Solenoid Valve (5 stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valve for Left/Right Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valve for Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remote Control Valve Characteristic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation Remote Control Valve Control Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Travel Remote Control Valve Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cushion Valve (heat circuit, with shuttle valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Selector Valve (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CX210C LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lower Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Recoil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Upper Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air Cleaner (double element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Solenoid Valve (5 stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Valve for Left/Right Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Valve for Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remote Control Valve Characteristic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation Remote Control Valve Control Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Travel Remote Control Valve Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cushion Valve (heat circuit, with shuttle valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Selector Valve (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23


CX210C
Lower Component
Travel Unit
Manufacturer KYB Corporation

Motor type Variable displacement piston motor
Automatic 2-speed switchover with parking brake
Intake amount 168.9/100.3 cm3/rev
Operating pressure 34.3 MPa (4975.341 psi)
Operating flow 210.6 L/min (55.5359 gpm)
Brake torque 25.1 kN・m (18515.98 lbf・ft.) min. (including reduction gear)
Relief valve set pressure 35.3 MPa at 40 L/min (5120.395 psi at 10.567 gpm)
Automatic 2-speed switchover pres-
25.8 MPa (3742.385 psi)
sure
Reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 43.246
Dry weight 263 kg (579.819 lb)
Take-up Roller
Weight 89.2 kg (196.6534 lb)
Upper Roller
Weight 17.8 kg (39.2425 lb)
Lower Roller
Weight 35.0 kg (77.1622 lb)
Recoil Spring
Item Weight [kg (lb)] Q'ty

Yoke 23.9 (52.6908) 1
Sems B M16 x 50 0.5 (1.1023) 4
Threaded rod 24.3 (53.5726) 1
Groove height N M48 1.0 (2.2046) 1
SP pin 8 x 80 0.1 (0.2205) 1
Recoil spring 61.7 (136.0259) 1
Grease cylinder assembly 30.0 (66.1390) 1
Sems B M16 x 60 0.3 (0.6614) 2
Assembly(Total) 143.6 (316.5855)
Mounting length of spring 556 mm (21.890 in.)
Shoe
Weight or Q'ty
600 grouser 1343 kg (2960.805 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
700 grouser 1559 kg (3437.003 lb)
Link 1 set
84551720B NA - August 2012
1002B-3
Weight or Q'ty
Shoe 49
Bolt 196
Nut 196
800 grouser 1701 kg (3750.059 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
900 grouser 1838 kg (4052.092 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
Upper Component
Swing Unit
Swing motor assembly

Swing motor
Manufacturer TOSHIBA MACHINE CO., LTD.
Motor type Fixed displacement piston motor
With parking brake
Intake amount 151 cm3/rev
Mechanical brake torque 821.5 N・m (606.011 lbf・ft) min.
Brake off pressure 3.2 MPa (464.172 psi) max.
Relief valve set pressure 29.4 MPa (4264.578 psi)
Swing reduction gear
Turntable bearing
Number of teeth 92
Weight 244 kg (537.931 lb)
Counterweight
Weight 4250 kg (9369.695 lb)
Engine-related
Engine
Engine model name Isuzu 4HK1X diesel engine

4-cycle, water-cooled, overhead camshaft type straight cylinder, direct fuel
Engine type
injection type (electronic control)
Number of cylinders-bore-stroke 4 - D115 mm (4.528 in.) - 125 mm (4.921 in.)
Total displacement 5.193 L (1.37188 gal.)
Compression ratio 17.5
Rated output 119.3 kW / 1800 min-1 (159.98 HP / 1800 rpm)
Maximum torque 621 N・m / about 1500 min-1 (458.10 lbf・ft. / about 1500 rpm)
Fuel consumption ratio 239 g/kW・h at 1800 min-1
Engine dry weight about 510 kg (about 1124.363 lb)
Engine dimension L1029.0 (40.5118) - W901.0 (35.4724) - H1055.0 (41.5354) mm (in.)
Cooling fan D650 mm (25.591 in.) - suction type - 7 vanes, plastic
With bell mouth-type fan guide
Pulley ratio 0.85 (reduction)
84551720B NA - August 2012
1002B-4
Starter motor 24 V 5 kW reduction type

Coolant capacity 14.5 L (3.831 gal.)
Oil pan capacity Max：20.5 L (5.416 gal.) Min：13.0 L (3.434 gal.) (not including oil filter)
Direction of rotation Right (viewed from fan side)
Compliant with JISD 0006-2000.
DPD
Weight 35 kg (77.162 lb)
Air Cleaner (double element)
Manufacturer Nippon Donaldson, Ltd.

Element (outer)
Element (inner)
Weight 7.5 kg (16.5348 lb)
Radiator
Manufacturer T.RAD Co., Ltd.

Weight 29.0 kg (63.9344 lb)
Oil cooler
Oil volume 12.0 L (3.170 gal.)
Weight 17.6 Kg (38.8016 lb)
Radiator
Weight 6.4 kg (14.1097 lb)
Air cooler
Capacity -
Weight 1.1 kg (2.4251 lb)
Fuel cooler
Capacity 0.44 L (0.1162 gal.)
Total weight 102 kg (224.873 lb)
Hydraulic Device
Hydraulic Pump
Manufacturer Kawasaki Heavy Industries, Ltd.

Main pump
Pump type Double variable displacement piston pump
Displacement capacity 118.5 x 2 cm3/rev
Rated 34.3 MPa (4975.341 psi)
Operating pressure
Maximum 36.8 MPa (5337.975 psi)
Input revolution speed 1800 min-1 (1800 rpm)
Maximum discharge flow 211 x 2 L/min (at 1800 min-1) [55.742 x 2 gpm (at 1800 rpm)]
Pilot pump
Pump type Gear pump
Displacement capacity 10 cm3/rev
Maximum discharge flow 18 L/min (at 1800 min-1) [4.755 gpm (at 1800 rpm)]
Hydraulic simultaneous constant output control
Maximum flow adjustment control through external commands (negative con-
Control method trol)
Setting through external command milli-amp
Horsepower adjustment control
Dry weight 136.4 kg (300.7121 lb)
84551720B NA - August 2012
1002B-5
Control-related
Control Valve

Maximum flow 213 L/min (at 1800 min-1) [56.270 gpm (at 1800 rpm)]
Overload set pressure 29.4 MPa (4264.578 psi) boom down
38.7 MPa (5613.577 psi) other
Main relief set pressure 34.3 MPa (4975.341 psi)
(at boosting) 36.8 MPa (5337.975 psi)
Foot relief set pressure 2.55 MPa (369.8869 psi)
Function Straight travel circuit
Boom-up/arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice (for arm operation)
2 pumps flow
Variable foot relief
Weight 200 kg (440.927 lb)
Solenoid Valve (5 stack)
Manufacturer Yuken Kogyo Co., Ltd.

Valve specifications
Maximum flow P→B 25 L/min (6.604 gpm) Other 5 L/min (1.321 gpm)
Rated pressure 4.5 MPa (652.742 psi)
Port size P.T.B. port G3/8
C1, C2, C3, C4, C5 ports G1/4
Solenoid specifications
Operating voltage DC 20 - 32 V
Power consumption 17 W max.
Weight 6.7 kg (14.7710 lb)
Valve for Left/Right Operations

Secondary pressure 0.64 - 2.45 MPa (92.8343 - 355.3815 psi) MPa primary short type
1,3 port 19°
Operating angle
2,4 port 25°
Valve for Travel Operation

Secondary pressure 0.64 - 2.45 MPa (92.8343 - 355.3815 psi) primary short type
Operating angle 12.4°
Weight 5.5 kg (12.1255 lb)
84551720B NA - August 2012
1002B-6
Remote Control Valve Characteristic Diagram

Operation Remote Control Valve Control Diagram
Ports 1, 3
Secondary pressure
[MPa (psi)]
Push rod stroke [mm (in.)]
Operating angle [deg.]
1 Secondary pressure
Ports 2, 4
Secondary pressure
[MPa (psi)]
84551720B NA - August 2012

1002B-7
Travel Remote Control Valve Control Diagram
Secondary pressure [MPa (psi)]
Pedal operating angle [deg.]
Cushion Valve (heat circuit, with shuttle valve)
Manufacturer Yanagisawa Seiki MFG. Co., Ltd.

Port size G 3/8 (A - P ports)
G 1/4 (Q - V ports)
Weight 12.5 kg (27.5579 lb)
Selector Valve (option)
2WAY
Manufacturer Nishina Industrial Co., Ltd.
Rated flow 25 L/min (6.604 gpm)
Operating method ISO, JOHN DEERE
Port size G3/8
Center Joint
Operating pressure High-pressure passage (ABCD) 34.3 MPa (4975.341 psi)

Drain port (E) 0.5 MPa (72.527 psi)
Pilot port (F) 3.9 MPa (565.709 psi)
Flow High-pressure passage (ABCD) 234 L/min (61.818 gpm)
Drain port (E) 10 L/min (2.642 gpm)
Pilot port (F) 21 L/min (5.548 gpm)
Port A Forward right G3/4
Port B Forward left G3/4
Port C Backward right G3/4
Port D Backward left G3/4
Port E Drain port G1/2
Port F Pilot port G1/4
84551720B NA - August 2012
1002B-8
Backhoe Attachment
Cylinder
Boom cylinder
Cylinder bore D120 mm (D4.724 in)
Rod diameter D85 mm (D3.346 in)
Maximum retracted length 1753 mm (69.016 in)
Stroke 1255 mm (49.409 in)
Weight 161 kg (354.946 lb)
Arm cylinder
Stroke 1460 mm (57.480 in)
Weight 251 kg (553.363 lb)
Bucket cylinder
Stroke 1010 mm (39.764 in)
Weight 145 kg (319.672 lb)
84551720B NA - August 2012

1002B-9
CX210C NLC
Lower Component
Travel Unit

25.8 MPa (3742.385 psi)
sure
Reduction gear
Take-up Roller
Weight 89.2 kg (196.6534 lb)
Upper Roller
Weight 17.8 kg (39.2425 lb)
Lower Roller
Weight 35.0 kg (77.1622 lb)
Recoil Spring

Yoke 23.9 (52.6908) 1
Sems B M16 x 50 0.5 (1.1023) 4
Threaded rod 24.3 (53.5726) 1
SP pin 8 x 80 0.1 (0.2205) 1
Recoil spring 61.7 (136.0259) 1
Sems B M16 x 60 0.3 (0.6614) 2
Shoe
Weight or Q'ty
500 grouser 1201 kg (2647.766 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
600 grouser 1343 kg (2960.805 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
84551720B NA - August 2012
1002B-10
Weight or Q'ty
600 grouser 1343 kg (2960.805 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
Upper Component
Swing Unit

Swing motor
With parking brake
Turntable bearing
Number of teeth 92
Weight 244 kg (537.931 lb)
Counterweight
Weight 4250 kg (9369.695 lb)
Engine-related
Engine

Engine type
84551720B NA - August 2012
1002B-11
DPD

Element (outer)
Element (inner)
Weight 7.5 kg (16.5348 lb)
Radiator

Weight 29.0 kg (63.9344 lb)
Oil cooler
Weight 17.6 Kg (38.8016 lb)
Radiator
Weight 6.4 kg (14.1097 lb)
Air cooler
Capacity -
Fuel cooler
Hydraulic Device
Hydraulic Pump

Main pump
Rated 34.3 MPa (4975.341 psi)
Operating pressure
Pilot pump
Pump type Gear pump
Dry weight 136.4 kg (300.7121 lb)
Control-related
Control Valve

Overload set pressure 29.4 MPa (4264.578 psi) boom down
38.7 MPa (5613.577 psi) other
84551720B NA - August 2012
1002B-12

2 pumps flow
Weight 200 kg (440.927 lb)

C1, C2, C3, C4, C5 ports G1/4
Weight 6.7 kg (14.7710 lb)

1,3 port 19°
Operating angle
2,4 port 25°

Weight 5.5 kg (12.1255 lb)
84551720B NA - August 2012

1002B-13

Ports 1, 3
Secondary pressure
[MPa (psi)]
Ports 2, 4
Secondary pressure
[MPa (psi)]
84551720B NA - August 2012

1002B-14

G 1/4 (Q - V ports)
Weight 12.5 kg (27.5579 lb)
2WAY
Port size G3/8
Center Joint

84551720B NA - August 2012
1002B-15
Backhoe Attachment
Cylinder
Boom cylinder
Stroke 1255 mm (49.409 in)
Weight 161 kg (354.946 lb)
Arm cylinder
Stroke 1460 mm (57.480 in)
Weight 251 kg (553.363 lb)
Bucket cylinder
Stroke 1010 mm (39.764 in)
Weight 145 kg (319.672 lb)
84551720B NA - August 2012

1002B-16
CX210C LR
Lower Component
Travel Unit

25.8 MPa (3742.385 psi)
sure
Reduction gear
Take-up Roller
Weight 89.2 kg (196.6534 lb)
Upper Roller
Weight 17.8 kg (39.2425 lb)
Lower Roller
Weight 35.0 kg (77.1622 lb)
Recoil Spring

Yoke 23.9 (52.6908) 1
Sems B M16 x 50 0.5 (1.1023) 4
Threaded rod 24.3 (53.5726) 1
SP pin 8 x 80 0.1 (0.2205) 1
Recoil spring 61.7 (136.0259) 1
Sems B M16 x 60 0.3 (0.6614) 2
Shoe
Weight or Q'ty
600 grouser 1343 kg (2960.805 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
700 grouser 1559 kg (3437.003 lb)
Link 1 set
Shoe 49
Bolt 196
84551720B NA - August 2012
1002B-17
Weight or Q'ty
Nut 196
800 grouser 1701 kg (3750.059 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
900 grouser 1838 kg (4052.092 lb)
Link 1 set
Shoe 49
Bolt 196
Nut 196
Upper Component
Swing Unit

Swing motor
With parking brake
Turntable bearing
Number of teeth 92
Weight 244 kg (537.931 lb)
Counterweight
Weight 5100 kg (11243.634 lb)
Engine-related
Engine

Engine type
84551720B NA - August 2012
1002B-18
DPD

Element (outer)
Element (inner)
Weight 7.5 kg (16.5348 lb)
Radiator

Weight 29.0 kg (63.9344 lb)
Oil cooler
Weight 17.6 Kg (38.8016 lb)
Radiator
Weight 6.4 kg (14.1097 lb)
Air cooler
Capacity -
Fuel cooler
Hydraulic Device
Hydraulic Pump

Main pump
Rated 34.3 MPa (4975.341 psi)
Operating pressure
Pilot pump
Pump type Gear pump
Dry weight 136.4 kg (300.7121 lb)
Control-related
Control Valve

Overload set pressure 29.4 MPa (4264.578 psi)
84551720B NA - August 2012
1002B-19
38.7 MPa (5613.577 psi)

23.0 Mpa (3336.234 psi)
25.0 Mpa (3626.342 psi)
2 pumps flow
Weight 200 kg (440.927 lb)

C1, C2, C3, C4, C5 ports G1/4
Weight 6.7 kg (14.7710 lb)

1,3 port 19°
Operating angle
2,4 port 25°

Weight 5.5 kg (12.1255 lb)
84551720B NA - August 2012

1002B-20

Ports 1, 3
Secondary pressure
[MPa (psi)]
Ports 2, 4
Secondary pressure
[MPa (psi)]
84551720B NA - August 2012

1002B-21

G 1/4 (Q - V ports)
Weight 12.5 kg (27.5579 lb)
2WAY
Port size G3/8
Center Joint

84551720B NA - August 2012
1002B-22
Backhoe Attachment
Cylinder
Boom cylinder
Stroke 1255 mm (49.409 in)
Weight 161 kg (354.946 lb)
Arm cylinder
Stroke 1460 mm (57.480 in)
Weight 251 kg (553.363 lb)
Bucket cylinder
Stroke 1010 mm (39.764 in)
Weight 145 kg (319.672 lb)
84551720B NA - August 2012

1002B-23
84551720B NA - August 2012

1002B-24
Section
1002C
Main Unit Weight
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Divided Weight (standard specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stand Alone Part Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shoe Weight (per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Arm Weigh. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CX210C NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Divided Weight (long crowler specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Arm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CX210C LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Divided Weight (standard specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Arm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1002C-1 PRINTED IN FRANCE
Main Unit Weight
Main Unit Weight

CX210C
Divided Weight (standard specifications)
Code Component name Weight[kg (lb)]

21699
A Operating weight
(47838.356)
B Upper component (including counterweight and turntable bearing) 9324 (20556.009)
C Counterweight 4269 (9411.583)
D Lower component (with grouser shoe) 7886 (17385.745)
17846
E Main unit weight
(39343.901)
F Attachments 3776 (8324.699)
G Boom (including cylinders) 2123 (4680.438)
H Arm (including cylinders and linkage) 1002 (2209.043)
84551720B NA - August 2012
1002C-3
Main Unit Weight
* The weights displayed are approximate weights.
Stand Alone Part Weight

Component name Weight [kg (lb)]
1 Travel unit 263 (579.819)
2 Take-up roller 89 (196.212)
3 Upper roller 18 (39.683)
4 Lower roller 35 (77.162)
5 Swing unit 235 (518.089)
6 Turntable bearing 263 (579.819)
7 Engine 589 (1298.530)
8 Radiator 140 (308.649)
9 Hydraulic pump 127 (279.989)
10 Fuel tank 157 (346.128)
11 Hydraulic oil tank 137 (302.035)
12 Control valve 199 (438.722)
13 Center joint 31 (68.344)
14 Boom 1342 (2958.619)
Shoe Weight (per side)

1 600 mm (23.622 in) grouser shoe 1343 (2960.824)
Arm Weigh
1 Standard arm 654 (1441.831)
2 Short arm 636 (1402.147)
3 Ultra short arm 537 (1183.889)
84551720B NA - August 2012

1002C-4
Main Unit Weight
CX210C NLC
Divided Weight (long crowler specifications)
Code Component name Weight [kg (lb)]

A Operating weight 20783 (45818.911)
E Main unit weight 17498 (38576.688)

84551720B NA - August 2012
1002C-5
Main Unit Weight


1 Travel unit 263 (579.819)
2 Take-up roller 89.2 (196.6534)
3 Upper roller 17.8 (39.2425)
4 Lower roller 35.1 (77.3827)
5 Swing unit 235 (518.089)
6 Turntable bearing 372.5 (821.2262)
7 Engine 589.3 (1299.1909)
8 Radiator 140.2 (309.0897)
10 Fuel tank 127.3 (280.6499)
11 Hydraulic oil tank 126.9 (279.7681)
13 Center joint 31.4 (69.2255)
14 Boom 1341.5 (2957.5167)

2 600 mm (23.622 in) grouser shoe 1343.1 (2961.0441)

Arm Weight
1 Standard arm 653.8 (1441.3898)
2 Short arm 636.2 (1402.5882)
3 Ultra short arm 537.3 (1184.5499)

1 Standard arm 653.8 (1441.3898)
2 Short arm 636.2 (1402.5882)
84551720B NA - August 2012

1002C-6
Main Unit Weight
CX210C LR
Divided Weight (standard specifications)
84551720B NA - August 2012

1002C-7
Main Unit Weight



1 Travel unit 263 (579.819)
2 Take-up roller 89.2 (196.6534)
3 Upper roller 17.8 (39.2425)
4 Lower roller 35.1 (77.3827)
5 Swing unit 235 (518.089)
6 Turntable bearing 263.3 (580.4802)
7 Engine 589.3 (1299.1909)
8 Radiator 140.2 (309.0897)
10 Fuel tank 157.1 (346.3480)
11 Hydraulic oil tank 136.8 (301.5940)
13 Center joint 31.4 (69.2255)
14 Boom 1832.5 (4039.9921)


Arm Weight
1 Ultra long arm 1060.1 (2337.1327)
84551720B NA - August 2012

1002C-8
Section
1002D
Maintenance Standards
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track Shoe (grouser shoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Attachment (backhoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Boom and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. Boom Cylinder and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. Boom and Boom Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Boom and Arm Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. Boom and Arm Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Arm and Arm Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. Arm and Bucket Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8. Arm and Arm Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9. Bucket and Bucket Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10. Bucket Link and Bucket Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11. Bucket and Arm Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
For Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
For Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
For Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
For Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1002D-1 PRINTED IN FRANCE
Drive Sprocket
* See the gauge list for measurement gauges.
Measurement
Standard value Usage limit
Part name Code dimension Judgment Solution
[mm (in.)] [mm (in.)]
[mm (in.)]
a Acceptable/
86 (3.386) 76 (2.992)
Unacceptable
D622.34 D612.34 Acceptable/
b D
(24.50157) (24.10787) Unacceptable
c Acceptable/
D D704 (27.717) D695 (27.362)
Unacceptable Cladding by welding
Drive sprocket
D689.39 Acceptable/ or replacement
d D -
(27.14134) Unacceptable
e Acceptable/
37.4 (1.4724) 32.4 (1.2756)
Unacceptable
p - Acceptable/
203.2 (8.0000)
Unacceptable
84551720B NA - August 2012

1002D-3
Take-up Roller
Measurement
Part name Code dimensions Judgment Solution
[mm (in.)] [mm (in.)]
[mm (in.)]
a - Acceptable/
D D560 (22.047)
Unacceptable
Acceptable/ Cladding by welding
Take-up roller b 22.5 (0.8858) 25.5 (1.0039)
Unacceptable or replacement
c Acceptable/
102 (4.016) 100 (3.937)
Unacceptable
Acceptable/
Shaft d D D85 (3.346) D84 (3.307) Replacement
Unacceptable
Acceptable/
d D D85 (3.346) D86 (3.386)
Unacceptable
Bushing Replacement
e Acceptable/
82 (3.228) 81 (3.189)
Unacceptable
Acceptable/
Hub f 24 (0.945) 23.6 (0.9291) Replacement
Unacceptable
84551720B NA - August 2012

1002D-4
Upper Roller
Measurement
[mm (in.)] [mm (in.)]
[mm (in.)]
a Acceptable/
D D150 (5.906) D138 (5.433)
Unacceptable
- Acceptable/ Cladding by welding
Carrier roller b 15 (0.591)
c - Acceptable/
104 (4.094)
Unacceptable
Acceptable/
Shaft d D D65 (2.559) D64 (2.520) Replacement
Unacceptable
Acceptable/
Bushing d D D65 (2.559) D66 (2.598) Replacement
Unacceptable
e Acceptable/
Bushing 69 (2.717) 68 (2.677) Replacement
Unacceptable
Acceptable/
Thrust plate f 9 (0.354) 8.5 (0.3346) Replacement
Unacceptable
g - Acceptable/
Cover 15 (0.591) Replacement
Unacceptable
84551720B NA - August 2012

1002D-5
Lower Roller
Measurement
[mm (in.)] [mm (in.)]
[mm (in.)]
a Acceptable/
D D150 (5.906) D142 (5.591)
Unacceptable
- Acceptable/ Cladding by welding
Track roller b 15 (0.591)
Acceptable/
d 173 (6.811) 179 (7.047)
Unacceptable
e Acceptable/
Shaft D D65 (2.559) D64 (2.520) Replacement
Unacceptable
e Acceptable/
D D65 (2.559) D66 (2.598)
Unacceptable
Bushing Replacement
Acceptable/
f D69 (2.717) D68 (2.677)
Unacceptable
g Acceptable/
Collar 23.3 (0.9173) 22.8 (0.8976) Replacement
Unacceptable
84551720B NA - August 2012

1002D-6
Track Shoe (grouser shoe)
Measurement
[mm (in.)] [mm (in.)]
[mm (in.)]
a Acceptable/
Shoe plate 37 (1.457) 24 (0.945) Replacement
Unacceptable
Acceptable/ Cladding by welding
Link b 116.4 (4.5827) 111.4 (4.3858)
c Acceptable/
D D66.65 (2.62402) D62.65 (2.46654)
Master bush- Unacceptable
Replacement
ing Acceptable/
d D D44.8 (1.7638) D44.8 (1.7638)
Unacceptable
e Acceptable/
Master pin D D44.22 (1.74094) D44.22 (1.74094) Replacement
Unacceptable
84551720B NA - August 2012

1002D-7
Measurement
[mm (in.)] [mm (in.)]
[mm (in.)]
Acceptable/
Link pitch f 203.2 (8.0000) 207.3 (8.1614)
Unacceptable
4 linked sec- Replacement
tions Acceptable/
f' 812.8 (32.0000) 829.2 (32.6457)
Unacceptable
Acceptable/
c' D D66.65 (2.62402) D62.65 (2.46654)
Unacceptable
Track bushing Replacement
Acceptable/
d' D D44.8 (1.7638) D44.8 (1.7638)
Unacceptable
Acceptable/
Track pin e' D D44.5 (1.7520) D44.5 (1.7520) Replacement
Unacceptable
84551720B NA - August 2012

1002D-8
Attachment (backhoe)
84551720B NA - August 2012

1002D-9
1. Boom and Swing Frame Installation Section
Measure-
ment di- Standard value Usage limits
Part mensions
Code Judgment Solution
name
(m-
(in) (mm) (in) (mm) (in)
m)
Swing a Acceptable/ -
685 26.969 693 27.283
frame Unacceptable
Acceptable/
Boom b 681.5 26.8307 679.5 26.7520 Replacement
Unacceptable
Clear- c 0.0197 - Shim ad- Shim ad- Acceptable/ Adjustment
0.5 - 2.5
ance 0.0984 justment justment Unacceptable with shims
Acceptable/
Pin d D D D90 D3.543 D89 D3.504 Replacement
Unacceptable
Bushing e Acceptable/
D D D90 D3.543 D91.5 D3.6024 Replacement
(boom) Unacceptable
84551720B NA - August 2012

1002D-10
2. Boom Cylinder and Swing Frame Installation Section
Measure-
Part mensions
name
(m-
m)
Swing a Acceptable/ -
106 4.173 112 4.410
frame Unacceptable
Boom
cylinder Acceptable/
b 105 4.134 103 4.055 Replacement
(foot sec- Unacceptable
tion)
1.0 - 2.5
Acceptable/
Unacceptable
Bushing
e Acceptable/
(boom D D D80 D3.150 D81.5 D3.2087 Replacement
Unacceptable
cylinder)
84551720B NA - August 2012

1002D-11
3. Boom and Boom Cylinder Installation Section
Measure-
Part mensions
name
(m-
m)
Boom
cylinder a Acceptable/
100 3.937 98 3.858 Replacement
(top sec- Unacceptable
tion)
Acceptable/
Boom b 525 20.669 521 20.512 Replacement
Unacceptable
1.0 - 2.5
Acceptable/
Unacceptable
Bushing
e Acceptable/
(boom D D D85 D3.346 D86.5 D3.4055 Replacement
Unacceptable
cylinder)
84551720B NA - August 2012

1002D-12
4. Boom and Arm Cylinder Installation Section
Measure-
Part mensions
name
(m-
m)
a Acceptable/
Boom 121 4.764 127 5.000 Replacement
Unacceptable
Arm cylin-
der Acceptable/
b 120 4.724 118 4.646 Replacement
tion)
0.5 - 1.8
Acceptable/
Unacceptable
Bushing
e Acceptable/
(arm D D D80 D3.150 D81.5 D3.2087 Replacement
Unacceptable
cylinder)
84551720B NA - August 2012

1002D-13
5. Boom and Arm Installation Section
Measure-
Part mensions
name
(m-
m)
a Acceptable/
Unacceptable
Acceptable/
Arm b 307.5 12.1063 305.5 12.0276 Replacement
Unacceptable
0.5 - 1.1
Acceptable/
Unacceptable
(arm) Unacceptable
Acceptable/
Boom f D D D90 D3.543 D91.5 D3.6024 Replacement
Unacceptable
g Acceptable/
Unacceptable
84551720B NA - August 2012

1002D-14
6. Arm and Arm Cylinder Installation Section
Measure-
ment dim- Standard value Usage limit
Part ens10ions
name
(m-
m)
a Acceptable/
Arm 121 4.764 127 5.000 Replacement
Unacceptable
Arm cylin-
der Acceptable/
b 120 4.724 118 4.646 Replacement
tion)
0.5 - 1.8
Acceptable/
Unacceptable
Bushing
e Acceptable/
(arm D D D80 D3.150 D81.5 D3.2087 Replacement
Unacceptable
cylinder)
84551720B NA - August 2012

1002D-15
7. Arm and Bucket Cylinder Installation Section
Measure-
Part mensions
name
(m-
m)
a Acceptable/
Arm 101 3.976 97 3.819 Replacement
Unacceptable
Bucket
cylinder Acceptable/
b 100 3.937 98 3.858 Replacement
tion)
0.5 - 1.8
Acceptable/
Unacceptable
Bushing
e Acceptable/
(bucket D D D75 D2.953 D76.5 D3.0118 Replacement
Unacceptable
cylinder)
84551720B NA - August 2012

1002D-16
8. Arm and Arm Link Installation Section
Measure-
Part mensions
name
(m-
m)
a Acceptable/
Arm link 32 1.260 30 1.181 Replacement
Unacceptable
Acceptable/
Arm b 296 11.654 294 11.575 Replacement
Unacceptable
1.0 - 1.5
Acceptable/
Unacceptable
(arm) Unacceptable
84551720B NA - August 2012

1002D-17
9. Bucket and Bucket Link Installation Section
Measure-
Part mensions
name
(m-
m)
a Acceptable/
Bucket 307 12.087 313 12.323 Replacement
Unacceptable
Bucket Acceptable/
b 306 12.047 304 11.969 Replacement
link Unacceptable
1.0 - 3.5
Acceptable/
Unacceptable
Bushing
e Acceptable/
(bucket D D D80 D3.150 D81.5 D3.2087 Replacement
Unacceptable
link)
84551720B NA - August 2012

1002D-18
10. Bucket Link and Bucket Cylinder Installation Section
Measure-
Part mensions
name
(m-
m)
a Acceptable/
Arm link 32 1.260 30 1.181 Replacement
Unacceptable
Bucket Acceptable/
b 296 11.654 294 11.575 Replacement
link Unacceptable
1.0 - 1.5
Bucket Acceptable/
d 96 3.780 98 3.858 Replacement
link Unacceptable
Bucket
cylinder e Acceptable/
95 3.740 93 3.661 Replacement
tion)
Clear- 0.0394 - Shim ad- Shim ad- Acceptable/ Adjustment
f 1.0 - 2.0
g Acceptable/
Pin D D D85 D3.346 D84 D3.307 Replacement
Unacceptable
Bushing
Acceptable/
(bucket h D D D85 D3.346 D86 D3.386 Replacement
Unacceptable
link)
Bushing
Acceptable/
(bucket- i D D D85 D3.346 D86 D3.386 Replacement
Unacceptable
cylinder)
84551720B NA - August 2012

1002D-19
11. Bucket and Arm Installation Section
Measure-
Part mensions
name
(m-
m)
a Acceptable/
Bucket 307 12.087 313 12.323 Replacement
Unacceptable
Acceptable/
Arm b 306 12.047 304 11.969 Replacement
Unacceptable
0.7 - 3.8
Bushing Acceptable/
d 16 0.630 8 0.315 Replacement
(bucket) Unacceptable
e Acceptable/
Pin D D D80 D3.150 D79 D3.110 Replacement
Unacceptable
Bushing Acceptable/
f D D D80 D3.150 D81.5 D3.2087 Replacement
(arm) Unacceptable
Bushing g Acceptable/
(bucket) Unacceptable
84551720B NA - August 2012

1002D-20
Inspection Gauge
For Drive Sprocket
For Take-up Roller
84551720B NA - August 2012

1002D-21
For Upper Roller
For Lower Roller
84551720B NA - August 2012

1002D-22
Section
1002E
Bolt Size and Torque Table
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Special Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1002E-1 PRINTED IN FRANCE
Special Torque Settings

Bolt nomi-
Tightening Tightening
Code Retightening location nal diame- Wrench
・m]
torque [N・・ft]
torque [lbf・
ter
1* Travel motor M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
2* Drive sprocket M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
3* Take-up roller M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
4* Upper roller M20 30 mm 1.181 in 521 - 608 384.34 - 448.51
5* Lower roller M18 27 mm 1.063 in 371 - 432 273.68 - 318.68
6* Track guard M18 27 mm 1.063 in 400 - 462 295.08 - 340.81
7 Shoe M20 30 mm 1.181 in 755 - 853 556.95 - 629.25
8 Counterweight M33 50 mm 1.969 in 1862 - 2058 1373.58 - 1518.16
9 Turntable bearing M20 30 mm 1.181 in 468 - 545 345.24 - 402.04
10* Swing unit M20 30 mm 1.181 in 539.4 - 629.6 397.910 - 464.448
11* Mount M16 24 mm 0.945 in 264.9 - 313.9 195.414 - 231.560
12* Engine Front bracket M10 17 mm 0.669 in 63.8 - 73.6 47.065 - 54.293
13* Rear bracket M16 24 mm 0.945 in 205.9 - 247.1 151.891 - 182.282
14 Radiator M16 24 mm 0.945 in 147.2 - 176.6 108.588 - 130.275
Hy- 17 mm 0.669 in
15* draulic Pump M20 hexagon hexagon 367 - 496 270.74 - 365.89
pump socket head socket head
16* Hydraulic oil tank M16 24 mm 0.945 in 232.4 - 276 171.439 - 203.60
17* Fuel tank M16 24 mm 0.945 in 232.4 - 276 171.439 - 203.60
18* Control valve M16 24 mm 0.945 in 267 - 312 196.97 - 230.15
19* Center Lock bar M12 19 mm 0.748 in 88.3 - 107 65.138 - 78.93
20* joint Joint M12 19 mm 0.748 in 109 - 127 80.41 - 93.68
21 M16 24 mm 0.945 in 149 - 173 109.92 - 127.62
Cab
22 M10 17 mm 0.669 in 19.6 - 29.4 14.459 - 21.688
CAUTION
For items marked with *, always apply Loctite #262 or the equivalent and tighten to the specified torque.
The tightening torque in kgf•m is determined with N・・m ÷ 9.8 ( lbf・
・ft ÷ 7.2 ).
84551720B NA - August 2012

1002E-3
84551720B NA - August 2012

1002E-4
84551720B NA - August 2012

1002E-5
84551720B NA - August 2012

1002E-6
Section
1002F
Overall View
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Arm [2.94 m (9.6457 ft)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Short Arm [2.40 m (7.8740 ft)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ultra-short Arm [1.91 m (6.2664 ft)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CX210C NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standard Arm [2.94 m (9.6457 ft)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Short Arm [2.40 m (7.8740 ft)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ultra-short Arm [1.91 m (6.2664 ft)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CX210C LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ultra Long Arm [6.40 m (20.9974 ft)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1002F-1 PRINTED IN FRANCE
Overall View
CX210C
Standard Arm [2.94 m (9.6457 ft)]
Note: 1. Numbers are subject to change without notice due to design change or other reason.
Note: 2. The diagrams give values that include the shoe lug height (a) [26 mm (1.024 in)].
b 1040 (40.945) d 800 (23.622) f 1430 (56.299)

c 2390 (94.094) e 440 (17.323) g 1340 (52.756)
84551720B NA - August 2012

1002F-3
Overall View
Short Arm [2.40 m (7.8740 ft)]

b 1040 (40.945) d 800 (31.496) f 1430 (56.299)

c 2390 (94.094) e 440 (17.323) g 1340 (52.756)
84551720B NA - August 2012

1002F-4
Overall View
Ultra-short Arm [1.91 m (6.2664 ft)]

b 1040 (40.945) d 800 (31.496) f 1430 (56.299)

c 2390 (94.094) e 440 (17.323) g 1340 (52.756)
84551720B NA - August 2012

1002F-5
Overall View
CX210C NLC
Standard Arm [2.94 m (9.6457 ft)]
b 1060 (41.732) d 500 (19.685) f 1290 (50.787)

c 1990 (78.346) e 430 (16.929) g 1250 (49.213)
84551720B NA - August 2012

1002F-6
Overall View
b 1060 (41.732) d 600 (23.622) f 1290 (50.787)

c 1990 (78.346) e 430 (16.929) g 1250 (49.213)
84551720B NA - August 2012

1002F-7
Overall View
Short Arm [2.40 m (7.8740 ft)]

b 1060 (41.732) d 500 (19.685) f 1290 (50.787)

c 1990 (78.346) e 430 (16.929) g 1250 (49.213)
84551720B NA - August 2012

1002F-8
Overall View
b 1060 (41.732) d 600 (23.622) f 1290 (50.787)

c 1990 (78.346) e 430 (16.929) g 1250 (49.213)
84551720B NA - August 2012

1002F-9
Overall View
Ultra-short Arm [1.91 m (6.2664 ft)]

b 1060 (41.732) d 500 (19.685) f 1290 (50.787)

c 1990 (78.346) e 430 (16.929) g 1250 (49.213)
84551720B NA - August 2012

1002F-10
Overall View
CX210C LR
Ultra Long Arm [6.40 m (20.9974 ft)]
84551720B NA - August 2012

1002F-11
Overall View
b 1040 (40.945) d 800 (31.496) f 1430 (56.299)

c 2390 (94.094) e 440 (17.323) g 1340 (52.756)
84551720B NA - August 2012

1002F-12
Section
1002G
New Machine Performance Judgment Table
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Standard Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure in Each Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder Falling Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Attachment Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Swing (180°) Brake Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Travel Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Off Travel Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Travel Sprocket Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shoe Tension Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount . . . . . . . . . . . . . . . . . . . . . . . 11

1002G-1 PRINTED IN FRANCE
Standard Table
CX210C
SP Mode (with standard bucket)
Item Unit Reference value

Idling 890 - 910 (890 - 910)
1490 - 1510 (1490 -
No load A mode
1510)
1 Engine speed min-1 (rpm) 1590 - 1610 (1590 -
No load H mode
1610)
1740 - 1760 (1740 -
No load SP mode
1760)
32.3 - 36.3 (4685.234 -
Standard
5265.448)
Main relief
35.1 - 39.1 (5091.384 -
Boosted pressure
5671.598)
36.2 - 42.2 (5250.943 -
Up
6121.264)
Boom relief
30.0 - 36.0 (4351.611 -
Down
5221.932)
37.0 - 43.0 (5366.986 -
Out
6237.307)
Arm relief
37.0 - 43.0 (5366.986 -
In
6237.307)
2 Pressure in each section MPa (psi) 37.0 - 43.0 (5366.986 -
Open
6237.307)
Bucket relief
38.0 - 44.0 (5512.040 -
Close
6382.361)
28.8 - 32.8 (4177.546 -
Swing relief Left and right
4757.760)
Left and right, front 32.3 - 36.3 (4685.234 -
Travel relief
and back 5265.448)
4th pump relief -
2.9 - 4.9 (420.656 -
Pilot pump
710.762)
For crusher -
Option relief
For breaker -
Natural fall distance (po- Boom cylinder retraction 5 (0.197) Max.
sition change) for each Arm cylinder extension 12 (0.472)Max.
3 mm (in.)
cylinder with no load (in Bucket cylinder retraction 13 (0.512)Max.
10 min.) Overall bucket tip falling 250 (9.843)Max.
Up (Stroke 688 mm
2.5 - 3.7
{27.087 in.})
Boom (bucket open)
Down (stroke 688
1.8 - 3.0
mm {27.087 in.})
4 Attachment speed sec
Out 2.0 - 3.2
Arm
In 2.5 - 3.7
Open 1.5 - 2.7
Bucket
Close 1.9 - 3.1
sec/rev 4.5 - 5.7
5 Swing speed (one rotation) Left and right
min-1 (rpm) 10.6 - 13.0 (10.6 - 13.0)
6 Swing brake angle (180°) Left and right deg 50°Max.
L/min
7 Swing motor leakage amount 10 (2.642)
(gpm)
84551720B NA - August 2012

1002G-3
Item Unit Reference value

sec/6 m
(sec/19.69 3.3 - 4.3
High speed ft.)
km/h 5.2 - 6.2 (3.2312 -
Travel speed (6 m {19.69 Forwards and back- (mile/h) 3.8525)
8
ft.} travel speed) wards sec/6 m
(sec/19.69 5.4 - 7.4
Low speed ft.)
km/h 2.9 - 3.9 (1.8020 -
(mile/h) 2.4233)
High speed 10.7 - 14.7
9 Travel sprocket speed (10 rotations) sec
Low speed 18.7 - 22.7
Travel turning amount High speed 1000 (39.370) Max.
Forwards and back-
10 (20 m {65.62 ft.} travel mm (in.)
wards Low speed 1000 (39.370) Max.
meandering amount)
290 - 310 (11.418 -
11 Shoe tension amount mm (in.)
12.204)
L/min
12 Travel motor leakage amount 15 (3.963)
(gpm)
Up and down 1.1 (0.0433)Max.
13 Swing ball race bearing movement distance mm (in.)
Left and right 3.8 (0.1496)Max.
14 Bucket tip movement amount Left and right mm (in.) 61 (2.402)Max.
Compression ratio 556 (21.890)
15 Recoil spring dimensions mm (in.)
Free 634 (24.961)
Travel high speed
Coil resistance tem- Boosted pressure
Coil resistance of each
16 perature 20°C (68.0 Swing brake Ω 40
solenoid valve
°F) Lever lock
Power save
SP mode 566 - 606
No load H mode mA 550 - 590
Milli- amp for hydraulic A mode 550 - 590
17 pump electromagnetic
proportional valve SP mode 580 - 620
2nd pump relief H mode mA 580 - 620
A mode 580 - 620
84551720B NA - August 2012

1002G-4
Measurement Method Pressure in Each Section

Measurement method
Engine Speed
1. Engine high idle
Measurement method 2. Oil temperature is 45 °C - 55 °C (113.0 °F - 131.0
1. No load operation mode at high idle: SP mode, H °F)
mode and A mode speed 3. Travelling and swing is measured between the
2. Operation mode at low idle: SP mode speed counter balance and motor.
4. Measure the main relief pressure before adjust-
Main unit posture: bucket on ground ing the overload pressure, and then measure the
overload pressure after the main pressure has
been increased to a level as high or higher than
the overload pressure.
Return the main pressure to regulation pressure
after measurement.
Main unit posture: operate each attachment in the
travel posture.
84551720B NA - August 2012

1002G-5
Cylinder Falling Amount Attachment Speed

Measurement method Measurement method
1. Have oil flow into each cylinder before measure- 1. Engine high idle
ment with the oil at 45 °C - 55 °C (113.0 °F - 131.0 2. Oil temperature is 45 °C - 55 °C (113.0 °F - 131.0
°F) (Record the oil temperature before and after °F).
measurement) 3. No load
2. Make the height of the boom foot pin and the
Main unit posture
bucket pin the same.
The arm cylinder is fully retracted, and the bucket Boom cylinder
cylinder is fully opened.
3. Engine is stopped. With the arm fully out and the bucket fully opened,
4. After 10 min., measure the extension amount and measure the operation time it takes the boom cy-
retraction amount of the boom, arm, and bucket clinder to go from fully upwards to the ground and
cylinder rod. also from the ground to fully upwards
5. Along with measuring the movement amount of ANNOTATION:
the cylinders after 10 min., measure the tip dis- When the boom is lowered, make sure not to di-
placement. rectly hit the concrete (place tires on the ground).
Main unit posture
Arm cylinder
a Same height With the arm cylinder fully out and the arm hori-
zontal to the ground, measure the operation time
it takes the arm cylinder to do a full stroke with
bucket cylinder fully out
84551720B NA - August 2012

1002G-6
Bucket cylinder Swing Speed

Measure the operation time for a full stroke at the Measurement method
maximum radius.
1. Engine high idle
2. Oil temperature is 45 °C - 55 °C (113.0 °F - 131.0
°F).
3. No load
4. The time required for the next rotation after one
rotation
Main unit posture
Swing (180°) Brake Angle

Measurement method
1. Engine high idle
2. Oil temperature is 45 °C - 55 °C (113.0 °F - 131.0
°F).
3. No load
4. Swing 180°and measure the flow angle after neu-
tral braking
Main unit posture: same as the swing speed
84551720B NA - August 2012

1002G-7
Travel Speed
Measurement method
1. Engine high idle and oil temperature is 45 °C - 55 °C (113.0 °F - 131.0 °F) with no load.
2. Measure the required time to travel 6 m after a 4 - 5 m (13.13 - 16.40 ft.) running start.
If the off travel distance is 1 m or more, however, use the off travel distance as a reference value to correct the
off travel, then measure the travel speed again.
3. Travelling should be done on concrete.
4. Conduct both high-speed and low-speed travelling.
Main unit posture
a 4 - 5 m (13.13 - 16.40 ft.) Run-

ning start
b 6 m (19.69 ft.) Travel
84551720B NA - August 2012

1002G-8
Off Travel Amount 3. Shoe tension amount should be standard.

4. Measure for both forward and backward traveling.
Measurement method 5. Measure for both high-speed and low-speed trav-
1. Engine high idle and oil temperature is 45 °C - 55 eling.
°C (113.0 °F - 131.0 °F) with no load. Main unit posture: same as with travel speed mea-
2. Measure the required time to travel 20 m (65.62 surement.
ft.) after a 4 - 5 m (13.13 - 16.40 ft.) running start.
a Off travel amount

b Reference line
84551720B NA - August 2012

1002G-9
Travel Sprocket Speed Shoe Tension Amount

Measurement method Measurement method
1. Engine high idle 1. Raise the shoe and, at the central position of the
2. Oil temperature is 45 °C - 55 °C (113.0 °F - 131.0 track, measure the gap between the underside of
°F). lower side frame and the topside of the shoe plate.
3. Raise a shoe, and after achieving a constant 2. Measure for both the left and right sides.
speed, measure the time required for the sprocket
Main unit posture
to rotate 10 times both forwards and backwards.
4. Measure for both high-speed and low-speed trav-
eling.
Main unit posture: 90°swing, shoe raised.
a Topside of shoe plate

b Underside of lower side frame
84551720B NA - August 2012

1002G-10
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount
Measurement method
1. Up and down direction measurement
1) Measure the up and down movement amount at two locations in front of and behind the ball race.
2) Move the arm cylinder out and close the bucket cylinder, and move the bottom surface of the bucket 30
cm (11.811 in.) above the ground.
Attach a dial gauge to the lowering section as shown in the figure below and do zero point adjustment.
3) Jack up the main unit and measure the amount of movement with the dial gauge.
* Jack up the main body until the swinging of the dial gauge becomes constant.
Main unit posture
a Front
b Rear
*1 Lowering
2. Left and right direction measurement

1) Measure the left to right movement amount at the front side of the ball race and the left to right movement
amount of the bucket tip.
2) The arm cylinder and bucket cylinder are in the open position, apply 30 - 40 kgf of force to one side, and
zero point adjustment is done for these conditions.
3) 30 - 40 kgf of force is applied to the opposite side and the left to right movement is measured.
Main unit posture
84551720B NA - August 2012

1002G-11
Attach a dial gauge to the ball

a race mounting bolt, and mea-
sure the amount of movement.
*1 Bearing
84551720B NA - August 2012

1002G-12
Section
1003
List of special tools
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Tools to purchase or to make locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Travel Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Take-up Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Upper Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lower Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grease Cylinder Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Center Joint Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Swing Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remote Control Valve Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CX210C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gas Filling Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CX210C/CX250C/CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CASE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Isuzu Engine Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4HK1-6HK1 Tier 4 Isuzu Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Attachment Special Tool (for Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CNH-EST DIAGNOSTIC TOOL (SCAN TOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Tools to purchase or to make locally

Note: Dimensions in the drawings are shown in mm
84551720B NA - August 2012

1003-3
Travel Motor Special Tool

CX210C
84551720B NA - August 2012

1003-4
Code Order No. Jig name Remarks

1 Pulley remover
2 Bearing press-fit jig 1
3 Bearing press-fit jig 2
4 Floating seal mounting jig
5 Rod 1
6 Angular bearing press-fit jig
7 Shim thickness adjustment jig
8 Rod 2
a Puller t 80 (3.150) am D370 (14.567)

b Guide shaft u 250 (9.843) an D296 (11.654)
c Hammer v D9 (0.354) ao D328.9 - 329.1 (12.9489 -
12.9566)
Stopper nuts [M8 x 1.25 w ap D331.5 - 331.6 (13.0512 -
d D70 (2.756)
(0.04921)] 13.0551)
e Guide A (flange and housing : x aq D331.3 - 331.4 (13.0434 -
D80 (3.150)
material DURACON) 13.0472)
f Guide B (flange) y 25 (0.984) ar C0.5 (0.0197)
g Guide C (housing) z D8 (0.315) as R0.5 (0.0197)
aa D345.2 - 345.3 (13.5906 -
h Press-fit auxiliary jig (flange) D100 (3.937) at
13.5944)
au D332.3 - 332.4 (13.0827 -
i (M8 thread depth) ab D51 (2.008)
13.0866)
j Surface knurling processing ac D91 (3.583) av D345.5 - 345.7 (13.6024 -
13.6102)
Including the assembly dia- aw D337.0 - 337.1 (13.2678 -
k ad 30 (1.181)
gram 13.2716)
l 32 (1.260) ae 34 (1.339) ax D332.2 - 332.4 (13.0788 -
13.0866)
m ay D344.5 - 344.6 (13.5630 -
2 (0.079) af D36 (1.417)
13.5669)
n 20 (0.787) ag D73 (2.874) az R0.1 - 0.2 (0.0040 - 0.0078)
o D24 (0.945) ah 4.9 - 5.1 (0.1930 - 0.2007) ba R1 (0.039)
p D33 (1.299) ai 24.9 - 25.1 (0.9804 - 0.9881) bb D280 (11.024)
q C1 (0.039) aj 11.2 - 11.5 (0.4410 - 0.4527) bc D294 (11.575)
r 60 (2.362) ak 14° - 16°
s 10 (0.394) al 11.5 (0.4528)
84551720B NA - August 2012

1003-5
84551720B NA - August 2012

1003-6

9 Thrust plate selection jig
10 Oil seal press-fit jig
11 Brake piston positioning jig
Snap ring removal and installa-
12
tion (removal) jig
13 Poppet seat removal jig
a e Including the assembly dia-

Base plate Hammer i
gram
Stopper nuts [M8 x 1.25
b Four guide pin f j Notch
(0.04921)]
c g [M6 x 1.0 (0.0394) thread
Puller k C1 (0.039)
depth]
d Guide shaft h Surface knurling processing l C0.5 (0.0197)
84551720B NA - August 2012

1003-7
Take-up Roller Special Tool

CX210C

1 Bushing removal jig
2 Bushing press-fit jig
3 Floating seal installation jig
84551720B NA - August 2012

1003-8
Upper Roller Special Tool

CX210C

2 Bushing press-fit jig 1
3 Bushing press-fit jig 2
84551720B NA - August 2012

1003-9
Lower Roller Special Tool

CX210C

2 Bushing press-fit jig
84551720B NA - August 2012

1003-10
Grease Cylinder Special Tool

CX210C
A Dust seal press-fit jig

B Removal jig
84551720B NA - August 2012

1003-11
Center Joint Special Tool

CX210C
Axle removal jig
1 Axle removal jig Cover (7) installation dimen-

*1
M16 - M20 full threaded bolt sions
2 L = 370 - 420 mm (14.567 -
16.535 in)
3 M16 - M20 female thread
Hexagon socket head bolt (5)
4
M8 x 25 (0.984)
Backing plate
Axle (1) outer diameter - about
5
5 mm (0.197 in)
t = about 5 mm (0.197 in)
Removal jig (for O-ring and

1
V-ring)
84551720B NA - August 2012
1003-12
Swing Motor Special Tool

CX210C

Tapered roller bearing/inner race
1
assembly jig
2 Oil seal assembly jig 1
3 Cylinder assembly jig
4 Brake piston assembly jig
a 0.8 (0.0315)
84551720B NA - August 2012

1003-13

5 Oil seal assembly jig 2
6 Pinion shaft assembly jig
a 0.8 (0.0315)
84551720B NA - August 2012

1003-14

7 Brake piston removal jig
84551720B NA - August 2012

1003-15
Remote Control Valve Special Tool

CX210C
Detailed diagram of jig main D27.016 - 27.020 (1.063623 -

a d D23.0 - 23.2 (0.9056 - 0.9133) g
unit 1.063779)
b Joint installation state e D31 (1.220) h 15.4 - 15.6 (0.6063 - 0.6141)
c D27.000 - 27.013 (1.062993 -
Detailed diagram of bushing f i 6.4 - 6.6 (0.2520 - 0.2598)
1.063503)
*1 SCM415N carburized *4 Hole *7 Bushing

*2 S45C *5 Shaft *8 2
*1 and *2 are inserted by tight-
*3 Bolt width *6
ening.

Joint disassembly
1
jig
84551720B NA - August 2012
1003-16
a 3.2 (0.1260)
Center hole possible [D2

*1
(0.079) or less]

2 Special jig 1 (for bushing removal)
Special jig 2 (for locking ring instal-
3
lation)
84551720B NA - August 2012

1003-17
Gas Filling Special Tool

CX210C/CX250C/CX350C

1 Gauge manifold
2 Charging hose
Quick joint 27.5
3
(1.0827)
Quick joint 23.5
4
(0.9252)
5 T joint
6 Service can valve
Vacuum pump
7
adapter
84551720B NA - August 2012

1003-18
Hydraulic Circuit
Vacuum pump and power sup-

Wrenches (17, 19, 24, 27 x 2,
1 ply 5 9 Recording sheet
32, 36 x 2)
(for vacuum pump)
2 Pressure gauge (10 MPa-1) 6 Rag 10 Pen
3 Pressure gauge (60 MPa-2) 7 Extension cable 11 Cleaning fluid
Hexagon wrench (8 mm, 6 Hydraulic oil tank lid
4 8
mm) (for vacuum pump)
84551720B NA - August 2012

1003-19
CASE SPECIAL TOOLS

Isuzu Engine Special Tools
4HK1-6HK1 Tier 4 Isuzu Engine
Illustration Isuzu Reference CASE Tool Number Description
8-9439-6856-0 380001712 Oil seal setting tool kit
5-8840-2627-0 380001719 Oil seal Installer
5-8840-2623-0 380001720 Remover; Nozzle sleeve
5-8840-2624-0 380001721 Installer; Nozzle sleeve
5-8840-2626-0 380001722 Installer; Bridge guide
5-8840-2360-0 380002574 Slinger puller
5-8840-2826-0 380002601 Fuel Injector Remover
5-8840-0019-0 380002602 Sliding Hammer
84551720B NA - August 2012

1003-20
5-8840-2222-0 380002604 Sealing cup Installer
5-8840-9061-0 380002611 Oil seal installer kit
5-8840-2675-0 (5-8531-
380002626 Compression Gauge (adapter)
7002-0)
8980131700 380002630 Main filter wrench
5-8840-0266-0 380300009 Angle gauge
5-8840-2625-0 380300013 Installer; Valve guide oil seal
5-8840-2628-00 380300014 Remover/Installer; Valve guide
5-8840-2815-0 380300015 Compression Gauge Adaptor
5-8840-2835-0 Common Probes Connector test adapter kit
84551720B NA - August 2012

1003-21
5-8840-2621-0 Common Tool Remover; Valve spring
Digital multimeter with an input

Not Illustrated 5-8840-2691-0 Common Tool
impedance of 10MΩ
5-8840-2674-1 Not needed Scissors gear spring wrench
8-9439-6862-0 Not needed Pivot ASM
8-9439-6818-0 Common tool Crankshaft gear puller
8-9439-6819-0 380002613 Crankshaft gear installer
5-8840-9018-0 380300022 Piston setting tool
1-8522-1029-0 380300005 Piston ring setting tool
84551720B NA - August 2012

1003-22
Attachment Special Tool (for Cylinder

Assembly)
Special Jigs Part Number List
• Select jigs for the cylinder head according to the rod diameter.
• Select jigs for the piston according to the cylinder bore.
CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
84551720B NA - August 2012

1003-23
CNH-EST DIAGNOSTIC TOOL (SCAN

TOOL)
The EST (Electronic Service Tool) system allows diag-
noses on machines and engines by detecting the oper-
ating parameters of electronic control components (con-
trol units, sensors etc.). It is also capable of reading fault
codes.
To use this tool, please refer to the book provided during
the CXC series training sessions.
Y-Cable 380060269 is required to connect the EST to the
controllers.
84551720B NA - August 2012

1003-24
Section
1004
FLUIDS AND LUBRICANTS
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OIL RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conditions applicable to diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lubricants must have the correct properties for each application.

IMPORTANT:
The conditions of use for individual fluids and lubricants must be respected.
HYDRAULIC FLUID
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
ENGINE OIL
The "CASE Tutela LE ENGINE OIL" is recommended for
your engine. This oil ensures correct lubrication of your
engine in all working conditions.
If the "CASE Tutela LE ENGINE OIL" cannot be obtained,
use the oil corresponding to one of the following cate-
gories:
API CJ-4.
ACEA E6.
OIL RANGE
1 With mineral base

2 With semi-synthetic base
3 With synthetic base
FUEL During cold weather [ lower than -7 °C ( 19.4 °F ) ], it

is temporarily acceptable to use a mixture of No. 1-D
The fuel must conform to Interim Tier 4/Stage 3B Ex- (S15) and No. 2-D (S15).
haust Gas Control Regulations. Consult the fuel supplier or the CASE dealer.
Use grade number 2-D (S15) fuel. If the temperature drops below the fuel cloud point, out-
Using other types of fuel may lead to stalled engine output deficiency or engine start problems may occur due
put or deterioration in fuel economy. to wax crystals.
84551720B NA - August 2012
1004-3
Conditions applicable to diesel fuel Using a non-recommended fuel may lead to damage of
the fuel injection pump, injector, DPD, and other fuel
The diesel fuel used must: supply systems or to the engine.
- be free from dust particles, even minute ones, CASE assumes no responsibility for these damages.
- have the proper viscosity, Note that the warranty will not be applied for these dam-
- have a high cetane number, ages.
- present great fluidity at low temperatures, It is recommended that the following safety information
- have low sulphur content, be considered in order to prevent damage to the engine
- have very little residual carbon. fuel supply system.
- Some fuel suppliers mix old engine oil and diesel fuel.
RECOMMENDED CONDITIONS Makers of larger engine permit the use of this kind of
THAT CAN BE APPLIED TO fuel.
However, do not use diesel fuel contaminated with en-
DIESEL FUEL gine oil in customer's engines.
- JIS (Japanese Industrial Standards): No. 2 Not only will this fuel damage the engine, it may also
- DIN (Deutsche Industrie Normen): DIN 51601 have a negative impact on the exhaust gas purification
- SAE-J-313C: SAE (Society of Automotive Engineers) function.
based on No. 2-D (S15) Before using diesel fuel, confirm with the supplier
- BS (British Standards) based on BS/2869-1970: Class whether the fuel complies with the above specifications.
A-1 IMPORTANT:
- EN 590 (less than 10 ppm sulfur) Consult the supplier or the CASE dealer regarding ap-
- Or fuel specified by the country using these standards propriate use of fuel additives.
and this machine Do not use fuel oil or gasoline as these may damage the
IMPORTANT: engine.
EPA regulation ultra low sulfur fuel only. IMPORTANT:
IMPORTANT: In order to prevent condensation during cold weather, fill
If a serious problem occurs when other fuels are used, the fuel tank to full after the completing the day's work.
the warranty is invalidated.
84551720B NA - August 2012

1004-4
Section
1005
Conversion Table
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Conversion Table
Metric to U.S
MULTIPLY BY TO OBTAIN
square meter 10.763 91 square foot
AREA:
hectare 2.471 05 acre
newton 3.596 942 ounce force
FORCE:
newton 2.224 809 pound force
millimeter 0.039 370 inch
LENGTH: meter 3.280 840 foot
kilometer 0.621 371 mile
MASS: kilogram 2.204 622 pound
MASS/AREA: kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY: gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME: kg/cubic meter 1.685 555 lb/cubic yd.
POWER: kilowatt 1.341 02 horsepower
kilopascal 0.145 038 lb/sq. inch
PRESSURE: bar 14.50385 lb/sq. inch
megapascal (MPA) 145.0385 psi
TEMPERATURE: degree C 1.8 x C +32 degree F
newton meter 8.850 748 lb/inch
TORQUE:
newton meter 0.737 562 lb/foot
VELOCITY: kilometer/hr 0.621 371 miles/hr.
cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
VOLUME: quart (US liquid)
litre 1.056 814
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
litre/min. 0.264 172 gallon/min. (US liquid)
VOLUME/TIME:
litre/min 0.219 969 gallon/min. (Imperial)
84551720B NA - August 2012

1005-3
Conversion Table
U.S to Metric
MULTIPLY BY TO OBTAIN
square foot 0.092 903 square meter
AREA:
acre 0.404 686 hectare
ounce force 0.278 014 newton
FORCE:
pound force 4.448 222 newton
inch 25.4 millimeter
LENGTH: foot 0.304 8 meter
mile 1.609 344 kilometer
pound 0.453 592 kilogram
MASS: gram
ounce 28.35
MASS/AREA: ton/acre 2241 702 kilogram/hectare
MASS/ENERGY: lbs/hp/hr. 608.277 4 gr/kW/hr.
MASS/VOLUME: lb/cubic yd. 0.593 276 kg/cubic meter
POWER: horsepower 0.745 700 kilowatt
lb/sq. inch 6.894 757 kilopascal
PRESSURE: lb/sq. inch 0.069 bar
psi lb/sq. inch 0.070 303 kg/sq. cm
psi 0.006 895 megapascal (Mpa)
TEMPERATURE: degree F 1.8 F - 32 degree C
lb/inch 0.112 985 newton meter
TORQUE:
lb/foot 1.355 818 newton meter
VELOCITY: miles/hr. 1.609 344 kilometer/hr
cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yd. 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
VOLUME: quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME: gallon/min. 3.785 412 litre/min.
84551720B NA - August 2012

1005-4
Section
1900
Abbreviations
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Abbreviations
Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B+ battery + terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multi–meter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
84551720B NA - August 2012
1900-3
Abbreviations
FT fuel temperature
FWD front
GEN generator
GND ground
HBCV hose burst check valves
HC hydrocarbon
HO2S superheat O2 sensor
HR hour
HRD high reach
IAC idle air control
IAT intake air temperature
IC integrated circuit
ID Plate ID plate (Name plate)
IMT intake manifold temperature
INL intake
INJ injection
ISO international organization for standardization
ISP intake shutter position
ITP intake throttle position
J/C joint connector
JIS japan Industrial Standard
KW a communication method (Keyword)
LED light emitting diode
LH left
LLC long life coolant
LM lifting magnet
M/V electromagnetic valve
MAF mass air flow
MAP manifold air pressure
Max maximum
MIL warning light (diagnostic)
milli-amp milli-amperage
Min minimum
MPU micro processing unit
high-strength N high-strength nut
NC normally closed
NO normally open
NOx nitrogen oxide
N-TDC top dead center revolution speed
PM particle material
O2S O2 sensor
OBD on-board diagnosis
OEM original equipment manufacturer
OPT option
OT oil temperature
P/L pilot light
PCV pump control valve/positive crankcase ventilation
P-I proportion-integration
PM particle material
PTO power take-off
PWM pulse width modulation wave
QOS quick on start system
QWS quick warming up system
R/L relay
RAM RAM (random access memory)
REF reference
RH right
ROM ROM (read only memory)
84551720B NA - August 2012

1900-4
Abbreviations
RP rail pressure
Rr rear
RWD rear
flush head S flush head screw
phillips pan head S phillips pan head screw
truss head S truss head screw
subassembly sub assembly
SAE society of atomotive engineers
SBF slow blow fuse
SCV suction control valve
SIG signal
SLD shield
SP pin special pin
ST starter/start
STD standards
SW switch
TDC top dead center
TEMP temperature
TP throttle position
TEMP temperature
UART universal asynchronous receiver transmitter
VB battery voltage
VGS Turbo variable geometry system turbo
high-strength W high-strength washer
toothed W toothed washer
W/H wire/harness
W/L warning light
W/S weld splice
WOT wide open throttle
84551720B NA - August 2012

1900-5
Abbreviations
84551720B NA - August 2012

1900-6
Section
2000
Removal and Installation of Engine Assembly
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

WARNING Removal of Engine Assembly

• Keep away from fire. 1. Remove the counterweight.(For details, see "Re-
• Be sure to release hydraulic pressure before moval and Installation of Counterweight".)
beginning work. 2. Remove the pump.(For details, see "Removal and
• The air conditioner circuit is filled with high- Installation of Hydraulic Pump".)
pressure gas, so beware of the gas released 3. Use a wrench [14 mm (0.551 in.)] to remove the
when loosening lines. bolts (1) and (2), and then remove the fan shroud
• Do not use open flames and do not allow (3).
sparks near the battery.
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches [7 mm (0.276 in.), 8 mm (0.315 in.), 9.5 mm
(0.3740 in.), 10 mm (0.394 in.), 12 mm (0.472 in.), 13
mm (0.512 in.), 14 mm (0.551 in.), 17 mm (0.669 in.),
36 mm (1.417 in.)]
• Box wrench [24 mm (0.945 in.)]
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank
4. Use a wrench to remove the bolts (1), and then re-

move the fan guard (2).
84551720B NA - August 2012

2000-3
5. Use a wrench [7 mm (0.276 in.)] to loosen the hose 8. Use a wrench [8 mm (0.315 in.)] to loosen the hose
band (1) on the radiator, and then remove the upper band (1) on the inter cooler, and then remove the
hose (2). hose (2).
• Use caps to cover the line and hose to prevent the
entry of water, dust or dirt.
6. Use a wrench [7 mm (0.276 in.)] to loosen the hose

band (1) on the radiator, and then remove the lower
hose (2).
9. Remove the hose bands (1) in the 3 locations.
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
drain the coolant.
10. Prepare a waste oil can (1).

• Drain the engine oil before removing the engine
oil hose.
7. Use a wrench [12 mm (0.472 in.)] to loosen the line
bolts (1) in 2 locations, and then remove the 2 lines
(2) and (3) from the compressor.
• Always remove the low-pressure (suction side)
line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.
11. Use a wrench [36 mm (1.417 in.)] to remove the 2

engine oil remote hoses (1).
• Mark the engine and hoses so that the connectors
match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
3 Line (discharge side)
84551720B NA - August 2012

2000-4
14. Use a wrench [14 mm (0.551 in.)] to remove the

1 nut (1), and then remove the wiring (2) from the
starter motor.

bolt (1), and then remove the negative-side battery
cable (2).
• When removing the terminal and harness, secure 15. Remove the hose band (1), and then remove the
them so that they do not interfere with the frame. fuel hose (2).
Also, cover with a rubber cap to protect against • Attach caps or plugs to the engine and hose to
sparks. prevent any entry of water, dust or dirt.
13. Use a wrench [8 mm (0.315 in.)] to remove the 1 nut 16. Remove the hose band (1), and then remove the
(1), and then remove the wiring (2) from the starter fuel hose (2).
motor.
• Attach caps or plugs to the engine and hose to
84551720B NA - August 2012

2000-5
17. Use a wrench [13 mm (0.512 in.)] to remove the 20. Loosen the hose band (1), and then remove the
2 bolts (1), and then remove the connector bracket heater hose (2).
(2).

hose band (1) from the bracket, and then remove
the connectors (2). 21. Use a wrench [7 mm (0.276 in.)] to loosen the hose
band (1), and then remove the radiator hose (2).
• Wrap the removed connectors in plastic after tying
them together. • Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.
19. Loosen the hose band (1), and then remove the
heater hose (2). 22. Use a wrench [7 mm (0.276 in.)] to loosen the hose
band (1), and then remove the air hose (2).
prevent any entry of water, dust or dirt. • Use caps to cover the line and hose to prevent
84551720B NA - August 2012

2000-6
23. Use a wrench [9.5 mm (0.3740 in.)] to loosen the 26. Use a wrench [13 mm (0.512 in.)] to remove the bolt
hose band (1), and then remove the air hose (2). (1), and then remove the radiator hose clamp (2).
• Use caps to cover the line and hose to prevent
27. Install the 2 shackles (1), and then use the wire rope
(2) and crane to secure the engine.
24. Remove the connectors (1) from the alternator.
25. Use a wrench [10 mm (0.394 in.)] to remove the nut

(1), and then remove the wiring from the alternator
(2).
84551720B NA - August 2012

2000-7
28. Use a box wrench [24 mm (0.945 in.)] to remove 29. Use the wire rope (1) and crane to lift the engine.
the 4 bolts (1) from the mount. Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.
Installation of Engine Assembly

1. To install the engine, perform the reverse of the re-
moval procedure.
After installing the engine, resupply coolant and en-
gine oil, perform fuel line air bleeding, and perform
filling for the air conditioner gas.
For details, see the individual explanations for each
procedure.
2. Run the engine at no-load idling and check for any
water or oil leaks.
3. Attach the hydraulic pump, covers, and counter-
weight.
For details, see the individual explanations for each
procedure.
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2000-8
Section
2001
Removal and installation of the fuel cooler engine

inter-cooler radiator and oil cooler
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal and Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Engine Intercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation of Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Fuel Removal of Fuel Cooler
Cooler 1. Mark the fuel cooler (5) and hoses (1) (2) so that the
connectors match at the time of assembly.
CAUTION
• Remove the fuel hose clamp (6).
• Be sure to stop the engine before beginning • Use pliers to loosen the hose bands (3) (4), and
work. then remove the hoses.
• As the fuel hose will be removed, strictly pro- • Fuel will spill out, so place a drip pan directly be-
hibit open flames. low the area.
• Install caps or plugs to the fuel cooler and hoses
Items to prepare to prevent any entry of water, dust or dirt.
• Wrenches [ 12 mm ( 0.472 in. ) ]

• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan
84551720B NA - August 2012

2001-3
2. Use a wrench [ 12 mm ( 0.472 in. ) ] to remove the Installation of Fuel Cooler
4 bolts (1), and then remove the fuel cooler (2).
Perform the reverse of the removal procedure.
• Tightening torque for bolt (1) installation: 25.0 N・ After connecting the hoses, carefully check for any fuel
m ( 18.442 lbf・ft. ) leaks.
When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for a bolt or other part, see
the Bolt Size and Torque Table.
Removal and Installation of Engine
Intercooler
CAUTION
work.
• As the fuel hose will be removed, strictly pro-
hibit open flames.
Items to prepare
• Wrenches [ 8 mm ( 0.315 in. ), 14 mm ( 0.551 in. ) ]
• Flathead screwdriver
• Cap
• Rag
• Cleaning fluid
84551720B NA - August 2012

2001-4
Removal of Intercooler Installation of Intercooler
1. Use a wrench [ 8 mm ( 0.315 in. ) ] or flathead To install, perform the reverse of the removal procedure.
screwdriver to loosen the hose bands (1) in the 2 Check for any air leaks.
locations, and then remove the 2 hoses (2) (3). When installing the bolts, tighten them to the specified
torque.
• Use caps to cover the intercooler and hoses to If the torque is not specified for a bolt or other part, see
prevent the entry of water, dust or dirt.
the Bolt Size and Torque Table.
Tightening torque for band (1) installation: 8.8 -
9.8 N・m ( 6.492 - 7.229 lbf・ft. )
2. Use a wrench [ 14 mm ( 0.551 in. ) ] to remove the

4 bolts (1), and then remove the intercooler (2).
• Tightening torque for bolt (1) installation: 55.0 N・
m ( 40.573 lbf・ft. )
84551720B NA - August 2012

2001-5
Removal and Installation of Removal of Radiator
Radiator 1. Use a wrench [19 mm (0.748 in.)] to remove the 3
bolts (1), and then remove the under cover (2).
WARNING
• Do not remove the radiator cap when the ra-
diator coolant temperature is high.
Hot liquid could spray out.
CAUTION
• Be sure to release the pressure within the cir-
cuit before beginning work.
work.
• Do not stand or pass under the suspended 2. Install the drain hose (1), and then prepare the drain
load. tank (2).
Items to prepare
• Wrenches [ 7 mm ( 0.276 in. ), 8 mm ( 0.315 in. ), 13
mm ( 0.512 in. ), 14 mm ( 0.551 in. ), 19 mm ( 0.748
in. ) ]
• Box wrench [ 12 mm ( 0.472 in. ) ]
• Pliers
• Shackles (with the required lifting capacity) x 2
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Drain tank
• Drain hose
• Rag 3. To make it easier to drain the coolant, remove the
• Cleaning fluid radiator cap (1).
• Wood planks, etc.
84551720B NA - August 2012

2001-6
4. Loosen the drain plug (1), and then drain the
coolant.

6 high-strength bolts (1), 6 plain washers (2), and
6 seal retainers (3), and then remove the cushion
seal.
Remove the 2 sems bolts (4), and then remove the
bracket.
8. Remove the drain plug (1), loosen the hose band

(2), and then remove the hose (3).

bolts (1), and then remove the cover (2).

hose (1) from the radiator cap.
• Install caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
7. Use a wrench [7 mm (0.276 in.)] to loosen the hose

band (1) in the 2 locations, and then remove the
upper hose (2) and lower hose (3) from the radiator.
• Use caps to cover the radiator and hoses to pre-
• Tightening torque for band (1) installation: 4.9 -
5.9 N・m (3.615 - 4.352 lbf・ft.)
84551720B NA - August 2012

2001-7
10. Use a wrench [14 mm (0.551 in.)] to remove the 3 13. Use a wrench [14 mm (0.551 in.)] to remove the 3
bolts (1), and then remove the brackets (2). bolts (1), and then remove the brackets (2).
11. Use a wrench [14 mm (0.551 in.)] to remove the 2 14. Use a box wrench [12 mm (0.472 in.)] to remove the
bolts (1), and then remove the fan guard (2). 8 bolts (2) from the fan shroud (1), and then move
the fan shroud (1) towards the engine.

bolts (1), and then remove the brackets (2). 15. Remove the 2 one-touch clips (1), and then remove
the front anti-insect net (2).
84551720B NA - August 2012

2001-8
16. Use a wrench [17 mm (0.669 in.)] to remove the 4 18. Lift until the fixtures (1) at the bottom of the radiator
bolts (1), the 8 washers (2) and the 4 rubber cush- become disconnected.
ions (3).
19. Thoroughly check that the location is safe before

lowering the radiator on square wooden piece.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (1).
17. Install the 2 shackles (1) to the top of the radiator,

and then use the wire rope (2) and liftcrane to lift the
radiator.
84551720B NA - August 2012

2001-9
Installation of Radiator Removal and Installation of Oil
To install, perform the reverse of the removal procedure. Cooler
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Bolt Size and WARNING
Torque Table".
Coolant capacity is 30.8 L (8.136 gal.). • Keep away from fire.
Finally, check that the level of coolant is correct.
CAUTION
work.
load.
Items to prepare
• Wrenches [ 13 mm ( 0.512 in. ), 17 mm ( 0.669 in. ),
19 mm ( 0.748 in. ) ]
• Hexagon wrench [ 10 mm ( 0.394 in. ) ]
• Pliers
• Screwdriver
• Eyebolts (M12 x 2)
• Cap
• Waste oil can
• Rag
• Cleaning fluid
84551720B NA - August 2012

2001-10
Removal of Oil Cooler 3. Use a wrench [13 mm (0.512 in.)] to remove the
6 high-strength bolts (1), 6 plain washers (2), and
• Drain the hydraulic oil from the hydraulic oil tank. 6 seal retainers (3), and then remove the cushion
See Draining Oil from Hydraulic Oil Tank for details of seal.
the procedure. Remove the 2 sems bolts (4), and then remove the
1. Use a wrench [19 mm (0.748 in.)] to remove the 3 bracket.

2. Prepare the waste oil can (1). bolts (1), and then remove the cover (2).
5. Remove the 2 one-touch clips (1), and then remove

the anti-insect net (2).
84551720B NA - August 2012

2001-11
6. Use a hexagon wrench [10 mm (0.394 in.)] to re- 8. Use a wrench [14 mm (0.551 in.)] to remove the 2
move the 2 upper hexagon socket head bolts (1) bolts (1), and then remove the fan guard (2).
and 2 lower bolts (1), and then use a wrench [8 mm
(0.315 in.)] to loosen the hose bands (2) and re-
move the lines (3) (4).
• Use caps to cover the oil cooler and lines to pre-

bolts (1), and then remove the brackets (2).


84551720B NA - August 2012

2001-12
11. Use a box wrench [12 mm (0.472 in.)] to remove the 13. Install the 2 eyebolts (M12) (1) on the top of the oil
8 bolts (2) from the fan shroud (1), and then move cooler.
the fan shroud (1) towards the engine.
• Fully tighten the eyebolts, and then loosen them
by a half turn.

bolts (1).
14. Install the 2 shackles (1) to the eyebolts, and then
use the wire rope (2) and liftcrane to lift the oil cooler
main unit.
84551720B NA - August 2012

2001-13
15. Thoroughly check that the location is safe before Installation of Oil Cooler
lowering the oil cooler on wood planks, etc.
1. Use a liftcrane to lift the oil cooler (1) main unit.
2. Mount the oil cooler (1), and then remove the 2

shackles (2), wire ropes (3), and 2 eyebolts (4).
84551720B NA - August 2012

2001-14
3. Use a wrench [17 mm (0.669 in.)] to secure the oil 5. Use a wrench [ 14 mm ( 0.551 in. ) ] to install the
cooler (1) with the 4 bolts (2). bracket (2) with the 3 bolts (1).
• Bolt (2) tightening torque: 88.0 N ・ m (64.917
lbf・ft.)
6. Use a wrench [ 14 mm ( 0.551 in. ) ] to install the

bracket (2) with the 3 bolts (1).

fan guard (2) with the 2 bolts (1).
4. Use a box wrench [ 12 mm ( 0.472 in. ) ] to install
the fan shroud (1) with the 8 bolts (2).
• Bolt (2) tightening torque: 25.0 N ・ m (18.442
lbf・ft.)

bracket (2) with the 3 bolts (1).
84551720B NA - August 2012

2001-15
9. Set the O-rings (2) on the oil cooler (1) side and 10. Use a wrench [ 8 mm ( 0.315 in. ) ] to install the
install the lines (3) (4) with 2 hexagon socket head hose (2) with the hose band (1).
bolts (5) each.
• Tightening torque for band (1) installation: 5.0 -
• The O-rings cannot be reused.Replace them with 6.0 N・m (3.688 - 4.425 lbf・ft.)
new parts.
11. Install the anti-insect net (1) with the 2 one-touch

clips (2).
84551720B NA - August 2012

2001-16
12. Install the bracket (8) with 2 sems bolt (4). 14. Use a wrench [19 mm (0.748 in.)] to install the under
Use a wrench [13 mm (0.512 in.)] to install the 6 cover (1) with the 3 bolts (2).
high-strength bolts (1), 6 plain washers (2), and 6
seal retainers (3), and then install the cushion seal.

If the torque is not specified, see the "Bolt Size and
13. Use a wrench [13 mm (0.512 in.)] to install the cover
(1) with the 5 bolts (2). Torque Table".
84551720B NA - August 2012

2001-17
84551720B NA - August 2012

2001-18
Section
2004
Removal and Installation of Turbo Charger
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Turbocharger assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Turbocharger assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING Turbocharger assembly Removal

The engine is extremely hot just after stopping. 1. Battery ground cable Disconnect
Wait for them to sufficiently cool before begin- 1) Disengage the battery ground cable from the
ning work. battery.
2. Coolant Drain
CAUTION
1) Drain the coolant from the radiator.
work. CAUTION
Items to prepare • After the coolant is discharged, make

sure to tighten the drain plug.
• Wrenches [8 mm (0.315 in.), 10 mm (0.394 in.), 13 mm
(0.512 in.), 14 mm (0.551 in.), 17 mm (0.669 in.)] 3. Turbocharger assembly Removal
• Cap
• Plug 1) Remove the air cleaner duct from the air
• Rag cleaner assembly and the turbocharger as-
• Cleaning fluid sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger assembly.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
• Remove the clip.
84551720B NA - August 2012

2004-3
5) Disengage the oil return pipe from the tur- 7) Disengage the water feed pipe from the tur-
bocharger assembly. bocharger assembly.
ANNOTATION:
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
6) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
8) Remove the exhaust manifold stay from the

cylinder block and the turbocharger assembly.
2 Exhaust manifold
3 Exhaust manifold stay
84551720B NA - August 2012
2004-4
9) Disengage the harness connector from the Turbocharger assembly

turbocharger assembly.
10) Remove the turbocharger assembly from the Installation
exhaust manifold.
1. Turbocharger assembly Installation
1) Temporarily tighten the turbocharger assem-
bly to the exhaust manifold.
1 Exhaust manifold
1 Exhaust manifold
2) Temporarily tighten the exhaust manifold stay

to the cylinder block and the turbocharger as-
sembly.
2 Exhaust manifold
3) Securely tighten the turbocharger assembly to

the exhaust manifold.
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft.}
84551720B NA - August 2012

2004-5
4) Securely tighten the exhaust manifold stay to 6) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
lb・ft.} Nut
lb・ft.} Bolt
ANNOTATION:
• Tightening order
5) Connect the water feed pipe to the tur-

bocharger assembly.
CAUTION
• Use new gaskets.

lb・ft.} Eyebolt
Tightening torque： 14 N・m {1.4 kgf・m / 1 Water return pipe
10.33 lbf・ft.} Clip 2 Water feed pipe

lb・ft.} Eyebolt
7) Connect the oil return pipe to the turbocharger
assembly.
CAUTION
Tightening torque： 9 N・m {0.9 kgf・m / 6.64

lbf・ft.}
84551720B NA - August 2012

2004-6
8) Connect the oil feed pipe to the turbocharger 10) Install the air intake hose to the turbocharger
assembly. assembly and the intercooler.
11) Install the air cleaner duct to the air cleaner
CAUTION assembly and the turbocharger assembly.
12) Connect the harness connector to the tur-
・ Use new gaskets. bocharger assembly.
Tightening torque： 17 N・m {1.7 kgf・m / 12 2. Coolant Filling
lb・ft.} Eyebolt 1) Loosen the valve using a wrench.
Tightening torque： 24 N・m {2.4 kgf・m / 17 2) Replenish the coolant with the radiator.
lb・ft.} Clip
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
3) Tighten the valve using a wrench.
CAUTION

lb・ft.}
4) Replenish the coolant with the radiator.
1 Turbocharger assembly 1 Valve

2 Oil feed pipe 2 Gasket
3 Oil return pipe
3. Battery ground cable Connect
9) Install the exhaust pipe to the turbocharger 1) Connect the battery ground cable to the bat-
assembly. tery.
84551720B NA - August 2012

2004-7
84551720B NA - August 2012

2004-8
Section
2005
Removal and Installation of EGR Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
EGR valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

EGR valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EGR valve Removal 3) Remove the EGR pipe A from the EGR cooler
A and exhaust manifold.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
3. EGR cooler assembly Removal

1) Disengage the water rubber hose from the
EGR cooler assembly.
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
4) Remove the EGR cooler A from the EGR pipe

B.
5) Remove the EGR pipe B from the EGR cooler
B.
6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.
1 Water rubber hose
2) Remove the EGR heat protector from the

EGR pipe A.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D
1 EGR heat protector 4. EGR valve Removal
84551720B NA - August 2012

2005-3
1) Disengage the harness connector from the EGR valve Installation

EGR valv.e
2) Remove the EGR valve from the EGR pipe D. 1. EGR valve Installation
1) Install the EGR valve to the EGR pipe D.
Tightening torque： 24 N・m { 2.4 kgf・m /
17 lb・ft. }
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D 1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D
CAUTION
2) Connect the harness connector to the EGR

valve.
2. EGR cooler assembly Installation
1) Temporarily tighten the EGR pipe C to the
EGR valve.
2) Temporarily tighten the EGR cooler B to the
EGR pipe C.
3) Temporarily tighten the EGR pipe B to the
EGR cooler B.
4) Temporarily tighten the EGR cooler A to the
EGR pipe B.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B
84551720B NA - August 2012
2005-4
5) Temporarily tighten the EGR pipe A to the 8) Securely tighten the EGR pipe B to the EGR
EGR cooler A and the exhaust manifold. cooler B.
17 lb・ft. } No.3 in the diagram
9) Securely tighten the EGR cooler A to the EGR
pipe B.
10) Securely tighten the EGR pipe A to the ex-
haust manifold.
11) Install the EGR heat protector to the EGR pipe
A.
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
ANNOTATION:
• Complete tightening order of the EGR
cooler assembly
1 EGR heat protector
12) Connect the water rubber hose to the EGR

cooler assembly.
1 Water rubber hose
3. Coolant Filling
1) Loosen the valve using a wrench.
6) Securely tighten the EGR pipe C to the EGR
valve. CAUTION
17 lb・ft. } No.1 in the diagram • Be careful not to let coolant over-
7) Securely tighten the EGR cooler B to the EGR flow splash on the exhaust system
pipe C. parts.
Tightening torque： 24 N・m { 2.4 kgf・m / • Coolant overflow should be wiped
17 lb・ft. } No.2 in the diagram off.
84551720B NA - August 2012
2005-5
3) Tighten the valve using a wrench. 4) Replenish the coolant with the radiator.
CAUTION
• Use new gaskets

20 lb・ft. }
1 Valve
2 Gasket

1) Connect the battery ground cable to the bat-
tery.
84551720B NA - August 2012

2005-6
Section
2006
Removal and Installation of Engine Hood
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Engine Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION Removal of Engine Hood

• Be sure to stop the engine before beginning 1. Open the engine hood (1) until the lock is engaged.
work. Wrap the nylon sling (2) around the engine hood (1),
• Do not perform this operation in strong wind. and then gently lift with the liftcrane until there is no
• Be sure to inspect the nylon sling and other force on the open lock stay (3).
lifting equipment before beginning work. Remove the pin (1) and washer (2) that are on the
• Do not stand or pass under the suspended engine hood side of the open lock stay, and then
load. remove the open rock stay (3) from the guide.
• When removing the gas damper, be sure to
do so while the lock is applied, because the
hood holding force may be reduced and the
hood may drop.
• Be careful not to let the hood fall and catch
fingers.
• The damper’s rod may fly out suddenly.
Completely extend the gas dumper when re-
moving it.
• Operate the liftcrane slowly and gently.
Items to prepare
• Wrench [ 13 mm ( 0.512 in. ), 17 mm ( 0.669 in. ), 19
mm ( 0.748 in. ) ]
• Nylon sling (with the required breaking load)
84551720B NA - August 2012

2006-3
2. Use the liftcrane and lift up the engine hood (2) until 4. Wrap the nylon sling (2) around the engine hood (1),
the damper (1) is completely extended and there is and then use the liftcrane to lift the engine hood (1).
no force on it.
Loosen the ring (3) of the damper’s head section,
and then remove the gas damper (1).
Installation of Engine Hood

3. After closing the engine hood (1), use a wrench 19 To install, perform the reverse of the removal procedure.
mm ( 0.748 in. ) to remove the 6 bolts (2) from the Tighten bolts being installed to the specified torque.
engine hood. For bolts for which the torque is not specified, check
of the "About This Shop Manual Section • Tightening
Torque • Retightening Torque Table" in the explanation
in the materials.
84551720B NA - August 2012

2006-4
Section
2007
Removal and Installation of Muffler
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING Removal of Muffler

• Keep fire away. 1. Use a Wrench [ 13 mm ( 0.512 in. ) ] to loosen the
• The machine is extremely hot just after the nut (1); remove the bolt (2), washers (3), and gasket
engine has been stopped. (4); and then remove the exhaust pipe (5).
Wait for it to sufficiently cool before begin-
ning work.
CAUTION
work.
Items to prepare
• Wrench [ 10 mm ( 0.394 in. ) ]
• Wrench [ 13 mm ( 0.512 in. ) ]
• Wrench [ 14 mm ( 0.551 in. ) ]
• Cap
• Rag 2. Remove the connectors (1).
• Cleaning fluid
3. Use a Wrench [ 10 mm ( 0.394 in. ) ] to loosen the

bolt (1), and then remove the cord clamp.
84551720B NA - August 2012

2007-3
4. Use a Wrench [ 19 mm ( 0.748 in. ) ] to loosen the Installation of Muffler

4 bolts (1), and then remove the muffler.
1. When installing the bolts, tighten them to the spec-
ified torque.
When the tightening torque is not specified for a bolt
or other part, see "Materials Explanation - Tighten-
ing Torque - Torque Table (one page)".
2. Place the DPD muffler (1) in the bracket, and install
the gasket (2), bolt (3), nut (4), and washers (5) on
the flanges. Move the DPD muffler over until the
DPD muffler flange touches the exhaust pipe (6)
flange surface, and then use a Wrench [ 13 mm
( 0.512 in. ) ] to temporarily tighten the flanges
together.
CAUTION
• Use caution when handling the DPD muf-
fler (1), DPD pressure sensor (7), and
DPD thermo-sensors (8) (9) and do not
subject them to any impacts etc.
• Do not reuse these parts if they are
dropped or fall.
3. Use a Wrench [ 19 mm ( 0.748 in. ) ] to tighten the

4 bolts (1) to secure the muffler.
84551720B NA - August 2012

2007-4
4. Use a Wrench [ 13 mm ( 0.512 in. ) ] to fully tighten 6. Install the connectors (1).
the bolt (1), nut (2), and washers (3) temporarily
tightened in Step 2.
7. After installation, run the engine at no-load idling

and check for any abnormalities.
5. Use a Wrench [ 10 mm ( 0.394 in. ) ] to tighten the
bolt (1) to install the cord clamp.
84551720B NA - August 2012

2007-5
84551720B NA - August 2012

2007-6
Section
2401
Primary specifications
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. Primary specifications
Engine main specifications
Item Engine model 4HK1X

Type Diesel/ 4-cycle /water cooling, inline 4 cylinder OHC
Shape of combustion chamber Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 115 mm {4.528 in.} x 125 mm {4.921 in.}
Displacement 5.193 L ｛316.88 cu・in. / 1.37188 gal.｝
Compression pressure ： 3.23 MPa { 32.9 kgf/cm2 / 468.5234 psi }
Idling rotation speed [ 800 min-1 ( 800 r/min ) ]
Intake ： 0.4 mm { 0.0157 in. } While cool
valve clearance
Exhaust ： 0.4 mm { 0.0157 in. } While cool
Ignition method Compression ignition
Injection order 1,3,4,2
Lubricant system
Lubricating type Pressure type
Oil pump type Gear type
Lubrication oil amount ： 20 - 27 L { 5.29 - 7.13 US gal. }
Oil filter type Full-flow / partial-flow united filter (cartridge type)
Oil cooling type Built-in type, water cooled
Cooling system
Cooling type Water cooling
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax type unit
： 82.0 °C { 179.60 °F } Without jiggle valve
Open valve temperature of the thermostat valve
： 85.0 °C { 185.00 °F } With jiggle valve
Coolant container ： 14.5 L { 3.831 US gal. }
fuel system
Injection nozzle type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Multi-hole type
Injection nozzle type
7 holes, inner diameter D0.14 mm {0.00551 in.}
Charging system
Generator type AC type
Output 24 V/50 A
Regulator type IC
Starting system
Starter type Reduction type
Output 24 V/5.0 kW
Preheat system type glow plug
Glow plug standard voltage/current 23 V/3.5 A
Cleaning system main specifications
Item Specifications
water pump Centrifugal impeller method
Pulley ratio 0.950
thermostat Wax pellet type
Open valve temperatur
Full-open temperature
84551720B NA - August 2012
2401-3
Electrical system main specifications
generator
Item Specifications
Isuzu parts number 8980921161
Nominal output 24 V/50 A
Rated rotation count [ 5,000 min-1 ( 5,000 r/min ) ]
Regulator type IC type
Regulated voltage 27.5 V - 29.5 V
weight ： 9.5 kg { 20.9440 lb }
starter
Type (Manufacturer) Nikko
voltage 24V
Rating Output 5 KW
Time 30 sec
Number of pinion teeth 13
Rotational direction (facing the pinion) Right
Weight (Approx.) ： 8.0 kg { 17.6371 lb }
Current/voltage 85 A or less/24 V
No-load characteristics
Revolution speed [ 3,300 min-1 ( 3,300 r/min ) ] or more
Current/voltage 400 A/18.5 V
Load characteristics Torque 28.4 N・m {2.9kgf・m / 20.950 lbf・ft.} or more
Revolution speed [ 1,250 min-1 ( 1,250 r/min ) ] or more
Current/voltage 1,400 A or less/9 V
Locking characteristics
Torque 88.2 N・m {9.0kgf・m / 65.064 lbf・ft.} or more
glow plug
Item Type
Preheat device model glow plug
Glow plug rated voltage/current 23 V/3.5 A
84551720B NA - August 2012

2401-4
Section
2415
Removal and Installation of Cylinder Head
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Cylinder head cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Cylinder head cover Removal Installation of Cylinder Head Cover

1. Cylinder head cover Removal 1. Cylinder head cover Installation
1) Disengage the oil level gauge guide tube from 1) Align the head cover gasket to the cylinder
the cylinder head cover. head cover.
2) Disengage the ventilation hose from the air 2) Install the cylinder head cover to the lower
breather. cover.
lb・ft.}
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.
1 Ventilation hose
2 Oil level gauge guide tube
3) Remove the cylinder head cover from the

lower cover.
4) Remove the head cover gasket from the cylin-
der head cover.
1 Cylinder head cover

2 Gasket
1 Cylinder head cover 3 Lower cover
2 Gasket
3) Connect the ventilation hose to the air
3 Lower cover breather.
84551720B NA - August 2012

2415-3
4) Connect the oil level gauge guide tube to the Removal and Installation of
cylinder head cover.
Tightening torque： 19 N・m {1.9 kgf・m / 14 Cylinder Head
lb・ft.}
Removal of Cylinder Head
battery.
2. Coolant Drain
CAUTION
3. Engine harness Disconnect

1 Ventilation hose 1) Disengage the engine harness from the en-
2 Oil level gauge guide tube gine assembly.
ANNOTATION:
• Disconnect each connector.
4. Turbocharger assembly Removal
1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
sembly.
bocharger assembly.
bocharger assembly.
ANNOTATION:
5) Remove the oil feed pipe from the oil port
cover.
ANNOTATION:
6) Disengage the oil return pipe from the tur-
bocharger assembly.
84551720B NA - August 2012

2415-4
7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
2 Oil feed pipe
3 Oil return pipe
8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
bocharger assembly.
ANNOTATION:
2 Exhaust manifold
84551720B NA - August 2012
2415-5
13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.
1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
5. EGR cooler assembly Removal B.
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
1 Water rubber hose

1 EGR valve
2) Remove the EGR heat protector from the 2 EGR pipe C
EGR pipe A. 3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D
6. EGR valve Removal

1) Disengage the harness connector from the
EGR valve.

84551720B NA - August 2012
2415-6
2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D
7. EGR cooler water pipe Removal

1) Remove the fan guide stay from the fan guide
and the fan guide bracket.
2) Remove the fan guide bracket from the cylin-
der head assembly.
1 EGR cooler water feed pipe

2 EGR cooler water return pipe
1 Fan guide 8. Intake throttle valve Removal

2 Fan guide stay 1) Remove the air duct from the intake throttle
3 Fan guide bracket valve.
84551720B NA - August 2012

2415-7
2) Disengage the harness connector from the in- 3) Disengage the harness connector from the
take throttle valve. EGR valve.
4) Disconnect the harness connector from the
ANNOTATION:
IMT sensor.
• Pull the lock operation portion to release the 5) Remove the harness clip from the inlet pipe.
lock.
1 Boost sensor
1 Lock operation section 2 IMT sensor
2 Lock release 3 EGR valve
3 Lock 4 Harness clip
5 Boost temperature sensor
3) Remove the intake throttle valve from the inlet
pipe. 6) Remove the inlet pipe from the case.
1 Boost temperature sensor 1 Case

2 Boost sensor 2 Gasket
3 Inlet pipe 3 Inlet pipe
4 Gasket
5 Intake throttle valve 10. Oil level gauge guide tube Removal
1) Remove the oil level gauge from the oil level
9. Inlet pipe Removal
gauge guide tube.
1) Disengage the harness connector from the 2) Disengage the oil level gauge guide tube from
boost sensor. the cylinder head cover.
2) Disconnect the harness connector from the 3) Disengage the oil level gauge guide tube from
boost temperature sensor. the case.
84551720B NA - August 2012

2415-8
4) Remove the oil level gauge guide tube from

the cylinder block.
1 No.1 injection pipe

1 Cylinder head cover 3 No.3 injection pipe
2 Oil level gauge guide tube 4 No.4 injection pipe
3 Case 5 Fuel leak-off pipe
4 Cylinder block 6 Fuel pipe
7 Common rail assembly
11. Glow plug Removal
1) Remove the glow plug connector from the 13. Fuel pipe Removal
glow plug. 1) Remove the fuel pipe from the fuel supply
2) Remove the glow plug from the cylinder head pump and the common rail assembly.
assembly.
ANNOTATION:
CAUTION
• Do not reuse the removed fuel pipe.
14. Fuel leak off pipe assembly Removal

1) Disengage the fuel leak-off pipe from the cylin-
der head assembly.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:
12. Injection pipe Removal • Remove the eyebolt tightened together with
the fuel feed pipe.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector 3) Disengage the fuel leak-off pipe from the com-
and the common rail assembly. mon rail assembly.
CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.
84551720B NA - August 2012

2415-9
4) Remove the fuel leak-off pipe from the case. 16. Cylinder head cover Removal
ANNOTATION: 1) Disengage the ventilation hose from the air
• Remove the clip. breather.
lower cover.
der head cover.

2 Cylinder head assembly
3 Fuel leak-off pipe
4 Fuel supply pump
15. Common rail assembly Removal 2 Gasket
3 Lower cover
fuel pressure sensor.
2) Remove the common rail assembly from the
inlet cover and the common rail bracket. 17. Lower cover Removal
3) Remove the common rail bracket from the oil 1) Remove the connector from the lower cover.
cooler assembly.
CAUTION
• Do not pull the wire, or pry the con-
nector with a screwdriver.
2) Disengage the injector harness from the injec-

tor.
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
3) Remove the injector harness from the cylinder

head assembly.
ANNOTATION:
• Remove the bracket tightening bolts and
2 Fuel pressure sensor then remove the injector harness together
3 Common rail bracket with the bracket.
84551720B NA - August 2012

2415-10
4) Remove the lower cover from the cylinder

head assembly.
Special tool: sliding hammer (refer to

section 1003)
1 Lower cover
2 Connector
5) Remove the gasket from the lower cover.

6) Remove the rubber plug from the cylinder
head assembly.
18. Injector Removal
1) Remove the injector leak-off pipe from the in-
jector.
2) Remove the injector from the cylinder head
assembly.
ANNOTATION:
• When it is difficult to remove the injector, use
a special tool.
Special tool: fuel injector remover (refer 1 Sliding hammer

to section 1003) 2 Fuel injector remover
3 Injector
CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.
84551720B NA - August 2012

2415-11
20. Camshaft Removal

1) Remove the camshaft bearing cap from the
cylinder head assembly.
2) Remove the camshaft bearing from the
camshaft bearing cap.
3) Remove the camshaft from the cylinder head.
4) Remove the camshaft bearing from the cylin-
der head assembly.
ANNOTATION:
• Temporarily assemble the removed caps
and bearings in the original position to avoid
a mix-up after the bearings have been in-
spected.
19. Rocker arm shaft Removal
1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.
21. Bridge Removal

1) Remove the bridge cap from the bridge.
CAUTION
• Be careful not to drop the bridge
2) Remove the rocker arm shaft from the cylinder cap into the engine.
head assembly.
2) Remove the bridge from the bridge guide.
ANNOTATION:
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
and the rocker arm assembly bracket tight- • After removing, organize to avoid a mix-up
ening bolts from both ends and remove with other installation locations.
them.
CAUTION
• Be careful not to remove the bolt
shown in the diagram.
1 Bridge cap
2 Bridge
22. Cylinder head assembly Removal
84551720B NA - August 2012

2415-12
1) Remove the cylinder head assembly from the Disassembly of Cylinder Head
cylinder block.
1. Engine hanger bracket Removal
ANNOTATION:
1) Remove the front engine hanger bracket from
• Loosening order of the head bolts the cylinder head assembly.
2) Remove the rear engine hanger bracket from
the cylinder head assembly.
CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
cylinder head, be careful not to
damage the gear.
1 Front engine hanger

2 Front engine hanger bracket
3 Rear engine hanger
4 Rear engine hanger bracket
1 Idle gear C
2. Inlet cover Removal
2) Remove the cylinder head gasket from the 1) Remove the case from the inlet cover.
cylinder block.
ANNOTATION:
CAUTION
• Remove it together with the EGR pipe D.
• Do not reuse the cylinder head gas-
ket. 2) Remove the inlet cover from the cylinder head
assembly.
84551720B NA - August 2012

2415-13
3) Remove the exhaust manifold bracket from

1 EGR pipe D
2 Case
3 Gasket 1 Distance tube
4 Inlet cover 2 Washer
3 Exhaust manifold bracket
CAUTION 4 Exhaust manifold bracket
5 Exhaust manifold
• Do not forget to remove the bolts in-
dicated by the arrow in the diagram. 4. Thermostat Removal
1) Remove the water outlet pipe from the cylin-
der head assembly.
2) Remove the thermostat from the cylinder
head assembly.
3) Remove the gasket from the thermostat.
5. Overheat switch Removal
1) Remove the overheat switch from the cylinder
head assembly.
6. Engine coolant temperature sensor Removal
1) Remove the engine coolant temperature sen-
sor from the cylinder head assembly.
3. Exhaust manifold Removal

2) Remove the exhaust manifold from the cylin-
der head assembly.
1 Overheat switch
2 Water temperature sensor
84551720B NA - August 2012

2415-14
7. CMP sensor Removal 3) Remove the idle gear C from the cylinder head
assembly.
1) Remove the CMP sensor from the cylinder
head assembly.
1 Idle gear C
CAUTION 2 Idle gear shaft
• Be careful not to subject the sensor 9. Valve spring Removal
to shock.
1) 1. Press the valve spring using the special
8. Idle gear C Removal tool.
1) Press the idle gear C cover using the driver.

ANNOTATION:
• Lightly tap the outer perimeter of the cover
using a screwdriver and tilt the cover.
2) Remove the idle gear C cover from the cylin-
der head assembly using the pliers.
Special tool: valve spring replacer (refer

to section 1003)
Special tool: pivot ASM (refer to section

1003)
84551720B NA - August 2012

2415-15
2) Remove the valve spring seat from the cylin-

der head assembly.
13. Valve guide Removal
1) Remove the valve guide from the cylinder
head assembly using the special tool.
2) Remove the split collar from the spring seat.

3) Remove the special tool from the cylinder
head assembly.
4) Remove the valve spring seat from the valve
spring.
5) Remove the valve spring from the cylinder
head assembly.
Special tool: valve guide replacer (refer
ANNOTATION: to section 1003)
• Store the removed valve springs according ANNOTATION:
to the cylinders.
• Tap the valve guides out from the bottom
10. Inlet valve Removal surface of the cylinder head.
1) Remove the inlet valve from the cylinder head
assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.
11. Exhaust valve Removal
1) Remove the exhaust valve from the cylinder
head assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.
14. Valve seat insert Removal

1) Heat the valve seat insert with the gas burner.
Heating temperature ： 700.0 - 800.0 °C {
1292 - 1472 °F }
： 2 section(s) Inner surface of the insert
ANNOTATION:
• Cool the valve seat insert naturally after
heating.
Specified time： 5 min Natural cool
2) Remove the valve seat insert from the cylinder
head assembly using the driver.
12. Valve stem oil seal Removal CAUTION

1) Remove the valve stem oil seal from the valve • Be careful not to damage the cylin-
guide using the pliers. der head.
CAUTION 15. Injector sleeve Removal

• Do not reuse the valve stem oil seal. 1) Remove the injector sleeve from the cylinder
head assembly using the special tool.
84551720B NA - August 2012
2415-16
1) Install the nut to the bridge guide.

ANNOTATION:
• Electrically weld the nut to the top of the
bridge guide.
2) Remove the bridge guide from the cylinder
head assembly using the sliding hammer.
Special tool: nozzle sleeve remover (refer

to section 1003)
ANNOTATION:
• Tap the injector sleeve out from the bottom
surface of the cylinder head.
1 Nut
17. Oil seal Removal

1) Remove the oil seal from the cylinder head
assembly.
ANNOTATION:
• Attach a rod from the inner surface of the
cylinder head, and tap it to remove it to the
outer side.
1 Injector sleeve
CAUTION
• Be careful not to damage the bot-
tom surface of the cylinder head.
• Do not reuse the removed injector
sleeve.
16. Bridge guide Removal
84551720B NA - August 2012

2415-17
Assembly of Cylinder Head 1 Cylinder head

2 Oil seal installer
1. Oil seal Installation
1) Install the oil seal to the cylinder head assem- 2. Bridge guide Installation
bly.
1) Apply the engine oil to the bridge guide.
2) Install the bridge guide to the cylinder head
assembly using the special tool.
Special tool: Oil seal installer (refer to

section 1003)
CAUTION Special tool: bridge guide setting tool

(refer to section 1003)
• Be careful not to damage the lip
section of the oil seal.
Specified length： 122.0 to 123.0 mm {4.8031

to 4.8425 in.} 1 in the diagram
Specified length： 37.5 mm {1.4764 in.} 2 in
the diagram
3. Injector sleeve Installation
1) Install the O-ring to the injector sleeve.
2) Apply the engine oil to the O-ring.
3) Apply the cement to the injector sleeve.
ANNOTATION:
• Apply Loctite 620 to the tapered section of
the injector sleeve.
84551720B NA - August 2012

2415-18
4) Apply the engine oil to the cylinder head as- Special tool: nozzle sleeve setting tool
sembly. (refer to section 1003)
ANNOTATION:
• Apply engine oil to the injector sleeve con-
tact surface.
1 Punch bar
2 Ball
3 Guide sleeve
1 O-ring with white paint 4 Injector sleeve
2 O-ring 5 Clamp
3 Loctite 620 application 6 Bolt
4 Engine oil application
5) Install the injector sleeve to the cylinder head

assembly using the special tool. CAUTION
• Allow the cylinder head to float so
that the ball comes out from the bot-
tom surface.
4. Valve seat insert Installation

1) Prepare the dolly block.
ANNOTATION:
• Prepare the one which has smaller outer
diameter than the valve seat insert.
2) Align the valve seat insert to the cylinder head.
3) Align the dolly block to the valve seat insert.
84551720B NA - August 2012

2415-19
4) Install the valve seat insert to the cylinder

head assembly using the press.
CAUTION
• When replacing the valve guide, re-
place it with the valve.
1 Dolly block
2 Valve seat insert 6. Valve stem oil seal Installation
3 Press
1) Install the valve spring seat to the cylinder
head assembly.
2) Apply the engine oil to the valve guide.
5. Valve guide Installation
ANNOTATION:
1) Apply the engine oil to the valve guide.
2) Install the valve guide to the cylinder head • Apply engine oil to the outer circumference
assembly using the special tool. of the valve guide.
CAUTION
• Use a new valve stem oil seal.
3) Install the valve stem oil seal to the valve

guide using the special tool.
Special tool: valve guide replacer (refer

to section 1003)
ANNOTATION:
• Tap the valve guides from the upper side of
the cylinder head.
Special tool: valve stem seal installer
(refer to section 1003)
Specified length： 17.0 - 17.9 mm {0.6693 -

0.7047 in.}
84551720B NA - August 2012
2415-20
CAUTION 2) Install the valve spring to the cylinder head

assembly.
• Inspect the valve stem oil seal for ANNOTATION:
deformation or cracks.
• Confirm that the garter spring has • Turn the valve spring to face the identifica-
not come loose. tion paint application area towards the cylin-
der head assembly.
7. Exhaust valve Installation
3) Install the spring seat to the valve spring.
1) Apply the engine oil to the exhaust valve. 4) Press the valve spring using the special tool.
2) Install the exhaust valve to the cylinder head
assembly.
ANNOTATION:
• Confirm that there is an E-mark on the valve.
8. Inlet valve Installation
1) Apply the engine oil to the inlet valve.
2) Install the inlet valve to the cylinder head as-
sembly.
ANNOTATION:
• Confirm that there is an I-mark on the valve.
Special tool: valve spring replacer (refer

to section 1003)
9. Valve spring Installation

1) Check the identification paint of the valve
spring. Special tool: pivot ASM (refer to section
1003)
Valve spring identification paint
Inlet Light blue
Exhaust White
5) Install the split collar to the spring seat.

ANNOTATION:
• Lightly tap the valve stem head to stabilize
the split collar.
1 Spring pitch (small)

2 Identification paint
84551720B NA - August 2012
2415-21
CAUTION
• Confirm that the split collar is in the
valve stem groove.
10. Idle gear C Installation

1) Apply the engine oil to the idle gear C.
ANNOTATION:
• Apply to the sliding surface of the gear.
2) Apply the engine oil to the idle gear shaft.
ANNOTATION:
• Apply engine oil to the outer circumference Special tool: sealing cup installer (refer to
of the idle gear shaft. section 1003)
3) Temporarily tighten the idle gear C to the cylin-

der head assembly.
CAUTION
• Confirm that the spigot of the idle
gear shaft is firmly installed to the
Between the idle gear C cover

1 end surface and cylinder head
chamfered edge section
Specified length ： 1.5 - 2.5 mm {0.0591 -

0.0984 in.}
1 Idle gear C 11. CMP sensor Installation
2 Idle gear shaft
2) Install the CMP sensor to the cylinder head
4) Securely tighten the idle gear C to the cylinder
assembly.
head assembly
Tightening torque： 95 N・m {9.7 kgf・m / 70 CAUTION
lb・ft.}
5) Apply the cement to the idle gear C cover. • Be careful not to subject the sensor
to shock.
ANNOTATION:
• Apply Loctite 962T to the outer circumfer- ANNOTATION:
ence of the idle gear C cover.
• Tighten together with the clip.
6) Install the idle gear C cover to the cylinder Tightening torque ： 8 N ・ m {0.8 kgf ・ m /
head assembly using the special tool. 5.90 lbf ・ ft. }
84551720B NA - August 2012

2415-22
2) Install the thermostat to the cylinder head as-

sembly
12. Overheat switch Installation

1) Install the overheat switch to the cylinder head
assembly.
1 Thermostat
ANNOTATION: 2 Cylinder head
• Apply Loctite 572 to the threaded portion.
Tightening torque ： 29 N ・ m {3.0 kgf ・ m / CAUTION
22 lb ・ ft.}
• Be careful not to mistake the as-
13. Engine coolant temperature sensor Installation sembly position and direction.
1) Install the engine coolant temperature sensor
to the cylinder head assembly. 3) Install the water outlet pipe to the cylinder
head assembly.
ANNOTATION: Tightening torque： 25 N・m {2.5 kgf・m / 18
• Apply Loctite 572 to the threaded portion. lb・ft.}
Tightening torque ： 25 N ・ m {2.5 kgf ・ m / 15. Exhaust manifold Installation
18 lb ・ ft.}
1) Install the exhaust manifold bracket to the
lb・ft.}
2) Install the gasket to the cylinder head assem-
bly.
ANNOTATION:
• Turn the protruding section of the gasket to-
wards the exhaust manifold and install.
3) Install the exhaust manifold to the cylinder
head assembly.
ANNOTATION:
• When assembling the washer, assemble the
1 Overheat switch distance nut section only.
2 Water temperature sensor Tightening torque： 34 N・m {3.5 kgf・m / 25
lb・ft.}
14. Thermostat Installation
1) Install the gasket to the thermostat.
CAUTION
84551720B NA - August 2012

2415-23
4) Install the exhaust manifold bracket to the ex-

haust manifold.
lb・ft.}
CAUTION
• Completely tighten the installation
bolt and nut when installing the
common rail assembly.
1 Distance tube
2 Washer 3) Install the case to the inlet cover.
3 Exhaust manifold bracket Tightening torque： 22 N・m {2.2 kgf・m / 16
4 Exhaust manifold bracket lb・ft.}
5 Exhaust manifold ANNOTATION:
• Install it together with the EGR pipe D.
16. Inlet cover Installation
1) Apply the liquid gasket to the inlet cover.
ANNOTATION:
• Align with the inlet cover groove and apply
ThreeBond 1207.
Bead width： 3 - 6 mm {0.098 - 0.217 in.}
CAUTION
• After applying liquid gasket, install
the inlet cover within 5 minutes.
2) Temporarily tighten the inlet cover to the cylin-

der head assembly.
1 EGR pipe D
CAUTION
2 Case
• Do not forget to install the bolts in- 3 Gasket
dicated by the arrow in the diagram. 4 Inlet cover
17. Engine hanger bracket Installation

1) Install the front engine hanger bracket to the
Tightening torque： 104 N・m {10.6 kgf・m
/ 77 lb・ ft.} Front engine hanger bracket
lb・ft.}
Front engine hanger
84551720B NA - August 2012

2415-24
2) Install the rear engine hanger bracket to the Installation of Cylinder Head
Tightening torque： 104 N・m {10.6 kgf・m 1. Cylinder head assembly Installation
/ 77 lb・ft.} Rear engine hanger bracket
CAUTION
lb・ft.} • Clean the aligning surface of the cylinder
Rear engine hanger head and cylinder block before installing
• Be careful not to damage the cylinder
head and cylinder block while cleaning.
1) Apply the liquid gasket to the cylinder block.

ANNOTATION:
• Use ThreeBond 1207B.
Bead width： 3.0 mm (0.1181 in.)
Bead height： 3.0 mm (0.1181 in.)
CAUTION
the cylinder head within 5 minutes.
1 Rear engine hanger 2) Install the cylinder head gasket to the cylinder
block.
2 Front engine hanger bracket
3 Rear engine hanger CAUTION
4 Rear engine hanger bracket
• Use a new cylinder head gasket.
3) Install the cylinder head assembly to the cylin-

der block.
CAUTION
• Be careful not to damage the cylin-
der head gasket.
ANNOTATION:
• Tightening order of the head bolts
84551720B NA - August 2012

2415-25
2) Install the bridge to the bridge guide.
CAUTION
• Confirm that the bridge moves
smoothly.
3) Apply the engine oil to the bridge cap.

4) Install the bridge cap to the bridge.
ANNOTATION:
• 1 to 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION:
• Apply molybdenum disulfide grease to the
seat surface and threaded portion of the CAUTION
M14 head bolts.
• Apply engine oil to the seat surface and • Be careful not to drop the bridge
threaded portion of the M10 head bolts. cap into the engine.
5) Tighten the head bolt using the torque wrench. 3. Camshaft Installation
/ 116 lb・ft.} 1) Align 1st cylinder to the compression top dead
6) Tighten the head bolt using the torque wrench. center.
/ 122 lb・ft.}
7) Tighten the head bolt using the special tool.
1 Front cover marking

Special tool: angle gauge (refer to section 0 degree marking on the crank-
2
1003) shaft damper
Tightening angle： 55 ° M14 bolt
8) Tighten the head bolt using the torque wrench.
Tightening torque： 38 N・m {3.9 kgf・m / 28 2) Apply the engine oil to the camshaft bearing.
lb・ft.} M10 bolt ANNOTATION:
Tightening torque： 167 N・m {17.0 kgf・m • Apply engine oil to the sliding surface of the
/ 123 lb・ft.} Check the tightening M14 bolt bearing.
2. Bridge Installation CAUTION
1) Apply the engine oil to the bridge. • Apply engine oil after cleaning the
bearing installation sections of
the camshaft bearing and cylinder
head.
84551720B NA - August 2012

2415-26
3) Install the camshaft bearing to the cylinder 8) Install the camshaft bearing cap to the cylinder
head assembly. head assembly.
4) Install the camshaft to the cylinder head as-
sembly. ANNOTATION:
ANNOTATION: • Turn the camshaft bearing cap so that the

arrow mark on the top surface faces the en-
• Mesh together the idle gear C and the gine front side, and assemble in numerical
camshaft gear so that the alignment mark order.
on the camshaft gear matches the top sur-
face of the cylinder head, and gently install Tightening torque： 28 N・m {2.8 kgf・m / 20
the camshaft. lb・ft.} Apply engine oil
5) Check alignment mark of the camshaft gear. 4. Rocker arm shaft Installation
CAUTION 1) Apply the engine oil to the bracket.

ANNOTATION:
• Confirm that the alignment mark is
not misaligned before installing the • Apply to each sliding surface.
• If the alignment mark is not at 2) Apply the engine oil to the rocker arm.
the correct position, reinstall the ANNOTATION:
camshaft.
• Confirm that the adjust screw is fully loos-
6) Apply the engine oil to the camshaft bearing. ened.
ANNOTATION: 3) Temporarily tighten the bolt to the cylinder

head assembly.
• Apply engine oil to the sliding surface of the
bearing. ANNOTATION:
• Apply engine oil to the threaded portion of
CAUTION the bolts.
• Apply engine oil after cleaning the 4) Temporarily tighten the nut to the cylinder
bearing installation sections of the head assembly.
camshaft bearing and camshaft
bearing cap. ANNOTATION:
• Apply engine oil to the threaded portion of
7) Install the camshaft bearing to the camshaft the nuts.
bearing cap.
5) Securely tighten the rocker arm shaft to the
ANNOTATION:
• Hold the entire rocker arm shaft horizontally
and gradually tighten it.
Rocker arm shaft tightening torque

Parts Tightening torque
： 21 N・m {2.1 kgf・m / 15
No.1 Nut
lb・ft.}
： 27 N・m {2.8 kgf・m / 20
No.2 Bolt
lb・ft.}
84551720B NA - August 2012

2415-27
Rocker arm shaft tightening torque CAUTION

： 56 N・m {5.7 kgf・m / 41 • Adjust the valve clearance while cool.
No.3 Bolt • Loosen all adjust screws before adjust-
lb・ft.}
： 27 N・m {2.8 kgf・m / 20 ment.
No.4 Bolt
lb・ft.}
1) Align 1st cylinder to the compression top dead

center.

1 Nut
0 degree marking on the crank-
2 Bolt 2
shaft damper
3 Bolt
4 Bolt 2) Prepare the feeler gauge.
Thickness： 0.4 mm {0.0157 in.} 2 pieces
5. Rocker arm shaft Adjustment
ANNOTATION:
ANNOTATION:
• Insert the thickness gauge between the
• Valve clearance adjustment rocker arm and bridge cap.
84551720B NA - August 2012

2415-28
• Insert the thickness gauge between the • Check if the valve shaft end on the opposite
bridge and valve. side is floating or touching at an angle.
• If it is floating or touching at an angle, slightly
3) Turn the adjust screw. loosen the bridge adjust screw and adjust
ANNOTATION: the valve shaft ends on both sides to touch
properly.
• When the movement of the thickness gauge
becomes stiff, secure the adjust screw nut Valve bridge clearance ： less than 0.1 mm
of the rocker arm. {less than 0.0039 in.}
Tightening torque： 22 N・m {2.2 kgf・m / 16 ANNOTATION:
lb・ft.}
• To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and
tighten the adjust screw nut.
lb・ft.}
4) Turn the adjust screw.

ANNOTATION:
• With the thickness gauge inserted, lightly
tighten the adjust screw of the bridge.
• Confirm that the leading end of the adjust
screw and valve shaft end have made con-
tact and the movement of the thickness
gauge has become stiff.
Adjustment table
1 2 3 4
Cylinder No.
IN EX IN EX IN EX IN EX
First cylinder compression top dead center O O O O
Fourth cylinder compression top dead center O O O O
6. Common rail assembly Installation 5) Securely tighten the nut to the common rail
assembly.
1) Temporarily tighten the common rail bracket Tightening torque： 22 N・m {2.2 kgf・m / 16
to the oil cooler assembly. lb・ft.}
ANNOTATION: ANNOTATION:
• The installation bolt and common rail as- • Refer to the tightening order in the diagram
sembly are tightened together. if the inlet cover is removed.
2) Align the common rail assembly to the inlet
cover.
3) Temporarily tighten the nut to the common rail
assembly.
ANNOTATION:
• The stud bolts of the inlet cover are tight-
ened together.
4) Temporarily tighten the bolt to the common rail
assembly.
84551720B NA - August 2012

2415-29
6) Securely tighten the bolt to the common rail 5) Securely tighten the fuel leak-off pipe to the
assembly. common rail assembly.
Tightening torque： 19 N・m {1.9 kgf・m / 14 Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft.} lb・ft.}
7) Connect the harness connector to the fuel 6) Securely tighten the fuel leak-off pipe to the
pressure sensor. fuel supply pump.
lb・ft.}
7) Install the clip to the fuel leak-off pipe.
lbf・ft.}

2 Fuel pressure sensor
3 Common rail bracket
7. Fuel leak off pipe assembly Installation

1) Temporarily tighten the fuel leak-off pipe to the 1 Common rail assembly
cylinder head assembly. 2 Cylinder head assembly
CAUTION 4 Fuel supply pump
8. Fuel pipe Installation
2) Temporarily tighten the fuel leak-off pipe to the
common rail assembly. 1) Install the fuel pipe to the fuel supply pump
and the common rail assembly.
CAUTION
CAUTION
• Use new fuel pipes.
fuel supply pump.
lb・ft.}
ANNOTATION: 2) Install the clip to the bracket.
• Tighten the fuel feed pipe together. lbf・ft.}
CAUTION 9. Injector Installation
• Use new gaskets. CAUTION
4) Securely tighten the fuel leak-off pipe to the • When reusing an injector, do not change
cylinder head assembly. the installation position.
Tightening torque： 12 N・m {1.3 kgf・m /
8.85 lbf・ft. } 1) Apply the engine oil to the bolt.
84551720B NA - August 2012

2415-30
2) Temporarily tighten the injector to the cylinder 3) Install the clip to the bracket.
head assembly. Tightening torque： 6 N・m {0.6 kgf・m / 4.43
lbf・ft.}
CAUTION

1 Injector 5 Fuel leak-off pipe
2 Installation bolt 6 Fuel pipe
3) Temporarily tighten the injection pipe to the
injector.
11. Lower cover Installation
CAUTION 1) Apply the liquid gasket to the rubber plug.
• Use new injection pipes. ANNOTATION:
4) Temporarily tighten the injection pipe to the • Apply ThreeBond 1207B.

5) Securely tighten the injector to the cylinder
head assembly.
lb・ft.}
6) Install the injector leak-off pipe to the injector.
CAUTION

10.33 lbf・ft.}
10. Injection pipe Installation
1) Securely tighten the injection pipe to the injec-
tor. 1 Rubber plug
Tightening torque： 30 N・m {3.0 kgf・m / 22 2 Liquid gasket
lb・ft.}
2) Securely tighten the injection pipe to the com-
mon rail assembly. CAUTION
Tightening torque： 25 N・m {2.5 kgf・m / 18 • After applying the liquid gasket, in-
lb・ft.} stall the lower cover within 5 min-
utes.
2) Install the rubber plug to the cylinder head

assembly.
3) Install the gasket to the lower cover.
4) Install the lower cover to the cylinder head
assembly.
lb・ft.}
84551720B NA - August 2012
2415-31
5) Install the injector harness to the cylinder head 1) Install the glow plug to the cylinder head as-
assembly. sembly.
ANNOTATION:
lb・ft.}
• Tighten the bolts on the bracket and in-
stall the injector harness together with the CAUTION
bracket.
• Be careful not to exceed the speci-
Tightening torque： 48 N・m {4.9 kgf・m / 35 fied torque when tightening.
lb・ft.}
2) Install the glow plug connector to the glow

plug.
1 Injector harness terminal Tightening torque： 1 N・m {0.1 kgf・m / 0.74
2 Injector harness bracket lbf・ft.}
CAUTION
6) Connect the injector harness to the injector.
Tightening torque： 2 N・m {0.2 kgf・m / 1.48 • Confirm that the glow plug connec-
lbf・ft.} tor does not interfere with the sur-
rounding parts.
CAUTION
13. Cylinder head cover Installation
tor side stud bolts. 1) Align the head cover gasket to the cylinder
head cover.
2) Install the cylinder head cover to the lower
cover.
lb・ft.}
ANNOTATION:
1 Lower cover
2 Connector
7) Install the connector to the lower cover.

lbf・ft.}
12. Glow plug Installation
84551720B NA - August 2012

2415-32
1) Install the inlet pipe to the case.

lb・ft.}
CAUTION

2 Gasket
3 Lower cover

breather.
14. Oil level gauge guide tube Installation 1 Case
1) Install the oil level gauge guide tube to the 2 Gasket
cylinder block. 3 Inlet pipe
2) Connect the oil level gauge guide tube to the
case. 2) Connect the harness connector to the IMT
Tightening torque： 19 N・m {1.9 kgf・m / 14 sensor.
lb・ft.} 3) Connect the harness connector to the EGR
3) Connect the oil level gauge guide tube to the valve.
cylinder head cover. 4) Connect the harness connector to the boost
Tightening torque： 19 N・m {1.9 kgf・m / 14 temperature sensor.
lb・ft.} 5) Connect the harness connector to the boost
4) Install the oil level gauge to the oil level gauge sensor.
guide tube. 6) Install the harness clip to the inlet pipe.
1 Boost sensor
2 IMT sensor
3 EGR valve
3 Case
4 Harness clip
4 Cylinder block
15. Inlet pipe Installation 16. Intake throttle valve Installation
84551720B NA - August 2012

2415-33
1) Install the intake throttle valve to the inlet pipe.

lb・ft.}

2 Boost sensor
3 Inlet pipe
4 Gasket
5 Intake throttle valve
2) Install the air duct to the intake throttle valve.

3) Connect the harness connector to the intake
throttle valve.
ANNOTATION:
• After connecting the harness connector, 1 EGR cooler water feed pipe
press in the lock operation portion to lock. 2 EGR cooler water return pipe
1) Install the EGR cooler water pipe to the engine

assembly.
ANNOTATION:
• Install the EGR cooler water feed pipe and
EGR cooler water return pipe.
lb・ft.} Clamp
2) Connect the radiator upper hose to the water
outlet pipe.
3) Install the fan guide bracket to the cylinder
head assembly.
lb・ft.}
1 Lock operation section Tightening torque ： 97 N ・ m {9.9 kgf ・ m}
2 Lock release The area where the spacer is used
3 Lock 4) Install the fan guide stay to the fan guide
bracket.
17. EGR cooler water pipe Installation lb・ft.}
84551720B NA - August 2012

2415-34
5) Install the fan guide stay to the fan guide. 5) Temporarily tighten the EGR pipe A to the
Tightening torque： 45 N・m {4.6 kgf・m / 33 EGR cooler A and the exhaust manifold.
lb・ft.}
1 Fan guide stay 1 EGR cooler A

2 Fan guide 2 EGR pipe A
3 Fan guide bracket 3 Exhaust manifold
4 Spacer
ANNOTATION:
18. EGR valve Installation
• Complete tightening order of the EGR
1) Install the EGR valve to the EGR pipe D. cooler assembly
lb・ft.}
CAUTION

EGR valve.
EGR pipe C.
EGR cooler B.
EGR pipe B.

1 EGR valve valve.
2 EGR pipe C Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft.} No.1 in the diagram
3 EGR cooler B
7) Completely tighten the EGR pipe C to the en-
4 EGR pipe B gine hanger bracket.
5 EGR cooler A Tightening torque： 48 N・m {4.9 kgf・m / 35
6 EGR pipe B lb・ft.} No.2 in the diagram
84551720B NA - August 2012
2415-35
8) Securely tighten the EGR pipe B to the 20. Turbocharger assembly Installation
bracket.
9) Securely tighten the EGR cooler B to the EGR
pipe C.
10) Securely tighten the EGR pipe B to the EGR
cooler B.
pipe B.
haust manifold.
lb・ft.} No.7 in the diagram 1 Exhaust manifold
13) Securely tighten the EGR pipe A to the EGR 2 Turbocharger assembly
cooler A.
Tightening torque： 28 N・m {2.9 kgf・m / 21 2) Temporarily tighten the exhaust manifold stay
lb・ft.} No.8 in the diagram to the cylinder block and the turbocharger as-
14) Install the EGR heat protector to the EGR pipe sembly.
A.
1 EGR heat protector 2 Exhaust manifold

cooler assembly.
lb・ft.}
1 Water rubber hose

84551720B NA - August 2012
2415-36
4) Securely tighten the exhaust manifold stay to 8) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
lb・ft.} Nut
lb・ft.} Bolt
ANNOTATION:
5) Install the water feed pipe to the cylinder

block.
CAUTION

lb・ft.} Eyebolt
1 Water return pipe
lb・ft.} Clip
6) Connect the water feed pipe to the tur- 2 Water feed pipe
bocharger assembly.
CAUTION Tightening torque： 35 N・m {3.5 kgf・m / 25

lb・ft.} Eyebolt
• Use new gaskets. 9) Install the oil return pipe to the cylinder block.

lb・ft.} Eyebolt
10.33 lbf・ft.} Clip
7) Install the water return pipe to the water pump
lb・ft.}
assembly.
CAUTION assembly.

lb・ft.} Eyebolt
lbf・ft.}
lb・ft.} Clip
11) Install the oil feed pipe to the oil port cover.
CAUTION

lb・ft.} Eyebolt
lb・ft.} Clip
84551720B NA - August 2012
2415-37
12) Connect the oil feed pipe to the turbocharger 2) Replenish the coolant with the radiator.
assembly.
CAUTION
CAUTION
• Use new gaskets. flow splash on the exhaust system
parts.
Tightening torque： 17 N・m {1.7 kgf・m / 12 • Coolant overflow should be wiped
lb・ft.} Eyebolt off.
lb・ft.} Clip 3) Tighten the valve using a wrench.
CAUTION

lb・ft.}
1 Valve
2 Gasket

tery.
24. Fuel Air bleed
1 Turbocharger assembly CAUTION
2 Oil feed pipe
3 Oil return pipe • To prevent engine failure, be sure to per-
form air removal after the installation or
removal of fuel system parts.
13) Install the exhaust pipe to the turbocharger
assembly.
14) Install the air intake hose to the turbocharger
assembly and the intercooler.
assembly and the turbocharger assembly.
bocharger assembly.
21. Engine harness Connect
1) Connect the engine harness to the engine as-
sembly.
ANNOTATION:
• Connect each connector.
22. Coolant Filling 1 Priming pump
1) Loosen the valve using a wrench. 2 Plug
84551720B NA - August 2012
2415-38
3 Drain plug 11) Tighten the plug using the wrench.

4 Case 12) Operate the priming pump.
5 Fuel filter element Number of times： 10 count(s) or more
ANNOTATION:
1) Prepare the pan.
2) Turn ON the starter switch. • Wait for the specified time after operating
the priming pump.
ANNOTATION:
Specified time： 1 min
• This is for the models with an electromag- 13) Loosen the plug using the wrench.
netic pump.
ANNOTATION:
3) Loosen the plug using the wrench.
4) Operate the priming pump. • Remove the air in the fuel filter.
Number of times： 20 count(s) or more
14) Tighten the plug using the wrench.
ANNOTATION: Tightening torque： 10 N・m {1.0 kgf・m /
7.38 lbf・ft.}
• Confirm that fuel comes out from around the
plug. CAUTION
5) Tighten the plug using the wrench. • Remove the fuel around the plug
6) Operate the priming pump. thoroughly after tightening.
ANNOTATION: 15) Operate the priming pump.
Number of times the operation is Performed:
• Wait for the specified time after operating 10 - 15 times
the priming pump. 16) Start the engine.
7) Loosen the plug using the wrench. CAUTION
ANNOTATION: • Do not accelerate the engine revo-

lution right after staring.
• Remove the air in the fuel filter.
8) Tighten the plug using the wrench. Idling: 5 s
9) Operate the priming pump. ANNOTATION:
• Accelerate the engine revolution gradually.
ANNOTATION:
Engine revolution hold: 3 min.
• Wait for the specified time after operating
the priming pump. ANNOTATION:
Specified time： 1 min • Accelerate the engine revolution to maxi-
10) Loosen the plug using the wrench. mum.
• Lower the rotation.
ANNOTATION:
84551720B NA - August 2012

2415-39
Inspection 3. Idle gear C Inspection

1. Bridge cap Inspection 1) Measure the clearance using the feeler
gauge.
1) Measure the bridge cap using the dial gauge.
ANNOTATION:
ANNOTATION:
• Measure the clearance in the axis direction
• Measure the contact surface of the bridge between the cylinder head and idle gear C.
cap and rocker arm.
Specified value: 0.090 - 0.145 mm {0.0035 -
Limit: 0.1 mm {0.0039 in.} Amount of wear on 0.0057 in.}
the bridge cap Limit: 0.2 mm {0.0079 in.}
CAUTION
• Replace the bridge cap if the mea-
sured value exceeds the limit value.
• Replace the bridge cap if it
has an abnormal wear such as
band-shaped wear.
1 Idle gear C
2) Measure the idle gear shaft using the vernier

caliper.
ANNOTATION:
• Outer diameter of the idle gear shaft
2. Bridge Inspection
Specified value: 30.00 mm {1.1811 in.} Diam-
1) Inspect the bridge. eter
ANNOTATION: Limit: 29.85 mm {1.1752 in.} Diameter
• Confirm that the bridge moves smoothly. 4. Inlet valve Inspection

2) Check the clearance of the bridge cap. 1) Measure the inlet valve using the micrometer.
Specified value: 0.020 - 0.057 mm {0.0008 - ANNOTATION:
0.0022 in.} Between the bridge and bridge cap
Limit: 0.1 mm {0.0039 in.} Between the bridge • Outer diameter of the valve stem
and bridge cap Measurement part: 3 section(s)
Specified value: 8.00 mm {0.3150 in.} Diam-
eter
Limit: 7.88 mm {0.3102 in.} Diameter
CAUTION
• Replace the inlet valve and valve
guide if the measured value is un-
der the limit value.
1 Bridge
2 Bridge guide
84551720B NA - August 2012

2415-40
2) Install the inlet valve to the valve guide.

3) Measure the valve guide clearance using the CAUTION
dial gauge.
ANNOTATION: guide if the measured value ex-
ceeds the limit value.
• Valve guide clearance
Specified value: 0.039 - 0.071 mm {0.0015 - 5) Inspect the inlet valve using the red lead
0.0028 in.} primer.
Limit: 0.2 mm {0.0079 in.}
ANNOTATION:
• Inspect the contact surface of the inlet valve
and valve seat.
Specified value: 2.7 mm {0.1063 in.} Contact
width
Limit: 3.0 mm {0.1181 in.} Contact width
CAUTION
• If the measured value exceeds the
limit value, fix the contact surface
of the valve seat using a sheet cut-
ter.
• If the contact position is not in the
center of the valve seat, fix the con-
tact surface of the valve seat using
1 Valve a sheet cutter.
The position [ 10 mm ( 0.394 in. • If the contact surface is not smooth,
2 fix the contact surface of the valve
) ] under the valve guide head
3 Valve guide seat using a sheet cutter.
CAUTION
guide if the measured value ex-
ceeds the limit value.
4) Measure the inlet valve using the micrometer.

ANNOTATION:
• Valve thickness
Specified value: 1.71 mm {0.0673 in.}
Limit: 1.30 mm {0.0512 in.}
84551720B NA - August 2012

2415-41
6) Adjust the valve seat. 10) Check the sinking amount of the inlet valve.
CAUTION 0.0406 in.}
Limit: 2.3 mm {0.0906 in.}
• Use a seat cutter suitable for the
valve seat angle and valve stem di-
ameter.
Valve seat angle: 30 °

External diameter of the valve stem: 8.0 mm
{0.3150 in.} Diameter
5. Exhaust valve Inspection

1) Measure the exhaust valve using the microm-
eter.
ANNOTATION:
7) Apply the compound to the valve seat. • Outer diameter of the valve stem
8) Install the inlet valve to the valve guide. Measurement part: 3 section(s)
9) Adjust contact surface to standard value using Specified value: 8.00 mm {0.3150 in.} Diam-
the valve lapper. eter
ANNOTATION: Limit: 7.88 mm {0.3102 in.} Diameter
• Lightly tap the inlet valve on the valve seat CAUTION

while turning it.
• Replace the exhaust valve and
valve guide if the measured value
is under the limit value.
CAUTION
• After fixing the valve, remove all 2) Install the exhaust valve to the valve guide.
compounds. 3) Measure the valve guide clearance using the
dial gauge.
ANNOTATION:
• Valve guide clearance
0.0038 in.}
Limit: 0.25 mm {0.0098 in.}
84551720B NA - August 2012

2415-42
Limit: 3.0 mm {0.1181 in.} Contact width
CAUTION
• If the measured value exceeds the
limit value, fix the contact surface
of the valve seat using a sheet cut-
ter.
• If the contact position is not in the
center of the valve seat, fix the con-
tact surface of the valve seat using
a sheet cutter.
• If the contact surface is not smooth,
fix the contact surface of the valve
seat using a sheet cutter.
1 Valve
The position [ 10 mm ( 0.394 in.
2
) ] under the valve guide head
3 Valve guide
CAUTION
valve guide if the measured value
exceeds the limit value.
4) Measure the exhaust valve using the microm-

eter. 6) Adjust the valve seat.
ANNOTATION: CAUTION
• Valve thickness • Use a seat cutter suitable for the
Specified value: 1.75 mm {0.0689 in.} valve seat angle and valve stem di-
Limit: 1.30 mm {0.0512 in.} ameter.
Valve seat angle: 45 °

External diameter of the valve stem: 8.0 mm
{0.3150 in.} Diameter
CAUTION
valve guide if the measured value 7) Apply the compound to the valve seat.
exceeds the limit value. 8) Install the exhaust valve to the valve guide.
9) Adjust contact surface to standard value using
5) Inspect the exhaust valve using the red lead the valve lapper.
primer.
ANNOTATION:
ANNOTATION:
• Tap the exhaust valve on the valve seat
• Inspect the contact surface of the exhaust while turning it.
valve and valve seat.
Specified value: 2.5 mm {0.0984 in.} Contact
width
84551720B NA - August 2012
2415-43
ANNOTATION:
• Fix it if it is possible.
2) Perform dye penetrant check.
ANNOTATION:
• Check if there is a problem which cannot be
detected by visual inspection.
3) Align the simple straight ruler to the cylinder
head assembly.
4) Measure the clearance using the feeler
gauge.
ANNOTATION:
CAUTION • Flatness of the bottom of the cylinder head
• After fixing the valve, remove all
compounds.
10) Check the sinking amount of the exhaust

valve.
0.0579 in.}
Limit: 2.8 mm {0.1102 in.}
Measurement part: 6 section(s)

Limit: 0.2 mm {0.0079 in.}
ANNOTATION:
• Flatness of the installation surface of the ex-
haust manifold and inlet cover.
6. Cylinder head assembly Inspection
CAUTION
• Clean the each part of the cylinder head
assembly before inspecting.
head while cleaning the cylinder head as-
sembly.
1) Inspect the cylinder head assembly.

ANNOTATION: Measurement part: 6 section(s)
• Installation surface of the cylinder head gas- Specified value: less than 0.05 mm {less than
ket 0.0020 in.}
• Combustion chamber Limit: 0.2 mm {0.0079 in.}
• Exhaust port
• Valve seat CAUTION
• Glow plug hole • Replace the cylinder head if the
measured value exceeds the limit
CAUTION
value.
• Replace the cylinder head if dam-
age such as a crack has been found
in the inspection.
84551720B NA - August 2012

2415-44
5) Inspect the water leak using the water pres-

sure tester.
Specified pressure: 490.0 kPa {71 psi}
Specified time: 3 min
ANNOTATION:
• Perform a hydraulic test with the injector
holder installed.
84551720B NA - August 2012

2415-45
84551720B NA - August 2012

2415-46
Section
2425
Removal and Installation of Cylinder Block
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Removal of Cylinder Block 1) Remove the fan guide from the fan guide
bracket.
battery.
2. Coolant Drain
CAUTION
3. Engine oil Drain

Remove the drain plug from the oil pan.
Drain the engine oil from the oil pan.
Install the drain plug to the oil pan.
Tightening torque： 70 N・m {7.1 kgf・m / 52 lb・ 1 Bolt
ft.} 2 Washer
4. Engine harness Disconnect 3 Rubber mount
Disengage the engine harness from the engine as-
4 Rubber mountassembly.
sembly.
5 Guide tube
CAUTION 6 Fan guide
5. Cooling fan Removal 2) Remove the fan guide bracket from the engine
assembly.
1) Remove the cooling fan from the adapter.
7. Cooling fan belt Removal
1) Remove the cooling fan belt from the engine
assembly.
1 Cooling fan
2 Adapter
6. Fan guide Removal

1 Adjust bolt
2 Fixing bolt
3 Fixing bolt
8. Crankshaft pulley Removal

1) Remove the crankshaft pulley from the crank-
shaft.
2) Remove the crankshaft damper from the
crankshaft pulley.
9. Crankshaft front oil seal Removal
1) Remove the crankshaft front oil seal from the
crankshaft using the special tool.
84551720B NA - August 2012
2425-3
tightened using a clip band to improve the

workability.
10. Water pump assembly Removal
1) Remove the adapter from the water pump as-
sembly.
2) Remove the spacer from the adapter.
3) Remove the fan pulley from the water pump
assembly.
4) Disengage the water hose from the water
pump assembly.
5) Disengage the water return pipe from the wa-
ter pump assembly.
6) Remove the water pump assembly from the
Special tool: rear oil seal remover (refer front cover.
to section 1003)
1 Adapter
1 Felt 2 Spacer
2 Slinger 3 Fan pulley
3 Crankshaft front oil seal 4 Water pump assembly
5 Gasket
11. Front cover Removal

1) Remove the front cover from the cylinder
block.
sembly.
bocharger assembly.
bocharger assembly.
CAUTION
ANNOTATION:
• Be careful not to damage the oil
seal press-fitting surface. • Remove the clip.
ANNOTATION:
cover.
• Remove the slinger and oil seal together. ANNOTATION:
• If the slinger of the remover is easy to come
off, the outer circumference of the jig can be • Remove the clip.
84551720B NA - August 2012

2425-4
6) Disengage the oil return pipe from the tur- 11) Remove the water feed pipe from the cylinder
bocharger assembly. block.
7) Remove the oil return pipe from the cylinder
block. ANNOTATION:
2 Oil feed pipe
3 Oil return pipe 1 Water return pipe
2 Water feed pipe
8) Disengage the water return pipe from the tur-
bocharger assembly. 12) Remove the exhaust manifold stay from the
9) Remove the water return pipe from the water cylinder block and the turbocharger assembly.
pump assembly.
bocharger assembly.
ANNOTATION:
2 Exhaust manifold

turbocharger assembly.
84551720B NA - August 2012
2425-5
14) Remove the turbocharger assembly from the 3) Remove the EGR pipe A from the EGR cooler
exhaust manifold. A and exhaust manifold.
1 EGR cooler A
1 Exhaust manifold 2 EGR pipe A
2 Turbocharger assembly 3 Exhaust manifold

13. EGR cooler assembly Removal B.
1) Disengage the water rubber hose from the 5) Remove the EGR pipe B from the EGR cooler
EGR cooler assembly. B.
C.
1 Water rubber hose

1 EGR valve
2 EGR pipe C
3 EGR cooler B
EGR pipe A.
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D

EGR valve.

84551720B NA - August 2012
2425-6
2) Remove the EGR valve from the EGR pipe D. 16. Intake throttle valve Removal
1) Remove the air duct from the intake throttle
valve.
2) Disengage the harness connector from the in-
take throttle valve.
ANNOTATION:
• Pull the lock operation portion to release the
lock.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D

1) Disengage the radiator upper hose from the
water outlet pipe.
2) Remove the EGR cooler water pipe from the 1 Lock operation section
engine assembly. 2 Lock release
ANNOTATION: 3 Lock

and EGR cooler water return pipe. 3) Remove the intake throttle valve from the inlet
pipe.

2 Boost sensor
3 Inlet pipe
4 Gasket

boost sensor.
boost temperature sensor.
EGR valve.
1 EGR cooler water feed pipe 4) Disconnect the harness connector from the
2 EGR cooler water feed pipe IMT sensor.
84551720B NA - August 2012
2425-7
5) Remove the harness clip from the inlet pipe. 4) Remove the oil level gauge guide tube from
the cylinder block.
1 Boost sensor 1 Cylinder head cover

2 IMT sensor 2 Oil level gauge guide tube
3 EGR valve 3 Case
4 Harness clip 4 Cylinder block
19. Glow plug Removal
1) Remove the glow plug connector from the
6) Remove the inlet pipe from the case. glow plug.
2) Remove the glow plug from the cylinder head
assembly.
1 Case
20. Injection pipe Removal
2 Gasket
3 Inlet pipe 1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector
18. Oil level gauge guide tube Removal CAUTION
gauge guide tube.
pipe.
2) Disengage the oil level gauge guide tube from
the cylinder head cover.
ing.
the case.
84551720B NA - August 2012

2425-8
4) Remove the fuel leak-off pipe from the case.

ANNOTATION:

5 Fuel leak-off pipe 1 Common rail assembly
6 Fuel pipe 2 Cylinder head assembly
7 Common rail assembly 3 Fuel leak-off pipe
4 Fuel supply pump
21. Fuel pipe Removal
23. Common rail assembly Removal
1) Remove the fuel pipe from the fuel supply
pump and the common rail assembly. 1) Disengage the harness connector from the
ANNOTATION: 2) Remove the common rail assembly from the
• Remove the clip. inlet cover and the common rail bracket.
3) Remove the common rail bracket from the oil
CAUTION cooler assembly.

der head assembly.
supply pump.
ANNOTATION:
• Remove the eyebolt tightened together with
the fuel feed pipe.
3) Disengage the fuel leak-off pipe from the com-
mon rail assembly.
24. Cylinder head cover Removal

1) Disengage the ventilation hose from the air
breather.
lower cover.
84551720B NA - August 2012

2425-9
3) Remove the head cover gasket from the cylin- 5) Remove the gasket from the lower cover.
der head cover. 6) Remove the rubber plug from the cylinder
head assembly.
26. Injector Removal
jector.
assembly.
ANNOTATION:
a special tool.

2 Gasket
3 Lower cover
25. Lower cover Removal

1) Remove the connector from the lower cover.
CAUTION
nector with a screwdriver. Special tool: injector remover (refer to
section 1003)
tor.
CAUTION

head assembly.
ANNOTATION:
then remove the injector harness together
with the bracket. Special tool: sliding hammer (refer to
4) Remove the lower cover from the cylinder section 1003)
head assembly.
1 Lower cover
2 Connector
84551720B NA - August 2012
2425-10
1) Loosen the adjust screw using the wrench.

ANNOTATION:
screws.
2) Remove the rocker arm shaft from the cylinder

head assembly.
ANNOTATION:
and the rocker arm assembly bracket tight-
ening bolts from both ends and remove
them.
CAUTION
1 Sliding hammer shown in the diagram.
2 Fuel injector remover
3 Injector
CAUTION
28. Camshaft Removal

der head assembly.
ANNOTATION:
27. Rocker arm shaft Removal spected.
84551720B NA - August 2012

2425-11
• Loosening order of the head bolts
29. Bridge Removal

CAUTION
CAUTION
• Be careful not to drop the bridge from the bottom surface of the
cap into the engine. cylinder head, be careful not to
damage the gear.
ANNOTATION:
• After removing, organize to avoid a mix-up
with other installation locations.
1 Idle gear C
2) Remove the cylinder head gasket from the

cylinder block.
1 Bridge cap CAUTION
2 Bridge
ket.
1) Remove the cylinder head assembly from the 31. Fuel supply pump Removal
cylinder block.
ANNOTATION: fuel supply pump.
84551720B NA - August 2012

2425-12
2) Remove the fuel supply pump from the cylin- 32. Starter assembly Removal
der block.
1) Disengage the earth cable from the starter as-
sembly.
2) Remove the starter assembly from the fly-
wheel housing.
1 Bolt
3) Remove the supply pump gear from the fuel 1 Oil pressure sensor
supply pump using the puller. 2 Oil port cover
3 Starter assembly
33. CKP sensor Removal

CKP sensor.
2) Remove the CKP sensor from the flywheel
housing.
CAUTION
• Be careful not to subject the sensor
to shock.
4) Remove the fuel supply pump from the supply

pump bracket.
CAUTION
• Do not hold the pipe of the fuel sup-
ply pump.
1 CKP sensor
2 Flywheel housing
34. Flywheel Removal

1) Remove the flywheel from the crankshaft.
1 Fuel supply pump ANNOTATION:
2 O-ring • Gradually loosen the flywheel installation
3 Supply pump bracket bolts in the order shown in the diagram.
84551720B NA - August 2012
2425-13
CAUTION CAUTION
• Fix the flywheel firmly so that it will • Be careful not to damage the oil
not rotate. seal press fitting surface.
35. Crankshaft rear oil seal Removal ANNOTATION:

1) Remove the crankshaft rear oil seal from the • Remove the slinger and oil seal together.
crankshaft using the special tool. • If the slinger of the remover is easy to come
off, the outer circumference of the jig can be
workability.
36. Oil pan Removal
1) Disengage the harness connector from the oil
level switch.
2) Remove the oil pan from the crankcase.
3) Remove the gasket from the oil pan.
37. Oil strainer Removal
1) Remove the oil strainer from the crankcase.
2) Remove the O-ring from the oil strainer.
Special tool: rear oil seal remover (refer

to section 1003)
1 M10 bolt
2 M8 bolt
1 Felt
2 Slinger 38. Flywheel housing Removal
3 Crankshaft rear oil seal 1) Remove the cover from the flywheel housing.
84551720B NA - August 2012

2425-14
2) Remove the flywheel housing from the cylin- 3) Measure the clearance using the feeler
der block and the crankcase. gauge.
CAUTION ANNOTATION:
• Do not forget to remove the bolt • Measure the clearance between the idle
shown in the diagram. gear and the thrust collar.
CAUTION
• Measure the play of the idle gear in
the axis direction before removing
the idle gear B.
Specified value： 0.080 - 0.155 mm {0.0031 -

0.0061 in.}
Limit： 0.20 mm {0.0079 in.}
CAUTION
• Replace the idle gear if the mea-
1 Bolt
39. Idle gear Measurement

1) Align the dial gauge to the idle gear.
ANNOTATION:
• Attach the dial gauge to the idle gear tooth
to be measured.
2) Inspect the backlash.
ANNOTATION:
40. Idle gear A Removal
• Gently move the gear right and left to read
the inconsistency on the dial gauge. 1) Remove the idle gear A from the idle gear A
shaft.
CAUTION
41. Oil pump assembly Removal
• Measure the idle gear backlash be-
fore removing the idle gear A. 1) Remove the oil pump assembly from the cylin-
der block.
0.0067 in.}
Limit： 0.30 mm {0.0118 in.}
CAUTION
42. Idle gear B Removal

1) Remove the idle gear B from the idle gear B
shaft.
2) Remove the idle gear B shaft from the cylinder
block.
84551720B NA - August 2012

2425-15
• Pull out the piston and connecting rod to-

gether to the cylinder head side.
CAUTION
• Be careful not to damage the oil jet.
5) Remove the connecting rod bearing from the

connecting rod.
ANNOTATION:
• Organize the removed bearings by the cylin-
ders using tags, etc.
44. Crankshaft Removal
43. Piston Removal
1) Clean the cylinder liner using the scraper. gauge.
• Remove carbon from the top of the cylinder • Measure the crankshaft clearance in the
liner using a scraper. axis direction at the bearing section no.7.
0.0081 in.}
2) Remove the connecting rod bearing cap from

the connecting rod.
ANNOTATION:
CAUTION
• Set the piston of the cylinder to be removed
to the bottom dead center. • Replace the thrust bearing if the
measured value is not within the
range of the standard value.
2) Remove the crankcase from the cylinder

block.
ANNOTATION:
• Loosening order
3) Remove the connecting rod bearing from the

connecting rod bearing cap.
ANNOTATION:
• Organize the removed bearings by the cylin-
ders using tags, etc.
4) Remove the piston from the cylinder block.
ANNOTATION:
ANNOTATION:
84551720B NA - August 2012
2425-16
• Remove the crankcase using the replacer

holes indicated by the arrow in the diagram.
： 3 section(s) Replacer hole
3) Remove the thrust bearing from the
crankcase.
4) Remove the crankshaft bearing from the
crankcase.
46. Cylinder liner Removal

1) Remove the cylinder liner from the cylinder
block.
5) Remove the crankshaft from the cylinder

block.
6) Remove the thrust bearing from the cylinder
block.
7) Remove the crankshaft bearing from the cylin-
der block.
45. Piston oil jet Removal
1) Remove the piston oil jet from the cylinder
block.
CAUTION
• Do not tilt the cylinder liner when
storing.
84551720B NA - August 2012

2425-17
Installation of Cylinder Block ： 118.001 ： 118.021

： 118.011
- 118.010 - 118.030
- 118.020
1. Cylinder liner Preparation Block inner mm mm mm
diameter (4.645709 (4.646496
(4.646102
CAUTION - 4.646063 - 4.646850
- 4.646457
in.) in.) in.)
• When replacing the cylinder liner, select
the cylinder liner following the procedure ： 118.001
below. - 118.010
： 117.991 - 118.000 mm
Liner outer mm
(4.645315 - 4.645669
1) Check marking of the cylinder block. diameter (4.645709
in.)
- 4.646063
ANNOTATION: in.)
• A marking on a cylinder block indicates the 2. Cylinder liner Installation
cylinder block bore grade.
CAUTION
• Since the cylinder liner is thin, handle it
carefully.
• Do not tilt the cylinder liner when storing.
2) Check the grade of the cylinder liner.
1) Clean the cylinder block using the air.

2) Clean the cylinder liner using the air.
3) Install the cylinder liner to the cylinder block.
ANNOTATION:
• Install the cylinder liner on the cylinder block
vertically.
CAUTION
• Do not tap or apply excessive force
1 Grade confirmation location when inserting the liner.
3) Select the cylinder liner.
Matching grades for cylinder block and liner outer

diameter
Marking on
1 2 3
the block
Liner outer
1X 3X
diameter
Cylinder block inner diameter, liner outer diameter

grade
Grade 1･1X 2･1X 3･3X
84551720B NA - August 2012

2425-18
CAUTION
• After replacing the cylinder liner,
be sure to measure the protrusion
amount of the cylinder liner.
4) Measure the cylinder liner using the dial

gauge.
Specified value ： 0.05 - 0.10 mm (0.00197
- 0.00394 in.) Protrusion amount of cylinder
liner
Limit： 0.03 mm (0.00118 in.) less than
ANNOTATION:
4. Crankshaft bearing Preparation
• The limit value indicates the difference in the
protrusion amounts with the adjacent cylin-
CAUTION
der liner.
• When replacing the crankshaft bearing,
select the crankshaft bearing following
the procedure below.
1) Check marking of the crankcase.

ANNOTATION:
• The marking on the crankcase indicates the
inner diameter grade of the cylinder block
journal section.
• Grade indications are lined up as No.1, 2, 3,
4, 5 from the left when looking at the mark-
ing section from the front side.
3. Piston oil jet Installation

1) Install the piston oil jet to the cylinder block.
CAUTION
• Be careful not to deform or damage
the nozzle part of the piston oil jet.

lb・ft.}
2) Check the marking on the crankshaft.

ANNOTATION:
• The marking on the crankshaft indicates the
outer diameter grade of the journal section.
• Grade indications are lined up as No.1, 2, 3,
4, 5 from the left when looking at the mark-
ing section from the front side.
84551720B NA - August 2012

2425-19
3) Select the crankshaft bearing.

ANNOTATION:
• Refer to the bearing selection table.
Bearing selection table

Grade combination Oil clearance
Cylinder block grade Crank journal grade 1, 2, 4, 5 3
： 0.041 - 0.068 mm (0.001614 ： 0.055 - 0.082 mm (0.002165
1 1
- 0.002677 in.) - 0.003228 in.)
： 0.039 - 0.065 mm (0.001535 ： 0.053 - 0.079 mm (0.002087
1 2
- 0.002559 in.) - 0.003110 in.)
： 0.043 - 0.070 mm (0.001693 ： 0.057 - 0.084 mm (0.002244
2 1
- 0.002756 in.) - 0.003307 in.)
： 0.041 - 0.067 mm (0.001614 ： 0.055 - 0.081 mm (0.002165
2 2
- 0.002638 in.) - 0.003189 in.)
CAUTION CAUTION
• Be careful not to mistake the bear- • Make sure there is no grime or oil on
ing shape when installing the the cylinder block contact surface
crankshaft bearing. for the crankshaft bearing.
2) Apply the grease to the thrust bearing.

ANNOTATION:
• Apply a small amount of grease to the thrust
bearing to prevent falling.
3) Install the thrust bearing to the cylinder block.
ANNOTATION:
• Install the thrust bearing on the No.5 journal
so that the oil groove faces the engine front.
1 Upper bearing
2 Oil hole
3 Grade identification color
4 Oil groove
5 Lower bearing
6 Grade identification color
5. Crankshaft Installation
1) Install the crankshaft bearing to the cylinder
4) Apply the engine oil to the crankshaft bearing.
block.
5) Apply the engine oil to the crankshaft.
ANNOTATION: 6) Put the crankshaft on the cylinder block.
• Install a bearing with an oil hole on the cylin-
der block.
84551720B NA - August 2012
2425-20
7) Install the thrust bearing to the cylinder block.

ANNOTATION:
• Install the thrust bearing on the No.5 journal
so that the oil groove faces the engine rear.
1 2 - 3 mm (0.079 - 0.118 in.)

2 3 - 4 mm (0.118 - 0.157 in.)
CAUTION
8) Install the crankshaft bearing to the
crankcase. • After applying the liquid gasket, in-
stall the crankcase within 5 min-
CAUTION utes.
• Make sure there is no grime or oil on 13) Put the crankcase on the cylinder block.
the crankcase contact surface for
the crankshaft bearing. CAUTION
9) Apply the grease to the thrust bearing. • Be careful not to let the thrust bear-
ing fall.
ANNOTATION:
14) Apply the disulfide molybdenum grease to the
• Apply a small amount of grease to the thrust bolt.
bearing to prevent falling.
ANNOTATION:
10) Install the thrust bearing to the crankcase.
ANNOTATION: • Apply to the threaded portion and seat sur-
face on the M14 bolt for crankcase installa-
• Install the thrust bearing on the No.5 journal tion.
so that the oil groove faces the engine rear.
CAUTION
• Do not apply grease to the M10 bolt.
ANNOTATION:
11) Apply the engine oil to the crankshaft bearing.

12) Apply the liquid gasket to the crankcase.
ANNOTATION:
• Apply ThreeBond 1207B to the crankcase
thoroughly so that there is no break in appli-
cation of the bead. 15) Tighten the bolt using the torque wrench.
lb・ft.} M14 bolt
16) Tighten the bolt using the torque wrench.
/ 97 lb・ft.} M14 bolt
84551720B NA - August 2012
2425-21
17) Tighten the bolt using the special tool. 7) Install the special tool to the piston
Special tool: angle gauge (refer to section Special tool: piston setting tool (refer to
1003) section 1003)
Tightening angle： 30 ° M14 bolt 8) Align the piston to the cylinder block.
Tightening torque： 37 N・m {3.8 kgf・m / 27 ANNOTATION:
lb・ft.} M10 bolt • Turn the piston so that the front mark faces
19) Tighten the bolt using the torque wrench. the engine front.
/ 105 lb・ft.} Check the tightening M14 bolt 9) Press the piston.
CAUTION CAUTION
• Confirm that the crankshaft turns • To avoid damaging the oil jet, place
smoothly after tightening the bolts. the crank pin on the cylinder on
which the piston will be installed at
top dead center.
6. Piston Installation
• To avoid damaging the piston ring,
1) Install the connecting rod bearing to the con- firmly attach the piston installer to
necting rod. the cylinder block and push it.
2) Apply the engine oil to the connecting rod • Be careful not to damage the crank
bearing. pin and cylinder liner.
• Attach a stopper so that the liner
CAUTION does not protrude.
• Apply engine oil only to the inter-
nal diameter of the connecting rod
bearing.
3) Apply the engine oil to the piston ring.

4) Apply the engine oil to the piston.
ANNOTATION:
• Thoroughly apply engine oil to the ring
grooves and piston side surface.
5) Adjust the piston ring.
ANNOTATION:
• Shift each piston ring joint by the specified
angle.
1 No.1 compression ring joint
Specified angle： 90 ° 2 No.2 compression ring joint
6) Apply the engine oil to the cylinder liner. 3 Oil ring joint
4 Front mark
10) Install the connecting rod bearing to the con-

necting rod bearing cap.
84551720B NA - August 2012

2425-22
11) Apply the engine oil to the connecting rod CAUTION

bearing.
• Do not allow tightening tools to
CAUTION touch the oil jet.
• Confirm that the crankshaft turns
• Apply engine oil only to the inter-
nal diameter of the connecting rod smoothly after tightening the con-
necting rod bolt.
bearing.
14) Apply the disulfide molybdenum grease to the
12) Align the connecting rod bearing cap to the
bolt.
connecting rod.
ANNOTATION:
ANNOTATION:
• Apply to the threaded portion and seat sur-
• Confirm that the numbers on the connecting
face of the bolts for the connecting rod in-
rod bearing cap and the connecting rod are
stallation.
the same.
lb・ft.}
16) Tighten the bolt using the special tool.
Front and back side discrimina-

1
tion boss
Grade mark of the large end Special tool: angle gauge (refer to section
2 1003)
hole diameter
3 Cylinder number Tightening angle： 60 °
17) Tighten the bolt using the special tool.
Tightening angle： 30 °
13) Install the connecting rod bearing cap to the Tightening torque： 98 N・m {10.0 kgf・m /
connecting rod. 72 lb・ft.} Check the tightening
ANNOTATION:
• Precautions when tightening the connecting
rod bolt
CAUTION
• Set each cylinder to the bottom
dead center while working.
7. Idle gear B Installation

1) Install the idle gear B shaft to the cylinder
block.
lb・ft.}
84551720B NA - August 2012

2425-23
2) Apply the engine oil to the idle gear B shaft. 8. Oil pump assembly Installation
1) Install the oil pump to the cylinder block.
CAUTION

lb・ft.}
9. Idle gear A Installation
center.
2) Apply the engine oil to the idle gear A.
3) Install the idle gear A shaft to the idle gear A.
3) Apply the engine oil to the idle gear B. 4) Align the idle gear A to alignment mark.
4) Install the idle gear B to the cylinder block.
Tightening torque： 110 N・m {11.2 kgf・m / ANNOTATION:
81 lb・ft.} • Align the L mark on the crank gear with the
O mark on the idle gear A.
5) Apply the engine oil to the bolt.
ANNOTATION:
• Apply engine oil to the threaded portion and
seat surface on the idle gear A installation
bolt.
1 Idle gear B
2 Thrust collar
3 Bolt
CAUTION
• Confirm that the idle gear B turns
smoothly after installing.
84551720B NA - August 2012

2425-24
6) Install the idle gear A to the cylinder block.

/ 98 lb・ft.}
1 Idle gear C 4 PTO gear 7 Oil pump drive gear

2 Camshaft gear 5 PTO idle gear 8 Supply pump gear
3 Idle gear B 6 Crankshaft gear 9 Idle gear A
10. Flywheel housing Installation CAUTION

1) Clean the cylinder block using the scraper.
• After applying the liquid gasket, in-
ANNOTATION: stall the flywheel housing within 5
minutes.
• Remove dust and oil from the flywheel hous-
ing installation area. 3) Install the flywheel housing to the cylinder
2) Apply the liquid gasket to the cylinder block. block.
ANNOTATION:
Tightening torque
• Refer to the diagram and apply the Three- ： 96 N・m {9.8 kgf・m
Flywheel housing side
Bond 1207B to the cylinder block. / 71 lb・ft.}
： 38 N・m {3.9 kgf・m
Cylinder block side
/ 28 lb・ft.}
Supply pump bracket ： 76 N・m {7.7 kgf・m
side / 56 lb・ft.}
ANNOTATION:
• Install the flywheel housing after aligning
with the knock pin position of the cylinder
block.
CAUTION
• Be careful not to forget to tighten
the bolt indicated in the diagram.
84551720B NA - August 2012

2425-25
12. Oil pan Installation

ANNOTATION:
• Apply ThreeBond 1207B to each joint of the
crankcase, flywheel housing and gear case.
Bead width： 3.0 mm (0.118 in.)
1 Bolt
4) Apply engine oil to the PTO gear shaft.

5) Install the PTO idle gear shaft to the PTO idle
gear.
6) Install the PTO idle gear to the cylinder block.
/ 99 lb・ft.}
CAUTION
stall the oil pan within 5 minutes.
2) Install the gasket to the oil pan.

3) Install the oil pan to the crankcase.
lb・ft.}
ANNOTATION:
7) Install the O-ring to the cover.

8) Install the cover to the flywheel housing.
lb・ft.}
11. Oil strainer Installation
1) Install the O-ring to the oil strainer.
2) Install the oil strainer to the crankcase.
lb・ft.}
4) Connect the harness connector to the oil level

switch.
13. Crankshaft rear oil seal Installation
1) Prepare the special tool.
1 M10 bolt
2 M8 bolt
84551720B NA - August 2012
2425-26
2) Apply the engine oil to the crankshaft rear oil

seal.
CAUTION
• Apply only to the lip section of the
oil seal.
3) Install the crankshaft rear oil seal to the

adapter.
4) Install the adapter to the crankshaft.
5) Install the adapter ring to the sleeve.
6) Install the sleeve to the adapter.
Special tool: oil seal installer (refer to

section 1003)
ANNOTATION:
• Install the crankshaft rear oil seal and
slinger together.
• In order to install the crankshaft rear oil seal,
use the one(s) in the following table from
among the parts included in the kit.
1 Sleeve
2 Adapter ring
7) Install the center bolt to the sleeve.

8) Tighten the center bolt using the wrench.
ANNOTATION:
• Tighten the center bolt until the sleeve
touches the adapter.
Legend Parts number

1: Adapter 5-8840-2709-0
2: Adapter tightening bolts 5-8840-2714-0
3: Center bolt 5-8840-2713-0
4: Sleeve 5-8840-9063-0
5: Collar 5-8840-2710-0
6: Adapter ring 5-8840-2711-0
7: Crankshaft rear oil seal -
84551720B NA - August 2012

2425-27
9) Inspect the crankshaft rear oil seal. 3) Tighten the bolt using the torque wrench.
ANNOTATION:
lb・ft.}
• Measure the distance between the crank- 4) Tighten the bolt using the special tool.
shaft head and the crankshaft rear oil seal.
Specified value ： 7.2 - 7.8 mm (0.2835 -
0.3071 in.)
Special tool: angle gauge (refer to section

1003)
Tightening angle： 120 °
15. CKP sensor Installation
1 Crankshaft
2 Crankshaft rear oil seal 1) Install the CKP sensor to the flywheel housing.
3 Measurement location CAUTION
4 Collar
5 Adapter ring • Be careful not to subject the sensor
6 Sleeve to shock.
7 Adapter
ANNOTATION:
14. Flywheel Installation • Tighten together with the clip.
1) Apply the disulfide molybdenum grease to the Tightening torque： 6 N・m {0.6 kgf・m / 4.43
bolt. lbf・ft.}
ANNOTATION: 2) Connect the harness connector to the CKP
sensor.
• Apply to the seat surface and threaded por-
tion on the flywheel installation bolts.
2) Install the flywheel to the crankshaft.
CAUTION
• Pay attention to the knock pin posi-
tion of the crankshaft.
ANNOTATION:
1 CKP sensor
2 Flywheel housing
16. Starter assembly Installation

1) Install the starter assembly to the flywheel
housing.
/ 78 lb・ft.}
84551720B NA - August 2012

2425-28
2) Connect the earth cable to the starter assem-

bly.
lb・ft.}
1 Fuel supply pump

2 Supply pump gear
3 Nut
1 Oil pressure sensor ANNOTATION:

2 Oil port cover • After installing the supply pump gear, refer
3 Starter assembly to the diagram and make an alignment mark
on it.
17. Fuel supply pump Installation
1) Install the O-ring to the fuel supply pump.
2) Install the fuel supply pump to the supply
pump bracket.
lb・ft.}
CAUTION
• Be careful not to let the O-ring get
twisted.

center.
1 Fuel supply pump

2 O-ring
3 Supply pump bracket
3) Install the supply pump gear to the fuel supply 0 degree marking on the crank-
pump. 2
shaft damper
lb・ft.} 5) Install the O-ring to the fuel supply pump.
84551720B NA - August 2012

2425-29
6) Temporarily tighten the fuel supply pump to 8) Securely tighten the fuel supply pump to the
the cylinder block. cylinder block.
lb・ft.} Nut
lb・ft.} Bolt
9) Connect the harness connector to the fuel
supply pump.
18. Front cover Installation
2) Apply the liquid gasket to the front cover.
ANNOTATION:
Bead width： 1.5 - 5.0 mm (0.0591 - 0.1969
in.)
1 Bolt Bead height： 0.3 - 1.5 mm (0.0118 - 0.0591
in.)
7) Check alignment mark of the supply pump CAUTION

gear.
ANNOTATION: stall the front cover within 5 min-
utes.
• Confirm that the alignment mark can be
seen through the plug hole on the left side
of the flywheel housing. 3) Install the O-ring to the front cover.
1 O-ring
1 Plug hole
2 Alignment mark 4) Install the front cover to the cylinder block.
CAUTION
CAUTION • Pay attention to the knock pin posi-
tion of the cylinder block.
• If the alignment mark could not be
confirmed, adjust the position of
the supply pump gear. Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft.}
84551720B NA - August 2012

2425-30
19. Water pump assembly Installation 6) Install the adapter to the water pump assem-
bly.
1) Install the water pump assembly to the front Tightening torque： 45 N・m {4.6 kgf・m / 33
cover. lb・ft.}
CAUTION

lb・ft.} 1 bolt in the diagram
lb・ft.}
1 Adapter
2 Spacer
3 Fan pulley
4 Water pump assembly
5 Gasket
20. Crankshaft front oil seal Installation

1 Bolt 1) Prepare the special tool.
2 Stud bolt
3 Oil relief valve
2) Connect the water hose to the water pump

assembly.
3) Connect the water return pipe to the water
pump assembly.
lb・ft.}
4) Install the fan pulley to the water pump assem-
bly.
7.38 lbf・ft.}
5) Align the spacer to the adapter.
section 1003)
ANNOTATION:
• Install the crankshaft front oil seal and
slinger together.
• In order to install the crankshaft front oil
seal, use the one(s) in the following table
from among the parts included in the kit.
84551720B NA - August 2012

2425-31

ANNOTATION:
Legend Parts number

1: Oil seal -
2: Adapter 5-8840-2705-0
3: Adapter ring 5-8840-2706-0
4: Adapter tightening bolt 5-8840-2714-0
5: Sleeve 5-8840-9062-0
6: Washer 5-8840-2707-0 9) Inspect the crankshaft front oil seal.
7: Center bolt 5-8840-2713-0
ANNOTATION:
2) Apply the engine oil to the crankshaft front oil • Measure the distance between the crank-
seal. shaft head and the crankshaft front oil seal.
CAUTION Specified value： 30.7 - 31.3 mm {1.2087 -

1.2323 in.}
oil seal.
3) Install the crankshaft front oil seal to the

adapter.
Oil seal press-fitting measure-

1
ment
2 Front cover
3 Crankshaft front oil seal
4 Crankshaft
21. Crankshaft pulley Installation

1 Crankshaft front oil seal
2 Adapter ring
3 Sleeve
4 Washer
84551720B NA - August 2012

2425-32
1) Install the crankshaft damper to the crankshaft

pulley.
lb・ft.}
ANNOTATION:
• Tighten the bolts in a diagonal line order.
CAUTION
2) Install the cylinder head gasket to the cylinder

block.
2) Install the crankshaft pulley to the crankshaft.
CAUTION
CAUTION
tion of the crankshaft. 3) Install the cylinder head assembly to the cylin-
der block.
/ 148 lb・ft.} Apply engine oil on the threaded CAUTION
area of bolt • Be careful not to damage the cylin-
ANNOTATION: der head gasket.
• Tightening order ANNOTATION:

• Tightening order of the head bolts
22. Cylinder head assembly Installation
CAUTION
ANNOTATION:
• Clean the aligning surface of the cylinder
head and cylinder block before installing • 1 - 18 in the diagram indicate the M14 bolts.
the cylinder head assembly. • 19 and 20 in the diagram indicate the M10
bolts.
head and cylinder block while cleaning. 4) Prepare the head bolt.
ANNOTATION:
ANNOTATION: seat surface and threaded portion of the
• Use ThreeBond 1207B. M14 head bolts.
• Apply engine oil to the seat surface and
Bead width： 3.0 mm (0.1181 in.) threaded portion of the M10 head bolts.
Bead height： 3.0 mm (0.1181 in.)
84551720B NA - August 2012
2425-33
5) Tighten the head bolt using the torque wrench. 24. Camshaft Installation
/ 116 lb・ft.}
center.
/ 122 lb・ft.}
7) Tighten the head bolt using the special tool.

2
shaft damper
1003)
Tightening angle： 55 ° M14 bolt 2) Apply the engine oil to the camshaft bearing.
8) Tighten the head bolt using the torque wrench. ANNOTATION:
lb・ft.} M10 bolt • Apply engine oil to the sliding surface of the
9) Tighten the head bolt using the torque wrench. bearing.
/ 123 lb・ft.} Check the tightening M14 bolt CAUTION
23. Bridge Installation • Apply engine oil after cleaning the
bearing installation sections of
1) Apply the engine oil to the bridge. the camshaft bearing and cylinder
2) Install the bridge to the bridge guide. head.
CAUTION
3) Install the camshaft bearing to the cylinder
• Confirm that the bridge moves head assembly.
smoothly. 4) Install the camshaft to the cylinder head as-
sembly.
3) Apply the engine oil to the bridge cap. ANNOTATION:
4) Install the bridge cap to the bridge.
• Mesh together the idle gear C and the
camshaft gear so that the alignment mark
on the camshaft gear matches the top sur-
face of the cylinder head, and gently install
the camshaft.
CAUTION
• Be careful not to drop the bridge
cap into the engine.
84551720B NA - August 2012

2425-34
5) Check alignment mark of the camshaft gear. 3) Temporarily tighten the bolt to the cylinder
head assembly.
CAUTION
ANNOTATION:
• Confirm that the alignment mark is
not misaligned before installing the • Apply engine oil to the threaded portion of
camshaft bearing cap. the bolts.
• If the alignment mark is not at 4) Temporarily tighten the nut to the cylinder
the correct position, reinstall the head assembly.
camshaft.
ANNOTATION:
6) Apply the engine oil to the camshaft bearing. • Apply engine oil to the threaded portion of
ANNOTATION: the nuts.
bearing. cylinder head assembly.
ANNOTATION:
CAUTION
• Apply engine oil after cleaning the and gradually tighten it.
bearing installation sections of the
camshaft bearing and camshaft
bearing cap. Rocker arm shaft tightening torque
7) Install the camshaft bearing to the camshaft ： 21 N・m {2.1 kgf・m / 15
bearing cap. No.1 Nut
lb・ft.}
8) Install the camshaft bearing cap to the cylinder ： 27 N・m {2.8 kgf・m / 20
head assembly. No.2 Bolt
lb・ft.}
ANNOTATION: ： 56 N・m {5.7 kgf・m / 41
No.3 Bolt
lb・ft.}
• Turn the camshaft bearing cap so that the ： 27 N・m {2.8 kgf・m / 20
arrow mark on the top surface faces the en- No.4 Bolt
lb・ft.}
gine front side, and assemble in numerical
order.
lb・ft.} Apply engine oil
1 Nut
2 Bolt
25. Rocker arm shaft Installation
3 Bolt
1) Apply the engine oil to the bracket. 4 Bolt
ANNOTATION:
• Apply to each sliding surface. 26. Rocker arm shaft Adjustment
2) Apply the engine oil to the rocker arm. ANNOTATION:
ANNOTATION: • Valve clearance adjustment
• Confirm that the adjust screw is fully loos- CAUTION
ened.
• Adjust the valve clearance while cool.
• Loosen all adjust screws before adjust-
ment.
84551720B NA - August 2012

2425-35

ANNOTATION:
• When the movement of the thickness gauge
becomes stiff, secure the adjust screw nut
of the rocker arm.
lb・ft.}

center.

ANNOTATION:
1 Front cover marking • Check if the valve shaft end on the opposite
0 degree marking on the crank- side is floating or touching at an angle.
2
shaft damper • If it is floating or touching at an angle, slightly
loosen the bridge adjust screw and adjust
2) Prepare the feeler gauge. the valve shaft ends on both sides to touch
Thickness： 0.4 mm {0.0157 in.} 2 pieces properly.
ANNOTATION: Valve bridge clearance ： less than 0.1 mm
(less than 0.0039 in.)
rocker arm and bridge cap. ANNOTATION:
bridge and valve. • To prevent turning, fix the bridge adjust
lb・ft.}
84551720B NA - August 2012

2425-36
Adjustment table
1 2 3 4
Cylinder No.
First cylinder compression top dead
O O O O
center
Fourth cylinder compression top dead
O O O O
center
27. Common rail assembly Installation 7) Connect the harness connector to the fuel
pressure sensor.
1) Temporarily tighten the common rail bracket
to the oil cooler assembly.
ANNOTATION:
• The installation bolt and common rail as-
sembly are tightened together.
cover.
assembly.
ANNOTATION:
ened together.
assembly. 1 Common rail assembly
5) Securely tighten the nut to the common rail 2 Fuel pressure sensor
assembly.
lb・ft.}
ANNOTATION: 28. Fuel leak off pipe assembly Installation
• Refer to the tightening order in the diagram 1) Temporarily tighten the fuel leak-off pipe to the
if the inlet cover is removed. cylinder head assembly.
CAUTION

CAUTION

fuel supply pump.
ANNOTATION:
6) Securely tighten the bolt to the common rail
assembly. • Tighten the fuel feed pipe together.
lb・ft.} CAUTION
4) Securely tighten the fuel leak-off pipe to the

8.85 lbf・ft.}
lb・ft.}
84551720B NA - August 2012
2425-37
6) Securely tighten the fuel leak-off pipe to the 2) Temporarily tighten the injector to the cylinder
fuel supply pump. head assembly.
lb・ft.} CAUTION
Tightening torque： 8 N・m {0.8 kgf・m / 5.90 • Be extremely careful not to damage
lbf・ft.}
1 Common rail assembly 1 Injector

2 Cylinder head assembly 2 Installation bolt
4 Fuel supply pump 3) Temporarily tighten the injection pipe to the
injector.
29. Fuel pipe Installation CAUTION
1) Install the fuel pipe to the fuel supply pump
• Use new injection pipes.
CAUTION 4) Temporarily tighten the injection pipe to the

• Use new fuel pipes. 5) Securely tighten the injector to the cylinder
head assembly.
lb・ft.} lb・ft.}
2) Install the clip to the bracket. 6) Install the injector leak-off pipe to the injector.
lbf・ft.} CAUTION
30. Injector Installation • Use new gaskets.
CAUTION Tightening torque： 14 N・m {1.4 kgf・m /

10.33 lbf・ft.}
• When reusing an injector, do not change
the installation position. 31. Injection pipe Installation
tor.
lb・ft.}
mon rail assembly.
lb・ft.}
84551720B NA - August 2012

2425-38
3) Install the clip to the bracket. 4) Install the lower cover to the cylinder head
Tightening torque： 6 N・m {0.6 kgf・m / 4.43 assembly.
lbf・ft.} Tightening torque： 18 N・m {1.8 kgf・m / 13
lb・ft.}
5) Install the injector harness to the cylinder head
assembly.
ANNOTATION:
stall the injector harness together with the
bracket.
lb・ft.}

6 Fuel pipe
32. Lower cover Installation 1 Injector harness terminal

1) Apply the liquid gasket to the rubber plug. 2 Injector harness bracket
ANNOTATION:
• Apply ThreeBond 1207B. 6) Connect the injector harness to the injector.
lbf・ft.}
CAUTION
1 Rubber plug
2 Liquid gasket
CAUTION
• After applying the liquid gasket, in- 1 Lower cover
stall the lower cover within 5 min- 2 Connector
utes.
2) Install the rubber plug to the cylinder head 7) Install the connector to the lower cover.
assembly. Tightening torque： 2 N・m {0.2 kgf・m / 1.48
3) Install the gasket to the lower cover. lbf・ft.}
84551720B NA - August 2012
2425-39

1) Install the glow plug to the cylinder head as-
sembly.
lb・ft.}
CAUTION
fied torque when tightening.

2 Gasket
3 Lower cover

breather.
2) Install the glow plug connector to the glow 35. Oil level gauge guide tube Installation
plug. 1) Install the oil level gauge guide tube to the
Tightening torque： 1 N・m {0.1 kgf・m / 0.74 cylinder block.
lbf・ft.} 2) Connect the oil level gauge guide tube to the
case.
CAUTION Tightening torque： 19 N・m {1.9 kgf・m / 14
• Confirm that the glow plug connec- lb・ft.}
tor does not interfere with the sur- 3) Connect the oil level gauge guide tube to the
rounding parts. cylinder head cover.
34. Cylinder head cover Installation lb・ft.}
4) Install the oil level gauge to the oil level gauge
1) Align the head cover gasket to the cylinder guide tube.
head cover.
cover.
lb・ft.}
ANNOTATION:

3 Case
4 Cylinder block
36. Inlet pipe Installation
84551720B NA - August 2012

2425-40
1) Install the inlet pipe to the case. 37. Intake throttle valve Installation
lb・ft.}
CAUTION lb・ft.}

2 Boost sensor
1 Case 3 Inlet pipe
2 Gasket 4 Gasket
3 Inlet pipe 5 Intake throttle valve
2) Connect the harness connector to the IMT

sensor. 2) Install the air duct to the intake throttle valve.
3) Connect the harness connector to the EGR 3) Connect the harness connector to the intake
valve. throttle valve.
4) Connect the harness connector to the boost ANNOTATION:
temperature sensor.
5) Connect the harness connector to the boost • After connecting the harness connector,
sensor. press in the lock operation portion to lock.
6) Install the harness clip to the inlet pipe.
1 Boost sensor 1 Lock operation section

2 IMT sensor 2 Lock release
3 EGR valve 3 Lock
4 Harness clip
5 Boost temperature sensor 38. EGR cooler water pipe Installation
84551720B NA - August 2012

2425-41
5) Install the fan guide stay to the fan guide.

lb・ft.}
1 Fan guide stay

2 Fan guide
3 Fan guide bracket
4 Spacer

lb・ft.}


assembly.
ANNOTATION:
lb・ft.} Clamp
outlet pipe.
1 EGR cooler C
head assembly.
Tightening torque： 50 N・m {5.1 kgf・m / 37 2 EGR pipe C
lb・ft.} 3 EGR valve
Tightening torque ： 97 N ・ m {9.9 kgf ・ m} 4 EGR pipe D
The area where the spacer is used
4) Install the fan guide stay to the fan guide
bracket. CAUTION
lb・ft.} • Use new gaskets.

valve.
EGR valve.
EGR pipe C.
EGR cooler B.
84551720B NA - August 2012
2425-42

EGR pipe B.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B
5) Temporarily tighten the EGR pipe A to the

EGR cooler A and the exhaust manifold.

valve.
gine hanger bracket.
8) Securely tighten the EGR pipe B to the
bracket.
1 EGR cooler A pipe C.
2 EGR pipe A Tightening torque： 24 N・m {2.4 kgf・m / 17
3 Exhaust manifold lb・ft.} No.4 in the diagram
ANNOTATION: cooler B.
• Complete tightening order of the EGR lb・ft.} No.5 in the diagram
cooler assembly 11) Securely tighten the EGR cooler A to the EGR
pipe B.
haust manifold.
13) Securely tighten the EGR pipe A to the EGR
cooler A.
84551720B NA - August 2012

2425-43
14) Install the EGR heat protector to the EGR pipe 2) Temporarily tighten the exhaust manifold stay
A. to the cylinder block and the turbocharger as-
sembly.

2 Exhaust manifold
cooler assembly. 3 Exhaust manifold stay

lb・ft.}
4) Securely tighten the exhaust manifold stay to
the cylinder block and the turbocharger as-
sembly.
lb・ft.} Nut
lb・ft.} Bolt
ANNOTATION:
1 Water rubber hose


block.
CAUTION

lb・ft.} Eyebolt
1 Exhaust manifold Tightening torque： 24 N・m {2.4 kgf・m / 17
2 Turbocharger assembly lb・ft.} Clip
84551720B NA - August 2012

2425-44
6) Connect the water feed pipe to the tur- 9) Install the oil return pipe to the cylinder block.
bocharger assembly.
CAUTION
CAUTION
Tightening torque： 35 N・m {3.5 kgf・m / 25 lb・ft.}
lb・ft.} Eyebolt 10) Connect the oil return pipe to the turbocharger
Tightening torque： 14 N・m {1.4 kgf・m / assembly.
10.33 lbf・ft.} Clip
7) Install the water return pipe to the water pump CAUTION
assembly.
CAUTION
• Use new gaskets. lbf・ft.}
lb・ft.} Eyebolt CAUTION
lb・ft.} Clip • Use new gaskets.
8) Connect the water return pipe to the tur-
bocharger assembly. Tightening torque： 17 N・m {1.7 kgf・m / 12
lb・ft.} Eyebolt
lb・ft.} Clip
1 Water return pipe

2 Water feed pipe

lb・ft.} Eyebolt
84551720B NA - August 2012

2425-45
12) Connect the oil feed pipe to the turbocharger 1) Press the cooling fan belt.
assembly.
ANNOTATION:
CAUTION • Measure the amount of cooling fan belt flex
by pressing on the point indicated by the ar-
row in the diagram with the specified pres-
sure.
standard ： 98.0 N {10.0 kg / 22 lb}
lb・ft.} Eyebolt
Tightening torque： 24 N・m {2.4 kgf・m / 17 Specified value ： 6.0 - 8.0 mm {0.2362 -
lb・ft.} Clip 0.3150 in.} Amount of flex
1 Crankshaft pulley
2 Generator
3 Fan pulley
2) Adjust the cooling fan belt to standard value

using the adjust bolt.
lb・ft.} Nut of the adjust plate
/ 93 lb・ft.} Bolt of the bracket side
2 Oil feed pipe
3 Oil return pipe
13) Install the exhaust pipe to the turbocharger

assembly.
15) Install the air cleaner duct to the air cleaner 1 Adjust bolt
assembly and the turbocharger assembly. 2 Adjust plate side nut
16) Connect the harness connector to the tur- 3 Bracket side bolt
bocharger assembly.
42. Cooling fan belt Installation 44. Fan guide Installation
1) Install the cooling fan belt to the engine as- 1) Install the fan guide bracket to the engine as-
sembly. sembly.
43. Cooling fan belt Adjustment lb・ft.}
84551720B NA - August 2012

2425-46
2) Install the fan guide to the fan guide bracket. 48. Coolant Filling
lb・ft.}
CAUTION
parts.
off.
CAUTION

1 Bolt lb・ft.}
2 Washer 4) Replenish the coolant with the radiator.
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
45. Cooling fan Installation

1) Install the cooling fan to the adapter.
lb・ft.}
1 Valve
2 Gasket

tery.
50. Fuel Air bleed
1 Cooling fan CAUTION

2 Adapter • To prevent engine failure, be sure to per-
46. Engine harness Connect removal of fuel system parts.
sembly.
ANNOTATION:
47. Engine oil Filling
1) Replenish the engine oil with the engine as-
sembly.
CAUTION
• Confirm the tightening of the oil pan
drain before adding engine oil.
84551720B NA - August 2012

2425-47
1 Priming pump 11) Tighten the plug using the wrench.

2 Plug 12) Operate the priming pump.
3 Drain plug Number of times： 10 count(s) or more
4 Case ANNOTATION:
5 Fuel filter element
1) Prepare the pan. the priming pump.
2) Turn ON the starter switch. specified time： 1 min
ANNOTATION: 13) Loosen the plug using the wrench.
• This is for the models with an electromag- ANNOTATION:

netic pump. • Remove the air in the fuel filter.
3) Loosen the plug using the wrench. 14) Tighten the plug using the wrench.
4) Operate the priming pump. Tightening torque： 10 N・m {1.0 kgf・m /
Number of times： 20 count(s) or more 7.38 lbf・ft.}
ANNOTATION:
CAUTION
plug. • Remove the fuel around the plug
thoroughly after tightening.
6) Operate the priming pump. 15) Operate the priming pump.
Number of times： 10 count(s) or more Number of times the operation is performed:
ANNOTATION: 10 - 15 times
16) Start the engine.
the priming pump. CAUTION
specified time： 1 min • Do not accelerate the engine revo-
7) Loosen the plug using the wrench. lution right after staring.
ANNOTATION:
Idling: 5 s
ANNOTATION:
9) Operate the priming pump. • Accelerate the engine revolution gradually.
Number of times： 10 count(s) or more Engine revolution hold: 3 min.
• Wait for the specified time after operating • Accelerate the engine revolution to maxi-
the priming pump. mum.
specified time： 1 min • Lower the rotation.
ANNOTATION:
84551720B NA - August 2012

2425-48
Inspection 5) Remove the cylinder liner from the cylinder

block.
1. Cylinder block Inspection 6) Align the simple straight ruler to the cylinder
block.
CAUTION 7) Measure the clearance using the feeler
• Clean the each part of the cylinder block gauge.
before inspecting. ANNOTATION:
block while cleaning. • Flatness of the cylinder block top surface
Measurement part: 6 section(s)
1) Inspect the cylinder block. Limit: 0.2 mm {0.0079 in.}
CAUTION CAUTION
• Replace the cylinder block if dam- • Replace the cylinder block if the
age such as a crack has been found measured value exceeds the limit
in the inspection. value.
2) Perform dye penetrant check.

ANNOTATION:
• Check if there is a problem which cannot be
detected by visual inspection.
CAUTION
• Replace the cylinder block if dam-
in the inspection.
3) Inspect the water leak using the water pres-

sure tester.
ANNOTATION: 8) Inspect the oil jet.
• Check if there is a problem which cannot be ANNOTATION:

detected by visual inspection. • Oil hole clogging
Specified pressure: 490 kPa {71 psi} • The fuel pipe deformation
Specified time: 3 min • Check valve operation
Pen valve pressure of check valve: 160 kPa
CAUTION {23.2 psi}
• Replace the cylinder block if dam-
in the inspection.
4) Measure the cylinder liner using the cylinder

gauge.
Measurement position: 15.0 - 20.0 mm
{0.5906 - 0.7874 in.} From the cylinder block
top surface
Specified value: 115.021 - 115.050 mm
{4.5284 - 4.5295 in.} Diameter
Limit: 115.20 mm {4.5354 in.} Diameter
CAUTION
• Replace the cylinder block if the
measured value exceeds the limit
value.
84551720B NA - August 2012

2425-49
84551720B NA - August 2012

2425-50
Section
2445
Lubrication System
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal and Installation of Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Oil Level Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Oil Level Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation of Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly of Oil Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal and Installation of Oil Port Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal of Oil Port Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation of Oil Port Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Lubrication System
Removal and Installation of Oil Installation of Oil Pan

Pan 1. Oil pan Installation
Removal of Oil Pan
ANNOTATION:
• Apply ThreeBond 1207B to each joint of the
1) Disengage the battery ground cable from the crankcase, flywheel housing and gear case.
battery.
Bead width： 3.0 mm { 0.1181 in. }
2. Engine oil Drain
1) Remove the drain plug from the oil pan.
2) Drain the engine oil from the oil pan.
3) Install the drain plug to the oil pan.
52 lb・ft. }
3. Oil pan Removal
level switch.
CAUTION

22 lb・ft. }
ANNOTATION:

switch.
2. Engine oil Filling
sembly.
CAUTION
drain before adding engine oil.
84551720B NA - August 2012

2445-3
Lubrication System
3. Battery ground cable Connect Removal and Installation of Oil

1) Connect the battery ground cable to the bat- Level Switch
tery.
Removal of Oil Level Switch
1. Engine oil Drain
Tightening torque： 70 N・m { 7.1 kgf・m / 52 lb・
ft. }
2. Oil level switch Removal
level switch.
2) Remove the oil level switch from the oil pan.
1 Spacer
2 Oil level switch
3 Spacer
84551720B NA - August 2012

2445-4
Lubrication System
Installation of Oil Level Switch Removal and Installation of Oil

1. Oil level switch Installation Pump Assembly
1) Install the oil level switch to the oil pan.
Removal of Oil Pump Assembly
CAUTION 1. Battery ground cable Disconnect
• Use new O-rings. 1) Disengage the battery ground cable from the
battery.
7.38 lbf・ft. } 2. Coolant Drain
2) Connect the harness connector to the oil level 1) Drain the coolant from the radiator.
switch.
CAUTION
3. Engine oil Drain

Tightening torque: 70 N・m { 7.1 kgfEm / 52 lb・ft.
}
1) Disengage the engine harness from the en-
gine assembly.
1 Spacer ANNOTATION:
2 Oil level switch • Disconnect each connector.
3 Spacer
2. Engine oil Filling 1) Remove the air cleaner duct from the air
1) Replenish the engine oil with the engine assembly.
sembly. 2) Remove the air intake hose from the tur-
CAUTION 3) Remove the exhaust pipe from the tur-
• Confirm the tightening of the oil pan bocharger assembly.
drain before adding engine oil. 4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
cover.
ANNOTATION:
bocharger assembly.
84551720B NA - August 2012

2445-5
Lubrication System
7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
2 Oil feed pipe
3 Oil return pipe
1 Water return pipe
8) Disengage the water return pipe from the tur- 2 Water feed pipe
bocharger assembly.
9) Remove the water return pipe from the water 12) Remove the exhaust manifold stay from the
pump assembly. cylinder block and the turbocharger assembly.
bocharger assembly.
ANNOTATION:
2 Exhaust manifold
84551720B NA - August 2012

2445-6
Lubrication System
13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.
1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
B.
6. EGR cooler assembly Removal 5) Remove the EGR pipe B from the EGR cooler
B.
1) Disengage the water rubber hose from the 6) Remove the EGR cooler B from the EGR pipe
EGR cooler assembly. C.
1 Water rubber hose

1 EGR valve
2 EGR pipe C
2) Remove the EGR heat protector from the 3 EGR cooler B
EGR pipe A. 4 EGR pipe B
5 EGR cooler A
6 EGR pipe D

EGR valve.

84551720B NA - August 2012
2445-7
Lubrication System
2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
and EGR cooler water return pipe.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D

1) Remove the fan guide stay from the fan guide
and the fan guide bracket.
2) Remove the fan guide bracket from the cylin-
der head assembly.

1 Fan guide 9. Intake throttle valve Removal

2 Fan guide stay 1) Remove the air duct from the intake throttle
3 Fan guide bracket valve.
84551720B NA - August 2012

2445-8
Lubrication System
2) Disengage the harness connector from the in- 6) Remove the inlet pipe from the case.
3) Remove the intake throttle valve from the inlet
pipe.
1 Case
2 Gasket
3 Inlet pipe
2 Boost sensor
11. Oil level gauge guide tube Removal
3 Inlet pipe
4 Gasket 1) Remove the oil level gauge from the oil level
5 Intake throttle valve gauge guide tube.
10. Inlet pipe Removal the cylinder head cover.
1) Disengage the harness connector from the the case.
boost sensor. 4) Remove the oil level gauge guide tube from
2) Disconnect the harness connector from the the cylinder block.
EGR valve.
IMT sensor.
5) Remove the harness clip from the inlet pipe.

3 Case
4 Cylinder block
1 Boost sensor 12. Glow plug Removal

2 IMT sensor
3 EGR valve glow plug.
4 Harness clip 2) Remove the glow plug from the cylinder head
5 Boost temperature sensor assembly.
84551720B NA - August 2012

2445-9
Lubrication System

supply pump.
ANNOTATION:
the fuel feed pipe.
mon rail assembly.
ANNOTATION:

2) Remove the injection pipe from the injector
CAUTION
pipe.
ing.

4 Fuel supply pump
16. Common rail assembly Removal

inlet cover and the common rail bracket.
cooler assembly.
6 Fuel pipe

pump and the common rail assembly.
ANNOTATION:
CAUTION 2 Fuel pressure sensor
• Do not reuse the removed fuel pipe. 3 Common rail bracket
15. Fuel leak off pipe assembly Removal 17. Cylinder head cover Removal
1) Disengage the fuel leak-off pipe from the cylin- 1) Disengage the ventilation hose from the air
der head assembly. breather.
84551720B NA - August 2012
2445-10
Lubrication System
2) Remove the cylinder head cover from the 4) Remove the lower cover from the cylinder
lower cover. head assembly.
der head cover.
1 Lower cover
2 Connector
2 Gasket
3 Lower cover 5) Remove the gasket from the lower cover.
18. Lower cover Removal head assembly.
1) Remove the connector from the lower cover. 19. Injector Removal
CAUTION jector.
nector with a screwdriver. assembly.
ANNOTATION:
tor. • When it is difficult to remove the injector, use
a special tool.
CAUTION

head assembly.
ANNOTATION:
with the bracket.
Special tool: injector remover (refer to

section 1003)
84551720B NA - August 2012

2445-11
Lubrication System
Special tool: sliding hammer (refer to 1) Loosen the adjust screw using the wrench.
section 1003)
ANNOTATION:
screws.
2) Remove the rocker arm shaft from the cylinder

head assembly.
ANNOTATION:
and the rocker arm assembly bracket tight-
ening bolts from both ends and remove
them.
CAUTION
1 Sliding hammer
3 Injector
CAUTION
• Be extremely careful not to damage 21. Camshaft Removal
der head assembly.
ANNOTATION:
spected.
20. Rocker arm shaft Removal

84551720B NA - August 2012
2445-12
Lubrication System
• Loosening order of the head bolts
22. Bridge Removal

CAUTION
CAUTION
• Be careful not to drop the bridge from the bottom surface of the
cap into the engine. cylinder head, be careful not to
damage the gear.
ANNOTATION:
• After removing, organize to avoid a mix-up
with other installation locations.
1 Idle gear C
2) Remove the cylinder head gasket from the

cylinder block.
1 Bridge cap CAUTION
2 Bridge
ket.
1) Remove the cylinder head assembly from the 24. Fuel supply pump Removal
cylinder block.
ANNOTATION: fuel supply pump.
84551720B NA - August 2012

2445-13
Lubrication System
2) Remove the fuel supply pump from the cylin- 25. Starter assembly Removal
der block.
1) Disengage the earth cable from the starter as-
sembly.
2) Remove the starter assembly from the fly-
wheel housing.
1 Bolt
3) Remove the supply pump gear from the fuel 1 Oil pressure sensor
supply pump using the puller. 2 Oil port cover
3 Starter assembly
26. CKP sensor Removal

CKP sensor.
2) Remove the CKP sensor from the flywheel
housing.
CAUTION
to shock.

pump bracket.
CAUTION
ply pump.
1 CKP sensor
2 Flywheel housing
27. Flywheel Removal

1) Remove the flywheel from the crankshaft.
1 Fuel supply pump ANNOTATION:
2 O-ring • Gradually loosen the flywheel installation
3 Supply pump bracket bolts in the order shown in the diagram.
84551720B NA - August 2012
2445-14
Lubrication System
CAUTION CAUTION
• Fix the flywheel firmly so that it will • Be careful not to damage the oil
not rotate. seal press-fitting surface.
28. Crankshaft rear oil seal Removal ANNOTATION:

1) Remove the crankshaft rear oil seal from the • Remove the slinger and oil seal together.
crankshaft using the special tool. • If the slinger of the remover is easy to come
off, the outer circumference of the jig can be
workability.
29. Oil pan Removal
level switch.
30. Flywheel housing Removal
1) Remove the cover from the flywheel housing.
2) Remove the flywheel housing from the cylin-
der block and the crankcase.
Special tool: rear oil seal remover (refer
to section 1003) CAUTION
• Do not forget to remove the bolt
1 Felt
2 Slinger
3 Crankshaft rear oil seal
1 Bolt
31. Idle gear Measurement
84551720B NA - August 2012

2445-15
Lubrication System
1) Align the dial gauge to the idle gear. Specified value: 0.080 - 0.155 mm { 0.0031 -
0.0061 in. }
ANNOTATION:
Limit: 0.20 mm { 0.0079 in. }
• Attach the dial gauge to the idle gear tooth
to be measured. CAUTION
2) Inspect the backlash. • Replace the idle gear if the mea-
ANNOTATION:
• Gently move the gear right and left to read
the inconsistency on the dial gauge.
CAUTION
• Measure the idle gear backlash be-
fore removing the idle gear A.
Specified value: 0.10 - 0.17 mm { 0.0039 -

0.0067 in. }
limit: 0.30 mm { 0.0118 in. }
CAUTION
sured value exceeds the limit value. 32. Idle gear A Removal
1) Remove the idle gear A from the idle gear A
shaft.
33. Oil pump assembly Removal
1) Remove the oil pump assembly from the cylin-
der block.

gauge.
ANNOTATION:
• Measure the clearance between the idle
gear and the thrust collar.
CAUTION
• Measure the play of the idle gear in
the axis direction before removing
the idle gear B.
84551720B NA - August 2012

2445-16
Lubrication System
Disassembly of Oil Pump Assembly Assembly of Oil Pump Assembly

1. Oil pump assembly Disassembly 1. Oil pump assembly Reassembly
1) Remove the driven gear from the body. 1) Install the ball to the body.
2) Install the spring to the body.
3) Install the cotter pin to the body.
2) Remove the cotter pin from the body.

3) Remove the spring from the body.
4) Remove the ball from the body.
1 Split pin
4) Apply the engine oil to the driven gear.

5) Install the driven gear to the body.
1 Split pin
84551720B NA - August 2012

2445-17
Lubrication System
Installation of Oil Pump Assembly 4) Align the idle gear A to alignment mark.
1. Oil pump assembly Installation ANNOTATION:
1) Install the oil pump to the cylinder block. • Align the L mark on the crank gear with the
O mark on the idle gear A.
CAUTION
• Use new gaskets. ANNOTATION:
Tightening torque: 31 N・m { 3.2 kgf・m / • Apply engine oil to the threaded portion and
22.87 lb・ft. } seat surface on the idle gear A installation
bolt.
2. Idle gear A Installation
6) Install the idle gear A to the cylinder block.
1) Align 1st cylinder to the compression top dead Tightening torque: 133 N・m { 13.6 kgf・m /
center. 98.11 lb・ft. }
2) Apply the engine oil to the idle gear A.
3) Install the idle gear A shaft to the idle gear A.
1 Idle gear C 4 PTO gear 7 Oil pump drive gear

2 Camshaft gear 5 PTO idle gear 8 Supply pump gear
3 Idle gear B 6 Crankshaft gear 9 Idle gear A
3. Flywheel housing Installation

ANNOTATION:
• Remove dust and oil from the flywheel hous-
ing installation area.
ANNOTATION:
• Refer to the diagram and apply the Three-
Bond 1207B to the cylinder block.
84551720B NA - August 2012

2445-18
Lubrication System
CAUTION 7) Install the O-ring to the cover.

8) Install the cover to the flywheel housing.
• After applying the liquid gasket, in- Tightening torque: 19 N・m { 1.9 kgf・m /
stall the flywheel housing within 5 14.02 lb・ft. }
minutes.
4. Oil pan Installation
3) Install the flywheel housing to the cylinder 1) Apply the liquid gasket to the crankcase.
block
ANNOTATION:
Tightening torque • Apply ThreeBond 1207B to each joint of the
: 96 N・m { 9.8 kgf・ m crankcase, flywheel housing and gear case.
Flywheel housing side
/ 70.82 lb・ft. } Bead width: 3.0 mm { 0.1181 in. }
: 38 N・m { 3.9 kgf・ m
Cylinder block side
/ 28.03 lb・ft. }
Supply pump bracket : 76 N・m { 7.7 kgf・ m
side / 56.06 lb・ft. }
ANNOTATION:
• Install the flywheel housing after aligning
with the knock pin position of the cylinder
block.
CAUTION
• Be careful not to forget to tighten
the bolt indicated in the diagram.
CAUTION

Tightening torque: 29 N・m { 3.0 kgf・m /
21.39 lb・ft. }
ANNOTATION:
1 Bolt
4) Apply engine oil to the PTO gear shaft.

5) Install the PTO idle gear shaft to the PTO idle
gear.
6) Install the PTO idle gear to the cylinder block.
98.85 lb・ft. }

switch.
5. Crankshaft rear oil seal Installation
1) Prepare the special tool.
84551720B NA - August 2012

2445-19
Lubrication System
2) Apply the engine oil to the crankshaft rear oil

seal.
CAUTION
oil seal.
3) Install the crankshaft rear oil seal to the

adapter.

section 1003)
ANNOTATION:
• Install the crankshaft rear oil seal and
slinger together.
• In order to install the crankshaft rear oil seal,
use the one(s) in the following table from
among the parts included in the kit.
1 Sleeve
2 Adapter ring

ANNOTATION:
Legend Parts number

1: Adapter 5-8840-2709-0
2: Adapter tightening
5-8840-2714-0
bolts
3: Center bolt 5-8840-2713-0
4: Sleeve 5-8840-9063-0
5: Collar 5-8840-2710-0
6: Adapter ring 5-8840-2711-0
7: Crankshaft rear oil -
seal
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2445-20
Lubrication System
9) Inspect the crankshaft rear oil seal. 3) Tighten the bolt using the torque wrench.
ANNOTATION:
57.54 lb・ft. }
• Measure the distance between the crank- 4) Tighten the bolt using the special tool.
shaft head and the crankshaft rear oil seal.
Specified value: 7.2 - 7.8 mm { 0.2835 -
0.3071 in. }

1003)
Tightening angle: 120°
7. CKP sensor Installation
1 Crankshaft
2 Crankshaft rear oil seal 1) Install the CKP sensor to the flywheel housing.
3 Measurement location CAUTION
4 Collar
5 Adapter ring • Be careful not to subject the sensor
6 Sleeve to shock.
7 Adapter
ANNOTATION:
6. Flywheel Installation • Tighten together with the clip.
1) Apply the disulfide molybdenum grease to the Tightening torque： 6 N・m { 0.6 kgf・m /
bolt. 4.43 lbf・ft. }
ANNOTATION: 2) Connect the harness connector to the CKP
sensor.
• Apply to the seat surface and threaded por-
tion on the flywheel installation bolts.
2) Install the flywheel to the crankshaft.
CAUTION
tion of the crankshaft.
ANNOTATION:
1 CKP sensor
2 Flywheel housing
8. Starter assembly Installation

1) Install the starter assembly to the flywheel
housing.
78.19 lb・ft. }
84551720B NA - August 2012

2445-21
Lubrication System
2) Connect the earth cable to the starter assem-

bly.
37.62 lb・ft. }
1 Fuel supply pump

2 Supply pump gear
3 Nut
1 Oil pressure sensor ANNOTATION:

2 Oil port cover • After installing the supply pump gear, refer
3 Starter assembly to the diagram and make an alignment mark
on it.
pump bracket.
14.02 lb・ft. }
CAUTION
twisted.

center.
1 Fuel supply pump

2 O-ring
3 Supply pump bracket
3) Install the supply pump gear to the fuel supply 0 degree marking on the crank-
pump. 2
shaft damper
47.21 lb・ft. } 5) Install the O-ring to the fuel supply pump.
84551720B NA - August 2012

2445-22
Lubrication System
6) Temporarily tighten the fuel supply pump to CAUTION

the cylinder block.
• Clean the aligning surface of the cylinder
head and cylinder block before installing
head and cylinder block while cleaning.

ANNOTATION:
Bead width: 3.0 mm { 0.1181 in. }
Bead height: 3.0 mm { 0.1181 in. }
1 Bolt
7) Check alignment mark of the supply pump

gear.
ANNOTATION:
• Confirm that the alignment mark can be
seen through the plug hole on the left side
of the flywheel housing.
CAUTION
2) Install the cylinder head gasket to the cylinder

block.
CAUTION
3) Install the cylinder head assembly to the cylin-

der block.
1 Plug hole CAUTION

2 Alignment mark • Be careful not to damage the cylin-
der head gasket.
CAUTION
the supply pump gear.
8) Securely tighten the fuel supply pump to the

cylinder block.
36.88 lb・ft. } Nut
56.06 lb・ft. } Bolt
9) Connect the harness connector to the fuel
supply pump.
10. Cylinder head assembly Installation ANNOTATION:
84551720B NA - August 2012

2445-23
Lubrication System
• Tightening order of the head bolts 4) Install the bridge cap to the bridge.
ANNOTATION:
• 1 to 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION:
seat surface and threaded portion of the
M14 head bolts.
• Apply engine oil to the seat surface and
threaded portion of the M10 head bolts.
Tightening torque: 157 N・m { 16.0 kgf・m / CAUTION
115.82 lb・ft. }
6) Tighten the head bolt using the torque wrench. • Be careful not to drop the bridge
Tightening torque: 165 N・m { 16.8 kgf・m / cap into the engine.
121.72 lb・ft. }
7) Tighten the head bolt using the special tool. 12. Camshaft Installation
center.

1003)
Tightening angle: 55°M14 bolt
8) Tighten the head bolt using the torque wrench. 1 Front cover marking
Tightening torque: 38 N・m { 3.9 kgf・m / 0 degree marking on the crank-
2
28.03 lb・ft. } M10 bolt shaft damper
Tightening torque: 167 N・m { 17.0 kgf・m / 2) Apply the engine oil to the camshaft bearing.
123.19 lb・ft. } Check the tightening M14 bolt
ANNOTATION:
11. Bridge Installation
1) Apply the engine oil to the bridge. bearing.
2) Install the bridge to the bridge guide.
CAUTION
CAUTION
• Apply engine oil after cleaning the
• Confirm that the bridge moves bearing installation sections of
smoothly. the camshaft bearing and cylinder
head.
3) Apply the engine oil to the bridge cap.
3) Install the camshaft bearing to the cylinder
head assembly.
84551720B NA - August 2012

2445-24
Lubrication System
4) Install the camshaft to the cylinder head as- 8) Install the camshaft bearing cap to the cylinder
sembly. head assembly.
• Mesh together the idle gear C and the • Turn the camshaft bearing cap so that the
camshaft gear so that the alignment mark arrow mark on the top surface faces the en-
on the camshaft gear matches the top sur- gine front side, and assemble in numerical
face of the cylinder head, and gently install order.
the camshaft.
20.66 lb・ft. } Apply engine oil
5) Check alignment mark of the camshaft gear.
CAUTION 13. Rocker arm shaft Installation

• Confirm that the alignment mark is 1) Apply the engine oil to the bracket.
not misaligned before installing the
camshaft bearing cap. ANNOTATION:
• If the alignment mark is not at • Apply to each sliding surface.
the correct position, reinstall the
camshaft. 2) Apply the engine oil to the rocker arm.
ANNOTATION:
6) Apply the engine oil to the camshaft bearing.
• Confirm that the adjust screw is fully loos-
ANNOTATION: ened.
• Apply engine oil to the sliding surface of the 3) Temporarily tighten the bolt to the cylinder
bearing. head assembly.
CAUTION ANNOTATION:
• Apply engine oil after cleaning the • Apply engine oil to the threaded portion of
bearing installation sections of the the bolts.
camshaft bearing and camshaft 4) Temporarily tighten the nut to the cylinder
bearing cap. head assembly.
7) Install the camshaft bearing to the camshaft ANNOTATION:
bearing cap. • Apply engine oil to the threaded portion of
the nuts.
ANNOTATION:
and gradually tighten it.
Rocker arm shaft tightening torque

: 21 N・m { 2.1 kgf・m / 15.49
No.1 Nut
lb・ ft. }
: 27 N・m { 2.8 kgf・m / 19.92
No.2 Bolt
lb・ ft. }
84551720B NA - August 2012

2445-25
Lubrication System
Rocker arm shaft tightening torque 1) Align 1st cylinder to the compression top dead
Parts Tightening torque center.
: 56 N・m { 5.7 kgf・m / 41.31
No.3 Bolt
lb・ ft. }
: 27 N・m { 2.8 kgf・m / 19.92
No.4 Bolt
lb・ ft. }

2
shaft damper
1 Nut 2) Prepare the feeler gauge.

2 Bolt thickness: 0.4 mm { 0.0157 in. } 2 pieces
3 Bolt
4 Bolt ANNOTATION:
14. Rocker arm shaft Adjustment rocker arm and bridge cap.
ANNOTATION: bridge and valve.
• Valve clearance adjustment 3) Turn the adjust screw.
CAUTION ANNOTATION:
• Adjust the valve clearance while cool. • When the movement of the thickness gauge
• Loosen all adjust screws before adjust- becomes stiff, secure the adjust screw nut
ment. of the rocker arm.
16.23 lb・ft. }
ANNOTATION:
• Check if the valve shaft end on the opposite
side is floating or touching at an angle.
• If it is floating or touching at an angle, slightly
loosen the bridge adjust screw and adjust
the valve shaft ends on both sides to touch
properly.
Valve bridge clearance: less than 0.1 mm {
less than 0.0039 in. }
ANNOTATION:
• To prevent turning, fix the bridge adjust
16.23 lb・ft. }
84551720B NA - August 2012
2445-26
Lubrication System
Adjustment table
Cylinder No. 1 2 3 4
First cylinder compression top dead
O O O O
center
Fourth cylinder compression top dead
O O O O
center
15. Common rail assembly Installation 6) Securely tighten the bolt to the common rail
assembly.
1) Temporarily tighten the common rail bracket Tightening torque: 19 N・m { 1.9 kgf・m /
to the oil cooler assembly. 14.02 lb・ft. }
ANNOTATION: 7) Connect the harness connector to the fuel
pressure
• The installation bolt and common rail as- the inlet cover is removed.
cover.
assembly.
ANNOTATION:
ened together.
assembly.
5) Securely tighten the nut to the common rail
assembly.
16.23 lb・ft. }
ANNOTATION: 2 Fuel pressure sensor
• Refer to the tightening order in the diagram 3 Common rail bracket
if the inlet cover is removed.
CAUTION

CAUTION
84551720B NA - August 2012
2445-27
Lubrication System
3) Temporarily tighten the fuel leak-off pipe to the 18. Injector Installation
fuel supply pump.
CAUTION
ANNOTATION:
• When reusing an injector, do not change
• Tighten the fuel feed pipe together. the installation position.
CAUTION
• Use new gaskets. 2) Temporarily tighten the injector to the cylinder
head assembly.
cylinder head assembly. CAUTION
8.85 lbf・ft. } the injector nozzle.
17.70 lb・ft. }
fuel supply pump.
17.70 lb・ft. }
lbf・ft. }
1 Injector
2 Installation bolt

injector.
head assembly.
1 Common rail assembly 22.13 lb・ft. }
2 Cylinder head assembly 6) Install the injector leak-off pipe to the injector.
4 Fuel supply pump CAUTION
10.33 lbf・ft. }
CAUTION
• Use new fuel pipes. tor.
Tightening torque: 44 N・m { 4.5 kgf・m / 22.13 lb・ft. }
32.46 lb・ft. } 2) Securely tighten the injection pipe to the com-
2) Install the clip to the bracket. mon rail assembly.
Tightening torque: 9 N・m { 0.9 kgf・m / 6.64 Tightening torque: 25 N・m { 2.5 kgf・m /
lbf・ft. } 18.44 lb・ft. }
84551720B NA - August 2012

2445-28
Lubrication System
3) Install the clip to the bracket. 4) Install the lower cover to the cylinder head
Tightening torque： 6 N・m { 0.6 kgf・m / assembly.
4.43 lbf・ft. } Tightening torque: 18 N・m { 1.8 kgf・m /
13.28 lb・ft. }
5) Install the injector harness to the cylinder head
assembly.
ANNOTATION:
bracket.
35.41 lb・ft. }

6 Fuel pipe
20. Lower cover Installation 1 Injector harness terminal

1) Apply the liquid gasket to the rubber plug. 2 Injector harness bracket
ANNOTATION:
• Apply ThreeBond 1207B. 6) Connect the injector harness to the injector.
Tightening torque: 2 N・m { 0.2 kgf・m / 1.48
lbf・ft. }
CAUTION
1 Rubber plug
2 Liquid gasket
CAUTION
• After applying the liquid gasket, in- 1 Lower cover
stall the lower cover within 5 min- 2 Connector
utes.
2) Install the rubber plug to the cylinder head Install the connector to the lower cover.
assembly. Tightening torque: 2 N・m { 0.2 kgf・m / 1.48
3) Install the gasket to the lower cover. lbf・ft. }
84551720B NA - August 2012
2445-29
Lubrication System

sembly.
14.75 lb・ft. }
CAUTION

2 Gasket
3 Lower cover

breather.
2) Install the glow plug connector to the glow 23. Oil level gauge guide tube Installation
plug. 1) Install the oil level gauge guide tube to the
Tightening torque: 1 N・m { 0.1 kgf・m / 0.74 cylinder block.
lbf・ft. } 2) Connect the oil level gauge guide tube to the
case.
CAUTION Tightening torque: 19 N・m { 1.9 kgf・m /
• Confirm that the glow plug connec- 14.02 lb・ft. }
tor does not interfere with the sur- 3) Connect the oil level gauge guide tube to the
rounding parts. cylinder head cover.
22. Cylinder head cover Installation 14.02 lb・ft. }
1) Align the head cover gasket to the cylinder guide tube.
head cover.
cover.
13.28 lb・ft. }
ANNOTATION:

3 Case
4 Cylinder block
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2445-30
Lubrication System
1) Install the inlet pipe to the case. 25. Intake throttle valve Installation
17.70 lb・ft. }
CAUTION 17.70 lb・ft. }

2 Boost sensor
1 Case 3 Inlet pipe
2 Gasket 4 Gasket
3 Inlet pipe 5 Intake throttle valve

sensor. 2) Install the air duct to the intake throttle valve.
3) Connect the harness connector to the EGR 3) Connect the harness connector to the intake
valve. throttle valve.
4) Connect the harness connector to the boost ANNOTATION:
temperature sensor.
5) Connect the harness connector to the boost • After connecting the harness connector,
sensor. press in the lock operation portion to lock.
1 Boost sensor 1 Lock operation section

2 IMT sensor 2 Lock release
3 EGR valve 3 Lock
4 Harness clip
5 Boost temperature sensor 26. EGR cooler water pipe Installation
84551720B NA - August 2012

2445-31
Lubrication System
5) Install the fan guide stay to the fan guide.

33.20 lb・ft. }
1 Fan guide stay

2 Fan guide
3 Fan guide bracket
4 Spacer

17.70 lb・ft. }


assembly.
ANNOTATION:
17.70 lb・ft. } Clamp
outlet pipe.
1 EGR cooler C
head assembly.
Tightening torque: 50 N・m { 5.1 kgf・m / 2 EGR pipe C
36.88 lb・ft. } 3 EGR valve
Tightening torque: 97 N・m { 9.9 kgf・m / 4 EGR pipe D
71.56 lb・ft. } The area where the spacer is
used
4) Install the fan guide stay to the fan guide CAUTION
bracket.
Tightening torque: 45 N・m { 4.6 kgf・m / • Use new gaskets.
33.20 lb・ft. }
valve.
EGR valve.
EGR pipe C.
EGR cooler B.
84551720B NA - August 2012
2445-32
Lubrication System

EGR pipe B.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B


valve.
17.70 lb・ft. } No.1 in the diagram
gine hanger bracket.
8) Securely tighten the EGR pipe B to the
bracket.
1 EGR cooler A pipe
2 EGR pipe A C.
3 Exhaust manifold Tightening torque: 24 N・m { 2.4 kgf・m /
ANNOTATION: 10) Securely tighten the EGR pipe B to the EGR
cooler
• Complete tightening order of the EGR B.
cooler assembly Tightening torque: 24 N・m { 2.4 kgf・m /
pipe
B.
haust manifold.
84551720B NA - August 2012

2445-33
Lubrication System
13) Securely tighten the EGR pipe A to the EGR 2) Temporarily tighten the exhaust manifold stay
cooler to the cylinder block and the turbocharger as-
A. sembly.
14) Install the EGR heat protector to the EGR pipe
A.
2 Exhaust manifold
15) Connect the water rubber hose to the EGR Tightening torque: 52 N・m { 5.3 kgf・m /
cooler assembly. 38.36 lb・ft. }
sembly.
38.36 lb・ft. } Nut
36.88 lb・ft. } Bolt
ANNOTATION:
1 Water rubber hose


block.
CAUTION

30.25 lb・ft. } Eyebolt
17.70 lb・ft. } Clip
1 Exhaust manifold
84551720B NA - August 2012
2445-34
Lubrication System
6) Connect the water feed pipe to the tur- 9) Install the oil return pipe to the cylinder block.
bocharger assembly.
CAUTION
CAUTION
Tightening torque: 35 N・m { 3.5 kgf・m / 16.23 lb・ft. }
25.82 lb・ft. } Eyebolt 10) Connect the oil return pipe to the turbocharger
Tightening torque: 14 N・m { 1.4 kgf・m / assembly.
10.33 lbf・ft. } Clip
7) Install the water return pipe to the water pump CAUTION
assembly.
CAUTION
• Use new gaskets. lbf・ft. }
25.82 lb・ft. } Eyebolt CAUTION
17.70 lb・ft. } Clip • Use new gaskets.
8) Connect the water return pipe to the tur-
bocharger assembly. Tightening torque: 17 N・m { 1.7 kgf・m /
17.70 lb・ft. } Clip
1 Water return pipe

2 Water feed pipe

84551720B NA - August 2012

2445-35
Lubrication System
12) Connect the oil feed pipe to the turbocharger 31. Engine oil Filling
assembly.
CAUTION sembly.

Tightening torque: 17 N・m { 1.7 kgf・m / drain before adding engine oil.
17.70 lb・ft. } Clip 32. Coolant Filling
CAUTION
parts.
off.
CAUTION

20.66 lb・ft. }
2 Oil feed pipe
3 Oil return pipe
13) Install the exhaust pipe to the turbocharger 1 Valve

assembly. 2 Gasket
15) Install the air cleaner duct to the air cleaner 33. Battery ground cable Connect
16) Connect the harness connector to the tur- 1) Connect the battery ground cable to the bat-
bocharger assembly. tery.
30. Engine harness Connect 34. Fuel Air bleed
1) Connect the engine harness to the engine as- CAUTION

sembly.
• To prevent engine failure, be sure to per-
ANNOTATION: form air removal after the installation or
84551720B NA - August 2012

2445-36
Lubrication System
9) Operate the priming pump.

Number of times: 10 count(s) or more
ANNOTATION:
the priming pump.
Specified time: 1 min
ANNOTATION:
1 Priming pump
2 Plug ANNOTATION:
3 Drain plug • Wait for the specified time after operating
4 Case the priming pump.
specified time: 1 min
1) Prepare the pan.
2) Turn ON the starter switch. ANNOTATION:
ANNOTATION: • Remove the air in the fuel filter.
• This is for the models with an electromag- 14) Tighten the plug using the wrench.
netic pump. Tightening torque： 10 N・m { 1.0 kgf・m /
7.38 lbf・ft. }
4) Operate the priming pump. CAUTION
• Remove the fuel around the plug
ANNOTATION: thoroughly after tightening.
plug. 15) Operate the priming pump.
Number of times the operation is performed:
5) Tighten the plug using the wrench. 10 - 15 times
6) Operate the priming pump. 16) Start the engine.
CAUTION
ANNOTATION:
• Do not accelerate the engine revo-
• Wait for the specified time after operating lution right after staring.
the priming pump.
Specified time: 1 min Idling: 5 s
ANNOTATION:
ANNOTATION:
ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
84551720B NA - August 2012

2445-37
Lubrication System
Inspection 4) Measure the cylinder block using the gauge.

1. Oil pump assembly Inspection ANNOTATION:
1) Measure the clearance using the feeler • Measure the bush inner diameter of the
gauge. cylinder block.
ANNOTATION:
• The clearance between the inner wall of the
body and each gear tooth tip.
0.0087 in.}
Limit: 0.30 mm {0.0118 in.}
5) Calculate the clearance from the measured

value.
ANNOTATION:
• The difference between the shaft outer di-
ameter and the bush inner diameter is the
clearance.
CAUTION 0.0028 in.}
• Replace the gear if the measured Limit: 0.20 mm {0.0079 in.}
value exceeds the limit value.
CAUTION
2) Measure the shaft using the micrometer. • Replace the gear if the clearance
exceeds the limit value.
ANNOTATION:
• Driven gear shaft outer diameter 6) Inspect the ball.
7) Inspect the spring.
Specified value: 15.989 - 16.000 mm {0.6295
- 0.6299 in.}
Limit: 15.900 mm {0.6260 in.}
3) Measure the body using the gauge.
ANNOTATION:
• Measure the bush inner diameter of the
body.
1 Ball
2 Spring
84551720B NA - August 2012

2445-38
Lubrication System
Engine oil Inspection Removal and Installation of Oil

1. Engine oil Inspection Port Cover
CAUTION Removal of Oil Port Cover
• The engine should be in a horizontal po- 1. Oil pressure sensor Removal
sition.
• Wait at least 5 minutes before starting the 1) Disconnect the harness connector from the oil
engine and after stopping the engine. pressure sensor.
2) Remove the oil pressure sensor from the oil
1) Remove the oil level gauge from the oil level port cover.
gauge guide tube.
ANNOTATION:
• Wipe off the engine oil remaining on the oil
level gauge.
guide tube.
gauge guide tube.
4) Inspect the engine oil.
ANNOTATION:
• Check the engine oil remaining on the oil
level gauge to inspect the engine oil level.
1 Oil pressure sensor
2 Oil port cover
3 Starter assembly
2. Oil port cover Removal

1) Disengage the oil feed pipe from the oil port
cover.
2) Remove the oil port cover from the cylinder
block.
3) Remove the O-ring from the oil port cover.
1 Upper limit
2 Lower limit
ANNOTATION:
• If the oil level is under the lower limit, add
engine oil.
• Replace the engine oil if engine oil is dirty.
1 O-ring
2 O-ring
84551720B NA - August 2012

2445-39
Lubrication System
Installation of Oil Port Cover 3) Connect the oil feed pipe to the oil port cover.
1. Oil port cover Installation CAUTION
1) Install the O-ring to the oil port cover. • Use new gaskets.

12 lb・ft. }Eyebolt
2. Oil pressure sensor Installation
1) Install the oil pressure sensor to the oil port
cover.
30 lb・ft. }
CAUTION
2) Connect the harness connector to the oil pres-

1 O-ring sure sensor.
2 O-ring
2) Install the oil port cover to the cylinder block.

35 lb・ft. }

2 Oil port cover
3 Starter assembly
1 Bolt - short
2 Bolt - long
84551720B NA - August 2012

2445-40
Section
2455
Cooling System
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal and Installation of Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection of Cooling Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cooling System
Removal and Installation of Water 2) Remove the fan guide bracket from the engine
assembly.
Pump Assembly
5. Cooling fan belt Removal
Removal of Water Pump Assembly 1) Remove the cooling fan belt from the engine
1. Battery ground cable Disconnect assembly.

battery.
2. Coolant Drain
CAUTION
3. Cooling fan Removal

1) Remove the cooling fan from the adapter
1 Adjuster bolt
2 Fixing bolt
3 Fixing bolt
6. Water pump assembly Removal

1) Remove the adapter from the water pump as-
sembly.
2) Remove the spacer from the adapter.
3) Remove the fan pulley from the water pump
assembly.
4) Disengage the water hose from the water
pump assembly.
5) Disengage the water return pipe from the wa-
1 Cooling fan ter pump assembly.
2 Adapter 6) Remove the water pump assembly from the
front cover.
4. Fan guide Removal
1) Remove the fan guide from the fan guide
bracket.
1 Adapter
2 Spacer
3 Fan pulley
1 Bolt
5 Gasket
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
84551720B NA - August 2012
2455-3
Cooling System
Installation of Water Pump Assembly 6) Install the adapter to the water pump assem-
bly.
1. Water pump assembly Installation Tightening torque： 45 N・m {4.6 kgf・m / 33
1) Install the water pump assembly to the front lb・ft.}
cover.
CAUTION

lb・ft.} 1 bolt in the diagram
lb・ft.}
1 Adapter
2 Spacer
3 Fan pulley
5 Gasket
2. Cooling fan belt Installation

1 Bolt
2 Stud bolt 1) Install the cooling fan belt to the engine as-
3 Oil relief valve sembly.
3. Cooling fan belt Adjustment
2) Connect the water hose to the water pump 1) Press the cooling fan belt.
assembly.
3) Connect the water return pipe to the water ANNOTATION:
pump assembly.
• Measure the amount of cooling fan belt flex
by pressing on the point indicated by the ar-
lb・ft.}
row in the diagram with the specified pres-
4) Install the fan pulley to the water pump assem-
sure.
bly.
Tightening torque： 10 N・m { 1.0 kgf・m / Standard： 98.0 N {10.0 kg / 22 lb}
7.38 lbf・ft. } Specified value ： 6.0 - 8.0 mm {0.2362 -
5) Align the spacer to the adapter. 0.3150 in.}
Amount of flex
1 Crankshaft pulley
2 Generator
3 Fan pulley
84551720B NA - August 2012
2455-4
Cooling System
2) Adjust the cooling fan belt to standard value 5. Cooling fan Installation
using the adjust bolt.
1) Install the cooling fan to the adapter.
lb・ft.}
lb・ft.}
Nut of the adjust plate
/ 93 lb・ft.} Bolt of the bracket side
1 Cooling fan
1 Adjust bolt 2 Adapter
2 Adjust plate side nut
3 Bracket side bolt
6. Coolant Filling
4. Fan guide Installation
1) Install the fan guide bracket to the engine as- 2) Replenish the coolant with the radiator.
sembly.
lb・ft.}
2) Install the fan guide to the fan guide bracket. • Be careful not to let coolant over-
parts.
lb・ft.}
off.
CAUTION

lb・ft.}
1 Bolt
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
1 Valve
2 Gasket
84551720B NA - August 2012
2455-5
Cooling System
7. Battery ground cable Connect Inspection

1) Connect the battery ground cable to the bat- 1. Water pump assembly Inspection
tery.
1) Inspect the water pump assembly.
ANNOTATION:
• Cracks and damage on the water pump
body
• Cracks and corrosion on the impeller
• Water leak from the seal unit
CAUTION
• If any abnormality is found in the
inspection, replace the water pump
assembly.
2) Inspect the bearing unit.

ANNOTATION:
• Rotate the fan while pushing the fan center
to the radius direction and inspect for any
significant looseness or abnormal sounds.
CAUTION
• If any abnormality is found in the
inspection, replace the water pump
assembly.
84551720B NA - August 2012

2455-6
Cooling System
Removal and Installation of Installation of Thermostat

Thermostat 1. Thermostat Installation
1) Install the gasket to the thermostat.
Removal of Thermostat
1. Battery ground cable Disconnect CAUTION
1) Disengage the battery ground cable from the • Use new gaskets.
battery.
2) Install the thermostat to the cylinder head as-
2. Coolant Drain sembly.
CAUTION
3. Thermostat Removal
1) Disengage the radiator upper hose from the
water outlet pipe.
2) Remove the water outlet pipe from the cylin-
der head assembly.
3) Remove the thermostat from the cylinder
head assembly.
4) Remove the gasket from the thermostat.
1 Thermostat
2 Cylinder head
CAUTION
• Be careful not to mistake the as-
sembly position and direction.
3) Install the water outlet pipe to the cylinder

head assembly.
lb・ft.}
outlet pipe.
2. Coolant Filling
CAUTION
parts.
off.
CAUTION

lb・ft.}
84551720B NA - August 2012

2455-7
Cooling System
4) Replenish the coolant with the radiator. Inspection

1. Thermostat Inspection
1) Inspect the thermostat.
ANNOTATION:
• Inspect the pellet, spring, shaft, jiggle valve,
and crimped sections for damage.
1 Valve
2 Gasket

tery.
1 Jiggle valve
2) Prepare the container.

ANNOTATION:
• Put water and the thermostat into a heatable
container.
3) Raise the water temperature.
ANNOTATION:
• In order to equalize the water temperature
in the container, stir well.
CAUTION
• Do not heat the thermostat directly.
84551720B NA - August 2012

2455-8
Cooling System
4) Measure the water temperature using the

thermometer.
ANNOTATION:
• Measure open valve temperature of the
thermostat.
Valve opening temperature： 80 - 84 °C {176
- 183 °F}
Temperature when fully open： 90 °C {194 °F}
Lift amount： 8.0 mm {0.3150 in.}
1 Piece of wood
2 Stirring rod
84551720B NA - August 2012

2455-9
Cooling System
Inspection of Coolant
1. Coolant Inspection
WARNING
• If the coolant temperature is high, do not perform the inspection.
• When removing the cap, be careful as the coolant will burst out if the coolant temperature is high.
CAUTION
• Be sure to use long life coolant which is specified or recommended by Isuzu.
• Using at an unspecified concentration may result in freezing due to decreased antifreezing per-
formance.
• Use a coolant concentration appropriate for the usage environment.
ANNOTATION:
• Before using, dilute the specified long life coolant to the specified concentration with soft tap water.
LLC
con-
Area where the equipment is used
centra-
tion
General area; Area where the lowest
： 30 ％
temperature is higher than (-12) degrees.
Cold area; Area where the lowest tem-
： 50 ％
perature is (-30) degrees.
Area where temperature drop to (-30) de-
： 55 ％
grees.
1) Inspect the radiator reverse tank.

ANNOTATION:
• If coolant level is MIN or less, add it until it reaches MAX.
CAUTION
• When adding coolant, use coolant appropriate for the usage environment.
Volume of coolant： 30.2 L {7.978 US gal.} Engine only

2) Inspect the water leak using the radiator cap tester.
Inspection pressure： 100.0 kPa {14.505 psi / 2 kgf/cm2}
ANNOTATION:
• Inspection locations
• Radiator assembly
• Water pump assembly
• Radiator hose
• Heater hose
84551720B NA - August 2012

2455-10
Cooling System
3) Measure the specific gravity using the hydrometer.

Engine coolant temperature： 0 - 50 °C {32 - 122 °F}While in inspection
ANNOTATION:
• Use a container that is deeper than the length of the hydrometer.
1 Radiator
2 Hydrometer
4) Measure the temperature using the thermometer.

Engine coolant temperature： 0 - 50 °C {32 - 122 °F}While in inspection
5) Calculate the concentration from the measured value.
Specific
gravity
LLC temperature °C ( °F )
ANNOTATION:
• Measuring the coolant concentration using a coolant scope is also possible.
84551720B NA - August 2012

2455-11
Cooling System
Inspection of Cooling Fan Belt 2) Adjust the cooling fan belt to standard
value using the adjust bolt.
1. Cooling fan belt Inspection Tightening torque： 76 N・m {7.7 kgf・
1) Inspect the cooling fan belt. m / 56 lb・ft.} Nut of the adjust plate
Tightening torque ： 127 N ・ m {12.9
ANNOTATION: kgf・m / 93 lb・ft.} Bolt of the bracket
side
• Inspect for wear or damage.
2) Cooling fan belt Adjustment
1) Press the cooling fan belt.
ANNOTATION:
• Measure the amount of cooling fan
belt flex by pressing on the point indi-
cated by the arrow in the diagram with
the specified pressure.
Standard： 98.0 N {10.0 kg / 22 lb}
Specified value： 6.0 - 8.0 mm {0.2362
- 0.3150 in.} Amount of flex
1 Adjust bolt
2 Adjust plate side nut
3 Bracket side bolt
1 Crankshaft pulley
2 Generator
3 Fan pulley
84551720B NA - August 2012

2455-12
Cooling System
Removal and Installation of Installation of Overheat Switch

Overheat Switch 1. Overheat switch Installation
1) Install the overheat switch to the cylinder head
Removal of Overheat Switch assembly.
1. Overheat switch Removal ANNOTATION:
1) Disconnect the harness connector from the • Apply Loctite 572 to the threaded portion.
overheat switch.
2) Remove the overheat switch from the cylinder Tightening torque： 29 N・m { 3.0 kgf・m /
head assembly. 22 lb・ft. }
2. Connect the harness connector to the overheat
switch.
1 Overheat switch
1 Overheat switch
84551720B NA - August 2012

2455-13
Cooling System
84551720B NA - August 2012

2455-14
Section
2465
Removal and Installation of Exhaust Manifold
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Removal of Exhaust Manifold 6) Disengage the water return pipe from the tur-
bocharger assembly.
1. Coolant Drain 7) Disengage the water feed pipe from the tur-
1) Drain the coolant from the radiator. bocharger assembly.
ANNOTATION:
CAUTION

battery.
sembly.
bocharger assembly.
bocharger assembly.
ANNOTATION:
bocharger assembly.
1 Water return pipe

2 Water feed pipe

2 Exhaust manifold
2 Oil feed pipe 9) Disengage the harness connector from the
3 Oil return pipe turbocharger assembly.
84551720B NA - August 2012
2465-3
10) Remove the turbocharger assembly from the 3) Remove the EGR pipe A from the EGR cooler
exhaust manifold. A and exhaust manifold.
1 Exhaust manifold
1 EGR cooler A
2 EGR pipe A
4. EGR cooler assembly Removal 3 Exhaust manifold
1) Disengage the water rubber hose from the

EGR cooler assembly. 4) Remove the EGR cooler A from the EGR pipe
B.
B.
C.
1 Water rubber hose

EGR pipe A.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D
5. Exhaust manifold Removal

2) Remove the exhaust manifold from the cylin-
1 EGR heat protector der head assembly.
84551720B NA - August 2012

2465-4
3) Remove the exhaust manifold bracket from Installation of Exhaust Manifold

1. Exhaust manifold Installation
1) Install the exhaust manifold bracket to the
17 lb・ft. }
2) Install the gasket to the cylinder head assem-
bly.
ANNOTATION:
• Turn the protruding section of the gasket to-
wards the exhaust manifold and install.
3) Install the exhaust manifold to the cylinder
head assembly.
ANNOTATION:
1 Distance tube
2 Washer • When assembling the washer, assemble the
3 Exhaust manifold bracket distance nut section only.
4 Exhaust manifold bracket Tightening torque： 34 N・m { 3.5 kgf・m /
5 Exhaust manifold 25 lb・ft. }
4) Install the exhaust manifold bracket to the ex-
haust manifold.
37 lb・ft. }
1 Distance tube
2 Washer
5 Exhaust manifold

EGR valve.
EGR pipe C.
EGR cooler B.
84551720B NA - August 2012

2465-5

EGR pipe B.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B


valve.
pipe C.
cooler B.
1 EGR cooler A pipe B.
2 EGR pipe A Tightening torque： 24 N・m { 2.4 kgf・m /
3 Exhaust manifold 17 lb・ft. } No.4 in the diagram
ANNOTATION: haust manifold.
• Complete tightening order of the EGR Tightening torque： 28 N・m { 2.9 kgf・m /
cooler assembly 21 lb・ft. } No.5 in the diagram
84551720B NA - August 2012

2465-6
11) Install the EGR heat protector to the EGR pipe 2) Temporarily tighten the exhaust manifold stay
A. to the cylinder block and the turbocharger as-
sembly.

cooler assembly. 2 Exhaust manifold

38 lb・ft. }
sembly.
38 lb・ft. } Nut
37 lb・ft. } Bolt
ANNOTATION:
1 Water rubber hose • Tightening order
5) Connect the water feed pipe to the tur-

bocharger assembly.
ANNOTATION:
1 Exhaust manifold Tightening torque： 14 N・m { 1.4 kgf・m /
2 Turbocharger assembly 10.33 lbf・ft. } Clip
84551720B NA - August 2012

2465-7
6) Connect the water return pipe to the tur- 8) Connect the oil feed pipe to the turbocharger
bocharger assembly. assembly.
CAUTION

12 lb・ft. } Eyebolt
17 lb・ft. } Clip
1 Water return pipe

2 Water feed pipe

25 lb・ft. } Eyebolt
assembly.
CAUTION 1 Turbocharger assembly

• Use new gaskets. 2 Oil feed pipe
3 Oil return pipe
6.64 lbf・ft. } 9) Install the exhaust pipe to the turbocharger
assembly.
bocharger assembly.
tery.
5. Coolant Filling
84551720B NA - August 2012

2465-8
2) Replenish the coolant with the radiator. Inspection

CAUTION 1. Exhaust manifold Inspection
• Be careful not to let coolant over- 1) Inspect the exhaust manifold.
ANNOTATION:
parts.
• Coolant overflow should be wiped • Inspect the exhaust manifold for cracks.
off. 2. Align the simple straight ruler to the cylinder head
assembly.
3. Measure the clearance using the feeler gauge.
CAUTION ANNOTATION:
• Use new gaskets. • Flatness of the exhaust manifold

20 lb・ft. }
Specified value： 0.3 mm {0.0118 in.}

Limit： 0.5 mm {0.0197 in.}
CAUTION
• Replace the exhaust manifold if flatness
1 Valve is above the limit value.
2 Gasket
84551720B NA - August 2012

2465-9
84551720B NA - August 2012

2465-10
Section
2470
Disassembly, Removal and Installation of DPD Assembly
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Disassembly of DPD Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Assembly of DPD Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly of DPD Assembly 2) Disengage the harness connector from the

exhaust differential pressure sensor.
1. Exhaust differential pressure sensor Safety Infor- 3) Remove the exhaust differential pressure sen-
mation sor from the DPD assembly.
CAUTION CAUTION
• Do not use a tool which causes vibra- • Remove the DPD differential pres-
tions such as an impact wrench when in- sure sensor with the attached
stalling and removing the DPD differen- bracket.
tial pressure sensor.
• Do not reuse a DPD differential pressure
sensor which has been subjected to
shock such as being dropped.
• Install or remove the DPD differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
stalled on the DPD differential pressure
sensor.
• Replace the DPD differential pressure
sensor if the 4 screws installed on the
DPD differential pressure sensor have
been loosened.
DPD differential pressure sen-

1
sor
3. Exhaust gas temperature sensor Safety Information
CAUTION
• Before removing, be sure to check the
DPD pressure difference, status, and in-
spection/maintenance contents using a
scan tool.
• Do not reuse an exhaust gas tempera-
ture sensor which has been subjected to
1 Screw
4. Exhaust gas temperature sensor Removal
2. Exhaust differential pressure sensor Removal 1) Disengage the harness connector from the
exhaust gas temperature sensor.
CAUTION
ANNOTATION:
• Before performing work, be sure to
check the DPD differential pressure sen- • To prevent incorrect assembling, make an
alignment mark on the connector before dis-
sor precautions.
connecting.
1) Disengage the differential pressure hose from 2) Remove the exhaust gas temperature sensor
the exhaust differential pressure sensor. from the DPD assembly.
84551720B NA - August 2012

2470-3
4) Remove the differential pressure pipe from

the DPD assembly.
1 Bracket
2 Differential pressure pipe
5) Remove the oxidation catalyst assembly from

the filter assembly.
6) Remove the filter assembly from the exhaust
silencer assembly.
Exhaust gas temperature sen-

1
sor 1
2
sor 2
5. DPD assembly Disassembly

1) Remove the bracket from the DPD assembly.
2) Loosen the differential pressure pipe using the
wrench. 1 Oxidation catalyst assembly
3) Remove the clip from the differential pressure 2 Filter assembly
pipe. 3 Exhaust silencer assembly
84551720B NA - August 2012

2470-4
Assembly of DPD Assembly 6) Temporarily tighten the clip to the differential

pressure pipe.
1. DPD assembly Reassembly 7) Securely tighten the clip to the differential
pressure pipe.
CAUTION Tightening torque： 10 N・m { 1.0 kgf・m /
• Do not reuse gaskets, bolts, and nuts. 7.38 lbf・ft. }
8) Securely tighten the differential pressure pipe
1) Temporarily tighten the filter assembly to the to the DPD assembly.
exhaust silencer assembly. Tightening torque： 35 N・m { 3.6 kgf・m /
26 lb・ft. } Pipe sleeve nut
ANNOTATION: 9) Install the bracket to the DPD assembly.
• Tighten together with the bracket. 18 lb・ft. }
2) Temporarily tighten the oxidation catalyst as-
sembly to the filter assembly.
ANNOTATION:
• Tighten together with the bracket.
• Place the DPD assembly tightened tem-
porarily on a flat surface to determine the
position so that the bracket installation area
is horizontal.
3) Securely tighten the filter assembly to the ex-
haust silencer assembly.
21 lb・ft. }
4) Securely tighten the oxidation catalyst assem-
bly to the filter assembly.
Tightening torque： 29 N・m { 3.0 kgf・m / 1 Bracket
21 lb・ft. } 2 Differential pressure pipe
2. Exhaust gas temperature sensor Installation
CAUTION
• Do not subject the tip of the exhaust gas
temperature sensor to shock when in-
stalling.
• Remove the old anti-seize lubricant on
the sleeve nut.
• Apply the anti-seize lubricant on the
threaded portion of the sleeve nut.
• Apply Never-Seez High Tempera-
ture Stainless Grade: 5-87411-039-0
anti-seize lubricant, manufactured by
Bostik in the United states.
1 Oxidation catalyst assembly • Replace the oxidation catalyst assembly
2 Filter assembly if damage has been found in the sensor
3 Exhaust silencer assembly installation section of the oxidation cata-
lyst assembly.
5) Temporarily tighten the differential pressure 1) Temporarily tighten the exhaust gas tempera-
pipe to the DPD assembly. ture sensor to the DPD assembly.
CAUTION CAUTION
• Remove the old anti-seize lubricant • To avoid damaging the sensor in-
on the sleeve nut. stallation sections due to sensor
• Apply the anti-seize lubricant on the incorrect assembly, tighten it by
threaded portion of the sleeve nut. hand.
ture Stainless Grade: 5-87411-039-0 ANNOTATION:
anti-seize lubricant, manufactured
by Bostik in the United states. • Exhaust gas temperature sensor identifica-
tion
84551720B NA - August 2012
2470-5
Connector CAUTION
Sensor type Screw size
color
Exhaust gas tempera- • Do not use a tool which causes vibra-
M12 x 1.75 Dark gray
ture sensor 1 tions such as an impact wrench when in-
Exhaust gas tempera- stalling and removing the DPD differen-
M12 x 1.25 Light gray tial pressure sensor.
ture sensor 2
• Do not reuse a DPD differential pressure
2) Securely tighten the exhaust gas temperature sensor which has been subjected to
sensor to the DPD assembly. shock such as being dropped.
Tightening torque： 30 N・m { 3.1 kgf・m / • Install or remove the DPD differen-
22 lb・ft. } tial pressure sensor together with the
3) Connect the harness connector to the exhaust bracket.
gas temperature sensor. • Be sure not to loosen the 4 screws in-
CAUTION sensor.
• Be careful not to twist the harness. sensor if the 4 screws installed on the
been loosened.
1 Screw
4. Exhaust differential pressure sensor Installation
CAUTION
check the DPD differential pressure sen-
sor precautions.
1) Install the exhaust differential pressure sensor

to the DPD assembly.
2) Connect the harness connector to the exhaust
differential pressure sensor.
Exhaust gas temperature sen- 3) Connect the differential pressure hose to the
1
sor 1 exhaust differential pressure sensor.
2 CAUTION
sor 2
ANNOTATION: • Be careful not to mistake the connecting

position of the differential pressure hose.
• Start the engine after assembling each part, • Since the differential pressure sensor
and check for gas leaks from each joint and may malfunction if exhaust gas leaks
for vibration. from the joint sections, confirm that
there is no exhaust gas leakage after the
3. Exhaust differential pressure sensor Safety Infor- engine starts.
mation
84551720B NA - August 2012

2470-6
Inspection
1. Filter assembly Inspection
1) Inspect the filter assembly.
ANNOTATION:
• Inspect the filter for erosion, crack, damage,
or clogging.
• Replace the filter assembly if light passes
through when shining light from the other
side of the filter.

1
sor
1 Filter
2 Filter case
2) Oxidation catalyst assembly Inspection

1) Inspect the oxidation catalyst assembly.
ANNOTATION:
• Inspect the catalyst section for ero-
sion, damage, or clogging.
3) Filter assembly Cleaning
CAUTION
• Clean the filter when clogged be-
cause gradual accumulation or
firm, sticky calcination occurs on
the filter since ashes are non-
flammable unlike particle materials
(PM).
• When cleaning, use a DPD ash
removal device which blows com-
pressed air instantaneously.
• For further details on the cleaning
procedure, check the DPD ash re-
moval device handling manual.
ANNOTATION:
• Attach the filter on the DPD ash removal
device.
84551720B NA - August 2012

2470-7
CAUTION
• Confirm that there is no air leakage
on the pipe connections by check-
ing the pressure gauge attached
to the pressure reducing valve to
avoid supplying air pressure to the
air tank over the limit value.
Limit： 0.5 MPa { 72.5 psi }

ANNOTATION:
• Operate the mechanical valve for 3 seconds
to clean the filter by backwashing.
• Repeat the 2 operations above 3 times or
ANNOTATION: more.
• Add air pressure of the specified pressure to
the air tank until it increases to the specified CAUTION
pressure, and then stop adding. • While cleaning, ashes may gush
Specified pressure： 0.4 MPa { 58.0 psi } from the air removal filter with
backwashing noise, so be sure to
wear protective equipments such
as a protective mask, protective
glasses, earplugs, etc. and keep
your face and hands away.
84551720B NA - August 2012

2470-8
Section
3001
Removal and Installation of Fuel Tank
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WARNING Removal of Fuel Tank

• Keep away from fire. 1. Remove the cap (1) and filter (2).
CAUTION
work.
load.
Items to prepare
• Shackle (with the required lifting capacity) x 4 2. Drain out all the fuel from the fuel tank into a drum
• Wire ropes (with the required breaking load) can.
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
• Wood planks
3. Use a Wrench [ 19 mm ( 0.748 in. ) ] to remove the

8 bolts (1), and then remove the top cover (2).
84551720B NA - August 2012

3001-3
4. Use a Wrench 19 mm ( 0.748 in. ) to remove the 6. Use a wrench 19 mm ( 0.748 in. ) to remove the 5
2 bolts (2) from the fuel tank front cover (tank) (1), bolts (1) from the fuel tank side cover (2), and then
and then remove the cover (tank). remove the side cover.
5. Use a wrench 19 mm ( 0.748 in. ) to remove the

6 bolts (1) and clamps (2), and then remove the
handle (3).
7. Use a wrench 19 mm ( 0.748 in. ) to remove the 5

Tightening torque for bolt installation: 63.7 - 73.5
N・m ( 46.991 - 54.220 lbf・ft. )

hose (2).
• Mark the fuel tank and hose so that the connec-
tors match at the time of assembly.
• Attach caps or plugs to the fuel tank and hoses to
84551720B NA - August 2012

3001-4
11. Use a wrench 19 mm ( 0.748 in. ) to remove the

4 bolts (1), and then remove the side covers (tank)
(2).
9. Remove the connector (1).
12. Install the 4 eyebolts (M12) (1) on top of the fuel

tank.
by a half turn.
10. Use a wrench 24 mm ( 0.945 in. ) to remove the 5

• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the locations where they
are and how many.
N・m ( 171.439 - 203.601 lbf・ft. )
84551720B NA - August 2012

3001-5
13. Connect the 4 shackles (1) to the eyebolts, then use Installation of fuel tank
the wire ropes (2) and liftcrane to lift.
Thoroughly check that the location is safe before To install, perform the reverse of the removal procedure.
lowering the fuel tank (3) on wood planks. Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check of
the "Section 1002E• Tightening Torque • Retightening
Torque Table".
Finally, carefully check for any fuel leaks.
84551720B NA - August 2012

3001-6
Section
3004A
Removal and Installation of Fuel Supply Pump
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removal of Fuel Supply Pump 1) Disengage the harness connector from the
fuel supply pump.
1. Battery ground cable Disconnect 2) Remove the fuel supply pump from the cylin-
1) Disengage the battery ground cable from the der block.
battery.
gine assembly.
ANNOTATION:
ANNOTATION:
1 Bolt
CAUTION
• Do not reuse the removed fuel pipe. 3) Remove the supply pump gear from the fuel
supply pump using the puller.
der head assembly.
supply pump.
ANNOTATION:
the fuel feed pipe.
mon rail assembly.
ANNOTATION:
• Remove the clip. pump bracket.
CAUTION
ply pump.

4 Fuel supply pump
1 Fuel supply pump
2 O-ring
5. Fuel supply pump Removal 3 Supply pump bracket
84551720B NA - August 2012
3004A-3
Installation of Fuel Supply Pump

pump bracket.
lb・ft.}
CAUTION
twisted.

center.
1 Fuel supply pump

2 O-ring
3 Supply pump bracket 1 Front cover marking
2
shaft damper
3) Install the supply pump gear to the fuel supply
pump. 5) Install the O-ring to the fuel supply pump.
Tightening torque： 64 N・m {6.5 kgf・m / 47 6) Temporarily tighten the fuel supply pump to
lb・ft.} the cylinder block.
1 Fuel supply pump 1 Bolt

2 Supply pump gear
3 Nut
7) Check alignment mark of the supply pump
gear.
• After installing the supply pump gear, refer • Confirm that the alignment mark can be
to the diagram and make an alignment mark seen through the plug hole on the left side
on it. of the flywheel housing.
84551720B NA - August 2012
3004A-4

lb・ft.}
fuel supply pump.
lb・ft.}
lbf・ft. }
1 Plug hole
2 Alignment mark
CAUTION
the supply pump gear.
8) Securely tighten the fuel supply pump to the

cylinder block.
lb・ft.} Nut 1 Common rail assembly
Tightening torque： 76 N・m {7.7 kgf・m / 56 2 Cylinder head assembly
lb・ft.} Bolt 3 Fuel leak-off pipe
9) Connect the harness connector to the fuel 4 Fuel supply pump
supply pump.
2. Fuel leak off pipe assembly Installation 3. Fuel pipe Installation
1) Temporarily tighten the fuel leak-off pipe to the 1) Install the fuel pipe to the fuel supply pump
cylinder head assembly. and the common rail assembly.
CAUTION CAUTION
• Use new gaskets. • Use new fuel pipes.
2) Temporarily tighten the fuel leak-off pipe to the Tightening torque： 44 N・m {4.5 kgf・m / 33
common rail assembly. lb・ft.}
CAUTION 2) Install the clip to the bracket.
• Use new gaskets. lbf・ft. }
fuel supply pump. 1) Connect the engine harness to the engine as-
sembly.
ANNOTATION:
ANNOTATION:
• Tighten the fuel feed pipe together.
CAUTION
tery.
cylinder head assembly. 6. Fuel Air bleed
8.85 lbf・ft. } CAUTION
84551720B NA - August 2012

3004A-5

ANNOTATION:
the priming pump.
ANNOTATION:
1 Priming pump
2 Plug ANNOTATION:
3 Drain plug • Wait for the specified time after operating
4 Case the priming pump.
1) Prepare the pan.
2) Turn ON the starter switch. ANNOTATION:
ANNOTATION: • Remove the air in the fuel filter.
• This is for the models with an electromag- 14) Tighten the plug using the wrench.
netic pump. Tightening torque： 10 N・m { 1.0 kgf・m /
7.38 lbf・ft. }
4) Operate the priming pump. CAUTION
ANNOTATION: thoroughly after tightening.
plug. 15) Operate the priming pump.
5) Tighten the plug using the wrench. 10 - 15 times
6) Operate the priming pump. 16) Start the engine.
CAUTION
ANNOTATION:
• Wait for the specified time after operating lution right after staring.
the priming pump.
Specified time： 1 min Idling: 5 s
ANNOTATION:
ANNOTATION:
ANNOTATION:
mum.
84551720B NA - August 2012

3004A-6
Section
3004B
Removal and Installation of Common Rail Assembly
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removal of Common Rail 3) Remove the intake throttle valve from the inlet
pipe.
Assembly
battery.
gine assembly.
ANNOTATION:
3. Intake throttle valve Removal
valve.
2) Disengage the harness connector from the in- 1 Boost temperature sensor
take throttle valve. 2 Boost sensor
3 Inlet pipe
ANNOTATION: 4 Gasket
• Pull the lock operation portion to release the 5 Intake throttle valve
lock.
boost sensor.
EGR valve.
IMT sensor.
1 Lock operation section

2 Lock release
3 Lock
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
84551720B NA - August 2012

3004B-3
6) Remove the inlet pipe from the case. 2) Remove the injection pipe from the injector
CAUTION
pipe.
ing.
1 Case
2 Gasket
3 Inlet pipe

gauge guide tube.
the cylinder head cover. 1 No.1 injection pipe
3) Disengage the oil level gauge guide tube from 2 No.2 injection pipe
the case. 3 No.3 injection pipe
4) Remove the oil level gauge guide tube from 4 No.4 injection pipe
the cylinder block. 5 Fuel leak-off pipe
6 Fuel pipe

ANNOTATION:
CAUTION

1 Cylinder head cover 1) Disengage the fuel leak-off pipe from the cylin-
2 Oil level gauge guide tube der head assembly.
3 Case 2) Remove the fuel leak-off pipe from the fuel
4 Cylinder block supply pump.
ANNOTATION:
1) Remove the clip from the bracket. the fuel feed pipe.
84551720B NA - August 2012

3004B-4
3) Disengage the fuel leak-off pipe from the com- Installation of Common Rail
mon rail assembly.
4) Remove the fuel leak-off pipe from the case. Assembly
ANNOTATION: 1. Common rail assembly Installation
• Remove the clip. 1) Temporarily tighten the common rail bracket
to the oil cooler assembly.
ANNOTATION:
• The installation bolt and common rail as-
cover.
3) Align the common rail assembly to the com-
mon rail bracket.
assembly.
ANNOTATION:
ened together.
1 Common rail assembly 5) Temporarily tighten the bolt to the common rail
2 Cylinder head assembly assembly.
3 Fuel leak-off pipe 6) Securely tighten the nut to the common rail
4 Fuel supply pump assembly.
9. Common rail assembly Removal lb・ft.}
1) Disengage the harness connector from the ANNOTATION:
• Refer to the tightening order in the diagram
if the inlet cover is removed.
inlet cover and the common rail bracket.
cooler assembly.
7) Securely tighten the bolt to the common rail

assembly.
lb・ft.}
84551720B NA - August 2012

3004B-5
8) Connect the harness connector to the fuel 7) Install the clip to the fuel leak-off pipe.
pressure sensor. Tightening torque： 8 N・m {0.8 kgf・m / 5.90
lbf・ft. }
1 Common rail assembly 1 Common rail assembly

2 Fuel pressure sensor 2 Cylinder head assembly
3 Common rail bracket 3 Fuel leak-off pipe
4 Fuel supply pump

CAUTION
CAUTION
• Use new fuel pipes.
lb・ft.}
2) Install the clip to the bracket.
CAUTION Tightening torque: 9 N・m { 0.9 kgf・m / 6.64
lbf・ft. }
3) Temporarily tighten the fuel leak-off pipe to the CAUTION
fuel supply pump.
ANNOTATION:
• Tighten the fuel feed pipe together. 1) Apply the engine oil to the injector sleeve.
CAUTION ANNOTATION:
• Apply to the injection pipe sleeve on the in-
jector side.
4) Securely tighten the fuel leak-off pipe to the 2) Temporarily tighten the injection pipe to the
cylinder head assembly. injector.
Tightening torque: 12 N・m { 1.3 kgf・m / 3) Temporarily tighten the injection pipe to the
8.85 lbf・ft. } common rail assembly.
5) Securely tighten the fuel leak-off pipe to the 4) Securely tighten the injection pipe to the injec-
common rail assembly. tor.
lb・ft.} lb・ft.}
6) Securely tighten the fuel leak-off pipe to the 5) Securely tighten the injection pipe to the com-
fuel supply pump. mon rail assembly.
lb・ft.} lb・ft.}
84551720B NA - August 2012

3004B-6
6) Install the clip to the bracket. 6. Inlet pipe Installation

4.43 lbf・ft. }
lb・ft.}
CAUTION

6 Fuel pipe 1 Case
7 Common rail assembly 2 Gasket
3 Inlet pipe
5. Oil level gauge guide tube Installation
1) Install the oil level gauge guide tube to the 2) Connect the harness connector to the IMT
cylinder block. sensor.
2) Connect the oil level gauge guide tube to the 3) Connect the harness connector to the EGR
case. valve.
Tightening torque： 19 N・m {1.9 kgf・m / 14 4) Connect the harness connector to the boost
lb・ft.} temperature sensor.
3) Connect the oil level gauge guide tube to the 5) Connect the harness connector to the boost
cylinder head cover. sensor.
Tightening torque： 19 N・m {1.9 kgf・m / 14 6) Install the harness clip to the inlet pipe.
lb・ft.}
guide tube.
1 Boost sensor
2 IMT sensor
3 EGR valve
1 Cylinder head cover 4 Harness clip
2 Oil level gauge guide tube 5 Boost temperature sensor
3 Case
4 Cylinder block 7. Intake throttle valve Installation
84551720B NA - August 2012

3004B-7
1) Install the intake throttle valve to the inlet pipe. CAUTION

lb・ft.} • To prevent engine failure, be sure to per-

2 Boost sensor
3 Inlet pipe
4 Gasket 1 Priming pump
5 Intake throttle valve 2 Plug
3 Drain plug
2) Install the air duct to the intake throttle valve. 4 Case
3) Connect the harness connector to the intake 5 Fuel filter element
throttle valve.
ANNOTATION: 1) Prepare the pan.
• After connecting the harness connector, 2) Turn ON the starter switch.
press in the lock operation portion to lock. ANNOTATION:
• This is for the models with an electromag-
netic pump.
ANNOTATION:
plug.
ANNOTATION:
1 Lock operation section • Wait for the specified time after operating
2 Lock release the priming pump.
3 Lock
ANNOTATION:
sembly. • Remove the air in the fuel filter.
ANNOTATION: 8) Tighten the plug using the wrench.

• Connect each connector. Number of times： 10 count(s) or more
9. Battery ground cable Connect ANNOTATION:
1) Connect the battery ground cable to the bat- • Wait for the specified time after operating
tery. the priming pump.
10. Fuel Air bleed Specified time： 1 min
84551720B NA - August 2012
3004B-8
10) Loosen the plug using the wrench. 15) Operate the priming pump.
ANNOTATION:
10 - 15 times
• Remove the air in the fuel filter. 16) Start the engine.
11) Tighten the plug using the wrench. CAUTION
Number of times： 10 count(s) or more • Do not accelerate the engine revo-
ANNOTATION:
• Wait for the specified time after operating Idling: 5 s
the priming pump. ANNOTATION:
ANNOTATION:
ANNOTATION:
14) Tighten the plug using the wrench. mum.
7.38 lbf・ft. }
CAUTION
84551720B NA - August 2012

3004B-9
84551720B NA - August 2012

3004B-10
Section
3005
Removal and Installation of Injector
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Removal of Injector 3) Remove the intake throttle valve from the inlet
pipe.
battery.
gine assembly.
ANNOTATION:
3. Intake throttle valve Removal
valve.
2) Disengage the harness connector from the in-
takethrottle valve. 1 Boost temperature sensor
ANNOTATION: 2 Boost sensor
3 Inlet pipe
• Pull the lock operation portion to release the 4 Gasket
lock.

boost sensor.
EGR valve.
IMT sensor.
1 Lock operation section

2 Lock release
3 Lock
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
84551720B NA - August 2012

3005-3
6) Remove the inlet pipe from the case.

1 Case 2 No.2 injection pipe
2 Gasket 3 No.3 injection pipe
3 Inlet pipe 4 No.4 injection pipe
6 Fuel pipe
gauge guide tube. 7. Cylinder head cover Removal
the cylinder head cover. 1) Disengage the ventilation hose from the air
3) Disengage the oil level gauge guide tube from breather.
the case. 2) Remove the cylinder head cover from the
4) Remove the oil level gauge guide tube from lower cover.
the cylinder block. 3) Remove the head cover gasket from the cylin-
der head cover.

2 Oil level gauge guide tube 1 Cylinder head cover
3 2 Gasket
Case
3 Lower cover
4 Cylinder block
8. Lower cover Removal

1) Remove the connector from the lower cover.
2) Remove the injection pipe from the injector CAUTION
CAUTION nector with a screwdriver.
pipe.
ing.
84551720B NA - August 2012

3005-4
2) Disengage the injector harness from the injec- Special tool: fuel injector remover (refer
tor. to section 1003)
CAUTION

head assembly.
ANNOTATION:
with the bracket.
4) Remove the lower cover from the cylinder
head assembly.
Special tool: sliding hammer (refer to
section 1003)
1 Lower cover
2 Connector
5) Remove the gasket from the lower cover.

head assembly.
9. Injector Removal
jector.
assembly.
ANNOTATION:
a special tool.
1 Sliding hammer
3 Injector
84551720B NA - August 2012

3005-5
CAUTION Installation of Injector

• Confirm that the sleeve is not pulled 1. Injector Installation
injector using a special tool. CAUTION
• Store each ID code plate on the in- • When reusing an injector, do not change
jector head with the cylinder num- the installation position.
• Be extremely careful not to damage 1) Apply the engine oil to the bolt.
the injector nozzle. 2) Temporarily tighten the injector to the cylinder
head assembly.
CAUTION
1 Injector
2 Installation bolt

injector.
CAUTION

head assembly.
lb・ft.}
6) Install the injector leak-off pipe to the injector.
CAUTION

10.33 lbf・ft. }
tor.
lb・ft.}
mon rail assembly.
lb・ft.}
84551720B NA - August 2012
3005-6
3) Install the clip to the bracket. 5) Install the injector harness to the cylinder head
Tightening torque： 6 N・m { 0.6 kgf・m / assembly.
4.43 lbf・ft. }
ANNOTATION:
bracket.
lb・ft.}

6 Fuel pipe
7 Common rail assembly 1 Injector harness terminal
2 Injector harness bracket
3. Lower cover Installation
1) Apply the liquid gasket to the rubber plug. 6) Connect the injector harness to the injector.
ANNOTATION: lbf・ft. }
• Apply ThreeBond 1207B.
CAUTION
1 Rubber plug
2 Liquid gasket
CAUTION 1 Lower cover

2 Connector
stall the lower cover within 5 min-
utes. 7) Install the connector to the lower cover.
2) Install the rubber plug to the cylinder head lbf・ft. }
assembly.
4. Cylinder head cover Installation
3) Install the gasket to the lower cover.
4) Install the lower cover to the cylinder head 1) Align the head cover gasket to the cylinder
assembly. head cover.
Tightening torque： 18 N・m {1.8 kgf・m / 13 2) Install the cylinder head cover to the lower
lb・ft.} cover.
84551720B NA - August 2012
3005-7
Tightening torque： 18 N・m {1.8 kgf・m / 13 4) Install the oil level gauge to the oil level gauge
lb・ft.} guide tube.
ANNOTATION:

3 Case
4 Cylinder block

lb・ft.}
CAUTION

2 Gasket
3 Lower cover

breather.
5. Oil level gauge guide tube Installation
1) Install the oil level gauge guide tube to the 1 Case
cylinder block. 2 Gasket
2) Connect the oil level gauge guide tube to the 3 Inlet pipe
case.
Tightening torque： 19 N・m {1.9 kgf・m / 14 2) Connect the harness connector to the IMT
lb・ft.} sensor.
3) Connect the oil level gauge guide tube to the 3) Connect the harness connector to the EGR
cylinder head cover. valve.
Tightening torque： 19 N・m {1.9 kgf・m / 14 4) Connect the harness connector to the boost
lb・ft.} temperature sensor.
84551720B NA - August 2012

3005-8
5) Connect the harness connector to the boost 3) Connect the harness connector to the intake
sensor. throttle valve.
ANNOTATION:
• After connecting the harness connector,
press in the lock operation portion to lock.
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip 1 Lock operation section
5 Boost temperature sensor 2 Lock release
3 Lock
7. Intake throttle valve Installation
Tightening torque： 24 N・m {2.4 kgf・m / 17 1) Connect the engine harness to the engine as-
lb・ft.} sembly.
ANNOTATION:
tery.
10. Fuel Air bleed
CAUTION

2 Boost sensor
3 Inlet pipe
4 Gasket
2) Install the air duct to the intake throttle valve.
1 Priming pump
2 Plug
3 Drain plug
4 Case
84551720B NA - August 2012
3005-9
1) Prepare the pan. 12) Operate the priming pump.

2) Turn ON the starter switch. Number of times： 10 count(s) or more
• This is for the models with an electromag- • Wait for the specified time after operating
netic pump. the priming pump.
3) Loosen the plug using the wrench. Specified time： 1 min
4) Operate the priming pump. 13) Loosen the plug using the wrench.
ANNOTATION:
ANNOTATION:
plug. 14) Tighten the plug using the wrench.
5) Tighten the plug using the wrench. 7.38 lbf・ft. }
Number of times： 10 count(s) or more CAUTION
ANNOTATION: • Remove the fuel around the plug
the priming pump.
Specified time： 1 min Number of times the operation is Performed:
7) Loosen the plug using the wrench. 10 - 15 times
ANNOTATION:
• Remove the air in the fuel filter. CAUTION
8) Tighten the plug using the wrench. • Do not accelerate the engine revo-
9) Operate the priming pump. lution right after staring.
Idling: 5 s
ANNOTATION:
ANNOTATION:
the priming pump. • Accelerate the engine revolution gradually.
Specified time： 1 min Engine revolution hold: 3 min.
10) Loosen the plug using the wrench. ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter. mum.
84551720B NA - August 2012

3005-10
Section
4001A
Electrical and Engine Basic Functions
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Monitor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor Display Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Eco Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DPD Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnostic Trouble Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Economy Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Neutral Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Idling Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auto Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
One-touch Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick Warm-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Idling Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Travel Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Static Horsepower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Back/Side View Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Swing Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Free Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Energy saving / Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pump Standby Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Swing Relief Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Stroke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Boom Down Energy Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Auto Energy Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Overload Reduction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
End Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Breaker Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Crusher Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Anti-theft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Enabling the anti-theft function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Immobilizer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Feed Pump Automatic Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Coolant Level Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hydraulic Oil Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Air Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DPD Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Automatic Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Manual Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Forced Manual Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hydraulic Assist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Monitor Control
Fuel Gauge
Summary
The fuel level is displayed as one of 9 levels, 0-8.
When the fuel level reaches Level 1, a warning is is-
sued.
If the sensor breaks down, the level becomes 0.
(When the sensor is normal, the Levels 1-8 are dis-
played.)
Configuration
• The table below shows the correspondence be-

tween the fuel sensor % and the bar graph level.
Lever angle [%] Bar graph level

100 8
83 7
67 6
50 5
33 4
17 3
1 2
0 1
* Currently, the above settings are common to all

models.
*1 Monitor
*2 Computer B • Refueling warning: When the gauge falls to Level
*3 Computer A 1, the "LOW FUEL" message is displayed on the
*4 Overhead monitor and the buzzer sounds for 5 sec..
*5 Fuel sensor • Monitor display: The following processing is used to
*6 Reserve (1 hour of work) prevent the monitor gauge from fluctuating due to
fluctuation of the fuel surface.
*7 Fuel tank
Sensor angle measurement period = 1 sec.
Gauge update period = 5 sec.
Operation explanation Gauge update judgment = Average of sensor angle
• Computer A reads out the resistance of the fuel level for past 20 sec. (20 times)
sensor installed in the fuel tank and communicates • Gauge display: For the work screen, an arc is dis-
it to the monitor. played at the center of the screen.
On the camera screen, displayed vertically on the
right edge of the screen.
Resistance [Ω] Fuel sensor [%]
• Trouble mode: If trouble occurs in the fuel level sen-
10 100 sor, the fuel gauge itself is not displayed.
38 50 If an abnormality occurs in monitor communication,
80 0 the display will not update.
84551720B NA - August 2012

4001A-3
Coolant Temperature Gauge

Purpose
Displays the coolant temperature using a meter and bar graph.(Coolant temperature check)
1 Coolant temperature gauge 3 Computer A 5 Coolant temperature sensor

2 Monitor 4 ECM 6 Engine
a Bar graph display

b Meter display
Operation explanation
1. When the key is turned ON, the coolant temperature meter indicates the current coolant temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the coolant temperature bar
graph is displayed on the left side.
3. The meter and bar graph are not displayed if coolant temperature sensor trouble is detected.
Remarks
The coolant temperature ranges are shown in the table below.
Meter indicator angle

Temperature [°C ( °F )] Bar graph level x 3
[deg.]
Lower than 50 ( 122.0 ) 0 - 15 1
50 ( 122.0 ) 15 2
77 ( 170.6 ) 58 3
82 ( 179.6 ) 66 4
97 ( 206.6 ) 90 5
100 ( 212.0 ) 118 6
102 ( 215.6 ) 137 7
105 ( 221.0 ) 165 8
84551720B NA - August 2012

4001A-4
Oil Temperature Gauge

Purpose
Displays the oil temperature on a meter.(Oil temperature check)
1 Oil temperature gauge 3 Computer A 5 Oil temperature sensor

2 Monitor 4 Hydraulic oil tank 6 Hydraulic pump
a Meter display
1. When the key is turned ON, the oil temperature meter indicates the current oil temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the oil temperature meter is
not displayed.
3. The meter is not displayed if oil temperature sensor trouble is detected.
Remarks
The oil temperature ranges are shown in the table below.
Meter indicator angle

Temperature [°C ( °F )]
[deg.]
Lower than 25 ( 77.0 ) 0 - 15
25 ( 77.0 ) 15
45 ( 113.0 ) 42
60 ( 140.0 ) 63
80 ( 176.0 ) 90
88 ( 190.4 ) 123
92 ( 197.6 ) 140
95 ( 203.0 ) 153
97 ( 206.6 ) 161
98 ( 208.4 ) 165
84551720B NA - August 2012

4001A-5
Monitor Display Dimming

Purpose
Adjusts the brightness of the backlight through operation that is linked to the working light and solar radiation sensor.
1 Monitor 3 Solar radiation sensor 5 Working light relay

2 Computer A 4 Working light switch
a Dimming level automatic adjustment using the solar radiation

sensor
b Working light-linked dimming using the working light relay
1. When the operator turns the key ON, the monitor screen brightness is set to "brightness (day)".
2. When the operator turns the working light ON, the monitor screen brightness is set to "brightness (night)" (=
working light-linked dimming).
• When working light-linked dimming is set to OFF on the rear screen, instead of using "brightness (night)" to
adjust the monitor screen brightness when the working light is ON, the brightness is judged using the solar
radiation sensor (= dimming level automatic adjustment).
• The brightness when the working light is OFF is set to "brightness (day)" regardless of whether working light-
linked dimming is set to ON or OFF.
3. The operator can set "brightness (day)" or "brightness (night)" in the menu screen.
• The screen brightness setting is stored inside the monitor, so the setting is saved even if a computer is re-
placed.
84551720B NA - August 2012

4001A-6
Eco Gauge
Purpose
Displays on the monitor whether energy-saving operation is being performed.(Eco function)
1 Eco gauge
2 Monitor
3 Computer A
1. The eco gauge is displayed on the monitor.
2. The eco-saving performance is judged in levels from 0 to 9.(The higher the number, the better the eco perfor-
mance.)
In SP mode, the maximum is 4.
In H mode, the maximum is 6.
In A mode, the maximum is 8.
In low idle, the maximum is 9.
84551720B NA - August 2012

4001A-7
DPD Gauge
Purpose
Displays an icon and bar graph on the monitor during DPD regeneration.
1 DPD gauge
2 Monitor
3 Computer A
1. DPD bar graph display conditions
1) The DPD clogging level is displayed on the DPD bar graph during normal operation.(5-level display)
When 5 white lamps are displayed, it indicates that the tank is full.
2) The regeneration progress is displayed on the DPD bar graph during DPD regeneration (5-level display).
The white lamps go off one by one, and when all have gone off, regeneration is complete.
2. DPD amber lamp display condition
1) The amber lamp turns on and flashes during manual DPD regeneration.
3. DPD green lamp display condition
1) The green lamp turns on and flashes during automatic DPD regeneration.
84551720B NA - August 2012

4001A-8
Diagnostic Trouble Code Indicator

Purpose
Displays a diagnostic trouble code (DTC) on the monitor when trouble occurs. (Makes troubleshooting easier)
1 Diagnostic trouble code

2 Monitor
3 Computer A
1. If trouble occurs, the "!" symbol and the diagnostic trouble code (DTC) are displayed in the top right of the
monitor.
• When multiple cases of trouble occur, they are displayed in turn at 5-second intervals.
• At the same time, "ELEC. PROBLEM" and "CHECK ENGINE" are displayed.
• Up to 8 items can be displayed.
2. When the trouble is repaired, the diagnostic trouble code (DTC) goes off.
84551720B NA - August 2012

4001A-9
Clock
Purpose
Displays the time on the monitor.
• The time is always displayed on the monitor.
• The clock continues to operate, without display, when the key is turned OFF. (Because it uses power from the
battery)
Fuel Economy Gauge

Purpose
Displays the fuel economy on the monitor.
1 Fuel economy gauge

2 Monitor
3 Computer A
1. The fuel economy gauge is displayed on the monitor after the key is turned ON.
2. When trouble occurs, the fuel economy gauge goes off and the diagnostic trouble code is displayed.
3. When the trouble is recovered from, the diagnostic trouble code goes off and the fuel economy gauge is dis-
played again.
84551720B NA - August 2012

4001A-10
Basic Operation
Neutral Start
Purpose
The engine will not start with the gate lever lifted.(It will not crank.)
This prevents accidental operation if the operation lever is touched when the engine is started.
Configuration
1 Key switch 4 Starter cut relay 7 Starter relay

2 Gate lock limit switch 5 Lever lock solenoid 8 Neutral start relay
3 Starter motor 6 Battery relay 9 ECM
1. Lower the gate lever.
2. The starter cut relay is excited and the excitation to the safety relay is cut off.
3. Engine cranking is prohibited.
4. If the gate lever is then raised, cranking is enabled.
84551720B NA - August 2012

4001A-11
Engine Start/Stop Control

Purpose
Engine starting and stopping
1 Computer A 3 Crank sensor 5 Speed

2 Cam sensor 4 ECM 6 Engine
1. Start the engine.
2. When the engine speed rises to 500 min-1 ( 500 rpm ) or higher, engine start is judged.
3. Stop the engine.
4. When the engine speed drops to less than 200 min-1 ( 200 rpm ), engine stop is judged.
a Start c 200 min-1 ( 200 rpm )

b 500 min-1 ( 500 rpm ) d Stop
84551720B NA - August 2012

4001A-12
Preheating
Purpose
Before cranking, the insides of the engine cylinders are automatically heated to improve starting.(Warm-up opera-
tion)
1 Key switch 3 ECM 5 Coolant temperature sensor

2 Computer A 4 Engine
1. Turn the key ON.
2. When the key is turned ON, the pre-glow time is calculated based on the current coolant temperature. At the
same time, the glow relay is excited and the glow lamp is turned on.
3. After pre-glow is completed, the glow lamp goes off and the operator is prompted to begin cranking.
4. Perform cranking to start the engine.
5. When engine start and cranking stop are recognized, the after-glow time is calculated from the current coolant
temperature.
84551720B NA - August 2012

4001A-13
Throttle
Purpose
Indicates the target engine speed.
1 Monitor 3 Throttle volume 5 Engine

2 Computer A 4 ECM
a Icon
1. Turn the key ON.
2. The target engine speed is calculated based on the throttle VOL voltage signal.
3. An icon that indicates the work mode is displayed on the monitor.
84551720B NA - August 2012

4001A-14
Idling Start
Purpose
When the engine starts, the engine speed starts in low idle regardless of the throttle volume position.(Warm-up
operation, engine protection)
1 Throttle volume 4 Pressure sensor (upper) 7 Pressure sensor (option 1)

2 Computer A 5 Pressure sensor (swing) 8 Pressure sensor (option 2)
3 One-touch idle switch 6 Pressure sensor (travel)
1. Idling start operation condition
Because idling start is a warm-up operation, it operates when the engine is started.
2. Idling start end conditions
The operation ends under the following conditions.
1) When an operation lever is operated.(When one of the following pressure sensors is turned ON: upper,
swing, travel, option 1, or option 2)
2) When the throttle volume is operated.
3) When the one-touch idle switch is pressed.
84551720B NA - August 2012

4001A-15
Auto Idle
Purpose
Automatically put the engine into an idling state [ 1200 min-1 ( 1200 rpm ) ] when the machine is not being operated.
(Energy saving)
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 Pressure sensor (option 1) 11 Pressure sensor (travel)
4 ECM 8 Pressure sensor (option 2)
1. Operation conditions for auto idle
Operation starts when all the conditions below are satisfied.
1) The auto idle mode switch is pressed, turning the auto idle mode ON.
2) An operating lever is not operated for a continuous period of 5 sec. (The upper, swing, travel, option 1,
and option 2 pressure sensor are OFF for a continuous period of 5 sec.)
2. End conditions for auto idle
Operation ends under the following conditions.
1) An operation lever is operated during auto idle. (The upper, swing, travel, option 1, or option 2 pressure
sensor is ON.)
2) The throttle volume is operated.
3) The one-touch idle switch is pressed.
84551720B NA - August 2012

4001A-16
One-touch Idle
Purpose
Reduces the engine speed when the one-touch idle switch is pressed. (Energy saving)
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 Pressure sensor (option 1) 11 Pressure sensor (travel)
4 ECM 8 Pressure sensor (option 2)
1. Operation conditions for one-touch idle
When the one-touch idle switch is pressed.
2. End conditions for one-touch idle
When the one-touch idle switch is pressed once more after the one-touch idle switch is pressed and the engine
has gone into low idle.
84551720B NA - August 2012

4001A-17
Auto Warm Up
Purpose
Incrementally raises the engine speed if the coolant temperature is low when the engine starts.
1. Operation conditions for auto warm up
Auto warm up operates if the coolant temperature is less than 50°C ( 122.0°F ) when the engine starts.
2. Summary
The engine speed increases incrementally as shown in the diagram.
1) Low idle; 5 min.
2) 1200 min-1 ( 1200 rpm ); 3 min.
3) 1500 min-1 ( 1500 rpm ); 3 min.
4) SP mode; 3 min.
a 5 min. d 3 min. g 1200 min-1 ( 1200 rpm )

b 3 min. e SP mode h Low idle
c 3 min. f 1500 min-1 ( 1500 rpm )
3. End conditions for auto warm up

Auto warm up is ended and operation shifts to idling start under the following conditions.
1) Coolant temperature is 50 °C ( 122.0 °F ) or more.
2) The one-touch idle switch is pressed.
3) The entire auto warm up process has ended (after 14 min.).
4) An operation lever is operated (upper, swing, travel, option 1, option 2 pressure sensor is ON).
84551720B NA - August 2012

4001A-18
Quick Warm-up
Summary
When the engine starts up, if the outside air temperature is low, a hydraulic load is put on to warm up the engine.
Configuration
*1 Key switch *6 Computer A *11 Option pressure switch

Pump flow proportional valve
*2 *7 ECM *12 2nd option pressure switch
(on hydraulic pump)
*3 Boom 2 proportional valve *8 Upper pressure sensor *13 Coolant temperature sensor
*4 Color monitor *9 Swing pressure sensor *14 Suction air temperature sensor
*5 Computer B *10 Travel pressure sensor
1. When the following conditions are all detected, quick warm-up starts.
• The engine must be starting up.
• The engine must not be warming up (Step 1: low idle 5 minutes).
• The machine must not be operating (upper, swing, travel, option 1, or option 2).
• The outside air temperature must be -15 °C (5.0 °F).
• The coolant temperature must be between 0 and 80 °C (32.0 and 176.0 °F).
• There must not be any sensor abnormality (P1, upper, swing, travel, option (1 or 2), coolant temperature,
outside air temperature.
• DPD regeneration must not be underway.
2. This control can be disabled with the Setup/Parameters screen.
3. When the engine starts, the speed incrementally increases according to the diagram below if the coolant tem-
perature is < 50 °C (122.0 °F). [If the coolant temperature is 50 °C (122.0 °F), a normal idling start occurs.]
4. When the quick warm-up starts, the system sets the pump flow proportional valve to the minimum flow (Current
740 mA).
5. After 1 sec., the system sets the boom 2 proportional valve current to 540 mA.
An icon that indicates the start of quick warm-up is displayed on the monitor for 2 sec..
84551720B NA - August 2012

4001A-19
6. After 1 sec., if the system detects event (a) below for 20 sec. or longer, it raises the boom 2 proportional valve
target current at a pace of 2 mA/20 sec..
When event (b) is detected, the system sets the boom 2 proportional valve target current to 540 mA.
Also, if no event is detected, the system holds the boom 2 proportional valve target current in its current state.
(a) P1 pressure < 10 MPa (1450.54 psi)
(b) P1 pressure > 15 MPa (2175.81 psi)
7. If the system does not detect either of the above two conditions, it ends or stops quick warm-up.
84551720B NA - August 2012

4001A-20
Idling Stop
Purpose
Automatically stops the engine after a certain time has passed. (Energy saving)
1 Monitor 3 Engine 5 One-touch idle switch

2 Computer A 4 Idle stop relay 6 Throttle volume
1. Operation conditions for idle stop mode
Idle stop operates after performance of 1 through 3.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the gate lever is raised, the engine speed is less than 1200 min-1 ( 1200 rpm ), and the throttle volume,
auto idle switch and one-touch idle switch are not operated for a continuous period of 15 sec., an alarm
displays on the monitor screen and a buzzer sounds.
3) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.
2. Operations conditions for idle stop and auto idle mode
Idling stop operates after performance of 1 through 4.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the operation lever is not operated for a continuous period of 5 sec., the engine speed is reduced to
1200 min-1 ( 1200 rpm ). (The upper, swing, travel, option 1, and option 2 pressure sensor are OFF for
a continuous period of 5 sec.)
3) If the throttle volume, auto idle switch and one-touch idle switch are not operated for a continuous period
of 3 min., an alarm displays on the monitor screen and a buzzer sounds.
4) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.
84551720B NA - August 2012

4001A-21
Idle up
Purpose
Raises the engine speed and maintains mechanical speed.
1 Throttle volume 3 Pressure sensor (travel) 5 Engine

2 Computer A 4 ECM
a Engine speed
1. Operation conditions for idle up

Operation starts when all the conditions below are satisfied.
1) Travel operation is performed. (Travel pressure sensor ON)
2. End conditions for idle up
1) The work mode is a mode other than SP mode.
2) A travel operation is not performed.
84551720B NA - August 2012

4001A-22
Travel Speed Selection

Purpose
The travel motor tilting angle is changed by switching the travel speed between low speed and high speed with the
switch. (Travel speed switchover)
Travel 2-speed switchover so-

1 Computer A 3 Travel motor 5
lenoid
Travel 2-speed switchover so-
2 4 Monitor
lenoid
1. When the key is turned ON, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the
monitor goes to low speed.
2. When the travel speed switchover switch is pressed, the travel 2-switchover solenoid turns ON, and the travel
mode icon on the monitor goes to high speed.
3. When the travel speed switchover switch is pressed again, the travel 2-speed switchover solenoid turns OFF,
and the travel mode icon on the monitor goes to low speed.
* Even when the travel 2-speed switchover solenoid is ON, the tilting angle will automatically switch over to low
speed due to a travel motor function if the travel motor drive pressure becomes high.
However, the travel 2-speed switchover solenoid is ON.
84551720B NA - August 2012

4001A-23
Swing Brake
Purpose
The swing brake is turned OFF when either the upper or swing is operating. (Operational ability is increased)
1 Computer A 3 Pressure sensor (swing) 5 Swing brake

2 Pressure sensor (upper) 4 Swing brake solenoid valve
1. Operation conditions for swing brake

Operation starts under the following conditions.
1) An upper operation is not being performed. (Upper pressure sensor OFF)
* The swing brake is applied 1 sec. after the upper pressure sensor turns OFF.
2) A swing operation is not being performed. (Swing pressure sensor OFF)
* The swing brake is applied 5 sec. after the swing pressure sensor turns OFF.
2. End conditions for swing brake
1) An upper operation is performed. (Upper pressure sensor ON)
2) A swing operation is performed. (Swing pressure sensor ON)
84551720B NA - August 2012

4001A-24
Static Horsepower Control

Purpose
Monitor the engine actual speed and the engine target speed and set the appropriate amount of horsepower. (En-
gine stop prevention, energy saving)
1 Hydraulic pump 4 ECM 7 Pressure sensor (travel)

Horsepower control propor-
2 5 Engine
tional valve
3 Computer A 6 Engine speed sensor
a Engine target speed

b Discharge volume fluctuation
Operation Explanation
1. The minimum milli-amp and maximum milli-amp is selected from the milli-amp set for each engine speed.
2. When the engine actual speed falls 30/min or more below the target engine speed, the milli-amp is gradually
lowered to the minimum.
3. When the engine actual speed is not 30/min or more below the target engine speed, the milli-amp is gradually
raised to the maximum.
4. When the engine speed is at a low speed, the milli-amp decreases.
5. When the engine speed is increasing after being at a low speed, the milli-amp increases.
84551720B NA - August 2012

4001A-25
Accessories
Working Light
Purpose
Press the working light switch to turn the working light on.(To improve visibility during night work.)
1 Monitor 3 Working light relay

2 Computer A 4 Working light switch
1. When the key is turned ON, the working light is OFF.
2. When the working light switch is pressed, the working light relay turns ON, and the working light icon on the
monitor turns ON.
The boom light and cab light turn on.
3. When the working light switch is pressed again, the working light relay turns OFF, and the working light icon on
the monitor turns OFF.
The boom light and cab light turn off.
84551720B NA - August 2012

4001A-26
Radio Mute
Purpose
Enables the radio volume to be turned ON or OFF with a one-touch operation.
1. Each time the radio mute switch (1) is pressed, the radio volume is switched between ON ⇔ OFF.
2. When the key is switched ON, the radio always starts with mute off (normal radio volume).
84551720B NA - August 2012

4001A-27
Safety
Engine Emergency Stop
Purpose
Stops the engine in an emergency.
1 Computer A 3 Engine emergency stop switch

2 Engine 4 ECM
1. If an emergency occurs while the engine is running, press the emergency stop switch.
2. When the ECM and computer A detect that the emergency stop switch is ON, the engine is stopped.
* To restart, make sure that the emergency stop switch is OFF, and then start cranking the engine.
84551720B NA - August 2012

4001A-28
Travel Alarm
Purpose
The travel alarm sounds when a travel operation is performed.(Safety function)
1 Computer A
2 Travel pressure sensor
3 Travel alarm
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4001A-29
1. Operation conditions for travel alarm

The operation starts under the following conditions.
1) When a travel operation is being performed.(Travel pressure sensor ON)
2. End conditions for travel alarm
1) When the travel operation is stopped.
2) When 10 sec. or longer elapses while a travel operation is being performed.
a Travel alarm
b Pressure sensor (travel)
c 10 sec.
84551720B NA - August 2012

4001A-30
Back/Side View Monitor

Purpose
Displays an image on the monitor from the camera that is installed on the shovel.(Improves rear visibility. Improves
safety)
1 Monitor 3 Camera select switch 5 Side camera

2 Camera screen switch 4 Rear camera
a Options
1. When the key is turned ON, the camera screen can be viewed by pressing the camera screen switch.
• Each time the camera screen switch is pressed, the screen alternates between the work screen and the
camera screen.
• In the camera screen, only the minimum required icons and gauges are displayed.
2. When the camera select switch is pressed in the camera screen, the screen display can be selected in the
order of rear → side → rear + side → rear.
• To perform camera selection, camera ON must be set in the camera setting screen.
• The camera select switch is enabled when multiple cameras are set.
The switch does not respond if there is only 1 rear camera.
3. If image interruption due to camera trouble (disconnection, etc.) is detected, the camera screen turns black
and ERROR is displayed.
* When the camera select switch is pressed in the work screen, the trip meter select switch function is activated.
* The camera screen switch is disabled if no cameras are mounted.
84551720B NA - August 2012

4001A-31
Swing Lock
Purpose
Turns the swing brake ON.
1 Monitor 4 Horn volume select switch 7 Swing brake

2 Working light switch 5 Computer A
3 Auto idle switch 6 Swing brake solenoid
1. Operation conditions for swing lock
1) Hold down the horn volume select switch, working light switch and auto idle switch at the same time for
3 sec.
* When the swing lock is ON and the key is OFF.Then, when the key is turned ON again, the swing lock stays
ON.
* When the swing lock and free swing are both ON, the swing lock is prioritized.
* When the swing lock is ON, the swing lock icon is displayed on the monitor.
* Even when an attachment operation or swing operation is performed while swing is ON, swing lock ON is
prioritized.(Be careful because if the swing operation is performed in this condition, the swing brake plate will
be dragged.)
2. End conditions for swing lock
1) While the swing lock is ON, hold down the horn volume select switch, working light switch and auto idle
switch at the same time for 3 sec.
84551720B NA - August 2012

4001A-32
Overload Warning
Summary
Overload warning device for lifting work with shovel
If the bottom pressure of the boom cylinder exceeds the stipulated pressure, it is judged that there is a danger of
the machine falling over and the monitor buzzer sounds (overload warning).
Configuration
*1 Overload switch *3 Computer B *5 Overload pressure sensor

*2 Color monitor *4 Computer A
1. When the overload switch is turned ON, the buzzer sound starts and stops according to the conditions below.
When the overload switch is OFF, the buzzer does not sound.
1) Overload warning start: The boom bottom pressure is greater than or equal to the set pressure continu-
ously for 1 sec.
2) Overload warning stop: The boom bottom pressure is less than or equal to the set pressure -2 MPa
(-290.10 psi) continuously for 1 sec.
2. The alarm pattern is a 1-second cycle - ON for 0.5 sec. and OFF for 0.5 sec.
*1 Overload switch *3 Monitor buzzer

*2 Boom bottom pressure *4 Set pressure
3. Display: The warning is only given with the monitor buzzer.

The lamps etc. do not illuminate.
84551720B NA - August 2012

4001A-33
Operability
Swing Speed Limit
Purpose
When the pump flow rises during a swing operation, the swing speed increases.
To prevent this, control of the pump flow is performed.(Swing speed control)
1 Computer A 5 Pressure sensor (N1) 9 Regulator

P1 flow control proportional
2 Throttle volume 6 Pressure sensor (N2) 10
valve
3 Pressure sensor (travel) 7 Pressure sensor (P1)
4 Pressure switch (option 1) 8 Pressure sensor (P2)
a Arm (1) d Option 1 g Boom (1)

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)
1. Operation conditions for swing speed limit control
Control is executed when all the conditions below are satisfied.
1) Independent swing operation (swing pressure sensor ON)
2) When travel or option operations are not being performed (travel and option pressure sensors OFF)
3) Work mode is SP or H mode(except CX350C/CX370C/350X3)
2. Swing speed limit end conditions
1) Ends immediately after a travel or option operation is performed (travel or option pressure sensor ON).
2) Ends gradually after an attachment operation is performed (upper pressure sensor ON).
84551720B NA - August 2012

4001A-34
Pressure Boost Control

Purpose
Raises the relief pressure.(Increases the digging force)
1 Computer A 6 Pressure sensor (option 2) 11 P2 pressure sensor

2 Engine 7 Control valve 12 Pump
3 Pressure sensor (upper) 8 Main relief valve 13 Monitor
4 Pressure sensor (travel) 9 Pressure boost solenoid 14 Regulator
5 Pressure sensor (option 1) 10 P1 pressure sensor 15 ECM
a Pressure boost icon

b Engine load ratio
84551720B NA - August 2012

4001A-35
1. Operation conditions for pressure boost control (SP or H mode)
The operation starts when all the following conditions are satisfied.
1) When high-load work is being performed (P1 or P2 is high pressure, upper pressure sensor ON, swing
pressure sensor OFF)
2) When the work mode is SP or H mode.
2. End conditions for pressure boost control (SP or H mode)
1) When 8 sec. or longer elapses after starting the pressure boost (pressure boost time expires)
* When the pressure boost time expires, pressure boost is not performed again unless the operation lever
is returned one time to neutral.
2) When an attachment operation is not performed (upper pressure sensor OFF)
3) When a travel or option operation is performed (travel or option pressure sensor ON)
* Pressure boost is not performed to protect the travel and option circuits.
3. Operation conditions for pressure boost control (A mode)
When the work mode is A mode, pressure boost is performed for the lifting work.
* When a travel or option operation is performed in A mode, the pressure boost is continued.
4. Time chart (when work mode = SP or H)
a Pressure boost solenoid valve d Icon g Less than 8 sec.

e Pressure sensor (travel) and/or
b High-load work
pressure sensor (option)
c Pressure sensor (upper) f 8 sec.
84551720B NA - August 2012

4001A-36
Free Swing
Purpose
Prevents swinging of the suspended load while swinging is stopped during lifting work.
1 Free swing（Locker switch） 3 Monitor 5 Swing motor

2 Computer A 4 Free swing solenoid valve 6 Control valve
a Free swing icon
1. Operation conditions for free swing
1) When the free swing switch is pressed.
* The free swing is disabled during a swing lock.
* The free swing icon is displayed on the monitor.
2. End conditions for free swing
1) When the free swing switch is pressed during free swing.
84551720B NA - August 2012

4001A-37
Energy saving / Noise

Pump Standby Pressure Control
Purpose
Reduces the pump load during non-operation.(Reduces the fuel consumption)
The control methods are the following 2.
1. The negative control relief pressure is varied and the negative control pressure is lowered to reduce the pump
load.
2. The pump discharge volume is set to the minimum flow.
1 Computer A 5 Pressure sensor (swing) 9 Pump 2

2 Control valve 6 Pressure sensor (travel) 10
valve
Negative control foot relief
3 Power save solenoid 7
valve
4 Pressure sensor (upper) 8 Pump 1
84551720B NA - August 2012
4001A-38
1. Operation conditions for pump standby
1) When an attachment, travel or swing operation is not being performed.(Upper, travel and swing pressure
sensors OFF)
2. End conditions for pump standby
1) When an attachment operation is performed.(Upper pressure sensor ON)
2) When a travel operation is performed.(Travel pressure sensor ON)
3) When a swing operation is performed.(Swing pressure sensor ON)
3. Operation for trouble
If an abnormality occurs in the upper, swing or travel pressure sensors, the P1 flow control proportional valve,
or the power save solenoid valve, the system judges that a machine operation is in progress.
84551720B NA - August 2012

4001A-39
Swing Relief Cut

Purpose
When independent swing operation is running, the pump flow is reduced, and the excess oil ejected from the swing
motor relief valve is eliminated.
1 Computer A 4 Pressure sensor (option 1) 7 Pressure sensor (P2)

2 Oil temperature sensor 5 Pressure sensor (N2) 8 Regulator
3 Pressure sensor (travel) 6 Pressure sensor (P1) 9
valve
a Arm (1) d Option 1 g Boom (1)

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)
1. Operation conditions for swing relief cut
The operation starts when all the conditions below are satisfied.
Oil temperature is 30 °C ( 86.0 °F ) or higher
1) When a swing operation is performed. (Swing pressure sensor ON)
2) Within 1 sec. after start of swing
3) When travel or option operations are not being performed.(Travel and option pressure sensors OFF)
2. Swing relief cut end conditions
1) When a swing operation is not being performed.(Swing pressure sensor OFF)
2) When a travel or option operation is performed.(Travel or option pressure sensor ON)
84551720B NA - August 2012

4001A-40
Stroke Control
Summary
In order to improve fuel efficiency, the pump pressure is lowered by reducing the orifice loss.
A 3-stack proportional valve is used for control.
Arm 2 control
1. In normal operations, flow volume loss is reduced by suppressing the spool opening for Arm 2.
2. In the second half of leveling work, the spool opening is opened to reduce P2-arm bottom pressure loss and to
give priority to the arm for flow volume, thus suppressing flow volume loss.
Configuration
• The larger the proportional valve output current, the more the secondary pressure output is suppressed.
*1 P2 pressure sensor *4 Computer B *7 Arm-in pressure sensor

Arm-in reverse proportional
*2 Travel pressure sensor *5 *8 Bucket-close pressure sensor
valve
*3 Computer A *6 Boom-up pressure sensor
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• Boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. When the system judges leveling to be starting, it releases the restriction on Arm 2.
4. If the events below occur when the system does not judge leveling to be starting, it releases the restriction
on Arm 2. When that is not the case, it restricts Arm 2.
• Boom-up lever operation is at half lever.
5. The operator stops arm-in full operation or travels.
6. The system restricts Arm 2.
* When Arm 2 is released from the restricted state, it is released gradually as a measure against shock from
the restriction release.
Boom 2 control
In leveling work, the boom spool is pressed back to reduce P1-arm bottom pressure loss and to allow more flow to
the arm and bucket.
Configuration
• When the output current is raised, the force pushing back the spool is increased.
84551720B NA - August 2012

4001A-41
*1 Boom-up proportional valve *4 Computer B *7 Bucket-close pressure sensor

*2 Travel pressure sensor *5 Boom-up pressure sensor
*3 Computer A *6 Arm-in pressure sensor
Operation
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• The boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. If the system detects any of the events below when the system judges leveling to be starting, it issues the
Boom-2-down proportional valve instruction.
• The boom-up lever operation is at half lever.
• During bucket-close operation
4. When the system does not judge leveling to be starting, it does not issue the Boom-2-down proportional valve
instruction.
5. The operator stops arm-in full operation or travels.
6. The system stops the Boom-2-down proportional valve instruction.
* When the Boom-2-down proportional valve instruction changes, as a measure against vibration, the Boom-
2-down proportional valve command current value is lowered gradually (for both ON→OFF and OFF→ON).
Bucket control
Mostly in the second half of leveling and when collecting dirt and sand during digging, the spool opening is opened
so that a larger volume can flow.
Configuration
The larger the output current, the more the secondary pressure output is suppressed.
Bucket-close reverse propor-

*1 Travel pressure sensor *4 *7 Bucket-close pressure sensor
tional valve
*2 Computer A *5 Boom-up pressure sensor
*3 Computer B *6 Arm-in pressure sensor
84551720B NA - August 2012
4001A-42
2. If any of the events below occurs, the system outputs current restricting the bucket secondary pressure.
• Not arm-in full operation
• The boom-up operation is not at half lever.
• During travel
84551720B NA - August 2012

4001A-43
Boom Down Energy Save

Purpose
Reduces the engine speed during swinging (except during lift swinging).
1 Computer A 4 Pressure sensor (P1) 7 Pressure sensor (swing)

2 ECM 5 Pressure sensor (P2) 8 Pressure sensor (upper)
3 Engine 6 Pressure sensor (N2) 9 Throttle volume
a Engine speed control
1. Operation conditions for boom down energy save
The operation starts when all the conditions below are satisfied.
1) When the work mode is H mode or lower.
2) When the boom down and swing operation is performed.Or when the swing operation is performed.
2. End conditions for boom down energy save
The operation ends when all the conditions below are satisfied.
1) When the work mode is SP mode.
2) When an operation other than boom down and swing is performed.Or when an operation other than swing
is performed.
* When control is established at the same time as auto energy save, the control that reduces the engine speed the
most is prioritized.
84551720B NA - August 2012

4001A-44
Auto Energy Save

Purpose
Reduces the engine speed when machine operations are not being performed.(Energy saving)
1 Computer A 4 Pressure sensor (P1) 7 Pressure sensor (swing)

2 ECM 5 Pressure sensor (P2) 8 Pressure sensor (upper)
3 Engine 6 Pressure sensor (N2)
a Engine speed control
1. Operation conditions for auto energy save.
1) When a machine operation is not being performed.
2. End conditions for auto energy save.
1) When a machine operation is performed.
* When control is established at the same time as boom down energy save, the control that reduces the engine
speed the most is prioritized.
84551720B NA - August 2012

4001A-45
Overload Reduction Control

Purpose
Prevents reductions in the engine speed by detecting sharp attachment operations and sharp loads during opera-
tion. (Lowers the pump milli-amp and prevents reductions in the engine speed.)
1. Operation conditions for transient load reduction control
The milli-amp of the pump horsepower proportional valve is temporarily reduced under the following conditions.
1) When a sharp attachment operation is performed. (Judged from the upper pressure sensor pressure
boost state.)
2) When there is a sharp load during operation. (Judged from the main pressure boost state of the P1 or
P2 pressure sensor.)
2. End conditions for transient load reduction control
The milli-amp of the pump horsepower proportional valve is restored under the following conditions.
1) When a sharp attachment operation is not being performed. (Judged from the upper pressure sensor
pressure boost state.)
2) When there is no sharp load during operation. (Judged from the main pressure boost state of the P1 or
P2 pressure sensor.)
84551720B NA - August 2012

4001A-46
End Attachment
Breaker Mode
Purpose
Maximum flow and maximum pressure settings can be set for each breaker used for up to 5 breakers.(Available for
models with an electromagnetic proportional relief valve only.)
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 breaker mode, but more can be added in the flow setting screen.
2. The breaker can be used when breaker mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. The suitability of the flow volume to the breaker will be judged.
If the acceptable flow volume has been exceeded, the message “CHECK FLOW RATE” will display.
* This message only displays during breaker operation. The display ends if operation is stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.
Crusher Mode
Purpose
Maximum flow and maximum pressure settings can be set for each crusher used for up to 5 crushers.(Available for
models with an electromagnetic proportional relief valve only.)
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 crusher mode, but more can be added in the flow setting screen.
2. The crusher can be used when crusher mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. When an arm in + crusher operation is performed, milli-amp control will be performed so that the arm-in oper-
ation will not be performed with 2 pumps flow.
* This is to prevent crusher operation from being stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.
84551720B NA - August 2012

4001A-47
Maintenance
Anti-theft
Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-theft
function is enabled.
The factory setting is for these knob terminals to be disconnected.
Anti-theft setting knob Connect VG (purple / green) and BG (black / green)
Password
Purpose
Locks the machine if is operated without authorization. (Anti-theft)
1. When the anti-theft function is ON, turn the key ON.
2. Enter the correct password at the password input screen.
* If an incorrect password is input, "ERROR" is displayed and the buzzer buzzes.
If the correct password is then input, the lock is released.
3. The machine lock is released and the normal screen is displayed.
* If the “ERROR” message is ignored and the engine is started, the machine will lock.
Machine lock conditions
• The engine speed is fixed at low idle.
• The swing brake cannot be released.
• The travel alarm buzzes continuously.
* In addition, if the operator tries to operate the machine in the machine lock state, the engine will be stopped.
Machine operation judgment conditions
• The P1 or P2 pressure rises to 5 MPa ( 725.27 psi ) or higher.
• The engine load ratio is 50 % or higher for 2 sec. cumulative.
• The upper, travel, P1, or P2 pressure sensor is removed.
84551720B NA - August 2012

4001A-48
Immobilizer Key
Purpose
Prevents starting of the engine with keys other than the designated key. (Anti-theft)
• When the key is switched ON, the immobilizer computer performs verification of the key.
• If the key is verified as the designated key, cranking is performed.
• If the key is not verified as the designated key, cranking is not performed.
* At this time, cranking will not be performed even if the key is turned up to ST.
84551720B NA - August 2012

4001A-49
Feed Pump Automatic Stop

Summary
The feed pump power supply is controlled and when the fuel tank is full (Level 8), the fuel feed is automatically
stopped.
Configuration
*1 Monitor *3 FUEL PUMP STOP RL *5 BUZZER

*2 FUEL PUMP RL *4 FUEL PUMP
The fuel pump rocker switch has three positions: Manual, OFF, and Auto.
• Auto mode
The switch is the toggle type. When it comes ON, the fuel feed starts.
When the fuel tank angle sensor reaches the full level (Level 8), the monitor relay is driven and the feed pump
power is switched OFF.
In place of that, the relay buzzes the buzzer to announce that the automatic feed has ended.
To silence the buzzer, the rocker switch must be switched to OFF or Manual.
• Manual mode
The switch is the momentary type. The feed pump only drives fuel feed while the switch is pressed.
84551720B NA - August 2012

4001A-50
Coolant Level Drop

Summary
If the engine coolant level drops, the low coolant level warning is issued.
Configuration
*1 Reserve tank *3 Computer A *5 Monitor

*2 Coolant level switch *4 Computer B *6 Buzzer
Operation
1. The radiator reserve tank level switch is detected and an warning is issued.
• SW ON: 0.33 - 0.53 L (0.0872 - 0.1400 gal.)
2. When the monitor receives the level drop signal, it carries out the following operation.
• Message: "LOW COOLANT" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7423" is displayed.
the key is ON.
• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
3. When 3 sec. have passed after the coolant level switch was detected going OFF, the low coolant level alarm
stops, the "LOW COOLANT" message goes off, and the buzzer stops.
84551720B NA - August 2012

4001A-51
Hydraulic Oil Filter Clog

Summary
If the hydraulic oil filter clogs, a warning is issued.
Configuration
*1 Monitor *4 Breaker mode switch *7 Hydraulic oil tank

Breaker/crusher (1st option)
*2 Computer B *5 *8 1st option pressure switch
pedal
*3 Computer A *6 Hydraulic oil filter clog switch
If clogging occurs in the return filter inside the hydraulic tank, a message is displayed on the monitor giving the
diagnostic trouble code and the warning buzzer sounds. (For breaker, multi-purpose machines only)
1. Configuration: When the clog detection pressure switch goes open, Computer A detects the clog and sends a
command to the monitor.
2. Clog detection: Starts 10 sec. after the engine starts.
When the clog switch contact opens, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
However, detection does not occur in the following cases.
• During breaker operation: Because pulsation is severe (In other words, no warning is issued while the breaker
is operating.)
• When the oil temperature is less than 30 °C (86.0 °F): Because the hydraulic oil viscosity is high and accurate
detection is not possible.
• When the clog detection switch is broken: For details, see the sections below.
3. Warning: When the monitor receives the filter clog command, it carries out the following operation.
• Message: "RETURN FILTER" is displayed.
the key is ON.
the key is ON.
84551720B NA - August 2012
4001A-52
4. Clog switch trouble detection: Before engine starting, the contact point of the clog detection switch should be
closed (B contact point).
However, if the circuit is open (continuously for 1 sec.), it is judged that the clog detection switch is disconnected,
the "Electrical system abnormality" message and diagnostic trouble code "7063" are displayed, and the buzzer
sounds for 5 sec..
5. Time chart:
*1 1st option pressure switch *3 Message trouble card

*2 Hydraulic oil filter clog switch *4 Monitor buzzer
84551720B NA - August 2012

4001A-53
Air Filter Clog

Summary
If clogging occurs in the air cleaner filter, a message is displayed on the monitor giving the diagnostic trouble code
and the warning buzzer sounds.
Configuration
*1 Color monitor *3 Computer A *5 Barometric pressure

*2 Computer B *4 Clog sensor *6 Air cleaner
1. When the clog detection pressure switch comes ON, Computer A detects the clog and sends a command to
the monitor via Computer B
2. Clog detection starts 10 sec. after the engine starts.
3. When the clog switch comes ON, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
4. When the monitor receives the filter clog command, it carries out the following operations.
• Message: "AIR FILTER" is displayed.
the key is ON.
the key is ON.
84551720B NA - August 2012

4001A-54
Fuel Filter Clog

Summary
If the fuel filter clogs, a warning is issued.
There are 2 types of clogs: Stage 1 and Stage 2.
Configuration
*1 Color monitor *3 Computer B *5 ECM

*2 Buzzer *4 Computer A *6 Fuel filter clog sensor
1. Turn the key ON.
• Control is performed by Computer A and is displayed on the monitor via Computer B.
2. When the system detects the following, it issues the fuel filter clog warning.
• The fuel filter clog signal from the ECM is ON continuously for 5 sec. or longer.
• The clog is judged by the ECM and only the results are sent to the computer via the CAN.
• The signal is sent with values of 0 - 2.
Signal numeric value Meaning Sensor pressure Error code

0 No clog
1 Clog stage 1 -30 kPa (-4.34 psi) max. 7426
2 Clog stage 2 -40 kPa (-5.79 psi) max. 7427
3. A message is displayed and the buzzer sounds.

• The "FUEL FILTER CLOG" warning message is displayed on the monitor.
• The buzzer sounds.
4. Engine protection
When a 2nd stage clog [40 kPa (5.80 psi) max.] occurs, the engine speed is fixed to 1700 min-1.
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4001A-55
DPD Regeneration
Purpose
The DPD (Diesel Particle Diffuser) is a device that purifies particulate matter (PM) from exhaust gases.
Particulate matter is collected in the DPD filter, and when a certain amount has accumulated, that particulate matter
is automatically combusted to regenerate the filter.
During normal work, the amount of PM accumulated is displayed on the DPD gauge.
Configuration
*1 ECM *5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V
There are the following 4 regeneration methods.
• Automatic regeneration: The filter is automatically regenerated during machine operation.
The machine can work normally.
• Manual regeneration: If automatic regeneration is incomplete or the amount of accumulated PM is large, the filter
is regenerated with a switch.
The machine cannot operate.
• Forced manual regeneration: During automatic regeneration, it is possible to interrupt automatic regeneration and
switch to manual regeneration.
• Slow regeneration: When manual regeneration is interrupted for a prolonged period, it is necessary to combust
the PM slower than normal.
The diagnostic trouble code is displayed and service engineer operation is required. The machine cannot operate.
1. Switch the key ON and operate.
The system displays the current amount of PM accumulated on the DPD bar graph.
The PM accumulated on the filter continually self-combusts due to high-temperature exhaust gases during
engine operation.
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4001A-56
2. When the work was at low load, because the exhaust gas temperature is low, the PM does not self combust
but accumulates.
When the DPD differential pressure is high or every 8 hours, the ECM forces up the exhaust gas temperature
to combust the accumulated PM. (See Automatic Regeneration.)
3. Normally, the above continuous regeneration and automatic regeneration keep the accumulated amount of PM
from going above a certain amount, but if the operating conditions are such that the accumulated amount of
PM becomes excessive, in order to avoid the risk of damage to the DPD assembly due to excessive tempera-
ture rise during regeneration, the ECM prohibits automatic regeneration and requests the operator to perform
manual regeneration.
The operator receives this request and starts regeneration. (See Manual Regeneration.)
4. While automatic regeneration is stopped, the operator can execute manual regeneration at any time with switch
operation. (See Forced Manual Regeneration.)
5. If the operator ignores the manual regeneration request and continues to work, this causes (excess PM collec-
tion) and the ECM issues the diagnostic trouble code.
When this point is reached, regeneration by the operator is no longer possible and special regeneration using
service tools has become necessary. (See Slow Regeneration.)
6. If any of the following troubles occurs during regeneration, the hydraulic pressure load is stopped.
Excess PM collection
When the accumulated amount of PM exceeds the limit and the excess PM collected state is reached, the system
behaves as follows.
• Ends the hydraulic pressure assist load.
• Lights the red lamp.
• Lights up the DPD gauge all red.
• Displays the "CHECK ENGINE" message.
Slow regeneration
Regeneration through a process that raises the temperature slower than for normal regeneration.
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4001A-57
Automatic Regeneration
Summary
The filter is automatically regenerated during machine operation. The machine can work normally.
The ECM determines the amount of PM accumulated from the difference in pressure before and after the DPD filter.
When a certain amount has accumulated, the ECM regenerates the filter automatically.
Also, if the operating time since the last regeneration reaches a certain level, the ECM automatically regenerates
the filter.
Configuration

1. Conditions for the start of automatic regeneration: When the automatic regeneration request comes from the
ECM, if the following conditions are met, automatic regeneration is started.
• Engine is starting
• The engine coolant temperature is at least 70 °C (158.0 °F) but less than 100 °C (212.0 °F).
• The difference in pressure before and after the DPD filter has been stable for a certain period of time.
• The gate bar limit switch is ON (hydraulic operation is enabled).
• There is no sensor or DPD related abnormality.
2. Start of automatic regeneration: If the conditions above are met, the computer starts the following control.
• Lights the DPD green lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
• Stops the auto idle/idle stop control.
3. Stopping automatic regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and automatic regeneration is stopped.
While automatic regeneration is stopped, the DPD green lamp goes out.
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4001A-58
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.

Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes OFF (hydraulic operation is disabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400 °C (752.0 °F) or higher, regeneration is stopped.
4. Ending automatic regeneration: The computer receives the automatic regeneration end signal from the ECM
and ends the control.
• Puts out the DPD green lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.
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4001A-59
Manual Regeneration
Summary
If automatic regeneration is incomplete or the amount of accumulated PM is large, the ECM requests manual re-
generation.
The machine cannot be operated during manual regeneration.
The computer controls the regeneration assist load.
Configuration

1. Requesting manual regeneration: When the manual regeneration request comes from the ECM to the com-
puter, it displays the following items on the monitor.
• Flashes the DPD amber lamp (2-second cycle at first, high-speed 0.6-second cycle afterward)
• Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
2. Manual regeneration start conditions: When the following conditions are all met and the DPD switch is pressed,
the computer sets the engine speed to 1000 min-1 (1000 rpm) and starts manual regeneration.
• The gate bar limit switch is OFF (hydraulic operation is disabled).
• The engine coolant temperature is at least 70 °C (158.0 °F) but less than 100°C (212.0 °F).
• There is no sensor or DPD related abnormality.
• When released, automatically goes to 1000 min-1 (1000 rpm).
3. Start of manual regeneration: If the conditions above are met, Computer A starts the following control.
• Lights the DPD amber lamp.
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4001A-60
• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
4. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
5. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
6. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• Computer A set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., Computer A sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., Computer A sets the pump flow proportional valve to 600 mA.
• After 30 sec., Computer A controls the pump flow proportional valve so that the DPD exhaust gas temperature
(before DOC) is constant at 270 °C (518.0 °F). (Lowers it gradually 50 mA/second. update period 15 sec.,
update width 5 mA)
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4001A-61
Forced Manual Regeneration

Summary
During automatic regeneration, it is possible to interrupt automatic regeneration and switch to manual regeneration.
This can only be executed while automatic regeneration is stopped.
Configuration

1. With automatic regeneration stopped and with the gate bar open, if the DPD switch is held down for 3 sec.,
Computer A sends the forced manual regeneration start request signal to the ECM via the DPD relay.
2. When the ECM receives the forced manual regeneration start request signal, the following is displayed on the
monitor.
• Lights up the amber lamp for 3 sec..
3. If the system meets the following conditions, the ECM judges that manual regeneration is necessary, puts out
the amber lamp, and returns to the automatic regeneration stopped state.
• If the state of it being impossible to complete automatic regeneration has continued or longer than 8 hours
• If the ECM judges that manual regeneration is not necessary
4. If the ECM judges that manual regeneration is necessary, the system receives the manual regeneration request
signal from the ECM, and waits for the manual regeneration switch to be pressed.
• After 10 sec., it flashes the amber lamp (2-second cycle).
Displays the "PUSH DPD SWITCH TO ACTIVATE" message on the monitor.
• The operator presses the DPD switch during this time.
• If the operator does not press the DPD switch at least 10 sec., the ECM puts out the amber lamp and returns
to the automatic regeneration stopped state.
(From here on is the same process as from 2 in manual regeneration.)
5. Lowers the engine speed to 1000 min-1 (1000 rpm) and starts manual regeneration.
6. Start of manual regeneration: If the conditions above are met, the computer starts the following control.
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4001A-62
• Lights the DPD amber lamp.

• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
7. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
8. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
9. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• The computer set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., the computer sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., the computer sets the pump flow proportional valve to 600 mA.
• After 30 sec., the computer controls the pump flow proportional valve so that the DPD exhaust gas temper-
ature (before DOC) is constant at 270 °C (518.0 °F). (Lowers it gradually 50 mA/second. update period 15
sec., update width 5 mA)
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4001A-63
Hydraulic Assist Load

Summary
During DPD manual regeneration, hydraulic load is added to raise the exhaust gas temperature.
1. When regeneration starts, the system sets the pump flow proportional value to the minimum flow (Current 740
mA).
2. After 1 sec., the system sets the boom 2 proportional valve to the maximum load (Current 600 mA).
3. After 1 sec., the system sets the current for pump flow proportional valve to 600 mA. (*1)
4. After 30 sec., the system controls the pump flow proportional valve so that the DPD exhaust gas temperature
(before DOC) is constant at 270°C (518.0 °F). (*2) (*3)
• Lowers it gradually 50 mA/sec..
• Current update width: 5 mA, update period 15 sec.
• If the DPD exhaust gas temperature (before DOC) exceeds 400°C (752.0 °F), addition of the hydraulic load
is stopped.
When the temperature falls below 250°C (482.0 °F), the addition of the hydraulic load resumes after 1 sec..
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4001A-64
Section
4001B
Service Support
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84551720B NA - August 2012
CONTENTS
Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECK Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MACHINE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FAULT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WORK HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SETUP Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MACHINE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Throttle Volume Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Password Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Option Flow Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Screen Brightness Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Service Support
Service Support
Screen Operations
Screen Display List
1 Travel speed select switch 3 Menu screen display switch 5 Wiper switch
2 Attachment select switch 4 Working light switch 6 Auto idling switch
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4001B-3
Service Support
CHECK Screen List check sensor and switch input/output states, as well as
the angle, load ratio and work radius, etc. at the applied
In CHECK mode, in addition to the machine status (milli- machine (liftcrane specifications machine, lifting magnet
amp, oil pressures, temperatures, etc.), it is possible to machine).
1 Section Detailed data for the selected item can be seen by press-
For the CHECK mode section types and their contents,

see the separate sheet.
ing .
By pressing and on the monitor,

MACHINE STATUS, FAULT HISTORY, etc. can be
selected.
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4001B-4
Service Support
MACHINE STATUS 2. Temperature and pressure

1. Engine and pump
kPa ( psi
BOOST PRESS. Boost pressure
)
min-1 ( BAROMETRIC kPa ( psi
ENGINE SPEED Engine speed Barometric pressure
rpm ) PRESS. )
ENGINE LOAD BOOST TEMP. °C ( °F ) Boost temperature
％ Engine load ratio
RATIO
Suction air tempera-
MPa ( Pump 1; Discharge AIR INLET TEMP. °C ( °F )
P1 PRESS. ture
psi ) pressure
FUEL TEMP. °C ( °F ) Fuel temperature
MPa ( Pump 2; Discharge
P2 PRESS. MANIFOLD IN-
psi ) pressure °C ( °F ) Manifold temperature
NER TEMP.
MPa ( Pump 1; Negative
N1 PRESS. COOLANT TEMP. °C ( °F ) Coolant temperature
psi ) control pressure
MPa ( Pump 2; Negative HYD.OIL TEMP. °C ( °F ) Oil temperature
N2 PRESS.
3. Pressure and solenoid
Horsepower control
P.SOL;PUMP-
mA proportional valve;
POWER
Actual milli-amp
Flow milli-amp pro-
P.SOL;PUMP-
mA portional valve; Ac-
FLOW
tual milli-amp
SOL;POWER-
on/off Power save solenoid
SAVE
UPPER PILOT MPa (

Upper pilot pressure
PRESS. psi )
SWING PILOT MPa (
Swing pilot pressure
PRESS. psi )
TRAVEL PILOT MPa (
Travel pilot pressure
PRESS. psi )
OPT.LINE
on/off 1st option operation
PRESS SW.
2ND OPT.LINE
on/off 2nd option operation
PRESS SW.
TRAVEL ALARM
on/off Travel alarm
OUT.
POWER SAVE
on/off Power save solenoid
SOL.
SWING BRAKE
on/off Swing brake solenoid
SOL.
FREE SWING
on/off Free swing solenoid
SOL.
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4001B-5
Service Support
4. Pressure and solenoid 5. Pressure and solenoid
BOOM-UP PILOT MPa ( Boom-up pilot pres- PILOT SW. on/off Pilot switch
PRESS. psi ) sure MPa ( Pump 1; Discharge
P1 PRESS.
ARM-CLOSE PI- MPa ( psi ) pressure
Arm-in pilot pressure
LOT PRESS. psi ) MPa ( Pump 2; Discharge
P2 PRESS.
BUCKET-CLOSE MPa ( Bucket-close pilot psi ) pressure
PILOT PRESS. psi ) pressure MPa ( Pump 1; Negative
N1 PRESS.
P.SOL;BOOM- psi ) control pressure
mA Boom-down solenoid
DOWN MPa ( Pump 2; Negative
N2 PRESS.
P.SOL;BOOM-UP mA Boom-up solenoid psi ) control pressure
P.SOL;ARM- P.SOL;OPT.LINE
mA Arm-in solenoid mA Option line solenoid
CLOSE RELIEF
P.SOL;BUCKET- Bucket-close sole- SOL;OPTION 2 pumps flow sole-
mA on/off
CLOSE noid 2SPEED noid
P.SOL;OFFSET- SOL;OPTION SE- Option selection so-
mA Offset left solenoid on/off
LEFT LECT lenoid
SOL;BUCKET Bucket-open sole- SOL;POWER
on/off on/off Power boost solenoid
OPEN noid BOOST
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4001B-6
Service Support
6. Engine 8. Engine
ENGINE OIL kPa ( psi min-1 (

Engine oil pressure ENGINE SPEED Engine speed
PRESS ) rpm )
COOLANT LLC reserve tank ENGINE LOAD
on/off ％ Engine load ratio
LEVEL SW. level switch RATIO
Air cleaner clog DPD kPa ( psi DPD exhaust gas dif-
AIR FILTER SW. on/off
switch DIFF.PRESS. ) ferential pressure
BATTERY VOLT- EXHAUST TEMP. Exhaust gas temper-
V Battery voltage °C ( °F )
AGE (DOC) ature (DOC)
BATTERY Alternator power EXHAUST TEMP. Exhaust gas temper-
on/off °C ( °F )
CHARGE generation (DPD) ature (DPD)
IDLE SHUT Idling stop relay out- P.SOL;RE-
on/off mA
DOWN OUT put GEN.ASSIST
2SPEED TRAVEL Travel 2nd speed so- Flow milli-amp pro-
P.SOL;PUMP-
SOL lenoid output mA portional valve; Ac-
FLOW
FAN REVERS- Option switchover tual milli-amp
ING SOL solenoid output MPa ( Pump 1; Discharge
P1 PRESS.
psi ) pressure
7. Fuel MPa ( Pump 1; Negative
N1 PRESS.
FUEL DENSITY
g/cm3 Fuel density
(RAW)
FUEL DENSITY
g/cm3 Fuel density
(15°C)
FUEL TEMP. (IN-
°C ( °F ) Fuel temperature
NER TANK)
FUEL SENSOR
％ Fuel sensor
POSITION
REFUEL AUTO- Fuel supply auto-
on/off
STOP OUT matic stop
HYD.OIL FILTER Hydraulic oil filter
on/off
SW. switch
LOCK STATUS1 - -
LOCK STATUS2 - -
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4001B-7
Service Support
9. Engine 11. Safety distances
ENGINE TAR- min-1 ( BOOM ANGLE deg Boom angle

Engine target speed
GET SPEED rpm ) OFFSET ANGLE deg Offset angle
min-1 ( ARM ANGLE deg Arm angle
ENGINE SPEED Engine speed
rpm ) P.SOL;BOOM-UP ％ Boom-up solenoid
ENGINE LOAD P.SOL;OFFSET-
％ Engine load ratio ％ Offset solenoid
RATIO LEFT
FUEL INJEC- P.SOL;ARM-
％ Fuel injection ratio mA Arm-in solenoid
TION LIMIT CLOSE
COMMON RAIL MPa ( Common rail pres- SAFETY DIS- Safety distance
PRESS. psi ) sure m ( ft. )
TANCE(TOP) (side)
C.RAIL MPa ( Common rail differ- SAFETY DIS- Safety distance
DIFF.PRESS. psi ) ential pressure m ( ft. )
TANCE(SIDE) (front)
SUPPLY-
kPa ( psi Supply pump pres-
PUMP(IN) 12. Hanging load
) sure (IN)
PRESS
TARGET FUEL Target fuel injection
mm3/st
INJECTION quantity
FUEL FLOW L/h
10. Work radius and height
BOOM BOTTOM MPa ( Boom bottom pres-

PRESS. psi ) sure
BOOM ROD MPa (
Boom rod pressure
PRESS. psi )
WORKING RA-
m ( ft. ) Work radius
DIUS
BOOM ANGLE deg Boom angle LIFTING LOAD kg ( lb ) Hanging load
OFFSET ANGLE deg Offset angle RATED LOAD kg ( lb ) Rated load
ARM ANGLE deg Arm angle TOTAL MOMENT kg.m Total moment
WORKING RA- Attachment indepen-
m ( ft. ) Work radius ATT.MOMENT kg.m
DIUS dent moment
LIFTING HEIGHT m ( ft. ) Work height
HEIGHT LIMIT m ( ft. ) Hanging limit height
LIFTING LOAD kg ( lb ) Hanging load
RATED LOAD kg ( lb ) Rated load
WARNING
on/off Liftcrane buzzer
BUZZER OUT
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4001B-8
Service Support
13. GPS information FAULT HISTORY

1. With FAULT HISTORY, the contents for the trouble
currently occurring and a log of trouble that has oc-
curred in the past can be checked.
To switch to a page from 1 to 15, press the monitor
switch while the MACHINE STATUS screen is

displayed and select the desired page.
1 Displayed/Not displayed
2 Occurrence count
3 Initial occurrence time
4 Final occurrence time
• Diagnostic trouble codes that occur display in

"DTC-1" - "DTC-4".
•
The cursor is moved with the and
switches. (The cursor moves between "DTC-1"
and "DTC-4".)
• The information for the diagnostic trouble code for
the location under the cursor is displayed with the
items from "STATUS" to "LAST HOUR".
• Up to 30 diagnostic trouble codes can be dis-
played.
switch while the FAULT HISTORY screen

is displayed and select the desired page.
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4001B-9
Service Support
WORK HISTORY
Operation times for mechanical parts, electrical parts,
etc., and operation counts for switches can be displayed.
1. Machine main unit 2. Work mode
KEY-ON TIME hour Key ON time SP-MODE OPERA- SP mode operation

hour
Engine operation TION TIME time
ENGINE-RUN TIME hour
time H-MODE OPERA- H mode operation
hour
OPERATION TIME hour Operation time TION TIME time
UPPER OPERA- A-MODE OPERA- A mode operation
hour Upper operation time hour
TION TIME TION TIME time
SWING OPERATION - - -
hour Swing operation time POWER-BOOST Boosted pressure
TIME hour
TRAVEL OPERA- TIME time
hour Travel operation time AUTO IDLE TIME hour Auto idle time
TION TIME
INDEPENDENT Independent travel ONE-TOUCH-IDLE
hour hour One-touch idle time
TRAVEL TIME operation time TIME
Lo-SPEED TRAVEL 1st speed travel oper-
hour
TIME ation time
Hi-SPEED TRAVEL 2nd speed travel op-
hour
TIME eration time
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4001B-10
Service Support
3. End attachment 5. Electrical part
WIPER-INT. OPER-
BREAKER OPERATION Breaker operation hour Wiper (INT) time
hour ATION TIME
TIME time WIPER-CNT. OPER-
CRUSHER OPERA- Crusher operation hour Wiper (CNT) time
hour ATION TIME
TION TIME time WASHER OPERA- Washer operation
OPT.1 PUMP OPERA- 1st option opera- hour
hour TION TIME time
TION TIME tion time WORKING LAMP Working light ON
OPT.2 PUMP OPERA- 2nd option opera- hour
hour ON TIME time
TION TIME tion time RADIO MUTE TIME hour Radio mute time
2ND OPT. OPERATION 2 pumps flow op- DISPLAY-MODE1 No camera screen
hour hour
TIME eration time TIME selection time
CRANE OPERATION Liftcrane opera- DISPLAY-MODE2 Camera screen dis-
hour hour
TIME tion time TIME play 1 selection time
MAGNET OPERATION Lifting magnet op- DISPLAY-MODE3 Camera screen dis-
hour hour
TIME eration time TIME play 2 selection time
4. Electrical part
KEY-ON COUNT hour Key ON count

ENGINE-START
hour Engine ON count
COUNT
IDLE SHUT Front window open
hour
DOWN COUNT count
WINDOW OPEN
hour Door open count
TIME
WINDOW OPEN
10 times Idle stop time
COUNT
DOOR OPEN Front window open
hour
TIME time
DOOR OPEN
10 times Door open time
COUNT
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4001B-11
Service Support
6. Air conditioner 7. Air conditioner
A/C OPERATION AC power supply Maximum cooling op-

hour COOL-MAX TIME hour
TIME ON time eration time
A/C BLOWER-Lo AC blower Lo set- T1 TARGET TEMP T1 Target tempera-
hour hour
TIME ting time ＜ T2 TIME ture T ＜ T2 time
A/C BLOWER-M1 AC blower M1 set- T2 TARGET TEMP T2 Target tempera-
hour hour
A/C BLOWER-M2 AC blower M2 set- T3 TARGET TEMP T3 Target tempera-
hour hour
A/C BLOWER-M3 AC blower M3 set- Maximum heating
hour HOT-MAX TIME hour
TIME ting time operation time
A/C BLOWER-M4 AC blower M4 set- RECIRC.AIR MAX- °C ( Maximum inside air
hour TEMP. °F ) temperature
TIME ting time
A/C BLOWER-Hi AC blower Hi set- RECIRC.AIR MIN- °C ( Minimum inside air
TIME ting time
MAG.CLUTCH RE- Electromagnetic INTAKE AIR MAX- °C ( Maximum outside air
LAY ON TIME clutch ON time
CLUTCH RELAY ON Electromagnetic INTAKE AIR MIN- °C ( Minimum outside air
10 times
COUNT clutch ON count TEMP. °F ) temperature
To switch to a page from 1 to 7, press the monitor switch
while the WORK HISTORY screen is displayed and

select the desired page.
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4001B-12
Service Support
ENGINE HISTORY
The engine speed, coolant temperature, fuel tempera-
ture, and suction air temperature distributions, etc. can
be displayed.
1. Actual speed distribution 2. Water temperature distribution
ROTATION ＜ R1 hour S 1025 TEMP. ＜ T1 hour T ＜ 77

R1 REV. SPEED ＜ T1 TEMP. ＜ T2 hour 77 T ＜ 82
hour 1025 S ＜ 1225
R2 T2 TEMP. ＜ T3 hour 82 T ＜ 97
hour 1225 S ＜ 1425
R3 T4 TEMP. ＜ T5 hour 100 T ＜ 103
hour 1425 S ＜ 1625
R4 T6 TEMP. hour 105 T
R4 REV. SPEED ＜ - - -
hour 1625 S ＜ 1825
R5 °C ( Maximum temper-
R5 REV. SPEED ＜ TEMP. MAX
hour 1825 S ＜ 2025 °F ) ature
R6
R6 REV. SPEED hour 2025 S
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4001B-13
Service Support
3. Fuel temperature distribution 5. Boost temperature distribution
TEMP. ＜ T1 hour T ＜ 40 TEMP. ＜ T1 hour T＜0

T1 TEMP. ＜ T2 hour 40 T ＜ 50 T1 TEMP. ＜ T2 hour 0 T ＜ 20
T6 TEMP. hour 90 T T6 TEMP. hour 100 T
- - - - - -
°C ( Maximum temper- °C ( Maximum temper-
TEMP. MAX TEMP. MAX
°F ) ature °F ) ature
6. Suction air temperature distribution

4. Suction air temperature distribution
PRESS. ＜ P1 hour P ＜ 100

TEMP. ＜ T1 hour T ＜ -20 P1 PRESS. ＜ P2 hour 100 P ＜ 140
T1 TEMP. ＜ T2 hour -20 T ＜ 0 P2 PRESS. ＜ P3 hour 140 P ＜ 180
T2 TEMP. ＜ T3 hour 0 T ＜ 15 P3 PRESS. ＜ P4 hour 180 P ＜ 220
T5 TEMP. ＜ T6 hour 45 T ＜ 60 P6 PRESS. hour 300 P
T6 TEMP. hour 60 T kPa ( Maximum pres-
PRESS. MAX
- - - psi ) sure
°C ( Maximum temper- kPa ( Minimum pres-
TEMP. MAX PRESS. MIN
°F ) ature psi ) sure
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4001B-14
Service Support
7. Oil pressure distribution 9. Load ratio distribution
PRESS. ＜ P1 hour P＜0 RATIO ＜ R1 hour R＜ 30

P1 PRESS. ＜ P2 hour 0 P ＜ 150 R1 RATIO ＜ R2 hour 30 R ＜ 40
P6 PRESS. hour 750 P R6 RATIO hour 80 R
kPa ( Maximum pres-
PRESS. MAX
psi ) sure 10. SP mode load ratio distribution
kPa ( Minimum pres-
PRESS. MIN
psi ) sure
8. Boost pressure distribution
RATIO ＜ R1 hour R ＜ 30
R1 RATIO ＜ R2 hour 30 R ＜ 40
R2 RATIO ＜ R3 hour 40 R ＜ 50
R3 RATIO ＜ R4 hour 50 R＜60
PRESS. ＜ P1 hour P＜0 R4 RATIO ＜ R5 hour 60 R ＜ 70
P2 PRESS. ＜ P3 hour 150 P ＜ 300 R6 RATIO hour 80 R
P3 PRESS. ＜ P4 hour 300 P＜450
P4 PRESS. ＜ P5 hour 450 P ＜ 600
P5 PRESS. ＜ P6 hour 600 P ＜ 750
P6 PRESS. hour 750 P
kPa ( Maximum pres-
PRESS. MAX
psi ) sure
kPa ( Minimum pres-
PRESS. MIN
psi ) sure
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4001B-15
Service Support
11. H mode load ratio distribution 13. DOC temperature distribution
RATIO ＜ R1 hour R ＜ 30 TEMP. ＜ T1 hour T ＜ 200

R1 RATIO ＜ R2 hour 30 R ＜ 40 T1 TEMP. ＜ T2 hour 200 T ＜ 300
R6 RATIO hour 80 R T6 TEMP. hour 700 T
- - -
12. Fuel density distribution °C ( Maximum temper-
TEMP. MAX
°F ) ature
14. DPD temperature distribution
DENSITY ＜ D1 hour D＜ D1
D1 DENSITY ＜ D2 hour D1 D ＜ D2
TEMP. ＜ T1 hour T ＜ 200
T1 TEMP. ＜ T2 hour 200 T ＜ 300
T2 TEMP. ＜ T3 hour 300 T ＜ 400
T3 TEMP. ＜ T4 hour 400 T ＜ 500
D6 DENSITY hour D6 D
T4 TEMP. ＜ T5 hour 500 T ＜ 600
T5 TEMP. ＜ T6 hour 600 T ＜ 700
T6 TEMP. hour 700 T
- - -
°C ( Maximum temper-
TEMP. MAX
°F ) ature
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4001B-16
Service Support
15. Supply pump inlet pressure distribution 17. DPD differential pressure distribution
PRESS. ＜ P1 hour P ＜ -40

P1 PRESS. ＜ P2 hour -40 P ＜ -30 PRESS. ＜ P1 hour P＜0
P2 PRESS. ＜ P3 hour -30 P ＜ -20 P1 PRESS. ＜ P2 hour 0 P＜5
P3 PRESS. ＜ P4 hour -20 P ＜ -10 P2 PRESS. ＜ P3 hour 5 P ＜ 10
P4 PRESS. ＜ P5 hour -10 P ＜ 0 P3 PRESS. ＜ P4 hour 10 P ＜ 15
P5 PRESS. ＜ P6 hour 0 P ＜ 10 P4 PRESS. ＜ P5 hour 15 P ＜ 20
P6 PRESS. hour 10 P P5 PRESS. ＜ P6 hour 20 P ＜ 25
kPa ( Maximum pres- P6 PRESS. hour 25 P
PRESS. MAX
psi ) sure kPa ( Maximum pres-
PRESS. MAX
kPa ( Minimum pres- psi ) sure
PRESS. MIN
psi ) sure kPa ( Minimum pres-
PRESS. MIN
psi ) sure
16. Hot shutdown
18. DPD regeneration count
ITEM-1 - -
ITEM-2 - -
ITEM-3 - -
ITEM-4 - - ITEM-1 - -
ITEM-5 - - ITEM-2 - -
ITEM-6 - - ITEM-3 - -
ITEM-7 - - ITEM-4 - -
ITEM-8 - - ITEM-5 - -
ITEM-9 - - ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
To switch to a page from 1 to 18, press the monitor switch
while the ENGINE HISTORY screen is displayed and

select the desired page.
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4001B-17
Service Support
HYDRAULIC HISTORY
The P1 and P2 pilot pressure can be displayed.
1. P1 pressure 2. P2 pressure
PRESS. ＜ P1 hour P＜ 10 PRESS. ＜ P1 hour P ＜ 10

P1 PRESS. ＜ P2 hour 10 P＜ 15 P1 PRESS. ＜ P2 hour 10 P ＜ 15
P6 PRESS. hour 35 P P6 PRESS. hour 35 P
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4001B-18
Service Support
3. N1 pressure 5. P1 + P2 pressure
PRESS. ＜ P1 hour P＜ 1.0 PRESS. ＜ P1 hour P＜ 20

P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5 P1 PRESS. ＜ P2 hour 20 P＜ 30
P6 PRESS. hour 3.5 P P6 PRESS. hour 70 P
4. N2 pressure 6. Operation count
PRESS. ＜ P1 hour P＜ 1.0 UPPER PILOT Upper operation

1000 times
PRESS count
P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5
SWING PILOT Swing operation
P2 PRESS. ＜ P3 hour 1.5 P＜ 2.0 1000 times
PRESS count
P3 PRESS. ＜ P4 hour 2.0 P＜ 2.5
TRAVEL PILOT Travel operation
P4 PRESS. ＜ P5 hour 2.5 P＜ 3.0 1000 times
PRESS count
P5 PRESS. ＜ P6 hour 3.0 P＜ 3.5 ARM-CLOSE PI- Arm-in operation
P6 PRESS. hour 3.5 P 1000 times
LOT PRESS. count
OPT.LINE 1st option opera-
1000 times
PRESS SW. tion count
2ND OPT.LINE 2nd option opera-
1000 times
PRESS SW. tion count
POWER BOOST Pressure boost
1000 times
SOL. operation count
SWING BRAKE Swing operation
1000 times
SOL. count
POWER-SAVE Power save oper-
1000 times
TIME ation count
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4001B-19
Service Support
7. Oil temperature distribution PART NUMBER

The software version for computers A, B, C can be dis-
played.
TEMP. ＜ T1 hour T ＜ 45
T1 TEMP. ＜ T2 hour 45 T ＜ 60
T2 TEMP. ＜ T3 hour 60 T ＜ 80
T3 TEMP. ＜ T4 hour 80 T ＜ 88
T4 TEMP. ＜ T5 hour 88 T ＜ 95
T5 TEMP. ＜ T6 hour 95 T ＜ 98
T6 TEMP. hour 98 T
- - -
°C ( Maximum tempera-
TEMP. MAX
°F ) ture
switch while the HYDRAULIC HISTORY screen is

displayed and select the desired page.
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4001B-20
Service Support
SETUP Screen List

The model selection, work mode speed, etc. can be
changed.
By pressing "Wiper switch" (5) and "Auto idling switch" Detailed data for the selected item can be seen by press-
(6) on the monitor, MACHINE SELECT, PARAMETERS, ing "Working light switch" (4).
etc. can be selected.
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4001B-21
Service Support
MACHINE SELECT
Machine data information, etc. are registered.
MACHINE 0 Japanese
Fix the selection. 1 English
TERRITORY 2 Thai
3 Chinese
0 JAPAN 4 German
1 NA 5 French
2 - 6 Italian
3 EU 7 Spanish
4 IHI 8 Portuguese
5 TURK 9 Dutch
6 CHINA 10 Danish
11 Norwegian
12 Swedish
BRAND
13 Finnish
14 Turkish
0 SUMITOMO 15 Arabic
1 LBX 16 Malay
2 CASE 17 Indonesian
3 IHI 18 Russian
19 Canadian French
LANGUAGE 20 Pictographs only
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4001B-22
Service Support
PARAMETERS 3. Work mode engine speed

The work mode speed and pump milli-amps can be set.
1. Engine
min-1 (
ITEM-1 SP mode speed
rpm )
min-1 (
min-1 ( ITEM-2 H mode speed
ITEM-1 Auto idling speed rpm )
rpm )
ITEM-2 ms*100 Auto idle time min-1 (
ITEM-3 A mode speed
rpm )
Transient load minimum milli-
ITEM-3 mA
amp (normally 50 mA) min-1 (
ITEM-4 Idling speed
rpm )
Semi-transient load minimum
ITEM-4 mA
milli-amp
Eco gauge update period (nor- 4. Energy save
ITEM-5 ms*100
mally 1000 ms)
2. Work mode milli-amp
min-1 ( Speed change amount during

ITEM-1
rpm ) boom-down swing operation
ITEM-1 mA SP mode milli-amp (Hi) ITEM-2 - -
ITEM-2 mA SP mode milli-amp (Low) min-1 ( Semi-auto idling speed change
ITEM-3
ITEM-3 mA H mode milli-amp (Hi) rpm ) amount
ITEM-4 mA H mode milli-amp (Low) ITEM-4 - -
ITEM-5 mA A mode milli-amp (Hi) ITEM-5 - -
ITEM-6 mA A mode milli-amp (Low) ITEM-6 - -
ITEM-7 mA Minimum milli-amp ITEM-7 mA Speed limit milli-amp
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4001B-23
Service Support
5.
ITEM-1 - -
ITEM-2 - -
ITEM-3 - -
ITEM-4 - -
ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
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4001B-24
Service Support
Setting
Model Select
Summary
The model information is input to set the control parameters specific to the model.
Configuration
• Screen
Move up and down to move the cursor, left and right to select a model, set the throttle to H mode, and decide with
the menu switch.
• · Reset by holding down the left and right. (The display changes to "?" for all items.)
* From Ver. 1.8.6
Without a reset, only the LANGUAGE and UNIT can be changed.
Other changes always require a complete reset.
Setting items, values and details
Select "SET UP" on the service screen and input the following items.
The setting item values and setting details are given below.
Explanation of item
Pag-
Item name Explanation Remarks
e
MACHINE Model
TERRITORY Destination
BRAND Brand
LANGUAGE Language
1 UNIT Unit 0: {MPa, °C}, 1: {psi, °F}, 2: {kgf/cm2, °C}
-
-
-
-
-
-
OVERLOAD WARNING Load warning
Interference preven-
ANTI INTERFERENCE Not currently supported
tion
ATT. TYPE Attachment type Used for interference prevention·crane·overload warning
2
OPTION LINE Option Line
GENERATOR Lifting magnet Not currently supported
-
-
-
84551720B NA - August 2012

4001B-25
Service Support
Pag-
Item name Explanation Remarks
e
-
Currently not supported; used for Computer ST trouble diag-
REMOTE SUPPORT Remote Support
nosis
Fuel abnormality Currently not supported; used for density sensor trouble di-
FMS
warning agnosis
3 RESERVE 1 Free Swing
RESERVE 2 Reserve 2 Not currently supported
RESERVE 3 Reserve 3 Not currently supported
-
-
-
Explanation of number
1. Model (Machine)
Omitted
2. Destination (Territory)
Value Details Remarks

0 JAPAN
Travel alarm continuous buzzing function ON (Cannot be set
1 NA
OFF)
2 - (Skipped number)
3 EU
4 IHI
5 TURK
6 CHINA
3. Brand

Background color = blue, Sumitomo logo displayed after model
0 SUMITOMO
selection completed
Background color = black, LBX logo displayed after model se-
1 LBX
lection completed
Background color = black, CASE logo displayed after model se-
2 CASE
lection completed
3 IHI Not currently supported, background color = ?
84551720B NA - August 2012

4001B-26
Service Support
4. Language
• Can be changed with "LANGUAGE" on the menu screen.

0 Japanese
1 English
2 Thai Not currently supported
3 Chinese
4 German
5 French
6 Italian
7 Spanish
8 Portuguese
9 Dutch
10 Danish
11 Norwegian
12 Swedish
13 Finnish
14 Turkish
15 Arabic
16 Malay Not currently supported
17 Indonesian Not currently supported
18 Russian
19 Canadian French
20 Pictographs only
5. Unit

0 Domestic, Europe (SI units) (MPa, °C)
1 North America (psi, °F)
2 Weight unit system (kgf/cm2, °C)
6. Load warning (OVERLOAD WARNING)

0 None
1 Liftcrane Not currently supported
2 Overload warning
3 Overload warning (rod pressure correction) Not currently supported
7. Interference prevention (ANTI INTERFERENCE)

0 None Not currently supported
1 Yes Not currently supported
8. Attachment type (ATT. TYPE)

0 STD
1 HD
2 Ultra-long
84551720B NA - August 2012
4001B-27
Service Support
9. Option line

None (Option adjustment screen cannot be
0
displayed)
1 Breaker
2 Double-acting no 2nd speed
3 Double-acting with 2nd speed
4 W/O multi-purpose pressure adjustment
5 W/ Multi-purpose pressure adjustment
10. Lifting magnet (Generator)

11. Remote Support

12. Fuel abnormality warning (FMS)

13. Free swing (Reserve 1)

0 None
1 Yes
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4001B-28
Service Support
Throttle Volume Default Setting

Summary
Corrects the throttle volume installation error.
Configuration
*1 Throttle volume *3 Computer B *5 ECM

*2 Color monitor *4 Computer A *6 ENG
1. Switch the key ON and select (Select Model). (See Select Model.)
2. Set all the model selection items and set the throttle volume to H mode, then finalize the selections.
3. The system performs the initial adjustment of the throttle volume. (*1)
• The adjustment results are retained in memory even after the key is switched OFF.
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4001B-29
Service Support
Password Setting
Summary
Set the anti-theft password.
Configuration
• Monitor: Connected to Computer B
• Anti-theft setting knob: On the cab main harness
1. With the key OFF, connect the anti-theft setting knob.
2. After connecting the knob, when you switch ON the key, the system displays the password setting screen.
3. After setting the 4-digit password, if you switch the key ON→OFF→ON→OFF, the system switches ON the
anti-theft function.
• All the key switching operations should be done within 2 sec.
4. When the anti-theft function comes ON, the monitor sets off the buzzer and the key icon is displayed.
* See Anti-theft (password type).
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4001B-30
Service Support
Adjusting the Clock *1 Color monitor

Summary
This adjusts the clock displayed on the monitor. Operation explanation
• For details on the clock, see the clock section. 1. When the key is turned ON, --:-- is displayed on
the monitor.
Configuration 2. The operator can set the time with "CLOCK AD-
JUST" on the menu screen.
Move left and right to move the cursor, up and
down to change the time, and decide with the
menu switch.
3. The system displays the time on the monitor.
• Since the clock data is stored in the monitor, the
time is retained even if Computer B is replaced.
When the monitor is replaced, it is necessary to
set the clock again.
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4001B-31
Service Support
Parameter Settings
* The following covers software Version 1.8.7.
Summary
Control parameters can be changed using the monitor.
For example, the time until auto idle is started or the current and speed for work mode can be set.
The items up to the 3rd page of the setting screen can overwrite the parameters changed with the key OFF.
Configuration
The diagram below shows the items that can be checked with each page of the setting screen.
Page Item name Unit Explanation Remarks

min-1
Lo-IDLE ENGINE SPEED Low idle engine speed
(rpm)
AUTO IDLE TIME sec Auto idle time
AUTO IDLE ENGINE min-1
Auto idling speed
SPEED (rpm)
IDLE SHUT DOWN TIME min Idle shut-down time 10 minutes max.
AUTO POWER BOOST Y/N Auto pressure boost function
Milli-amp for pump horsepower control
1 PUMP POWER AT START mA proportional valve (mA); when ATT op-
erations start
PUMP POWER DOWN mA proportional valve (mA); negative offset
amount
Flow control (breaker mode) with en-
REV. LIMIT AT BREAKER Y/N Not currently supported
gine speed
Can only be changed for 20
ENABLE POWER SAVE Y/N Power save function
tons - 29 tons.
Cannot be switched OFF on
ENABLE TRAVEL ALARM Y/N Travel alarm function
North American models
TRV. ALARM-ON TIME sec Travel alarm sounding time Range = 1..30, Step = 1
Previous travel speed data hold func-
MEMORIZE TRV. SPEED Y/N
tion
ENABLE EPF Y/N EPF Yes/No
MPa
2 OVERLOAD PRESS. Overload set pressure
(psi)
MAINTENANCE MES-
Y/N Service due message
SAGE
FORCED DIM. BY W.LAMP Y/N working light linked dimming
AUTO CLOCK ADJUST Y/N For automatic adjustment Not currently supported
TIME DIFFERENCE WITH -
hour Not currently supported
UTC
ITEM-1 Y/N Eco gauge display
ITEM-2 - -
ITEM-3 - -
ITEM-4 - -
3 ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
84551720B NA - August 2012

4001B-32
Service Support
Page Item name Unit Explanation Remarks

ITEM-1 mA
proportional valve (SP_Hi)
ITEM-2 mA
proportional valve (SP_Low)
ITEM-3 mA
proportional valve (H_Hi)
ITEM-4 mA
proportional valve (H_Low)
4
ITEM-5 mA
proportional valve (A_Hi)
ITEM-6 mA
proportional valve (A_Low)
ITEM-7 mA
proportional valve (Min)
ITEM-8 - -
ITEM-9 - -
ITEM-1 Y/N Quick warm-up control ON/OFF
ITEM-2 - Development parameter
5 ITEM-5 - Development parameter
min-1
ITEM-1 Engine speed (SP)
(rpm)
min-1
ITEM-2 Engine speed (H)
(rpm)
min-1
ITEM-3 Engine speed (A)
(rpm)
6 ITEM-4 - -
ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
1. Select an item with the cursor, then input the number with ←→.
2. Decide the selection with the menu switch, then press the menu switch again to leave the screen.
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4001B-33
Service Support
Option Flow Pressure Setting The target command current value is sent from Com-
puter A via CAN communication.
Summary • 2 pumps flow solenoid: Connected to and controlled
Sets the option line flow /pressure. by Computer A.
Sets the breaker/crusher maximum flow and maxi- When this solenoid is ON, if a backup operation is
mum pressure. carried out, 2 pumps flow.
After making the setting, follow the procedure and cor- 2 pumps will not flow if a backup operation is not
rect so that the pressure becomes the set pressure. carried out even if this solenoid is ON.
Configuration • With the X2, the 2 pumps flow switch was installed
• The 1st option, 2nd option pressure switch: Con- on the console as a rocker switch, but with X3, this
nected to Computer A was eliminated.
Used during pressure adjustment to judge whether Instead, this is decided beforehand with the option
or not operation is independent breaker (crusher) line setting screen.
operation. • Option line setting screen items: consists of follow-
• Bucket-close, arm-in, boom-up pressure sensor: ing five items
Connected to Computer B and sent to Computer A 1. Attachment selection,
via the CAN. 2. Breaker No. (or Crusher No.)
Used during pressure adjustment to judge whether 3. Maximum flow setting
or not operation is independent breaker (crusher) 4. Maximum pressure setting
operation. 5. Pressure adjustment
• Oil temperature sensor: Connected to Computer A
Used to judge whether or not the temperature per- For Item 1), when a multi-purpose circuit is set with
mits pressure adjustment. model selection, the maximum pressure settings
• Engine speed sensor: Connected to the ECM and and pressure adjustment items in 4) and 5) are only
recognized by Computer A via the CAN. displayed when pressure adjustment is set with the
Used to judge whether or not the speed permits model selection.
pressure adjustment. • Message displayed on the option line setting screen:
• P1 pressure sensor: Connected to Computer A There is one message display area at the top of the
Used to judge whether pressure is being relieved screen and one at the bottom of the screen.
according to the set pressure. "PRESSURE ADJUSTING INCOMPLETE" or "AD-
• Option line switching solenoid: Connected to and JUST PRESSURE" is displayed in the top message
controlled by Computer A. display area.
When this solenoid is ON, it switches to the breaker "BREAKER OPERATION REQUIRED/CRUSHER
circuit and at the same time that the relief pressure OPERATION REQUIRED", "SET IN SP-MODE",
reaches the breaker setting, the return hydraulic oil "INCREASE ENGINE RPM", "INCREASE OIL
falls directly into the tank through the filter. TEMP.", "ADJUSTING PRESSURE", "PRESSURE
• Pump flow proportional valve: Connected to and ADJUSTING. COMPLETE", PRESSURE ADJUST-
controlled by Computer A. ING INCOMPLETE", or "CHECK FLOW RATE" is
So that the preset maximum flow is not exceeded in displayed in the bottom message display area.
breaker/crusher mode.
• Option relief pressure proportional valve: Con-
nected to Computer B
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4001B-34
Service Support
Operation explanation The icon appears for the model setting only with
flow setting.)
1. The operator enters the option line setting screen Other breakers, 2-5, and crushers, 2-5, are not
from the menu. set.
The system cuts away option line switching sole- When an breaker or crusher is selected that has
noid, pump flow not been set, four hyphens (---) are displayed for
proportional valve, option relief pressure propor- the "SET MAX FLOW" and "SET MAX PRES-
tional valve, 2 pumps flow from normal controls SURE".
and sets to setting mode.
• If the maximum flow and maximum pressure
• There are two ways to enter the option line set- have not yet been set, that breaker or crusher
ting screen. cannot be selected with a work screen.
One is from the menu screen. To put it the other way, everything set here can
The other is by holding down the ATT select be selected with a work screen.
switch for one second. Since the X3 has only one ATT selection switch,
When the former method is used, the ATT when the flow volume is set here for all the
when one enters the option line setting screen breakers or crushers, care is required because
is Breaker 1. (However, if a double-acting cir- selecting the target ATT requires pressing the
cuit is selected with the model selection, it is switch a number of times.
Crusher 1.) * When items that had been set are reset, the
When the latter method is used, the display reset items can no longer be selected.
moves to the currently selected ATT and a
switch guide is displayed on the monitor. (Nor- 4. The operator sets the maximum flow from the
mally, this is from Breaker 1. (However, if "SET MAX FLOW" item and sets the maximum
double-acting circuit is selected with the model pressure from the "SET MAX PRESSURE" item.
selection, it is from Crusher 1).)
• As selection options for the maximum flow, the
2. The operator selects the breaker or the crusher system has available 20 levels for the flow vol-
from the "Attachment selection". (When ume, 10 for without 2 pumps flow and 10 for with
multi-purpose circuit is selected with model se- 2 pumps flow.
lection: For a breaker or crusher, "Attachment • However, the maximum flow depends on the
selection" is not displayed and the selection can- model. Even though 20 levels are displayed
not be changed.) for all models, the flow volumes for the levels
For a breaker, the system sets the item immedi- depend on the model. (See (Number table) flow
ately below to "Breaker No." and for a crusher, adjustment levels below.)
"Crusher No.". • When the flow volume is set, if a stand-alone
At the same time, the system switches the option option operation is executed, the flow propor-
line switching solenoid to ON for a breaker or OFF tional valve command current value is output
for a crusher. to achieve that flow volume. (Breaker mode or
3. The operator selects a number from 1 to 5 with crusher mode processing is executed.)
the "Breaker No. (or Crusher No.)" item. • The range in which the maximum pressure can
The system displays the maximum flow and max- be set depends on the model, but for all models,
imum pressure corresponding to that number the settings are made in increments of 0.5 MPa
in the two items immediately below "SET MAX (72.527 psi). (See (Number table) pressure ad-
FLOW" and "SET MAX PRESSURE". justment range below.)
• No maximum pressure can be set that exceeds
• The factory setting is that the maximum flow and the relief valve pressure setting range.
maximum pressure setting are only for Breaker
• When an item that had been set is reset, four
1 and Crusher 1. hyphens (---) are displayed for either the "SET
(* The pressure is not adjusted, so for pressure MAX FLOW" or the "SET MAX PRESSURE"
adjustment model setting, the icon does not ap- and when you exit the options adjustment
pear even if the ATT select switch is pressed.
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4001B-35
Service Support
screen, the information that had been set is • During adjustment, if any operation other than
reset. breaker (crusher) operation is done, the sys-
• If the pressure adjustment is not selected with tem stops the adjustment, displays "BREAKER
the model selection, the option flow setting ends OPERATING REQUIRED" on the monitor, and
after just setting the maximum flow. waits for operation of the breaker (crusher) in-
• When multi-purpose circuit is selected with dependently.
model selection, when the flow volume for 2
7. The operator continues operating the breaker
pumps flow is set with breaker mode, "CHECK
(crusher).
FLOW RATE" is displayed on the monitor.
The system waits for the pressure to stabilize for
Once that flow volume is decided, the "CHECK
2 sec., then starts the adjustment.
FLOW RATE" display goes out.
The system continues to compare the actual P1
5. When the operator has changed the maximum pressure and the target set pressure and when
flow or maximum pressure, the system redoes the the difference between them is no more than 0.5
option relief pressure proportional valve adjust- MPa (72.527 psi) (*) continuously for at least 5
ment again. sec., it judges the adjustment to be complete.
The system displays "ADJUST PRESSURE" on The system displays "PRESSURE ADJUSTING.
the monitor. COMPLETE" on the monitor and puts out the
6. The operator checks that the work mode is SP "PRESSURE ADJUSTING INCOMPLETE" dis-
and that the oil temperature is 30 °C (86.0 °F) play.
minimum and operates the breaker (crusher).
The system displays "ADJUSTING PRESSURE" • During adjustment, the system updates the op-
tion relief pressure proportional valve current
on the monitor.
every 500 ms in increments of 5 mA.
At the same time, the "PRESSURE SETTING"
and "CURRENT PRESSURE" items are dis- • If the pedal continues to be held down even after
the setting value is finalized, the setting value is
played.
updated every 5 sec..
• When the operator stops the operation, the dis- • If the pressure adjustment does not end within
play returns to "BREAKER OPERATION RE- 30 sec., "PRESSURE ADJUSTING INCOM-
QUIRED". PLETE" is displayed on the monitor.
• When the work mode is not SP, "SET IN
8. When the operator presses the menu switch to
SP-MODE" is displayed instead of "ADJUST-
exit the option line setting screen, the system
ING PRESSURE".
stores the settings into memory.
• During one-touch idle or while the engine is
stopped, "INCREASE ENGINE RPM" is dis- • If the setting screen was entered from the menu
played instead of "ADJUSTING PRESSURE". screen, the display returns to the menu screen.
• When the operator operates in SP mode, if the If the setting screen was entered from the
oil temperature is less than 30 °C (86.0 °F), main screen by holding down the ATT select
"INCREASE OIL TEMP." is displayed instead of switch for 1 sec., the display returns to the main
"ADJUSTING PRESSURE". screen.
At the same time, the "TARGET OIL TEMP." and
"CURRENT OIL TEMP." items are displayed.
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4001B-36
Service Support
Screen Brightness Setting 2. Working Light ON: The monitor brightness is re-
duced and the display changes automatically to
<Summary> the "Brightness (night)" setting.
Decides the brightness of the backlight through oper- 3. Brightness settings: "Brightness (day)" and
ation that is linked to the working light and solar radi- "Brightness (night)" can be set on the menu
ation sensor. screen.
<Operation explanation> 4. Dimming by solar radiation sensor: When the
The screen brightness can be selected on the menu working light-linked dimming is set OFF on the
screen. menu screen, the dimming level is adjusted au-
Dimming setting can be changed on the service tomatically to the ambient brightness by the solar
screen. radiation sensor.
1. Working Light OFF: Normal (with key ON),
"Brightness (day)" setting
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4001B-37
Service Support
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4001B-38
Section
4001C
Function, Structure, Operation
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CONTENTS
Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


1. Engine number
1 Engine number stamping
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4001C-3
2. Function, Structure, Operation

1) Engine structural diagram
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4001C-4
2) Description of functions and operations

Engine electronic control
The control provided by the control unit applies to the range from injection to air intake and exhaust in-
cluding fuel injection amount, injection timing, air intake restriction, EGR and idling speed.
Cylinder block
The cylinder block is made of cast iron, and it has the equal center distance for each bore and a high
rigidity, and the center of the crankshaft matches the center of the block.
The bearing cap has the ladder frame structure, and is tightened using the plastic region rotational angle
tightening method.
Cylinder liner
The cylinder liner is selected in accordance with the inner diameter of the cylinder block bore, and its
identification number is stamped on the left side of the cylinder.
Piston
The piston is a strut cast autothermatic piston made of aluminum alloy, and the combustion chamber is
the round re-entrant type.
Cylinder head
The cylinder head is made of cast iron, and has four valves per each cylinder.
The angle tightening method has been adopted to the cylinder head bolt to further improve its reliability
and durability.
Crankshaft
The tufftrided steel is being used, and the grade of each journal diameter is engraved on the No.1 balance
weight.
EGR system
The EGR system is controlled by the engine control module (ECM) according to various data including
the water temperature, engine RPM, and engine load to recirculate the exhaust gas for purification.
The primary components are the EGR valve, EGR cooler, and various sensors.
Connecting rod cap bolt
The angle tightening method has been adopted to the connecting rod cap bolt to further improve its reli-
ability and durability.
Common rail type electronic control injection system
The common rail type electronic control injection system consists of the supply pump that sets the target
pressure of high-pressure fuel to supply the fuel, the common rail that measures the high-pressure fuel
and the fuel injector that injects the fuel in the form of a fine mist.
Each of these are controlled by the ECM based on various signals to control the injection timing and
injection amount in accordance with the working condition.
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4001C-5
Fuel injector
The fuel injector has adopted the 7-hole nozzle, and adjusts the fuel injection amount and injection timing
by opening or closing the electromagnetic valve on the injector head portion.
The ECM corrects variation in the fuel injection amount from fuel injector to fuel injector in accordance
with the ID code data in the memory.
When adjusting the fuel injector, the ID code date must be recorded in the ECM.
Fuel filter with sedimenter
The fuel filter with sedimenter removes the water by using the difference in the relative density between
diesel oil and water, and notifies the operator through the indicator when it becomes full of water.
Preheat system
The preheat system consists of the ECM, glow relay, glow plug and glow indicator light.
The preheat system is activated when the engine coolant temperature is low to help engine start.
Lubricating system
It uses and oil filter with a full-flow bypass, and cools down the pistons using the water-cooled oil cooler
and the oil jet.
DPD
An integrated DPD oxidation catalyst is installed for reducing exhaust gas.
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4001C-6
3) Fuel system
Fuel system diagram
1 Electromagnetic pump 4 Fuel injector 7 Fuel return pipe

2 Fuel filter 5 Supply pump 8 Pre-fuel filter
3 Common rail 6 Fuel tank
CAUTION
• Since the high-precision fuel system has been adopted, take care to prevent any foreign
matter from entering the fuel system.
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4001C-7
Common rail
1 Pressure sensor
2 Pressure limiter
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4001C-8
Fuel supply pump
1 Fuel temperature sensor 4 Camshaft key 7 Joint bolt

2 Suction control valve 5 Camshaft nut
3 High pressure pipe 6 Union
CAUTION
• There is a gauze filter assembled inside the union of the fuel supply pump, but the union
should not be removed to prevent any foreign matter from entering.
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4001C-9
1 Union
2 Gauze filter
3 Supply pump
4 Strainer
5 Joint bolt
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4001C-10
Injector
1 ID plate
2 Terminal stud
3 Injector drive section
4 Injector assembly
5 Gasket
6 O-ring
Leak-off pipe installation sec-
7
tion
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4001C-11
Fuel filter
1 Priming pump
2 Plug
3 Case
4 Drain plug
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4001C-12
4) Cooling system
The coolant system is the forced-circulation system, and its main components are the water pump, thermo-
stat and radiator.
1 Water jacket 7 Cooling fan 13 Thermostat, 2 units

2 Drain plug 8 Radiator cap 14 Water temperature sensor
3 Oil cooler 9 Heater core 15 Bypass route
4 Water pump 10 Radiator reserve tank 16 Turbocharger
5 Drain cock 11 Air removal plug 17 EGR cooler
6 Radiator 12 Water outlet pipe
Water pump
The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.
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4001C-13
1 Fan guide 3 Impeller

2 Bearing 4 Seal unit
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4001C-14
Thermostat
The thermostat is the wax pellet type, and consists of 2 units.
One unit is the bottom bypass type and its initial open valve temperature is 82°C {185 °F}, and the other
unit is the inline type and its initial open valve temperature is 85°C {185 °F}.
The structure allows the water temperature to be fine adjusted, and it is assembled inside the thermostat
housing unit.
1 Jiggle valve 3 Valve 5 Piston

Stamp mark (initial open valve
2 4 Gasket
temperature)
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4001C-15
5) Lubrication system
A full-flow bypass integrated filter element, water cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.
*1 Delivery Valve *9 Oil Cooler *17 Conn-rod Bearing

*2 Oil Port *10 Thermo Valve *18 Oiling jet
*3 Full Flow Oil Filter *11 Oil gallery *19 Oil pump
*4 Oil pressure switch *12 Valve Mechanism *20 Strainer
*5 Oil Pressure Indicator Lamp *13 Crankshaft Bearing *21 Flywheel P.T.O
*6 Fuse *14 Crank Valve *22 Turbochager
*7 Starter Switch *15 Relief Valve *23 Engine Oil Pan
*8 Battery *16 Gear Train
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4001C-16
Oil pump structural diagram
1 Driven gear assembly 4 Oil pump drive gear 7 Driven gear assembly
2 Oil pump body 5 Oil pump body 8 Oil pump drive gear
3 Drive gear assembly 6 Drive gear assembly
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4001C-17
6) Induction system Turbocharger structural diagram
1 Connector 4 Turbine housing 7 Coolant outlet

2 Rod 5 Exhaust adapter 8 Oil outlet
3 Oil inlet 6 Coolant inlet 9 Compressor housing
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4001C-18
7) Exhaust system
1 DPD assembly 3 Exhaust temperature sensor 2

2 Exhaust temperature sensor 1 4
sor
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4001C-19
8) Emission control device

EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and the generation of NOx
is suppressed.
By controlling the EGR system, high operability and exhaust gas reduction are both achieved.
The control current from the ECM activate the solenoid to control the EGR valve lift amount.
The EGR position sensor detects the actual valve lift amount and the data is used for precise control of
the EGR amount.
The EGR operates when the engine RPM, engine coolant temperature, intake temperature, and atmo-
spheric pressure satisfy certain criteria.
Thereafter, the valve opening angle is calculated according to the engine RPM and the desired fuel injec-
tion amount.
The calculated valve opening angle is used to determine the motor drive duty and the valve is driven
accordingly.
The intake throttle valve closes when the EGR operates to ensure an appropriate internal pressure of the
intake manifold.
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4001C-20
*1 Intake throttle position sensor *7 Engine speed *13 Exhaust

*2 EGR valve *8 Engine load *14 Intake throttle valve
*3 EGR position sensor *9 Outlet port of coolant *15 Boost temperature sensor
*4 ECM *10 Inlet port of coolant *16 Boost sensor
*5 IAT/MAF sensor *11 EGR cooler
*6 Intake air *12 IMT sensor
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4001C-21
9) Electrical system
Charging system
The main components of the charging system are the battery, generator, and battery discharge indicator
light circuit.
Generator is a self-rectifier type with a regulator built in.
Generator
The generator is the brushless type.
The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator,
bearing, pulley, etc.
The moving parts are the rotor and pulley.
The field coil is fixed to the rear bracket.
6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated
in the stator coil to a direct current.
3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode.
In addition, 3 small diodes that are referred to as trio-diode are used to supply the field current.
This generator has 3 terminals of B terminal (direct current output terminal), L terminal and R terminal.
Since the L terminal is connected to the field coil, it works as an input terminal together with the R terminal
until the generator starts generating power.
Also, it functions as an output terminal. (current capacity is 1 A)
When the L terminal voltage reaches the battery voltage, the charge light turns off.
Since the both bearings are sealed, periodic lubrications are not required.
The IC regulator cannot be disassembled, so it should be handled as an assembly.
1 Rectifier 5 Pulley 9 Regulator

2 Field coil 6 Front bracket 10 Bearing
3 Stator 7 Rotor
4 Bearing 8 Rear bracket
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4001C-22
Starter system
The starter is 5 kW and uses a reduction type.
Gear housing and armature end bearing housing are made of aluminum.
Brush assembly is an replaceable type.
Starter circuit is started using a battery.
The battery cable is connected to a large terminal on the starter.
The wiring is connected from the terminal to the engine control switch and the starter relay.
Starter
The starter is an outer gearing mesh method reduction starter adopting the magnetic shift type.
When the starter switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch
closes and the armature rotates.
At the same time, the pinion is pushed to the front via the shift lever to mesh with the ring gear.
When the ring gear rotates, the crankshaft is turned to start the engine.
After the engine is started, the plunger returns, the pinion separates from the ring gear, and the armature
stops rotating when the starter switch is turned OFF.
When the engine rotation becomes faster than the pinion, the pinion is caused to turn in reverse, but the
pinion just idles due to the one-way clutch function, so the armature is not driven.
1 Lever assembly 4 Armature 7 Clutch

2 Magnetic switch assembly 5 Brush holder 8 Pinion
3 Yoke 6 Internal gear
Preheat system
The preheat system has adopted the QOS system glow plug type.
Also, the energization control is performed by the ECM.
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4001C-23
10) Engine control system

Engine control system overview and implementation
The engine control system is an electronic control system that controls the engine to be always in the
optimal combustion state according to the driving condition, and consists of the electronic control fuel
injection system, EGR, and idling control.
Also, besides controlling the engine, the engine control system has the QOS system, engine RPM sig-
nal output, self-diagnosing function, and CAN communication SAE J1939/21 and SAE J1939/11 system
control functions.
System control schematic
The specifications vary depending on the actual unit, so refer to the manual of the actual unit.
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4001C-24
Correction
Engine coolant temperature
correction
Barometric Pressure
a Fuel temperture boost pres-
sure correction
Correction between sylinders
Q-key correction
QR correction
Accelerator position sensor in- SCV opening time determina-

*1 *8 *15 SCV
put tion
Injector coil energizing time
*2 Boost sensor input *9 *16 Supply pump
Timing determination
*3 CKP sensor input *10 CAN communication *17 Fuel tank
*4 CMP sensor input *11 Machine control unit *18 Injector coil
*5 Engine control module (ECM) *12 Water temperture sensor input *19 Injector
*6 Basic fuel injection amount *13 Common rail pressure sensor
*7 Correction *14 Common rail
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4001C-25
Fuel injection correction

The ECM calculates the basic injection amount based on the signals from the accelerator position sensor,
boost sensor, crankshaft position sensor, camshaft position sensor, etc.
At this time, the open or close timing of the SCV and the energizing time of the injector are controlled
based on the conditions such as the common rail pressure and engine coolant temperature to make
optimal corrections to the injection timing and injection amount.
About initial Q correction
ECM implements the initial Q correction when the initial Q correction is under the specified engine rotation
during engine start.
Also, ECM cannot implement the initial about initial Q correction and cannot start the engine because it
does not recognize the engine rotation when it is under the engine rpm the system can recognize.
Engine speed [ min-1 ( r/min ) ]
*1 Idle speed
Starting Q specified engine
*2
speed
*3 Minimum firing engine speed
System realization engine
*4
speed
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4001C-26
About high altitude correction

ECM calculates the current altitude using signals from the atmospheric pressure sensor.
According to the conditions such as the current altitude, the fuel amount is corrected properly.
Fuel flow limit (mm3/st)
Barometric pressure kPa (psi)
*1 Highland
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4001C-27
Control during overheat

To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100
°C {212 °F}.
When the engine coolant temperature increases further, the fuel flow is also restricted further.
When the temperature reaches 110 °C {230 °F}, a failure is recorded in the ECM.
When the temperature is near 120 °C {248 °F}, the fuel flow is restricted to a certain level.
The setting varies depending on the actual unit manufacturer.
The actual unit is designed to issue an alarm from 105 °C {221 °F}.
By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation
condition with fuel flow restriction.
Fuel flow
Water temperature
*1 Warning indication DTC set
If the ECM is equipped with an emergency stop function by a high engine coolant temperature, it stops
the engine when the temperature has reached 105 °C {221 °F}.
Fuel flow
Water temperature
*1 Engine emergency stop
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4001C-28
Engine emergency stop function

The ECM is designed to make an emergency engine stop when an input from the engine stop switch,
decrease in the engine oil pressure, increase in the engine coolant temperature or overrun occurs.
As for emergency stop made due to decrease in the engine oil pressure, increase in the engine coolant
temperature or overrun, the control is performed when the corresponding function is added to the calibra-
tion of the ECM.
Input from engine stop switch
The engine stops when the battery voltage is applied to the ECM terminal No.121.
*1 Engine stop switch

*2 Starter switch (ON)
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4001C-29
Decrease in engine oil pressure

When the engine oil pressure drops to 100 kPa {1.02 kgf/cm2 / 14.51 psi} or lower, an alarm for engine
oil pressure decrease is issued and the engine is stopped.
Increase in engine coolant temperature
When the engine coolant temperature increases to 105°C {221 °F} or higher, an alarm for engine coolant
temperature increase is issued and the engine is stopped.
Overrun
When the engine RPM reaches to the specified value, an alarm for overrun is issued and the engine is
stopped.
It varies depending on the actual unit manufacturer.
I/O Table
Sensor input Injection control output

• CKP sensor • Suction control valve
• CMP sensor • TWV (injector)
• Water temperature sensor
• Fuel temperature sensor Actuator control output
• IAT sensor
• IMT sensor • EGR DC motor
• Fuel pressure sensor • Intake throttle motor
• Boost temperature sensor
• Barometric pressure sensor Relay, lamp control output
• Accelerator position senser
• EGR position sensor • Glow relay
• Intake throttle position sensor • Starter cut relay
• DPD differential pressure sensor • ECM main relay
• Exhaust temperature sensor • Hour meter relay
(1: in front of filter, 2: in front of oxidation catalyst) • Diagnosis lamp
• Boost sensor • Glow lamp
• Oil pressure sensor ECM • Engine hydraulic lamp
• MAF sensor • Boost temperature sensor pilot
• Fuel sensor lamp
• Overheat lamp
• Engine overrun lamp
Switch input
• DPD regenerate lamp
• Starter switch (ON/start) • Fuel temperature lamp
• Diagmostic swich • Fuel filter pressure lamp
• Idling control selector switch • DPD lamp
• Idling control switch (UP/Down)
• Mode map switch 0
• Mode map switch 1
• Mode map switch 2 Communication
• Reguration mode switch
• Load advance switch • Speed signal
• SCV switch • Diagnostic scan tool
• Memory clear switch • CAN (ECU on machine side)
• Engine stop switch
• DPD switch
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4001C-30
Electronic control fuel injection system

This is the system in which the ECM obtains information such as the engine RPM and engine load and
sends the electrical signals based on the information to the supply pump, injectors, etc.to properly control
the fuel injection amount and injection timing for each cylinder.
Injection amount control
To make the injection amount optimal, the fuel injection amount is controlled by regulating the injector
based on mainly the signals from the engine RPM and accelerator opening angle or the instructed rotation
from the control unit in the actual unit.
・Boost Press.
a ・Coolant Temp,
・Barometric Press.
Maximum Fuel Injection Quan- Fuel Injection Quantity Correc-

*1 Accelerator Pedal Position *4 *7
tity tion
Injector ON Time Determina-
*2 Engine Speed *5 Reduction Rate *8
tion
*3 Basic Fuel Injection Quantity *6 Final Fuel Injection Quantity *9 Cylinder by Cylinder Correction
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4001C-31
Injection pressure control

The injection pressure is controlled by regulating the fuel pressure inside the common rail.
The proper pressure inside the common rail is controlled by calculating from the engine RPM, fuel injection
amount, etc., and the appropriate amount of the fuel is discharged by regulating the supply pump to be
force-fed to the common rail.
Injection timing control
This control is performed by calculating the proper fuel injection timing mainly from the engine RPM or
injection amount in substitution for the timer function to regulate the injector.
Injection rate control
To improve combustion inside the cylinder, only a small amount of the fuel is injected first to be ignited,
and then the second injection is performed when ignition is made.
This control for injection timing and injection amount is performed through regulating the injector.
Maximum fuel injection amount
The maximum fuel injection amount is the amount of fuel injection calculated by adjustment of initial in-
jection amount under certain water temperature, limitation of maximum injection amount for the boost
p ressure, and control of injection amount for the high altitude due to the atmospheric pressure.
Inter-cylinder correction
It is not used for this engine.
System schematic
Each sensor
a Accelerator, Boost, Water
temperature, etc.
*1 Electromagnetic pump *5 Fuel pressure sensor *9 CMP sensor

*2 Fuel filter *6 Common rail *10 CKP sensor
*3 Pre fuel filter *7 Pressure limiter *11 ECM
*4 Supply pump *8 Injctor *12 Fuel tank
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4001C-32
Fuel system
The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before
supplied to the common rail.
At this time, the fuel amount to be supplied to the common rail is controlled by regulating the suction
control valve based on the signal from the ECM.
1 Electromagnetic pump 4 Fuel injector 7 Fuel return pipe

2 Fuel filter 5 Supply pump 8 Pre-fuel filter
3 Common rail 6 Fuel tank
Fuel filter clog warning function and engine RPM restriction function
When the clogged fuel filter is kept used, the ECM detects DTC P0093, and the output restriction is im-
plemented.
The first stage
In order to notify a filter clogging before DTC P0093 is detected, the first stage alarm is issued when the
output value from the fuel filter pressure sensor falls below the specified threshold value.
The alarm stops when the output value exceeds the threshold value.
The second stage
The second stage alarm is issued when the output value from the fuel filter pressure sensor falls below
the threshold value even after the first stage alarm occurs.
The second stage alarm remains as issued until the starter switch is turned OFF.
At the same time as the second stage alarm is issued, the target engine RPM is reduced gradually at a
constant rate.
When the output value from the sensor exceeds the specified threshold value, reduction of the restricted
engine RPM is stopped, and the regulation is continued maintaining the restricted engine RPM at that
time.
When the output value from the sensor falls below the threshold value again, the restricted engine RPM
is reduced further.
When the starter switch is turned OFF and then turned back ON, the restriction is once cancelled.
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4001C-33
1 Supply pump
2 Warning light
3 Monitor
4 Monitor, CAN communication
5 Fuel tank
6 Pre-filter
7 Electromagnetic pump
8 Fuel filter pressure sensor
9 Main filter
1 First stage
2 Second stage
*1 Lamp
*2 Starter SW
*3 Engine Speed [ min-1 ( r/min ) ]
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4001C-34
Removing air from fuel system

Place an appropriate pan under the air removal plug.
Turn the starter switch ON, and activate the electromagnetic pump.
Loose the air removal plug of the fuel filter sufficiently, and operate the priming pump 20 times or more
until the fuel comes out from near the plug.
Tighten the plug, and operate the priming pump 10 times or more until the fuel permeates.
Wait for approx.
1 minute, and then loosen the plug to remove the air in the fuel filter.
This should be repeated at least 3 times until no air comes out from the plug.
Securely tighten each plug, and wipe off the fuel spilled around.
Operate the priming pump 10 - 15 times until the fuel permeates and then is fed to the engine.
a On the machine with electro-

magnetic pump
*1 Pre fuel filter

*2 Electromagnetic pump
*3 Fuel filter
*4 Supply pump
*5 Fuel tank
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4001C-35
EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas
to the intake air, the combustion temperature is lowered and the generation of NOx is suppressed.
The EGR amount is controlled by opening and closing the EGR valve provided between the exhaust
manifold and intake manifold.
The EGR amount is determined from the engine RPM and engine load ratio and the EGR valve is operated
to control the EGR amount.
By installing the EGR cooler on the path of the EGR gas, high-temperature gas is cooled by the EGR
cooler and then mixed with fresh air to further lower the burning temperature in order to reduce NOx
amount.
Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the
opposite direction to increase the EGR amount.
EGR control
The ECM controls the EGR valve lift amount by operating the motor according to the engine status such
as the engine RPM and engine load.
The valve lift amount is detected by the EGR position sensor.
Darker portions in the diagram represent large valve lift amounts and the darkest portion represents the
lift amount of nearly 100 ％.
Accelerator position
Engine speed
*1 No idle EGR
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4001C-36
EGR system schematic diagram
*1 Intake thottle position sensor *7 Engine speed *13 Exhaust

*2 EGR valve *8 Engine load *14 Intake throttle valve
*3 EGR position sensor *9 Outlet port of coolant *15 Boost temperature sensor
*4 ECM *10 Inlet port of coolant *16 Boost sensor
*5 IAT/MAF sensor *11 EGR cooler
*6 Intake air *12 IMT sensor
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4001C-37
EGR and turbine noise

Some engines may generate high frequency noise due to the turbine rotation.
This high frequency noise can be muted using an appropriate silencer.
For some OEMs which use in residential areas is not assumed, the silencer for muting the high frequency
noise may be omitted from the specifications, leaving the noise.
The high frequency noise tends to become lower while controlling the EGR and louder when EGR control
is not provided.
*1 Without EGR
*2 Wiht EGR
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4001C-38
Turbocharger control
The turbocharger is a system that provides efficient supercharge to archive the turbo effect by overcoming
the turbo’s weakness of low exhaust energy during low engine revolution.
The turbocharger optimizes the turbine revolution by varying the nozzle opening angle within the turbine
housing to adjust the turbo inlet area according to the revolution and load of the engine and control the
supercharging pressure.
The ECM sends the target nozzle opening angle based on the information from each sensor to the turbo
control unit through CAN communication to control the boost pressure properly in accordance with the
engine load requirements.
The turbo control unit drives the turbo actuator based on the information received from the ECM and
controls the nozzle vane through the control rod.
The turbo actuator has a position sensor installed.
The turbo control unit performs feedback control based on the information from the position sensor, etc.
The actual nozzle opening angle is determined at this time, and the nozzle vane opening angle is optimally
adjusted through the nozzle control rod.
*1 Turbine wheel
*2 Nozzle
*3 Turbo actuator
*4 Exhaust gas inlet
*5 Control rod
*6 Exhaust gas outlet
*1 Engine control module (ECM) *5 CAN-H *9 Turbo motor

*2 ECM *6 CAN-L *10 Turbo position sensor
*3 POWER *7 Turbo control unit
*4 GND *8 Turbo actuator
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4001C-39
Turbo actuator activation

The actuator is activated based on the signal from the turbo control unit to move the nozzle control rod.
The nozzle vane operates the nozzle control rod through the operation plate.
a The gap is narrow

b The gap is wide
*1 At low engine RPM *3 Nozzle vane *5 Turbo actuator

*2 At high engine RPM *4 Nozzle control rod *6 Unison ring
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4001C-40
Engine operation control

There are the following 4 types of operation control instructions, and the selection varies depending on
each specification.
Voltage input by APS, 1 - 4 V
Accelerator opening angle instruction given through CAN communication control, 0 - 100 ％, RPM in-
struction RPM instruction given through mode map switch control, RPM instruction and change instruc-
tion given by APS
Increase and decrease instruction for each rotation given by the idle switch
Mode map switch
The mode map switch has 6 rotation control mode types of H, S, L, B, I and LM.
The rotation settings are H > S > L > B, I > LM.
For H, S, L and B, the rotation speed can be decreased by the APS, but any change cannot be made
from the APS for I and LM.
When the regulation mode switch input is present in addition to the mode map switch, the following 2
types of control methods are available.
H, S, L and B of the mode map switch change as follows depending on the APS input.
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4001C-41
Meaning of mode map switch and each mode In the APS, a change toward the engine RPM decrease
direction can be made from each mode point.
The specified engine RPM for H, S, L and B are determined depending on the calibration of the ECM.
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4001C-42
CAN communication
When CAN controller does not exist on the actual unit side
*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 LCD
*5 TCM
*6 Shift Control
When CAN controller exists on the actual unit side
*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 TCM
*5 Shift Control
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4001C-43
Mode map switch control
*1 Accelerator position sensor *5 Idle down switch *9 Reguration mode switch

*2 Engine stop switch *6 Mode map switch 0 *10 Load advance switch
*3 Idling selector switch *7 Mode map switch 1
*4 Idle up switch *8 Mode map switch 2
Outer switch
Operation mode Control
MAP0 MAP1 MAP2
OFF OFF OFF
H OFF ON ON Basic operations
ON ON ON
S ON OFF OFF Maximum rotation count control #1
L OFF ON OFF Maximum rotation count control #2
I OFF OFF ON Constant rotation operation #1
B ON ON OFF Maximum rotation count control #3
LM ON OFF ON Constant rotation operation #2
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4001C-44
I, LM and H modes
*1 Regulation mode switch

*2 Idle speed
*3 Max. speed
H, S, L, and B modes
*1 Idle speed
*2 Max. speed
H, S, L, and B modes (irrigation pump)
*1 Idle speed
*2 Max. speed
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4001C-45
Accelerator position switch

By operating the accelerator position switch, the output voltage changes between 1 V and 4 V.
Voltages between 0.2 V and 1.05 V are recognized as 1 V.
When the voltage is lowered below 0.2 V or raised above 1.05 V, an error is detected.
In addition, if the ECM terminals 85 and 86 are not at the same potential, DTC P2138 is detected.
Accelerator pedal position sen-

*1
sor
Accelerator position switch, with APS learning control If the APS learning control is available, for example,
when the ignition cycle ends with the accelerator position as 2 V (1), the accelerator position learning
causes the 2 V status to be recognized as the opening angle 0 ％ and the control range is set to 2 V to 4
V (2).
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4001C-46
Regulation mode switch

When an input from the regulation mode switch is present, the engine RPM changes as follows.
*1 Regulation mode switch
Idling control
By operating the idling control change switch during the warm-up operation, the minimum idling RPM can
be adjusted.
In addition, by operating the idling control change switch, the minimum idling RPM can be automatically
set to the optimum value in accordance with the engine coolant temperature.
ANNOTATION:
• The specifications vary depending on the actual unit, so availability of functions also differ.
Idling control change switch
By operating the idling control change switch, the idling control functions can be switched.
The idling control switch
By operating idling control switch, the idling RPM can be adjusted.
ANNOTATION:
• As for the installation positions of the idling control change switch and idling control switch, refer to the
manual of the actual unit.
The engine RPM upper limit varies depending on the engine model, actual unit specifications and en-
gine warming-up condition.
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4001C-47
Up
While the Up side of the switch is pressed, the engine RPM is increased and the idling RPM can be raised.
Down
While the Down side of the switches is pressed, the engine RPM is decreased and the idling RPM can
be lowered.
However, the engine RPM cannot be decreased below the minimum idling RPM.
Control during starter switch OFF state
There are 2 types of controls provided when the starter switch is turned OFF after the idling control switch
is operated, and either one of them is performed depending on the specification.
The engine RPM adjusted by the idling control switch is recorded in the ECM, and the next operation is
performed with the engine RPM at the time when the starter switch is turned OFF.
The engine RPM adjusted by the idling control switch is not recorded in the ECM, and the next operation
is performed with the default engine RPM.
As for confirmation and questions regarding the specifications, contact an Isuzu service related person.
Idle manual control
*1 Starter switch *3 Idle down switch

*2 Idle up switch *4 Engine speed
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4001C-48
Engine RPM output to tachometer

The ECM outputs the engine rpm pulse to the tachometer as a tachometer output.
The tachometer displays the engine RPM based on the engine RPM pulse sent from the ECM.
a Output from machine control

unit by machine
*1 CKP sensor *4 CAN communication *7 Tachometer

*2 Engine speed *5 Control unit on machine side
*3 Engine control module (ECM) *6 Tachometor output
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4001C-49
Preheat control
QOS system
The ECM determines the glow time according to the engine coolant temperature, and activates the glow
relay and the QOC indicator light..
The QOS system is a system to facilitate engine start in a low temperature as well as reducing the
amount of white smoke and noise generated immediately after engine start.
When the starter switch is turned ON, the ECM detects the temperature of the engine coolant based
on the signal sent from the water temperature sensor to change the glow time, so the engine can be
always started under the optimum conditions.
Also, the after-glow function can stabilize the idling immediately after engine start.
a LCD or Lamp
*1 Starter switch (ON) *4 QOS indicator lamp *7 Glow plug

*2 Battery *5 (ECM)
*3 Glow relay *6 Water temperature sensor
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4001C-50
DPD
DPD uses the oxidation catalyst to clean NOx and HC, and uses a dedicated filter to collect PM emitted
from the engine.
When PM has accumulated on the filter, the filter regeneration is performed.
The ECM detects the accumulation status of PM from the DPD differential pressure sensor or mileage.
When the accumulated amount of PM or mileage has reached a certain value, automatic regeneration
of the filter is performed.
During regeneration, the filter is heated up to burn the accumulated PM.
To adjust the burning temperature to the optimum value, the ECM detects the exhaust temperature
using the the exhaust temperature sensor and control fuel injection to raise the temperature to burn the
accumulated PM.
When regeneration has started, it must complete within a certain period of time.
After regeneration has completed, the purification status of the filter can be determined by checking the
exhaust differential pressure.
When excessive amount of accumulated PM has been detected, regeneration is not performed because
burning cannot be controlled, but the check engine warning light is turned ON instead.
1 Engine 5 ECM 9 Oxidation catalyst

2 MAF sensor 6 DPD switch 10
sor
3 Air cleaner 7 Silencer 11
sor
4 Various sensors 8 Filter
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4001C-51
ECM
About ECM function
The ECM constantly monitors the information sent from various sensors, and controls the each system
of the powertrain.
The ECM performs the diagnostic functions of the system, detects operational problems of the system,
warns the operator via the monitor, and records the DTC.
The DTC identifies the area where the problem has occurred to assist the repair operation performed
by the technician.
The ECM outputs voltages (e.g., 5 V) to supply power to various sensors and switches.
The ECM controls the output circuit by controlling the ground or power supply circuit via one of the
devices.
ANNOTATION:
• As for the ECM installation position, refer to the manual of the actual unit.
ECM and components

The ECM is designed to maintain regulation levels of exhaust gases while obtaining excellent fuel effi-
ciency.
The ECM monitors various engine functions via the sensors such as the crankshaft position sensor.
ECM voltage
The ECM applies the standard voltage to various switches and sensors.
The ECM is able to apply voltage in such a way because the ECM resistance value is very high.
The voltage that is actually applied to the circuit is low.
Therefore, the test light may not illuminate even if it is connected to the circuit.
The voltmeter that is normally used at maintenance factories may not display a correct reading because
its input impedance is too low.
An accurate voltage reading can be obtained by using a digital multimeter with an input impedance of
10MΩ (for example, 5-8840-2691-0).
Electrically Erasable Programmable Read Only Memory, EEPROM
EEPROM contains various programs and calibration information necessary for the ECM to control the
power train operations.
If abnormalities are found with the EEPROM, replace the ECM.
The program and calibration information for the ECM power train control includes the engine type, en-
gine number, ECM part number, DTC, inter-cylinder correction learning value, QR, Q tune, and EGR
correction learning value.
Notes on ECM maintenance
The ECM has been designed to withstand the regular current consumption associated with the actual
unit operation.
Make sure that the circuit does not overload.
When performing tests for an open circuit or short circuit, do not ground or apply voltage to the circuit
of the ECM, unless otherwise instructed.
When performing these circuit tests, make sure to use the digital multimeter 5-8840-2691-0.
ANNOTATION:
• Use the ECM which has the part No. corresponding to the actual unit.
When performing welding work on the actual unit, start the work after disconnecting the negative
terminal of the battery.
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4001C-52
Turning OFF of the ECM power supply

In approximately 10 seconds after turning the starter switch to OFF, the internal power supply of the ECM
is not turned to OFF.
When it is necessary to turn OFF the ECM power supply, e.g., when clearing the memory, it is required
to wait for 10 seconds or longer after turning the starter switch OFF.
*1 Starter switch ON
*2 Starter switch OFF
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4001C-53
Engine components location diagram

Locations, shapes and existence or nonexistence of components vary depending on the specifications of
the actual unit.
1 Overheat switch 6 IMT sensor 11 Fuel pressure sensor

2 Water temperature sensor 7 Boost temperature sensor 12 EGR valve
3 Glow plug 8 Fuel temperature sensor 13 CMP sensor
4 Injector 9 Suction control valve 14 Oil level switch
5 Boost sensor 10 Oil pressure sensor 15 CKP sensor
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4001C-54
Supply pump
The supply pump highly pressurizes the fuel using the engine torque, and force-feeds the fuel to the
common rail.
Also, the suction control valve, fuel temperature sensor, feed pump, etc, are installed on the supply pump.
1 Suction control valve

2 Fuel temperature sensor
3 Feed pump
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4001C-55
Suction control valve

The suction control valve is installed on the supply pump portion, and controls the fuel force-feed to the
common rail.
The ECM controls the fuel discharge amount by regulating the energizing time to the suction control valve.
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4001C-56
Fuel temperature sensor

The fuel temperature sensor is installed on the supply pump, and the thermistor changes the resistance
value according to the temperature change.
The resistance value becomes lower when the fuel temperature is high, and it becomes higher when the
fuel temperature is low.
The ECM applies 5 V to the fuel temperature sensor through the pull-up resistor, and it calculates the fuel
temperature from changes in the voltage and uses it for controlling the supply pump, etc.
The voltage becomes lower when the resistance is lower, and it becomes higher when the resistance is
higher.
ANNOTATION:
• Do not replace the fuel temperature sensor.
When an abnormality is found, replace the supply pump assembly.
Common rail
The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel
to each cylinder.
The fuel pressure sensor and the pressure limiter are installed on the common rail.
1 Pressure limiter
3 Common rail
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4001C-57
Pressure limiter
The pressure limiter is activated when the pressure in the common rail becomes abnormally high to re-
lease the pressure inside the common rail.
1 Pressure limiter
Fuel pressure sensor

The fuel pressure sensor is installed on the common rail, and detects the fuel pressure inside the common
rail to convert into the voltage signal and sends it to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is
lower.
The ECM calculates the actual fuel pressure from the voltage signal sent from the sensor, and uses it to
control the fuel injection, etc.
Injector
The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection.
The ECM internally boosts the voltage for driving the injector to apply it to the injector, and uses it for fuel
injection amount control and injection timing control by regulating the energizing time of the injector.
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4001C-58
Water temperature sensor

Water temperature sensor is installed on the engine block, and the thermistor changes the resistance
value according to the temperature change.
The resistance value becomes smaller when the engine coolant temperature is high, and the value be-
comes larger when the engine coolant temperature is low.
The ECM applies 5 V to the water temperature sensor through the pull-up resistor, and calculates the
engine coolant temperature from changes in the voltage.
This value is used in various control mechanisms, such as for fuel injection control.
The voltage becomes higher when the resistance is higher, and it becomes lower when the resistance is
lower.
Overheat switch
The overheat switch is installed on the water outlet pipe, and is turned ON when the engine coolant
temperature exceeds 105°C {221 °F}.
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4001C-59
Crankshaft position sensor

The crankshaft position sensor is installed on the flywheel housing and the CKP signal is generated every
time when the protruding section of the flywheel passes the sensor.
The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the
camshaft position sensor, and uses the information for the fuel injection control and calculation of the
engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used instead when the
crankshaft position sensor is faulty.
Camshaft position sensor

The camshaft position sensor is installed behind the cylinder head, and generates a CMP signal when
the camshaft cam passes by it.
The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the
camshaft position sensor, and uses the information for the fuel injection control and calculation of the
engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used instead when the
crankshaft position sensor is faulty.
1 Camshaft gear
2 Rotational direction
3 CMP sensor
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4001C-60
Oil pressure sensor

The oil pressure sensor is installed near the starter motor of the cylinder block, and it detects the pressure
of the engine oil to convert into the voltage signal and send it to the ECM.
lower.
Accelerator position sensor

The accelerator position sensor is installed on the console panel of the actual unit to supply the voltage
signal which varies in accordance with the accelerator volume angle to the ECM.
The ECM calculates the accelerator pedal position from the voltage signal, and uses it for fuel injection
control and many other controls.
ANNOTATION:
• As for the installation position of the accelerator position sensor, refer to the manual of the actual unit.
Atmospheric pressure sensor
The atmospheric pressure sensor is installed on the actual unit side, and it replaces the atmospheric
pressure with the voltage signal.
The ECM calculates the atmospheric pressure from the voltage signal, and uses the atmospheric pres-
sure to correct the fuel injection amount.
ANNOTATION:
• As for the installation position of the atmospheric pressure sensor, refer to the manual of the actual unit.
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4001C-61
EGR position sensor

This sensor is installed inside the EGR valve to detect the EGR valve lift amount.
ANNOTATION:
• Do not disassemble the EGR position sensor.
When an abnormality is found, replace the EGR valve assembly.
Boost sensor
The boost sensor detects the boost using the pressure hose between the boost sensor and intake pipe
to convert into the voltage signal and sends it to the ECM.
lower.
The ECM calculates the boost from the voltage signal sent from the sensor, and uses it to control the fuel
injection, etc.
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4001C-62
The boost temperature sensor

The boost temperature sensor is installed to the EGR valve upstream side of the intake manifold.
The sensor is the thermistor type, and the resistance value inside the sensor changes in accordance with
the change in the temperature.
Fuel filter pressure sensor

The fuel filter pressure sensor is installed on the fuel filter, and converts the negative pressure in the fuel
filter into the voltage signal.
The ECM calculates the negative pressure in the fuel filter based on the voltage signal to determine clog-
ging in the fuel filter.
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4001C-63
Intake air temperature and mass air flow sensors

Intake air temperature sensor
The intake air temperature sensor is installed on the duct between the air cleaner and turbocharger.
The intake air temperature sensor is variable resistance inside the mass air flow sensor to measure the
temperature of air taken into the engine.
When the intake air temparture sensor is cold, the resistance of the sensor is high.
When the air temperature rises, the resistance of the sensor becomes low.
For high sensor resistance, the ECM detects a high voltage of the signal circuit.
For low sensor resistance, the ECM detects a low voltage of the signal circuit.
Mass air flow sensor
The mass air flow sensor measures the amount of air taken into the engine, and it is installed on the duct
between the air cleaner and turbocharger.
The mass air flow sensor consists of the mass air flow sensor and intake air temperature sensor to mea-
sure some of air flowing in the duct.
A small amount of air taken into the engine indicates deceleration or idle RPM.
A large amount of air indicates acceleration or high load.
Intake throttle valve

The intake throttle valve is installed on the inlet of the inlet manifold.
The ECM controls the opening angle of the intake throttle valve according to the condition of engine
operation.
The motor inside the intake throttle valve is controlled based on the duty ratio signals sent from the ECM.
The opening angle of the intake throttle valve is adjusted when the duty ratio is changing from 0 ％ to the
appropriate ratio.
The valve closes when the du％ty signal increases, and the valve opens when the duty signal decreases.
The opening angle of the intake throttle valve is detected by the position sensor.
The position sensor outputs the signal representing the intake throttle valve opening angle.
The ECM detects a low signal voltage when the opening angle is small or the valve is at the closed
position.
Also, the ECM detects a high signal voltage when the opening angle is large.
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4001C-64
DPD differential pressure sensor

The DPD differential pressure sensor is installed near DPD.
DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas dif-
ferential pressure between in front and rear of DPD filter.
The ECM detects a lower signal voltage when the differential pressure is small due to a small amount of
accumulated PM.
The ECM detects a higher signal voltage when the differential pressure is large due to a large amount of
accumulated PM.
The ECM uses this voltage signal for controlling DPD regeneration and determining purification after re-
generation.
It also uses the signal voltage to detect filter failures such as a too low differential pressure.
Exhaust gas temperature sensor

The exhaust gas temperature sensors are the variable resistors that are installed at 2 locations on the
DPD housing, and one is installed in front of the DPD oxidation catalyst, and the other is installed in front
of the filter.
The exhaust gas temperature sensor 1 that is located in front of the filter measures the temperature of the
exhaust gas before entering the DPD filter, and the exhaust gas temperature sensor 2 that is located in
front of the oxidation catalyst measures the temperature of the exhaust gas before entering the oxidation
catalyst.
When the exhaust gas temperature sensor is cold, the resistance of the sensor is high.
When the exhaust temperature rises, the resistance of the sensor decreases.
The ECM detects a high voltage in the signal circuit when the sensor resistance is high.
Also, the ECM detects a low voltage in the signal circuit when the sensor resistance is low.
The ECM uses this voltage signal for temperature control during the DPD regeneration.
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4001C-65
IMT sensor
The IMT sensor is a variable resistance installed on the intake manifold to measure the intake temperature
of the intake manifold.
When the sensor is cold, the sensor resistance is high.
When the intake temperature rises, the sensor resistance decreases.
For low sensor resistance, the ECM detects a low voltage of the signal circuit.
Turbo actuator
The turbo actuator is installed on the turbocharger.
The ECM communicates with the turbo control unit based on the engine load, etc., and the turbo control
unit controls the turbo actuator.
The nozzle control of the turbocharger is activated by the operation of the motor built into to the turbo
actuator to control the variable nozzle.
The ECM performs control that changes the boost pressure by adjusting the variable nozzle opening
angle in accordance with the load requirement for the engine.
*1 Turbine wheel
*2 Nozzle
*3 Turbo actuator
*4 Exhasut gas inlet
*5 Control rod
*6 Exhasut gas outlet
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4001C-66
Turbo control unit

The turbo control unit is installed on the actual unit.
The ECM communicates with the turbo control unit based on the engine load, etc., and the turbo control
unit performs control by operating the motor built into the the turbo actuator.
Also, it receives the signal from the position sensor built into the turbo actuator, and provides the ECM
with feedback on the turbocharger operation amount through communication with the ECM.
*1 Connector lock position
Monitor
By turning ON the diagnostic switch, the DTC is indicated by blinking.
ANNOTATION:
• As for the installation position of the monitor, refer to the manual of the actual unit.
DLC
DLC is the connector for communication and connection between the trouble diagnosis scanning tool and
various controllers.
ANNOTATION:
• As for the DLC installation position, refer to the manual of the actual unit.
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4001C-67
Diagnostic switch
The diagnostic switch shorts the DLC terminal No.1 and No.4 or No.5 and flashes the monitor to indicate
the DTC.
ANNOTATION:
• As for the installation position and shape of the diagnostic switch, refer to the manual of the actual unit.
Memory clear switch
This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and the
memory clear switch.
ANNOTATION:
• As for the installation position of the memory clear switch, refer to the manual of the actual unit.
Mode change switch (0, 1, 2)
The operation can be performed at the engine RPM specified for each mode by switching the mode
change switch.
ANNOTATION:
• As for the installation position of the mode change switch, refer to the manual of the actual unit.
1 Starter switch
2 Engine stop switch
3 Fuel meter
4 Memory clear switch
5 Mode switch
6 Water temperature gauge
7 Oil temperature gauge
8 Hour meter
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4001C-68
ECM power distribution diagram

Some sensors may not be connected to the ECM depending on the specifications of the actual unit.
Since some sensors may perform input/output with the ECM depending on the CAN communication, con-
firm the specifications of the actual unit.
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4001C-69
Accelerator pedal position sen-

*1 *18 Memory clear switch *35 Power ground
sor
*2 BARO sensor *19 diagnosis switch *36 Power ground
*3 *20 MAF sensor *37 Power ground
sor
*4 fuel filter pressure sensor *21 IAT sensor *38 Power ground
Exhaust temperature sensor 1
*5 *22 CKP sensor *39 diagnosis lamp
(in front of filter)
*6 Exhaust temperature sensor 2 *23 Fuel pressure sensor *40 Oil pressure lamp
*7 Engine stop switch *24 Starter switch (ON) *41 Glow plug lamp
*8 Idling selector switch *25 Starter switch (START) *42 Boost temperature lamp
*9 Idle up switch *26 Main relay *43 Over heat lamp
*10 Idle down switch *27 Starter switch *44 Engine over run lamp
*11 Mode map switch 0 *28 Battery *45 DPD regemerate lamp
*12 Mode map switch 1 *29 Dropping resistor *46 Fuel temperature lamp
*13 Mode map switch 2 *30 Case ground *47 Fuel filter pressure lamp
*14 Reguration mode switch *31 Signal ground *48 DPD lamp
*15 Load advance switch *32 Signal ground *49 Glow relay
*16 DPD regeneration switch *33 Power ground *50 Glow plug
*17 SCV switch *34 Power ground *51 ECM
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4001C-70
*1 Boost sensor *10 Starter cut relay *19 Intake thrttle motor
*2 EGR position sensor *11 Hour meter relay *20 Fuel injector 1 (Cylinder #1)
*3 Intake throttle position sensor *12 Starter *21 Fuel injector 1 (Cylinder #3)
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4001C-71
*4 Fuel temperature sensor *13 Tacho meter *22 Fuel injector 1 (Cylinder #2)
*5 CMP sensor *14 TOOL *23 Fuel injector 1 (Cylinder #5)
*6 Boost temperature sensor *15 OEM unit *24 Fuel injector 1 (Cylinder #6)
*7 Oil pressure sensor *16 Terminator *25 Fuel injector 1 (Cylinder #4)
*8 Water temperature sensor *17 Turbo unit *26 Suction control valve
*9 IMT sensor *18 EGR DC motor *27 ECM
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4001C-72
ECM pin assignment
60 pin connector
Pin No. Pin name Connection

1 OP-COM1A Injector power supply 1, First cylinder
2 OP-COM1B Injector power supply 1, Fourth cylinder
3 - -
4 - -
5 OM-EBM3 EGR valve DC servomotor power input W
6 SP-5V4 Boost sensor power supply
7 SP-5V8 -
8 IA-MAT IMT sensor signal
9 IA-THL Fuel temperature sensor signal
10 IA-THBST Boost temperature sensor signal
11 IA-PFUEL Fuel pressure sensor signal
12 IA-OILPRESS Oil pressure sensor signal
13 IA-MAP Boost sensor signal
14 IA-IDMPOS Intake throttle position sensor signal
15 OP-SCVHI SCV-HI drive
16 OP-COM2A Injector power supply 2, Third cylinder
17 OP-COM2B Injector power supply 2, Second cylinder
18 - -
19 - -
20 OM-EBM2 EGR valve DC servomotor power input V
21 SP-5V5 Crankshaft position sensor, fuel pressure sensor power supply
22 SP-5V6 Camshaft position sensor power supply
23 SP-5V7 Oil pressure sensor power supply
24 - -
25 IA-THW Water temperature sensor signal
Boost sensor, EGR position sensor, intake throttle position sensor, fuel temperature sensor
26 SG-5VRT4
GND
27 - -
84551720B NA - August 2012
4001C-73

28 SG-SLD5 Crankshaft position sensor shield
29 IA-OPLO -
30 OP-SCVHI SCV-HI drive
31 OS-INJ1 Injector 1, First cylinder
32 - -
33 OS-INJ4 Injector 4, Second cylinder
34 - -
35 OM-EBM1 EGR valve DC servomotor power input U
36 - -
37 - -
38 - -
39 - -
40 SG-5VRT7 Oil pressure sensor, water temperature sensor GND
41 SG-5VRT5 Intake air temperature sensor, crankshaft position sensor, fuel pressure sensor GND
42 SG-5VRT6 Camshaft position sensor, boost temperature sensor GND
43 SG-SLD6 Camshaft position sensor GND
44 - -
45 IA-SCVLO SCV-LO drive
46 OS-INJ3 Injector 3, Fourth cylinder
47 - -
48 OS-INJ2 Injector 2, Third cylinder
49 OM-IDM1 Intake throttle motor, +
50 OM-IDM2 Intake throttle motor, -
51 - -
52 IS-EBMPOS1 EGR position sensor signal U
53 IS-EBMPOS2 EGR position sensor signal V
54 IS-EBMPOS3 EGR position sensor signal W
55 SG-5VRT8 IMT sensor GND
56 IF-CAM Camshaft position sensor signal
57 IF-CRANK Crankshaft position sensor signal
58 SG-SLD8 Fuel pressure sensor shield
59 - -
60 IA-SCVLO SCV-LO drive
84551720B NA - August 2012

4001C-74
94 pin connector

61 PG-POWER GND
62 PG-POWER GND
63 PG-POWER GND
64 PG-POWER GND
65 PG-POWER GND
66 PG-POWER GND
67 PS-+B Power supply
68 SP-5V1 Accelerator position sensor power supply
69 SP-5V2 Atmospheric pressure sensor power supply
70 SP-5V3 DPD differential pressure sensor, fuel filter pressure sensor power supply
71 - -
72 CC-KW2000 Data link connector
(CC- -
73
BOOTRX)
74 - -
75 - -
76 - -
77 - -
78 - -
79 IA-THE1 Exhaust gas temperature sensor 1 signal
80 IA-THE2 Exhaust gas temperature sensor 2 signal
81 IA-IAT Intake air temperature sensor signal
82 IA-MAF Mass air flow sensor signal
83 IA-FIPRESS Fuel filter pressure sensor signal
84 IA-EXHP DPD differential pressure sensor signal
85 IA-ACCEL1 Accelerator pedal position sensor 1 signal
86 IA-ACCEL2 Accelerator pedal position sensor 2 signal
87 IA-BARO Atmospheric pressure sensor signal
88 CC-ISOCAN-L ISO CAN-Low
90 SG-5VRT1 Accelerator position sensor GND
91 - -
92 - -
93 - -
94 - -
(CC- -
95
BOOTTX)
96 (MOD1) -
97 PG-SIGN GND
98 - -
99 IS-SCVSW SCV switch signal
100 IS-START Starter switch start signal
101 IS-LOAD Load advance switch signal
102 IS-REG Regulation mode switch signal
103 IS-SWLO1 -
104 IS-IDLMNL Idling control change selector switch signal
105 IS-MDMAP0 Mode map switch 0 signal
106 IS-IDLUP Idling control switch Up signal
109 IS-IDLDWN Idling control switch Down signal
CC-ISO-
110 ISO CAN-High
CAN-H
DPD differential pressure sensor, fuel filter pressure sensor, exhaust gas temperature sen-
112 SG-5VRT3
sor 1, exhaust gas temperature sensor 2 GND
84551720B NA - August 2012
4001C-75

113 SG-12VRT Mass air flow sensor GND
114 OS-MAINR ECM main relay
115 SG-SLD1 Accelerator position sensor shield
116 - -
117 SP-12V Mass air flow sensor power supply
118 - -
119 PG-SIGN GND
120 - -
121 IS-ENGSTP Engine stop switch signal
122 IS-DPDREG DPD switch
123 OS-OVRL Engine overrun light
124 OS-OILPL Engine oil pressure light
125 OS-BOOSTL Boost temperature sensor pilot light
126 OS-OVHL Overheat light
127 OS-OPL1 -
128 OF-TACHO Tachometer
129 OS-DPDREG DPD regeneration light
130 OS-DIAGL Diagnosis light
131 OS-EGRTL -
132 CC-CAN-L CAN-Low
134 IS-IGKEY Starter switch ON signal
135 SG-5VRT2 Atmospheric pressure sensor GND
136 OS-MAINR ECM main relay signal
137 PG-CASE GND
138 - -
139 PS-MAFBAT dropping resistor
140 IS-SWHI1 -
141 IS-DIAG Diagnostic switch signal
142 IS-MEMCL Memory clear switch signal
143 IS-DGSEL Diagnostic switch signal
144 IS-SWHI2 -
145 OS-GLOWL Glow light
146 OS-OPL2 -
OS-FI-
147 Fuel filter clogging light
PRESSL
148 OS-THLL Fuel temperature light
149 OS-DPDSL DPD light
150 OS-HOUR Hour rne白r relay
151
152 OS-STARTR Starter cut relay
153 OS-GLOWR glow relay
154 CC-CAN-H CAN-High
84551720B NA - August 2012

4001C-76
Section
4001E
Symptom
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Frequent DPD regeneration by manual regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Long DPD regeneration time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine start failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine hunting, rough idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Excessive white smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Excessive black smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Abnormal noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Large fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Large oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Insufficient engine output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Symptom
Frequent DPD regeneration by manual regeneration

1. DPD system manual regeneration frequently Description of Symptom
The manual regeneration is frequently requested by blinking the DPD manual regeneration lamp or indicating
Press DPD switch.
Or, it is requested more frequently than before.
{Automatic regeneration cannot be performed frequently}
ANNOTATION:
• Depending on the manufacturer of the actual unit, the indication may not be shown.
2. DPD system manual regeneration frequently Diagnostics
• Preliminary inspection
Inspect the fuel quality.
Inspect the engine oil level and quality.
Inspect whether the hourmeter operates correctly.
If excessive amount of black smoke is observed, inspect the black smoke.
Inspect the inside of the DPD filter for excessive ash deposits.
Check the scan tool data list.
Check the service technical report.
Confirm the ECM carry part number.
Check the operator's operating habits and conditions.
Recommend the owner to voluntarily carry out regeneration as necessary.
Check whether the idling time is too long under the normal operation conditions.
Check whether operation is frequently performed at low speed under the normal operation conditions.
Check whether long downhill driving is performed under the normal operation conditions.
Check whether the idling time is too long in DPD regeneration.
Check whether operation is frequently performed at low speed in DPD regeneration.
Check whether PTO is activated frequently and for long period of time in DPD regeneration.
Check whether the engine operating time is short in DPD regeneration.
Check whether accelerator is switched frequently between ON and OFF in DPD regeneration.
• Inspection of the sensor
Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off.
{The hose of the DPD differential pressure sensor has a specified installation direction}
• Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting.
Inspect the DPD differential pressure sensor for incorrect installation.
Inspect the DPD differential pressure sensor for damage.
Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its
inlet.
Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display
Check the exhaust temperature sensor at various temperatures, and inspect for the possibility of sensor ab-
normalities.
Check the mass air flow sensor for abnormalities and operation delay with the scan tool data display MAF.
Check the boost pressure and atmospheric pressure when the starter switch is ON and the engine is not started.
It is normal if both data displays are within 7.0kPa {0.07 kgf/cm2 / 1.0 psi}.
• Inspection of the air intake system
Inspect the air cleaner and air intake duct for clogging, holes, and leakage.
Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted.
Inspect the intake throttle valve for anchoring.
Inspect the inside of the intake manifold for clogging or air leaks.
Inspect the air intake system for modification.
Inspect the mass air flow sensor for contamination and damage.
Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage.
• Inspection of the exhaust system
Inspect for any condition that restricts the flow of the exhaust system.
Inspect for absence or damage of the exhaust system gasket.
Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust temperature sensor, and DPD
differential pressure sensor's hose and pipe.
Inspect the exhaust system for modification.
Inspect the DPD filter for damages, cracks, melt and excessive deposits.
Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits.
If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deterio-
rated or damaged.
84551720B NA - August 2012
4001E-3
Symptom
Long DPD regeneration time

1. DPD system regeneration long time Description of Symptom
The regeneration requires more time than expected.
Or, it takes longer than before.
2. DPD system regeneration long time Diagnostics
Inspect the fuel quality.
Check the scan tool data list.
Check the service technical report.
Check whether DPD regeneration and engine warm up control are mixed up.
Check the operator's operating habits and conditions.
Check whether the manual regeneration is started when the engine is cold in DPD regeneration.
Check whether the idling time is too long in DPD regeneration.
Check whether operation is frequently performed at low speed in DPD regeneration.
Check whether the engine operating time is short in DPD regeneration.
Check whether accelerator is switched frequently between ON and OFF in DPD regeneration.
Check whether the temperature in the work environment is excessively high in DPD regeneration.
• Inspection of the sensor
Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off.
{The hose of the DPD differential pressure sensor has a specified installation direction}
Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting.
Inspect the DPD differential pressure sensor for incorrect installation.
Inspect the DPD differential pressure sensor for damage.
Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its
inlet.
Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display
Check the exhaust gas temperature sensor at various temperatures, and inspect for the possibility of sensor
abnormalities.
• Inspection of the cooling system
Inspect the engine coolant level.
Inspect the engine coolant leakage.
Inspect the cooling fan belt slip.
Inspect the operation of the cooling fan clutch.
Inspect the operation of the thermostat.
Inspect the operation of the water pump.
Inspect the radiator for clogging.
Inspect whether the cooling amount of the cooling system is not low due to modification.
• Inspection of the air intake system
Inspect the air cleaner, air intake duct, and intercooler for clogging, holes, or leakage.
Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted.
Inspect the intake throttle valve for anchoring.
Inspect the inside of the intake manifold for clogging or air leaks.
Inspect the air intake system for modification.
Inspect the mass air flow sensor for contamination and damage.
Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage.
• Inspection of the exhaust system
Inspect for any condition that restricts the flow of the exhaust system.
Inspect for absence or damage of the exhaust system gasket.
Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust gas temperature sensor, and
DPD differential pressure sensor's hose and pipe.
Inspect the exhaust system for modification.
Inspect the DPD filter for damages, cracks, melt and excessive deposits.
Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits.
If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deterio-
rated or damaged.
• Other inspections
Inspect for possible factors of overheat.
84551720B NA - August 2012

4001E-4
Symptom
Engine start failure

1. Engine start failure Description of Symptom
The cranking revolution is low.
The cranking revolution is normal, but the engine does not start.
The engine starts but cannot maintain its revolution stably or does not reach normal revolution speeds.
2. Engine start failure Diagnostics
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Check whether the actual unit has a significant load.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is grime or clogging of the fuel filter.
Whether there is an improper connection of connectors.
Particularly for the crankshaft position sensor and camshaft position sensor.
Whether the battery terminal voltage has dropped.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location Proper connections,
cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumu-
lates easily.
Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any
plugs for air removal.
Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout.
Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion
direction of the actual unit.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
84551720B NA - August 2012

4001E-5
Symptom
*1 Pre fuel filter

*3 Fuel filter
• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc.
Use of low-viscosity fuel such as kerosene causes wear on the supply pump plunger and may result in the
discharge abnormalities and cause start failure.
In such cases, replacement of the supply pump is required.
When a start failure has occurred, check with the customer about the fuel used.
If low-viscosity fuel such as kerosene has been used, instruct the customer not to use low-viscosity fuel because
the malfunction recurs even after replacing the supply pump.
A mixed oil biofuel containing long-term storage fuel and organic substances is easily oxidizable.
An oxidized fuel causes wear on the camshaft related parts in the supply pump and may result in start failure
due to discharge abnormalities.
In such cases, replacement of the supply pump is required.
Since the replacement of the supply pump due to the use of mixed oil biofuel containing long-term storage
fuel and organic substances is at the customer’s expense, instruct the customer not to use mixed oil biofuel
containing long-term storage fuel and organic substances.
When using fuel with a high water content, add the larger sedimenter to the pre-fuel filter to prevent water from
entering into the fuel system.
Abnormalities of the supply pump, non-pressure fuel supply
The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a con-
dition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute
pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to
the supply pump abnormalities.
ANNOTATION:
• Since the crankshaft position sensor abnormalities will not be diagnosed unless cranking is performed 14
revolutions or more, crank for more than 14 seconds at 60 r/min or more.
84551720B NA - August 2012
4001E-6
Symptom
For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC
may not be detected.
For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft
position sensor related DTC is detected.
Engine speed (r/min)
P0093 Judgment required en-

*1
gine speed
*2 Minimum fining engine speed
*3
speed
Absolute pressure
Engine speed (r/min)
*1 Non-criteria range
*2 P0093 Criteria range
*3 Range in P0093 is established
Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing
degradation Abnormalities of the injector, no fuel injection
System down due to failure Engine body abnormalities such as seizure, insufficient compression pressure, and
other mechanical failures, etc.
ACG failure Failure related to the actual unit equipment such as the oil pressure pump, etc.
Effect of the post-installed accessories such as wireless devices and lights, etc.
ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions,
bending, etc.
Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
84551720B NA - August 2012
4001E-7
Symptom
Repair if abnormalities are found.
84551720B NA - August 2012

4001E-8
Symptom
Engine stalling
1. Engine stalling Description of Symptom
Engine cranks but takes a long time to start.
The engine ultimately operates, or starts but stops soon.
2. Engine stalling Diagnostics
Check whether the actual unit has a significant load.
Since the crankshaft position sensor abnormalities will not be diagnosed with cranking less than 14 revolutions,
crank for more than 14 seconds at 60 min-1 ( r/min ) or more.
DTC check.
For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC may
not be detected.
For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft po-
sition sensor related DTC is detected.
Check whether fuel is contained.
Particularly for the crankshaft position sensor and camshaft position sensor.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
lates easily.
84551720B NA - August 2012

4001E-9
Symptom
*1 Pre fuel filter

*3 Fuel filter
• Diagnostic aids
Air intake system abnormalities such as filter clogging and air intake piping abnormalities, etc.
The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a condi-
tion continues for 3 seconds or more in which the engine revolution speed is 900 min-1 ( r/min ) and the absolute
pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to
supply pump abnormalities.
84551720B NA - August 2012

4001E-10
Symptom
Engine speed [ min-1 (

r/min ) ]
P0093 Judgment required en-

*1
gine speed
*2 Minimum fining engine speed
*3
speed
Absolute pressure
Engine speed [ min-1 ( r/min ) ]
*1 Non-criteria range
*2 P0093 Criteria range
*3 Range in P0093 is established
Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing
degradation
Abnormalities of the injector, no fuel injection
System down due to failure
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
ACG failure
Failure related to the actual unit equipment such as the oil pressure pump, etc.
ECM failure
Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending,
etc.
Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits.
84551720B NA - August 2012

4001E-11
Symptom
Engine hunting, rough idling

1. Engine hunching, rough idling Description of Symptom
The engine has variable engine idling, or has change in idling revolution speed.
In a severe case, the engine or the actual unit may vibrate.
In either case, the engine stall may occur if the symptom gets worse.
2. Engine hunching, rough idling Diagnostics
DTC check.
Whether the battery terminal voltage has dropped.
lates easily.
84551720B NA - August 2012

4001E-12
Symptom
*1 Pre fuel filter

*3 Fuel filter
• Diagnostic aids
Switch input circuit system abnormalities Abnormalities of the sensor input circuit system such as the acceler-
ator position sensor, harness, and water temperature sensor
Accelerator position sensor system abnormalities
etc.
Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending,
etc.
Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits.
84551720B NA - August 2012

4001E-13
Symptom
Excessive white smoke in the exhaust gas

1. Excessive white smoke in the exhaust gas Description of Symptom
Excessive white smoke when driving.
2. Excessive white smoke in the exhaust gas Diagnostics
DTC check.
Whether there is an improper connection of injector connectors.
• Diagnostic aids
Fuel quality when using a product with a low cetane number or a product other than those specified
Use of low-viscosity fuel such as kerosene may result in abnormal wear on the seat area of the injector and
cause abnormal spray and white smoke.
In such cases, replacement of the injector is required.
Since the replacement of the injector due to the use of low-viscosity fuel such as kerosene is at the customer's
expense, instruct the customer not to use low-viscosity fuel such as kerosene.
Idling for a long time
Failure of the water temperature sensor, fuel temperature sensor, intake air temperature sensor, boost sensor
failure, or air pressure sensor
Engine body failure such as insufficient compression pressure, piston related failure, turbocharger failure, and
raised oil or sucked down oil, etc.
ECM failure
84551720B NA - August 2012

4001E-14
Symptom
Excessive black smoke in the exhaust gas

1. Excessive black smoke in the exhaust gas Description of Symptom
Excessive black smoke when driving.
2. Excessive black smoke in the exhaust gas Diagnostics
ANNOTATION:
DTC check.
ANNOTATION:
Whether there is grime or clogging in the air cleaner element.
Whether there are any fuel leaks, pipe damage, or dents in the fue lsystem.
ANNOTATION:
• Diagnostic aids
Fuel quality when using a product other than those specified, etc.
Abnormalities of the EGR control system
Abnormalities of the exhaust system such as exhaust pipe abnormalities, etc.
Water temperature sensor malfunction
Boost sensor failure
Engine body failure such as insufficient compression
pressure, piston related failure, turbocharger failure, and raised oil, etc.
84551720B NA - August 2012

4001E-15
Symptom
Abnormal noise
1. Abnormal noise Description of Symptom
Engine combustion noise is abnormal.
2. Abnormal noise Diagnostics
Refer to the actual unit manual and inspect the abnormal noise.
DTC check.
• Diagnostic aids
Air intake system abnormalities such as EGR valve abnormalities, etc.
Abnormalities of the injector, no fuel injection
etc.
ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions,
bending, etc.
Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits.
84551720B NA - August 2012

4001E-16
Symptom
Large fuel consumption Proper wiring connections, tightening, and dis-

connection
1. Large fuel consumption Description of Symptom Whether the ECM ground is free of dirt, etc. and
Fuel consumption is significantly larger than indi- securely installed in the correct location.
cated in the actual unit manual. Proper connections, cracks, and twists in the
2. Large fuel consumption Diagnostics pipes and hoses related to fuel, air, and oil.
Before using this section, perform the functional Whether there are any fuel leaks, pipe damage,
inspection and OBD system check to check all of or dents in the fuel system.
the following. Abnormalities of the air intake system parts
Since the fuel consumption varies widely depend- Abnormalities of the exhaust system parts
ing on the handling of the actual unit, check the • Diagnostic aids
reference fuel consumption (A) of the actual unit Fuel system abnormalities such as fuel running
manufacturer. out, fuel freezing, mixture of air into the fuel pip-
Reference fuel consumption [ L ( gal. ) {qts}/hour ing, filter abnormalities, piping abnormalities, fuel
] quality, fuel tank, etc.
Check the actual fuel consumption (B). Air intake system abnormalities such as EGR
Actual fuel consumption [ L ( gal. ) {qts}/hour ] valve abnormalities, etc.
If B is greater than A, refer to the actual unit man- Abnormalities of the injector such as excessive
ual and check the setting of the unit. fuel injection
Check whether the actual unit does not have a Engine body abnormalities such as seizure, insuf-
significant load. ficient compression pressure, and other mechan-
Refer to the inspections and maintenance list in ical failures, etc.
the operation manual and perform the inspection Failure related to the actual unit equipment such
based on the operation time of the actual unit. as the oil pressure pump, etc.
Refer to the actual unit manual to inspect an ECM failure Inspect the connector for connection
actual unit whose operation time exceeds 3,000 failures and the harness for abnormalities such as
hours. abrasions, bending, etc.
The ECM and monitor are operating correctly. Inspect that the wires inside the harness are sepa-
DTC check. rate and have not caused a short circuit with other
Check the condition of the actual unit, and locate circuits.
the appropriate symptom. Perform inspections for functional diagnosis, and
Check with the customers whether they are using confirm the operation, control of each part, etc.
the specified engine oil and fuel. Repair if abnormalities are found.
Check whether engine oil change or periodical For the inspection locations of the engine air in-
maintenance for the air cleaner filter or fuel filter, take and exhaust system
etc. has been performed. Inspect the air intake and exhaust system for ab-
normalities such as clogging, collapsing and dam-
Careful visual inspection is required for several age.
symptom procedures. Other than the inspection locations of the engine
This can lead to fixing a problem without further body, inspect the air cleaner, intercooler, and muf-
inspections, and can save valuable time. fler.
84551720B NA - August 2012

4001E-17
Symptom
1 EGR valve 4 To the intercooler

2 From the intercooler 5 Exhaust pipe
3 From the air cleaner 6 EGR cooler
84551720B NA - August 2012

4001E-18
Symptom
Large oil consumption Check with the customers whether they are using
the specified engine oil and fuel.
1. Large oil consumption Description of Symptom • Visual inspection
The oil consumption amount described in the man- Careful visual inspection is required for several
ual of the actual unit is significantly exceeded. symptom procedures.
2. Large oil consumption Diagnostics This can lead to fixing a problem without further
inspections, and can save valuable time.
Before using this section, perform the functional The inspection includes the following.
inspection and OBD system check to check all of Whether bluish white smoke continuously comes
the following. out.
Since the oil consumption varies widely by han- Whether blow-by gas comes out excessively.
dling of the actual unit, check the reference oil Whether oil is mixed into the coolant.
consumption (A) of the actual unit manufacturer. Proper connections, cracks, and twists in the
Reference oil consumption/hour pipes and hoses related to oil.
Reference oil consumption per engine: 4 L ( 1.06 Extensively check for any leaks or blockage.
gal. ) {4.2 qts}/100 hours Check the actual oil Whether there is any fuel leak, pipe damage, or
consumption (B). dents in the lubricant system.
Actual oil consumption/hour Abnormalities of the air intake system parts such
Refer to the inspections and maintenance list in as the turbocharger inspection
the operation manual and perform the inspection • Diagnostic aids
based on the operation time of the actual unit. Air intake system abnormalities such as sucked
Refer to the actual unit manual to inspect an down oil or raised oil and excessive blow-by gas
actual unit whose operation time exceeds 3,000 Engine body abnormalities such as oil combustion
hours. and excessive blow-by gas
The ECM and monitor are operating correctly. Perform inspections for functional diagnosis, and
DTC check. confirm the operation, control of each part,etc.
Check the condition of the actual unit, and locate Repair if abnormalities are found.
the appropriate symptom.
84551720B NA - August 2012

4001E-19
Symptom
Insufficient engine output

1. Insufficient engine output Description of Symptom
The engine output is lower than expected, the output does not change when the accelerator lever (throttle lever)
is lifted up, the operation is not effective.
2. Insufficient engine output Diagnostics
Before using this section, perform the functional inspection, OBD system check to confirm the following all
items.
The ECM and the monitor are operating properly.
DTC check.
Check the actual unit condition, and locate the corresponding symptom.
Check with the customer if the customer is using the specified engine oil and fuel.
For insufficient output, various causes can be suspected, so thoroughly investigate the relationship between
the engine and the actual unit side.
Check what kind of operations cause insufficient output.
If hesitation or lug-down is included in the symptoms of insufficient output, it is related to the control on the
actual unit side, so contact the manufacturer of the actual unit.
If a trouble diagnosis scan tool is available, the engine output at the rated point can be easily verified by check-
ing the boost at the rated point.
Whether there is grime or clogging in the air cleaner element.
Increased resistance due to grime, clogging, or air intake piping collapsing particularly in the air cleaner element
among the air intake system parts
• Diagnostic aids
Fuel system abnormalities such as running out of fuel, fuel freezing, air intrusion in the fuel pipe, filter abnor-
mality, pipe abnormality, fuel quality, and fuel tank
Air intake system abnormalities such as filter clogging and air intake pipe abnormality
Exhaust system abnormalities such as exhaust pipe abnormality
Abnormalities of the sensor input circuit system including the accelerator position sensor and the harness
Abnormalities of the switch input circuit system
Engine unit abnormalities including other mechanical failures such as compression pressure, valve clearance,
turbocharger, supply pump, injector, and common rail
Failures related to actual unit side equipment such as hydraulic pump
Influence of the post-mounted electrical components such as wireless devices and lights
Inspect for connector improper connections, harness abnormalities such as abrasions and bends, and short
circuits with other circuits due to wire split inside harness.
Also, perform inspections for functional diagnosis, and check the operation and control of each part.
Make repairs if any abnormality is found.
Output reduction due to fuel flow restriction imposed upon overheat
Insufficient output due to fuel flow restriction during operation at high altitude
• Control when overheating
To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100 °C
(212 °F).
When the engine coolant temperature increases further, the fuel flow is also restricted further.
When the temperature is near 120 °C (248 °F), the fuel flow is restricted to a certain level.
The setting varies depending on the actual unit manufacturer.
The actual unit is designed to issue an alarm from 105 °C (221 °F).
By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation condi-
tion with fuel flow restriction.
84551720B NA - August 2012

4001E-20
Symptom
Fuel flow
*1 Warning indication
*2 DTC set
• High altitude correction

The ECM calculates the current altitude in accordance with the signal from the atmospheric pressure sensor.
Depending on the conditions of altitude, etc. at this time, the SCV opening and closing timing and injector
energizing time are controlled and the fuel flow is corrected to be optimum.
Fuel flow limit (mm3/st)
Barometric pressure kPa (psi)
*1 Highland
84551720B NA - August 2012

4001E-21
Symptom
84551720B NA - August 2012

4001E-22
Section
4001F
Functional Inspection
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Inspection of the monitor warning light blinking circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection of the scan tool (Electronic Service Tool) power circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection of the starter circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compression pressure inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection of the starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection of the air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of the EGR control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection of the glow control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Functional inspection of the DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OBD system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection of the monitor warning light illumination circuit system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Inspection of the monitor warning Inspection of the scan tool

light blinking circuit system (Electronic Service Tool) power
1. Inspection of the monitor warning light blinking cir- circuit system
cuit system Description of Function
The monitor is supplied with power supply voltage 1. Inspection of the scan tool power circuit system De-
via the starter switch and shows an abnormality dis- scription of Function
play due to a signal from the ECM. The ECM and other ECU communicate with the
The ECM makes the monitor show an abnormality trouble diagnosis scan tool via the DLC.
display during a lamp check when the starter switch The power voltage of the trouble diagnosis scan tool
is ON and when the DTC is set. is supplied by the battery or AC power.
It also blinks the monitor depending on the detected
CAUTION
DTC when the body ground terminal and diagnostic
switch terminal of the DLC are shorted. • Draw power for the trouble diagnosis
A monitor circuit is incorporated inside the ECM and scan tool from the battery or AC power.
monitors operation of the warning light. • The power supply voltage is the same as
2. Inspection of the monitor warning light blinking cir- the battery voltage of the actual unit.
cuit system Inspection
Inspection if the monitor continues showing an ab- 2. Inspection of the scan tool power circuit system In-
normality display and does not flash when the diag- spection
nostic switch is switched ON Inspection when the trouble diagnosis scan tool
1) Perform the OBD system check. does not power on
2) Turn OFF the starter switch. 1) Inspect the battery voltage of the actual unit
3) Connect the DMM between the DLC diagnos- using the DMM.
tic switch terminal and GND. Standard value: 18V
4) Turn ON the starter switch. 2) Charge or replace the battery if it is below the
5) Confirm that the voltage displayed on the standard value.
DMM exceeds the standard value. 3) Check that the battery cable of the trouble di-
Standard： 18 V agnosis scan tool does not have a defective
6) Inspect the diagnostic switch circuit between connection.
the ECM and DLC using the DMM if it is under 4) Repair the connection if a problem is discov-
the standard value. ered.
• No open circuit or high resistance should be 5) Check that the battery cable of the trouble di-
found. agnosis scan tool does not have an open or
Standard value: 100 Ω or less short circuit.
• No short circuit with GND should be found. 6) Request repair of the battery cable if a prob-
Standard value: 10 MΩ or more lem is discovered.
7) Repair if a problem is discovered.

8) Turn OFF the starter switch.
9) Confirm that there is continuity between the
DLC body ground and GND.
10) Turn ON the starter switch.
11) Short the DTC.
ANNOTATION:
• Short the No.4 terminal and No.12 terminal.
12) Check if the monitor is blinking.
ANNOTATION:
• If it does not blink, inspect the monitor blink-
ing circuit system.
13) Replace the ECM.
Removal of ECM
Installation of ECM
14) After replacing the ECM, perform EGR learn-
ing.
16) Short the body ground terminal and diagnostic
switch terminal of the DLC.
18) Perform the OBD system check.
84551720B NA - August 2012

4001F-3
Inspection of the starter circuit 8) Inspect the starter relay.

system • Connect the battery between the coil side
terminals and check the continuity between
1. Inspection of the starter circuit system Description the switch side terminals.
of Function Standard value: 100Ω or less
The starter relay on the ECM is turned to ON when
the starter switch moves to the START position. 9) Replace the relay if a problem is discovered.
When the starter relay is turned to ON, the starter 10) Inspect the starter switch start signal circuit.
operates to start the engine. • No open circuits or high resistance should
2. Inspection of the starter circuit system Inspection be found between the starter switch and
Inspection when the starter does not operate ECM.
1) Turn the emergency stop switch to OFF. Standard value: 100 Ω or less
• No short circuits with the GND should be
ANNOTATION: found between the starter switch and ECM.
Standard value: 10 MΩ or more
• If the actual unit does not have an emer-
gency stop switch setting, do not perform 11) Repair the circuit if a problem is discovered.
this operation. 12) Inspect the starter circuit.
2) Check the DTC. • No open circuit should be found between
the starter switch and starter cut relay.
ANNOTATION:
• No open circuit should be found between
• If the DTC P0117, P0340, P0341, P0615, the starter cut relay and starter relay.
P0651, or P1625 is detected, inspect the • No open circuit should be found between
corresponding DTC. the starter relay and GND.
3) Turn OFF the starter switch. the starter relay and starter.
4) Remove the starter cut relay.
5) Inspect the starter cut relay. 13) Repair the circuit if a problem is discovered.
14) Inspect the starter.
• Check the continuity between the switch Inspection of the starter
side terminals. 15) Replace the starter if a problem is discovered.
Standard value: 100 Ω or less 16) Replace the ECM.
6) Replace the relay if a problem is discovered. Removal of ECM
7) Remove the starter relay. Installation of ECM
ing.
84551720B NA - August 2012

4001F-4
Compression pressure inspection

1. Engine compression pressure inspection Inspection
ANNOTATION:
• Warm-up the engine.
assembly.
ANNOTATION:
• Remove all glow plugs.
2) Remove the injector harness connector from
the lower cover.
SST: compression gauge (refer to section
1003)
1 Injector harness connector
3) Install the special tool to the cylinder head as-

sembly.
ANNOTATION:
• Insert the compression gauge adapter into
the installation hole of the glow plug to install
the compression gauge.
1 Compression gauge
2 Compression gauge adapter
ANNOTATION:
SST: compression gauge adapter (refer to • Measure the compression pressure.
section 1003) • Rotate the starter, and read the indication
of the compression pressure when the com-
pression gauge needle stabilizes at approx-
imately 200 min-1 { 200 rpm }.
• Measure the compression pressure of all
cylinders.
Specified value： 2840.0 - 3240.0 kPa { 28.96
- 33.04 kgf/cm2 / 412 - 470 psi }
Limit： 1960.0 kPa { 19.99 kgf/cm2 / 284 psi }
84551720B NA - August 2012
4001F-5
Difference between each cylinder：294.0 kPa Inspection of the starting system

{ 3.00 kgf/ cm2 / 43 psi }
1. Starting system check Description of Function
CAUTION This diagnosis chart is an organized approach to
identifying a condition that causes the status for
• Note that air will burst out through when an engine does not start.
the glow plug hole during rotation. The appropriate system diagnosis can be per-
formed with this diagnostic chart.
ANNOTATION:
• The battery should be fully charged when per-
• When the starter switch is turned to ON with forming this diagnosis.
the injector harness connector removed, the • The battery cable should be securely connected
ECM determines a malfunction and records when performing this diagnosis.
a DTC, so make sure the DTC has been • The rotation speed during cranking should be nor-
cleared after the inspection is completed. mal when performing this diagnosis.
• The appropriate fuel should be sufficiently sup-
plied when performing this diagnosis.
• No fuel leaks should be found when performing
this diagnosis.
• No air should be mixed into the fuel when perform-
ing this diagnosis.
• The air cleaner element should be clean when
performing this diagnosis.
• The fuel filter should be clean when performing
this diagnosis.
2. Starting system check Inspection
Inspection when the starter operates and cranks but
the engine does not start
1) Turn the emergency stop switch to OFF.
ANNOTATION:
• If the actual unit does not have an emer-
gency stop switch setting, do not perform
this operation.
2) Inspect the overheat switch circuit.
ANNOTATION:
• If the actual unit does not have a overheat
switch setting, do not perform this operation.
3) Repair the circuit if a problem is discovered.
4) Check the DTC.
ANNOTATION:
• If the DTC is detected, inspect the corre-
sponding DTC.
5) Check the SCV F/B display using a trouble
diagnosis scan tool while cranking the engine.
Standard： 900 mA
6) Repair the SCVLO drive circuit if it is below
the standard value.
7) Remove the harness connector from the SCV.
8) Crank the engine.
ANNOTATION:
• If the engine starts, diagnose the DTC
P0090.
9) Inspect the fuel system if the engine does not
start.
10) Inspect the engine coolant temperature sen-
sor.
11) Inspect the fuel pressure sensor.
12) Inspect the EGR position sensor.
84551720B NA - August 2012

4001F-6
13) Inspect the injector. Inspection of the fuel system

14) Inspect the engine mechanical timing.
15) Inspect the installation status of the flywheel. 1. Fuel system check Description of Function
16) Inspect the air intake system. The fuel system is composed of the fuel filter, supply
17) Inspect the exhaust piping for collapsing, pump, common rail, and injector, and each of them
damage, and exhaust leakage. connects with the fuel pipe.
18) Repair or replace the part found to have a 2. Fuel system check Inspection
problem. Inspection when there is a possibility that there is
an abnormality in the fuel system
1) Inspect the quality of fuel.
Appropriate fuel should be used.
2) Check the amount of fuel.
Sufficient amount should be supplied.
3) Perform the fuel discharge inspection for the
supply pump.
Fuel discharge inspection
The fuel discharge should be normal and no
air should be mixed.
4) Confirm that the genuine fuel filter, pre filter,
and filters other than for the electromagnetic
pump are added to the fuel piping of the actual
unit.
ANNOTATION:
• A problem such as the detection of the DTC
P0093 may occur as the resistance of fuel
increases due to the added filter.
5) Remove it if the filter is added.
6) Inspect the main fuel filter, pre-fuel filter, and
electromagnetic pump filter.
• No excessive contamination or clogging
should be found.
• No air should be mixed in.
7) Clean or replace if a problem is discovered.
8) Inspect the fuel pipe.
No damage, clogging, or improper connec-
tions should be found.
9) Repair or replace if a problem is discovered.
10) Inspect the fuel tank.
• No dust should be mixed in.
• The fuel supply pipe should have no mis-
alignment or damage.
• The tank should have no collapsing or dam-
age.
• The fuel pipe should not be arranged incor-
rectly.
• The fuel filler should have no clogging.
• No water should be mixed into the tank.
11) Repair or replace the fuel tank if a problem is
discovered.
12) Remove air.
84551720B NA - August 2012

4001F-7
Inspection of the air intake system Inspection of the exhaust system

1. Air intake system check Description of Function 1. Exhaust system check Description of Function
The exhaust system is comprised of the exhaust
CAUTION pipe, tail pipe, etc.
2. Exhaust system check Inspection
• If the air intake system part is installed by Inspection when there is a possibility that there is
the actual unit manufacturer, refer to the
an abnormality in the exhaust system
manual of the actual unit.
1) Inspect the exhaust pipe and tail pipe.
The air intake system is comprised of the air
cleaner, air intake piping, turbocharger, etc. • No collapsing, damage, or exhaust leakage
should be found.
The intake air is supplied to the engine through the
air cleaner and intake manifold. 2) Repair or replace if a problem is discovered.
2. Air intake system check Inspection 3) Repair the actual unit.
Inspection when there is a possibility that there is
an abnormality in the air intake system
1) Inspect the air cleaner.
• No excessive contamination or clogging
should be found.
2) Clean or replace if a problem is discovered.
3) Inspect the air intake piping.
• No collapsing, damage, or air leakage
should be found.
• There are no distorted or improper piping ar-
rangements which may lead to an increase
in the air intake resistance.
• The lead valve should have no damage.
5) Inspect the turbocharger.
• The turbine axis should have no abnormal
looseness.
• There are no oil leaks.
84551720B NA - August 2012

4001F-8
Inspection of the EGR control Inspection of the glow control

system system
1. EGR control system check Description of Function 1. Glow control system check Description of Function
The ECM controls the EGR valve based on the en-
gine revolution speed, engine coolant temperature, CAUTION
intake air temperature, fuel injection amount, and
atmospheric pressure. • The starter ECM control specification
and safety relay specification are the
The EGR valve is driven by the EGR motor, and the
same for the QOS circuit.
EGR valve opening is detected by the EGR position
sensor.
2. EGR control system check Inspection The QOS system is comprised of the ECM, glow
Inspection when there is a possibility that there is relay, glow plug, and QOS indicator light.
an abnormality in the locations relating to the EGR. When the starter switch is turned to ON under low
engine coolant temperature, the ECM determines
1) Check the DTC. the glow time according to the engine coolant tem-
perature, and starts the glow relay and QOS indica-
ANNOTATION:
tor light.
• If the DTC is detected, inspect the corre- The ECM will turn to OFF the glow relay and QOS
sponding DTC. indicator light after a certain period of time.
2. Glow control system check Inspection
2) Start the engine and warm it up until the Inspection when there is a possibility that there is
coolant temperature exceeds the standard an abnormality in the locations relating to the QOS
value. system control
Specified value： 70 °C { 158 °F }
3) Check the EGR position display using a trou- 1) Perform the OBD system check.
ble diagnosis scan tool. 2) Check the DTC.
Specified value： (-3) - 3％
ANNOTATION:
4) Perform the actuator test EGR control using a
trouble diagnosis scan tool if the EGR position • If the DTC P0117, P0118, P0380, or P0381
display is outside the standard value. is detected, inspect the corresponding DTC.
5) Execute an Up and Down command to the
EGR valve and check the EGR position dis- 3) Turn ON the starter switch.
play. 4) Check the operation of the QOS indicator
Specified value： (-3) - 3％ light.
6) Inspect the EGR piping if the EGR position ANNOTATION:
display is outside the standard value.
No damage or gas leaks should be found. • If the QOS does not operate, the QOS in-
7) Repair or replace if a problem is discovered. dicator light will illuminate when the starter
8) Start the engine and warm it up until the switch is turned to ON by the light check
coolant temperature exceeds the standard function.
value. • The QOS indicator light turns off within 10
Specified value： 70 °C { 158 °F } seconds.
9) Check the EGR position display using a trou- 5) Inspect the circuit if the QOS indicator light
ble diagnosis scan tool. does not illuminate or turn off.
Specified value： (-3) - 3％
10) Replace the EGR valve if the EGR position • No fuse should be blown.
display is outside the standard value. • No open circuit should be found between
EGR valve Removal the fuse and QOS indicator light.
EGR valve Installation • No open circuit or short circuit should be
11) When replacing the EGR valve, perform EGR found between the QOS indicator light and
learning to the ECM. ECM.
• The QOS indicator light should not have a
burned-out bulb.
6) Repair or replace the circuit if a problem is
discovered.
7) Inspect the glow relay.
8) Replace the relay if a problem is discovered.
9) Remove all glow plugs.
84551720B NA - August 2012

4001F-9
10) Measure the resistance between the glow Functional inspection of the DPD
plug terminal and GND using the DMM.
Standard： 6 Ω At room temperature 1. DPD control system check Description of Function
The ECM detects the condition of PM accumula-
ANNOTATION: tions from the DPD differential pressure sensor.
• If it is outside the standard value, inspect the The DPD differential pressure sensor changes the
corresponding glow plug. signal voltage in accordance with changes in the
exhaust gas pressure difference between the front
11) Replace the glow plug if a problem is discov- and the rear of the DPD filter.
ered. When the DPD differential pressure sensor reaches
12) Connect the DMM to the glow plug connector to a certain amount of PM accumulation, or a certain
and GND. period of operating hours, DPD automatic regener-
13) Turn ON the starter switch. ation starts.
14) Perform the actuator test glow plug relay using If the automatic regeneration cannot be completed
a trouble diagnosis scan tool. due to working, the DPD manual regeneration indi-
ANNOTATION: cator light in the monitor panel blinks to prompt the
driver to perform manual regeneration.
• Turn the command to OFF and check the When regeneration has once started, it must be
voltage value of the DMM. completed within a certain period of time.
Standard： 0 V After completion of DPD regeneration, purification
15) Inspect the circuit if it is outside the standard status of the filter is determined based on the ex-
value. haust differential pressure.
When the ECM detects excessive amount of PM ac-
ANNOTATION: cumulation, it becomes so hot that it is eroded dur-
ing regeneration process and cannot control com-
• No short circuit to battery or ignition power bustion; therefore, DPD regeneration is not allowed
supply should be found between the glow
to start.
relay and glow plug.
2. DPD control system check Inspection
16) Repair or replace the circuit if a problem is Inspection for determining the failure location in the
discovered. DPD system
17) Perform the actuator test glow plug relay using
1) Perform the inspection of the engine control
a trouble diagnosis scan tool.
system.
ANNOTATION: 2) Turn the starter switch ON for 30 seconds.
3) Check that the monitor panel functions nor-
• Turn the command to ON and check the mally.
voltage value of the DMM.
• DPD automatic regeneration indicator light
Standard： 18 V illuminates in green
18) Inspect the circuit if it is below the standard
• DPD manual regeneration indicator light il-
value. luminates in orange
• No fuse should be blown. ANNOTATION:
the fuse and glow relay. • If it does not illuminate, inspect the circuit of
• No open circuit should be found between the DPD indicator light.
the glow relay and glow plug. • Not all are displayed depending on actual
• No open circuit should be found between unit manufacturers.
the glow relay and ECM.
4) Turn the starter switch OFF for 30 seconds.
19) Repair or replace the circuit if a problem is 5) Inspect the amount of engine oil.
discovered. 6) Connect the trouble diagnosis scan tool to the
20) Replace the ECM. DTC.
Removal of ECM 7) Start the engine.
Installation of ECM 8) Display the scan tool data DPD regeneration
21) After replacing the ECM, perform EGR learn- switch using a trouble diagnosis scan tool.
ing. 9) Check if the data displayed on the DPD regen-
eration switch of the trouble diagnosis scan
tool is turned to ON or OFF when changing
each switch.
ANNOTATION:
• If the ON or OFF operation does not link,
inspect the DPD switch and harness.
10) Inspect the installation condition of the DPD
84551720B NA - August 2012

4001F-10
11) Inspect the exhaust differential pressure sen- ANNOTATION:

sor.
• The area where 2 status values meets will
• Damage on the DPD differential pressure point to either A, B, C, or D.
sensor
16) Operate the trouble diagnosis scan tool.
• Foreign matter or contamination which inter-
feres with the DPD differential pressure sen- ANNOTATION:
sor inlet
• Wrong detection or slow response for the • Use a trouble diagnosis scan tool to reset
DPD differential pressure sensor the DPD status.
12) Inspect the exhaust system. • If it is range A or B, perform the DPD forced
13) Inspect the air intake system. regeneration test with the trouble diagnosis
14) Start the engine and maintain idling for 30 sec- scan tool.
onds. • If it is range C or D, perform the DPD forced
15) Confirm that the DPD manual regeneration in- slow regeneration test with the trouble diag-
dicator light blinks. nosis scan tool.
• If it is not blinking, use the trouble diagno- • After the DPD forced slow regeneration is
sis scan tool to confirm DPD accumulation completed, replace the engine oil.
status and DPD time status and applicable 17) Check the DTC detection with the trouble di-
area based on the DPD status table. agnosis scan tool if the regeneration does not
• Compare DPD accumulation status and start.
DPD time status and use the DPD status ta- ANNOTATION:
ble to determine DPD regeneration process
status. • If no DTC is detected, confirm data display
• To use the DPD status table, confirm the related to DPD regeneration control.
data display values on the trouble diagnosis 18) Inspect the corresponding DTC if the regener-
scan tool and readings in the DPD status ation is not completed and the scan tool dis-
table. plays an error message.
ANNOTATION:
• If no error message has been displayed, in-
spect the DPD filter for damage, cracks, or
melting.
• If no error message has been displayed, in-
spect the oxidation catalyst for degradation,
damage, cracks, melting, or excessive sed-
DPD Ac- iment.
cumula- • If no error message has been displayed, in-
tion Sta- spect for the cause of overheating.
tus • If no error message has been displayed, in-
spect for a problem in the fuel system.
19) Confirm that the data display of exhaust tem-
perature 1 is below the standard value using a
trouble diagnosis scan tool if the regeneration
completed.
Specified value： 130 °C { 266 °F }
ANNOTATION:
DPD Distance Status
• If it is the standard value or greater, idle the
engine until it reaches the standard value or
Range lower.
A Normal range
20) Accelerate the engine revolution to maximum
DPD amber lamp binks but revolution speed without load.
B manual regeneration is possi- 21) Check the data display of the exhaust differen-
ble. tial pressure when the data display of exhaust
Exhaust differential pressure is temperature 1 reaches the standard value.
C excessive high range and man- Specified value： 150 °C { 302 °F }
ual regeneration is inhibited. 22) Check the exhaust differential pressure data
Time status is abnormal range display using a trouble diagnosis scan tool.
D and manual regeneration is in- Specified pressure ： 0.5 - 1.8 kPa { 0.01 -
hibited. 0.02 kgf/ cm2 / 0.07 - 0.26 psi }
84551720B NA - August 2012
4001F-11
ANNOTATION: OBD system check

• If it is the standard value or lower, perform 1. OBD system check
ash removal. OBD system check Description of Function
• If it is the standard value or greater, inspect The OBD system check is a systematic method for
for the abnormalities in the DPD differential checking problems caused by functional failures in
pressure sensor system. the engine control system, and is also the starting
23) Replace the ECM if any problem can be seen point for all diagnoses for driveability complaints.
through the inspections above. By correctly using this diagnostic step, it is possible
ECM Removal to reduce the time for diagnosis and prevent the
ECM Installation replacement of parts that are not defective.
24) Set the injector ID code on the ECM. ANNOTATION:
25) Perform the unit difference learning of the fuel
supply pump to the ECM. • Points to remember regarding the OBD system
check
• If there are no complaints on driveability, do not
perform these diagnostic steps unless otherwise
instructed in other sections.
• Check the service technical report before starting
the diagnosis.
• Do not delete the DTCs unless it is instructed in a
diagnostic step.
• If a malfunction is found in the engine starting sys-
tem, inspect the starting system.
• The battery should be fully charged.
• The battery cable should be normal and securely
connected.
• The GND of the ECM should be securely con-
nected in the correct position.
• The harness connector of the ECM should be
clean and correctly connected.
2. OBD system check Inspection
Inspection for determining the failure location in the
OBD system
2) Check the abnormality display of the monitor.
ANNOTATION:
• If the actual unit does not have a monitor
setting, do not perform this operation.
• If the monitor is off, an abnormality display is
performed for the monitor illumination circuit
system.
3) Short the DTC.
ANNOTATION:
• Short the No.4 terminal and No.12 terminal.
ANNOTATION:
• If the monitor is not blinking, inspect the
monitor blinking circuit system.
84551720B NA - August 2012

4001F-12
5) Use the trouble diagnosis scan tool to confirm Inspection of the monitor warning
the DTCs of the ECU that has communication
established. light illumination circuit system
Loss of communication with the trouble diag-
1. Inspection of the monitor warning light illumination
nosis scan tool occurs due to the abnormali-
circuit system Description of Function
ties in the communication circuit of ECM and
The monitor is supplied with power supply voltage
the trouble diagnosis scan tool.
via the starter switch and shows an abnormality dis-
play due to a signal from the ECM.
ANNOTATION: The ECM makes the monitor show an abnormality
display during a lamp check when the starter switch
• If the starter does not operate, inspect the is ON and when the DTC is set.
starter circuit system. It also blinks the monitor depending on the detected
• If the engine does not start, check the DTC. DTC when the body ground terminal and diagnostic
• If the DTC is detected, inspect the corre- switch terminal of the DLC are shorted.
sponding DTC. A monitor circuit is incorporated inside the ECM and
• If no DTC has been detected, inspect the monitors operation of the light.
starting system. 2. Inspection of the monitor warning light illumination
7) Check the engine stalling for problems. circuit system Inspection
8) Check the engine hunching and rough idling Inspection if the monitor does not show an abnor-
for problems. mality display when the starter switch is switched
9) Check if there are problems with insufficient ON
engine output, blowup failure, or engine hesi- 1) Perform the OBD system check.
tation. 2) Inspect the monitor bulb.
10) Check for problems with sudden stopping. 3) Replace the valve if a problem is discovered.
11) Check for problems with sudden change. 4) Inspect the monitor circuit.
12) Check for problems with insufficient output or
blowup failure. • No open circuit or high resistance should be
13) Check for problems with engine hesitation or found between the fuse and monitor.
acceleration failure. • No open circuit or high resistance should be
14) Check for problems with dark smoke. found between the monitor and ECM.
15) Check for problems with white smoke.
16) Check for problems with the idling revolution
6) Replace the ECM.
speed maladjustment.
Removal of ECM
17) Check for problems with the idling revolution
Installation of ECM
speed not decreasing.
18) Check for problems with frequent DPD regen-
ing.
eration by the manual regeneration.
19) Check for problems with long DPD regenera-
tion time.
84551720B NA - August 2012

4001F-13
84551720B NA - August 2012

4001F-14
Section
4001G
Maintenance precautions
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS

1. Maintenance precautions • When assembling or installing a compo-

nent, make sure to tighten them at the
1) Precautions on maintenance specified torque to ensure secure installa-
To prevent the engine from being damaged tion.
and to ensure the reliability of engine perfor- Important precautions for handling this en-
mance, be careful of the following points when gine
performing maintenance works. The holes and gaps in the fuel system in-
When placing the engine on the ground, make cluding inside the injector where the fuel
sure that the bearing surface of the oil pan passes through are manufactured with high
does not directly contact the ground. precision.
Use an appropriate wood frame, etc. to sup- Therefore, these are extremely sensitive to
port the engine at the engine foot portion and any foreign matter, and may be severely
the flywheel housing portion. damaged due to foreign matter accidentally
There is only a small gap between the oil pan intruded.
and oil pump strainer, so be careful not to For this reason, extreme care must be taken
damage the oil pan and oil strainer. to prevent any foreign matter from entering.
• While the air duct or air cleaner is removed, When performing maintenance on the fuel
cover the open section of the intake to pre- system, take extreme care to prevent any
vent foreign matters from entering the cylin- foreign matter from entering the system.
der. • Before starting maintenance, clean the fuel
If a foreign matter enters the cylinder, it may line and its surroundings.
seriously damage the cylinder when the en- • Be sure to wash your hands before starting
gine starts. maintenance.
• When maintaining the engine, be sure to Do not put on cotton work gloves.
disconnect the negative battery cable. • When the fuel hose or fuel pipe is removed,
Failure to do this may cause the harness or cover the opening with a plastic bag and fix
electrical components to be damaged. it with a piece of tape.
If energizing is required for inspection, be
careful not to cause a short. WARNING
• Before assembly, apply the engine oil to the When the high-pressure piping of
slide contact surface of the engine.
the fuel system is removed, be sure
This work ensures appropriate lubrication
to replace it with a new one.
when first starting the engine.
If it is reused, the sealing surface
• When the valve train component, piston, may be damaged to cause fuel leak-
piston ring, connecting rod, connecting rod
age.
bearing, and/or crankshaft journal bearing
are removed, line them up in the correct or-
der so that their original positions are clear. • When replacing the fuel hose and/or fuel
pipe, do not unpack new components be-
• When installing, install it in the same posi-
tion as when it was removed. fore starting installation.
• When assembling the engine, replace the • When the fuel pipe, injection pipe, fuel injec-
gasket, oil seal, and O-ring with new ones. tor, fuel supply pump, and/or common rail
are removed, seal each opening immedi-
• For a component with the liquid gasket ap-
plied, carefully remove the old liquid gasket ately.
and clean the component so that no oil, wa- • Store the eyebolt and gasket in a clean parts
ter, and/or dust remain. box with a cover so that foreign matter does
Thereafter, apply the specified liquid gasket not attach to them.
to each component before assembly. • Fuel leakage may cause a fire.
Therefore, be sure to wipe spilled fuel af-
• Assemble components with the liquid gas-
ket applied within 5 minutes of applying the ter completing the maintenance work and
liquid gasket. confirm that there is no fuel leakage before
If 5 minutes have passed, remove the old starting the engine.
liquid gasket and apply liquid gasket again.
84551720B NA - August 2012

4001G-3
2) Cautions on electronic system Current that occurred during welding may

lead to failure and/or damage to the elec-
Using circuit test tools
tronic control system.
Unless specifically instructed in the diag-
Damage caused by electrostatic discharge
nostic procedure, do not use a test light
As the electronic components used in the
when diagnosing the powertrain electronic
electronic control system are designed to
system.
operate at extremely low voltages, they
When a probe connector is required in the
can be easily damaged by electrostatic
diagnostic procedure, use the connector
discharge, and some types of electronic
test adapter kit.
components can be damaged by static
electricity of 100 V or less, which cannot be
felt by a person.
Note that a voltage of 4000 V is required for
a person to be able to detect electrostatic
discharge.
There are various ways a person can build
up an electrostatic charge.
The most common way to build up an elec-
trostatic charge is through methods based
on friction or induction.
An example of when a person builds an
electrostatic charge by friction is when
he/she slides across the seat of the ma-
chine.
A person wearing insulated shoes can
SST: connector test adapter kit (refer to build an electrostatic charge by induction
section 1003) if he/she momentarily touches the ground
Commercial electronic equipment while standing near a highly charged object.
Commercial electronic equipment refers A charge of the same polarity flows out, and
to commercially available electronic equip- with a highly opposing polarity, that person
ment attached to the unit after it has been becomes charged.
shipped from the factory. As static electricity causes damage, be
Be careful, as such accessories are not cautious when handling or testing electronic
taken into particular consideration at the components.
machine design stage.
Commercial electronic equipment may CAUTION
cause malfunctions in the electronic control
system, even if the equipment is properly • To prevent damage due to electro-
attached. static discharge, do not touch the
This includes equipment not connected to connector pins of the ECM or the
the electronic system of the machine, such electronic components soldered
as mobile telephones and radios. onto the circuit board of the ECM.
Therefore, when diagnosing power train • To prevent damage due to elec-
problems, confirm whether such commer- trostatic discharge, do not open
cial electronic equipment is attached first the packaging of a replacement
and then remove them from the machine if part until installation preparation
such equipment is attached. for the replacement part is com-
If the problem has not been resolved after pleted.
removing the equipment, perform the diag- • To prevent damage due to electro-
nosis using the regular procedure. static discharge, connect the part
packaging to a properly working
CAUTION ground connection of the actual
unit before removing the part
• Make sure that commercial elec- from its packaging.
tronic equipment is connected to
• To prevent damage due to electro-
a circuit that is not involved with static discharge, when handling a
the circuits of the electronic con- part while sliding across the seat,
trol system for both power and sitting down from a standing po-
ground. sition, or walking a certain dis-
tance, touch a properly working
Welding operation for the actual unit ground connection before attach-
When performing welding to the actual unit, ing the part.
make sure to disconnect the battery in prior
to the operation.
84551720B NA - August 2012

4001G-4
Fuel injection system 3) Programming

Fuel piping
Programming guideline
WARNING When the ECM or injector has been re-
placed, the EST cannot be used to write
The high pressure pipe and injector injector data into the ECM - it can either
pipe in the fuel system should not be done with the Isuzu EIDSS or the en-
be reused. gine service monitor on the machine. Doug
When it is once removed, make Reinhardt wrote up the procedure in his
sure to replace it with new one. service training document, XC Engine Ser-
vice Monitor. Need clarification from Isuzu
The pressure limiter or fuel pressure sensor on use of the EIDSS.
should not be replaced individually. As for the programming method, refer to the
When a failure is found, the common rail instruction manual of the trouble diagnosis
assembly and all fuel pipes should be re- scan tool.
placed. Prior confirmation item for programming
When performing programming, check the
ECM part No. as necessary.
engine type as necessary.
engine No. as necessary.
injector ID code as necessary.
Items require programming
When the ECM has been replaced, perform
programming.
When the engine has been replaced, per-
form programming.
When the injector has been replaced, per-
form programming.
1 Injector pipe
3 Pressure limiter
4 Common rail
84551720B NA - August 2012

4001G-5
84551720B NA - August 2012

4001G-6
Section
4004
Removal and Installation of Starter Motor
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code HA8111000 3. Use a wrench [19 mm (0.748 in.)] to remove the 4
WARNING N・m (46.991 - 54.220 lbf・ft.)
• Do not use open flames and do not allow
CAUTION
work.
Items to prepare
mm ( 0.551 in. ), 17 mm ( 0.669 in. ), 19 mm ( 0.748
in. )]
• Rag
• Cleaning fluid 4. Use a wrench [13 mm (0.512 in.)] to remove the bolt
(7), and then remove the clamp (8).
Removal of Starter Motor
bolts (1), and then remove the battery holder (2).
N・m (14.459 - 21.688 lbf・ft.)
5. Use a wrench [8 mm (0.315 in.)] to remove the nut

(9), then remove the wiring (10).

bolt (3), and then remove the battery cable (4) on
the negative side.
• When removing the terminal and harness, secure
them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against
sparks.
84551720B NA - August 2012

4004-3
6. Use a wrench [14 mm (0.551 in.)] to remove the nut Installation of Starter Motor
(11), and then remove the wiring (12).
Tighten bolts and nuts to the specified torque.
If the torque is not specified for a bolt or other part, see
the "Standard Torque Data for Cap Screws and Nuts".

bolt (13), and then remove the wiring on the ground
side (14).

nuts (15), then remove the starter motor (16).
Tightening torque for nut installation: 82.4 N ・ m
(60.786 lbf・ft.)
84551720B NA - August 2012

4004-4
Section
4005
Removal and Installation of Alternator
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 55301AA10 4. Remove the connector (5).
WARNING
• Do not use open flames and do not allow
CAUTION
work.
Items to prepare
22 mm ( 0.866 in. ) ] 5. Use a wrench [8 mm (0.315 in.)] to remove the bolt
• Rag (7), and then remove the clamp (6).
• Cleaning fluid
Removal of Alternator
1. Remove the fan belt.
(For details, see "Removal and Installation of Fan
Belt".)
bolts (1), and then remove the battery holder (2).
N・m (14.459 - 21.688 lbf・ft.)
6. Use a wrench [10 mm (0.394 in.)] to remove the bolt

(8), and then remove the wiring (9).

bolt (3), and then remove the battery cable (4) on
the negative side.
• When removing the terminal and harness, secure
them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against 7. Use a wrench [8 mm (0.315 in.)] to remove the nut
sparks. (10), then remove the wiring (11).
84551720B NA - August 2012

4005-3
8. Use a wrench [22 mm (0.866 in.)] to remove the bolt Installation of Alternator
(12), and then remove the alternator (13).
Tightening torque for bolt installation: 127.0 N・m To install, perform the reverse of the removal procedure.
(93.686 lbf・ft.) Adjust the fan belt according to the "Fan Belt Installa-
tion" tension adjustment procedures in "Fan Belt Re-
placement".
84551720B NA - August 2012

4005-4
Section
4008
Preheating System
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal and Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Glow plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Preheating System
Removal and Installation of Glow Installation of Glow Plug

Plug 1. Glow plug Installation
Removal of Glow Plug sembly.
1. Battery ground cable Disconnect Tightening torque： 20 N・m {2.0 kgf・m / 14
lb・ft.}
battery. CAUTION
2. Glow plug Removal • Be careful not to exceed the speci-
glow plug.
assembly.
2) Install the glow plug connector to the glow

plug.
lbf・ft.}
CAUTION
• Confirm that the glow plug connec-
tor does not interfere with the sur-
rounding parts.

tery.
84551720B NA - August 2012

4008-3
Preheating System
Glow plug Inspection

1. Glow plug Inspection
1) Measure the resistance using the circuit
tester.
Resistance： under 5.00 Ω
CAUTION
• Replace the glow plug if the mea-
sured value is not within the range
of standard value.
• Use a set of 4 glow plugs from the
same manufacturer.
84551720B NA - August 2012

4008-4
Section
4020A
Electrical Equipment Layout Diagram
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Main Unit Left Side Layout Diagram (radiator chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine Section Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Main Unit Right Side Layout Diagram (pump chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main Unit Center Section Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cab Layout Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab Layout Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Layout Around Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Stand Alone Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Main Unit Left Side Layout Diagram (radiator chamber)
84551720B NA - August 2012

4020A-3
1 Air cleaner sensor 6 Fusible link (IGN) 65 A 11 Battery relay

2 Air cleaner 7 Fuse: +B 50 A 12 Battery
3 Cushion valve 8 Fuse: ST 50 A 13 Receiver dryer sensor
4 Swing pilot pressure sensor 9 Fuse: Computer 20 A 14 Washer motor
5 Glow relay 10 Starter relay
84551720B NA - August 2012

4020A-4
Engine Section Layout Diagram
84551720B NA - August 2012

4020A-5

1 6 Boost temperature sensor 11 Cam position sensor
sensor
2 Boost pressure sensor 7 Starter motor 12 Crank position sensor
Engine hydraulic pressure sen-
3 Overheat switch 8 13 Intake manifold sensor
sor
4 Common rail pressure sensor 9 Suction control valve
5 EGR valve 10 Fuel temperature sensor
84551720B NA - August 2012

4020A-6
84551720B NA - August 2012

4020A-7
1 Sensor hose DPD FT 3 Pressure sensor DPD 5 Thermo-sensor DPD CT

2 Sensor hose DPD RR 4 Thermo-sensor DPD FT 6 MAF sensor
84551720B NA - August 2012

4020A-8
Main Unit Right Side Layout Diagram (pump chamber)
84551720B NA - August 2012

4020A-9

1 Magnetic fuel pump 6 Lever lock 11
tional valve
2 P1 pressure sensor 7 Swing brake 12 Oil temperature sensor
3 P2 pressure sensor 8 2-stage relief 13 N2 pressure sensor
4 5 stack solenoid valve 9 2-stage travel
Actual milli-amp for flow control
5 Power save 10
proportional valve
84551720B NA - August 2012

4020A-10
Main Unit Center Section Layout Diagram
1 Arm pressure sensor 4 Suction air sensor 7 Bucket pressure sensor

2 N1 pressure sensor 5 Upper pressure sensor
3 Boom pressure sensor 6 Travel pressure sensor
84551720B NA - August 2012

4020A-11
Cab Layout Diagram 1
84551720B NA - August 2012

4020A-12
1 Air conditioner sunlight sensor 6 Rocker switch 11 Air conditioner control panel
2 Monitor display 7 Wiper motor 12 Engine emergency stop switch
3 Knob 8 Radio 13 Rocker switch
4 Cigar lighter 9 Throttle volume 14 Gate lock limit switch
5 Wiper controller 10 Key cylinder
84551720B NA - August 2012

4020A-13
Cab Layout Diagram 2
84551720B NA - August 2012

4020A-14
1 Computer B 3 ECM (engine control module) 5 Relay

2 Computer A 4 Fuse box
No. Name No. Name No. Name

CN. A9 ECM relay CN. A14 Neutral start relay CN. A19 Beacon relay
CN. A10 DPF relay CN. A15 Key ON relay CN. A20 Room lamp relay
CN.A11 Battery relay CN. A16 Horn relay CN. A21 Right speaker relay
CN. A12 Idle stop relay CN. A17 Boom, house light relay CN. A22 Left speaker relay
CN. A13 Starter cut relay CN.A18 Cab top light relay
No. Name No. Name

F1 Key switch 15 A F11 Wiper, washer 15 A
F2 ECM (engine control module) 20 A F12 Travel alarm, signal lamp 10 A
F3 GPS computer 15 A F13 Cigar lighter, seat suspension 10 A
F4 Backup (radio, room lamp) 10 A F14 DC converter 10 A
F5 Gate lock lever 10 A F15 Air conditioner unit 5A
F6 Solenoid 10 A F16 Air conditioner blower motor 15 A
F7 Horn 10 A F17 Air conditioner compressor 5A
F8 Cab top light 15 A F18 Option power supply 10 A
F9 Boom, house light 15 A F19 Feed pump 15 A
F10 Option power supply 15 A F20 Option line solenoid 10 A
84551720B NA - August 2012

4020A-15
Layout Around Operator Seat
84551720B NA - August 2012

4020A-16
Air conditioner
1 Cup holder 5 Throttle volume 9
control panel
Engine emer-
2 Starter switch 6 Tilt lever right 10
gency stop switch
Rocker switch
3 7 Tilt lever left 11 Gate lever
space
4 Radio 8 Ashtray
84551720B NA - August 2012

4020A-17
Stand Alone Parts Diagram

*1: EU
*2: NA
*3: LX
Parts without the * mark are common to EU, NA, and LX models.
Name Shape Circuit Remarks
Specification; For +24

VDC
Battery relay
Sumitomo part No.;
KHR1241
Specification; 5.0 kW -24

V
Starter motor
Isuzu part No.; 898070-
3211
Specification; 50 A -24 V
Alternator Isuzu part No.; 898092-
1161
Model; 130E41R
Battery Sumitomo part No.;
KHR3944
Sumitomo part No.;

Washer motor
KHR2261 (tank + motor)
84551720B NA - August 2012

4020A-18
Specification; 65 A
Fusible link
Sumitomo part No.;
(fuse box)
KHR1592
Specification; 50 A
Fusible link
Sumitomo part No.;
(safety relay)
KHR3850
Fuse Model; 7224-8511 (20 A)

(computer) 7224-8512 (15 A)
Model; RA30Y2
30SKB1KΩK
Throttle volume
Sumitomo part No.;
KHR2751
Specification; 24 VDC
Sumitomo part No.;
Starter switch
KHR20050 *1,*2
KHR20060 *3
84551720B NA - August 2012

4020A-19
Sumitomo part No.;

Fuel level sensor
KHR10670
Charge fuel pump Sumitomo part No.;
KHH11880
Reserve tank limit Sumitomo part No.;

switch KHH10840
Sumitomo part No.;

Vacuum sensor
KHH10330
84551720B NA - August 2012

4020A-20

Glow plug
7776
EGR motor EGR valve accessory

EGR position sen- EGR valve Isuzu part
sor No.; 898170-5910
Common rail accessory

Common rail
Common rail Isuzu part
pressure sensor
No.; 898027-4560

Cam angle sensor
0240
Crank angle sen- Isuzu part No.; 897606-

sor 9430
Oil pressure sen- Isuzu part No.; 898027-

sor 4560
84551720B NA - August 2012

4020A-21
Boost pressure Isuzu part No.; 180220-

sensor 0140
Boost tempera- Isuzu part No.; 81246-

ture sensor 8300
Supply pump accessory

Fuel temperature
Supply pump Isuzu part
sensor
No.; 897306-0448
Supply pump accessory

Suction control
Supply pump Isuzu part
valve
No.; 897306-0448

Injector
8560
Suction air tem- Isuzu part No.; 897601-

perature and flow 9670
sensor Sumitomo part No.;
(MAF sensor) KHH13270
84551720B NA - August 2012

4020A-22
Engine coolant
temperature sen-
9360
sor

Barometric pres- 7780
sure sensor Sumitomo part No.;
KHH0536
Sumitomo part No.;

Computer A
KHR29002
Relay Sumitomo part No.;
KHR3802
Sumitomo part No.;

DC-DC converter
KHR2447
Alarm Sumitomo part No.;

(feed pump) KHR4024
84551720B NA - August 2012

4020A-23
Sumitomo part No.;

Feed pump
KHR12840
Sumitomo part No.;

Feed pump switch
KHR12900
Lamp Specification; 24 V 70 W
(front right hous- Sumitomo part No.;
ing) KHR2475
Specification; 24 V 70 W
Lamp
Sumitomo part No.;
(boom)
KHR0957
Specification; 24 V 70 W
Lamp
Sumitomo part No.;
(cab top)
KHR16240
84551720B NA - August 2012

4020A-24
Speaker Sumitomo part No.;

(right) (left) KHR3366
Sumitomo part No.;

Monitor display KHR23592 *1,*2
KHR23582 *3
Specification; 50.0 MPa

Pressure sensor
Sumitomo part No.;
(P1) (P2)
KHR10290
Pressure sensor
(N1) (N2) (swing) Specification; 5.0 MPa
(upper) (travel) Sumitomo part No.;
(arm in) (bucket KHR26940
close) (boom up)
Pressure switch Specification; 0.49 MPa

(option) (2nd op- Sumitomo part No.;
tion) KHR21490
84551720B NA - August 2012

4020A-25
Pressure switch Sumitomo part No.;

(filter) KHR14470
5 stack solenoid Sumitomo part No.;

valve KHJ14520
2 stack solenoid
Sumitomo part No.;
valve
KHJ14780
(knob switch type)
2 stack solenoid
Sumitomo part No.;
valve
KHJ14000
(pedal type)
P1 flow control Sumitomo part No.;

proportional valve TIP0002128
84551720B NA - August 2012

4020A-26
Horsepower con-
Sumitomo part No.;
trol proportional
LJ00684
valve
Model; KAB 555

Sumitomo part No.;
KAB seat
KHN11490 *1,*2
KHN13560 *3
Hydraulic oil tem- Sumitomo part No.;

perature sensor KHR2433
Knob; Right Model; With 4 switches

(with one-touch Sumitomo part No.;
switch) KHJ24640
Knob; Left Model; With 4 switches

(with horn switch Sumitomo part No.;
and radio mute) KHJ24630
84551720B NA - August 2012

4020A-27
Sumitomo part No.;

KHR3852
Travel alarm
Basic frequency; 2560
Hz
Sumitomo part No.;

Horn (low) KHR21430
Basic frequency; 350 Hz
Sumitomo part No.;

Horn (high) KHR21440
Basic frequency; 415 Hz
Lever lock limit Sumitomo part No.;

switch KHR14930
84551720B NA - August 2012

4020A-28
Specification; 24 V, 10 W
Lamp
Sumitomo part No.;
(room lamp)
KHN2714
Accessory socket Sumitomo part No.;
KHR2501
Cigar lighter 24 V Sumitomo part No.;
KHR11210
Air conditioner Sumitomo part No.;

unit KHR2716
Limit switch
Sumitomo part No.;
(front window)
KHR2950
(door)
84551720B NA - August 2012

4020A-29
Sumitomo part No.;

Wiper controller
KHN3392
Sumitomo part No.;

Wiper motor
KHN25780
Solar radiation Sumitomo part No.;

sensor KHR10540
Receiver dryer Sumitomo part No.;

(switch) KHR13590
Air conditioner
Sumitomo part No.;
compressor
KHR3197
(magnetic clutch)
84551720B NA - August 2012

4020A-30
Motor actuator
(air mix) (mode) Sumitomo part No.;
(inside/outside KHR27530
air)
Sumitomo part No.;

EVA sensor
KHR27650
Interior tempera- Sumitomo part No.;

ture sensor KHR27490
Relay
Sumitomo part No.;
(compressor)
KHR2836
(blower OFF)
Sumitomo part No.;

Blower motor
KHR27850
84551720B NA - August 2012

4020A-31
Sumitomo part No.;

Blower amp
KHR27840
Air conditioner Sumitomo part No.;

switch panel KHR27251
Engine emer- Sumitomo part No.;

gency stop switch KHR28530
Sumitomo part No.;

Beacon switch
KHR15480 *1
Sumitomo part No.;

Glow relay
KHH13260
84551720B NA - August 2012

4020A-32
Horn volume se- Sumitomo part No.;

lect switch KHR28540 *1,*2
3 stack propor-
tional valve Sumitomo part No.;
(boom up, arm in, KHJ23870
bucket close)
Fuel filter sensor Sumitomo part No.;

(Isuzu) KHH13230
DPD exhaust gas

pressure differen-
3682
tial pressure sen-
Sumitomo part No.;
sor
KHH13330
(Isuzu)

DPD temperature
3300
sensor
Sumitomo part No.;
(Isuzu) (CT)
KHH13360
84551720B NA - August 2012

4020A-33

DPD temperature
3290
sensor
Sumitomo part No.;
(Isuzu) (FT)
KHH13350

Turbo computer 1241
(Isuzu) Sumitomo part No.;
KBH13650
EGR manifold
temperature sen- Isuzu part No.; -
sor Sumitomo part No.; -
(Isuzu)
VGS TURBO Sumitomo part No.; -
84551720B NA - August 2012

4020A-34
Section
4020B
Connection Connector Pin Layout
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Computer A
84551720B NA - August 2012

4020B-3
Monitor
84551720B NA - August 2012

4020B-4
Section
4020C
Sequence Circuit Diagram
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lever Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Symbol List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Code table
FRONT WINDOW LIMIT

A1 COMPUTER H8 CCD CAMERA S54
SWITCH
RESERVE TANK LOW
A2 ENGINE CONTROLLER K2 RELAY-GLOW PLUG S55
SWITCH
A4 WIPER CONTROLLER K3 RELAY-HORN S61 REFUEL PUMP SWITCH
A6 BLOWER CONTROLLER K5 RELAY-ROTARY LIGHT S62 AIR CLEANER SENSOR
RELAY-AIR CONDITIONER
A13 CONTROLLER B K6 S70 HORN VOLUME SWITCH
CONDENSER FAN
PRESSURE SWITCH FILTER
A14 TURBO CONTROLLER K7 RELAY BATTERY S71 INDICATOR (BREAKER OP-
TION)
RELAY-WORKING LIGHT
COOLANT TEMPERATURE
B1 K10 (UPPERSTRUCTURE / AT- S85 BEACON (EU)
SENSOR
TACHMENT)
HYDRAULIC OIL TEMPERA- RELAY-WORKING LIGHT DC-DC (24V-12V) CON-
B2 K11 U1
TURE SENSOR (CAB) VERTER
FUEL TEMPERATURE SEN- ROTARY LIGHT CONNEC-
B3 K17 BLOWER OFF RELAY X2
SOR TOR
OPTIONAL POWER CON-
B5 EVAPORATOR SENSOR K30 REFUEL PUMP RELAY X3
NECTOR
ENGINE OIL PRESSURE ENGINE TEST POINT CON-
B21 K31 REFUEL PUMP STOP RELAY X4
SWITCH NECTOR
SWING PILOT PRESSURE CONTROLLER TEST POINT
B22 K34 RELAY STARTER CUT X5
SWITCH CONNECTOR
UPPER PILOT PRESSURE CAB SEAT COMPRESSOR
B26 K35 RELAY ROOM LAMP X6
SENSOR MOTOR CONNECTOR
TRAVEL PILOT PRESSURE ANTI-THEFT SYSTEM CON-
B27 K36 RELAY SPEAKER LEFT X9
SENSOR NECTOR
SECOND OPTION PILOT CIR-
B28 K37 RELAY SPEAKER RIGHT X15 ACCESSORY SOCKET
CUIT 1 PRESSURE SWITCH
PUMP PRESSURE SENSOR
B40 K63 RELAY ECM X23 CLEAR MEMORY 1
(NEGA-CONT. P2)
B42 K64 RELAY KEY ON X24 CLEAR MEMORY 2
(P1)
B43 K65 RELAY BATTERY RL X25 TO CONTROLLER C
(NEGA-CONT. P1)
B44 K66 RELAY IDLE STOP X26 EST CONECTOR B
(P2) (BLUE BAND)
OVERLOAD INDICATOR
B45 K67 RELAY DPF X27 TO GPS UNIT
PRESSURE SWITCH
B47 BOOST PRESSURE SENSOR K68 RELAY NEUTRAL START X32 TO DRM
AMBIENT AIR (BAROMET-
B48 K69 RELAY STARTER X33 FOR CRANE
RIC) PRESSURE SENSOR
CRANKSHAFT POSITION
B49 M1 STARTER MOTOR X34 FOR FAN REVERSE
SENSOR
BOOST TEMPERATURE 12V OUTPUT(FOR RADIO
B51 M3 WIPER MOTOR X36
SENSOR EU)
COMMON RAIL PRESSURE PILOT PRESSURE SOLE-
B52 M4 WASHER MOTOR Y2
SENSOR NOID VALVE (BLUE BAND)
SWING BRAKE SOLENOID
B61 SUNLOAD SENSOR M5 MOTOR (AIR CHANGING) Y3
VALVE (WHITE BAND)
AIR VENT DIRECTION CON- 2 STAGE TRAVEL SOLENOID
B82 REFUEL PUMP STOP ALARM M6 Y4
TROL MOTOR VALVE (RED BAND)
PRESS. SENSOR (PILOT MOTOR ACTUATOR (AIR POWER-UP SOLENOID
B83 M7 Y5
ARM CLOSE) MIX) VALVE (YELLOW BAND)
PRESS. SENSOR (PILOT POWER SAVE SOLENOID
B84 M8 BLOWER MOTOR Y6
BUCKET CLOSE) VALVE (GREEN BAND)
PRESS. SENSOR (PILOT MAIN PUMP POWER PRO-
B85 M14 FUEL FEED PUMP MOTOR Y7
BOOM UP) PORTIONAL SOLENOID
84551720B NA - August 2012
4020C-3
AIR CONDITIONER MAGNET

B86 EGR INTAKE TEMP. SENSOR M20 ELECTRIC FUEL PUMP Y8
CLUTCH
OPTION 2 SPEED SOLENOID
B87 CAM ANG(MRE) SENSOR M23 VGS TURBO Y9
VALVE (BLUE TAPE)
INTAKE THROTTLE DC-MO- MAIN PUMP FLOW PROPOR-
B88 FUEL FILTER SENSOR M24 Y11
TOR TIONAL SOLENOID
EXHAUST GAS RECIRCULA- FREE SWING SOLENOID
B89 EXSHAUST PRESS. SENSOR M25 Y18
TION VALVE VALVE (NA)
EXSHAUST TEMP. SEN- OPT.1 KNOB (R) -R SOLE-
B90 P1 INSTRUMENT PANEL Y23
SOR(CNT) NOID VALVE (BLUE TAPE)
EXSHAUST TEMP. SEN- SWITCH PANEL (LEFT- OPT.1 KNOB (R) -L SOLE-
B91 P2 Y24
SOR(FNT) HAND) NOID VALVE (RED TAPE)
SWITCH PANEL (RIGHT- OPT.2 KNOB (L) -R SOLE-
B92 HORN LOW (LEFT) P3 Y25
HAND) NOID VALVE (BLUE TAPE)
AIR CONDITIONER SWITCH OPT.2 KNOB (L) -L SOLENOID
B93 HORN HIGH (RIGHT) P6 Y26
PANEL VALVE (RED TAPE)
PRESS. SWITCH (1ST OP- OPTION SELECT SOLENOID
B94 P15 RADIO SET (NA) Y27
TION) VALVE (RED TAPE)
AIR INTAKE SENSOR MASS SUCTION CONTROL VALVE
B95 R1 GLOW PLUG Y35
& TEMP (SCV)
WORKING LIGHT (UPPER- BOOM UP PROPORTIONAL
E1 R3 THROTTLE VOLUME Y59
STRUCTURE) SOLENOID VALVE (NO TAPE)
ARM CLOSE PROPOTIONAL
WORKING LIGHT (ATTACH- THERMISTOR INNER TEM-
E2 R4 Y60 SOLENOID VALVE (RED
MENT) PERATURE
TAPE)
BUCKET CLOSE PROPO-
E3 WORKING LIGHT (CAB) R5 FUEL SENSOR Y61 TIONAL SOLENOID VALVE
(BLUE TAPE)
OPTION PRESS. PROPOR-
E4 CAB LIGHT R7 RESISTOR (MAF) Y62
TIONAL SOLENOID VALVE
E51 CIGAR LIGHTER S1 KEY SWITCH Y63 INJ1 (#1)
ENGINE EMERGENCY STOP
E52 AIR CONDITIONER S9 Y64 INJ2 (#3)
SWITCH
G1 BATTERY S13 OVERLOAD SWITCH (EU) Y65 INJ3 (#4)
FREE SWING (NA) ; OP-
G2 ALTERNATOR S22 Y66 INJ4 (#2)
TIONAL (EU)
HYDRAULIC FUNCTION
OPTION SELECT SOLENOID
H2 TRAVEL ALARM S51 CANCELLATION LEVER Y67
VALVE (BLUE TAPE)
SWITCH
AIR CONDITIONING COM- OPTION 2SPEED SOLENOID
H4 SPEAKER RIGHT S52 Y68
PRESSOR CLUTCH SWITCH VALVE (RED TAPE)
H5 SPEAKER LEFT S53 DOOR LIMIT SWITCH
84551720B NA - August 2012

4020C-4
Overall
84551720B NA - August 2012

4020C-5
84551720B NA - August 2012

4020C-6
Block diagram
Computer A
84551720B NA - August 2012

4020C-7
Computer B
84551720B NA - August 2012

4020C-8
ECM
84551720B NA - August 2012

4020C-9
Monitor
84551720B NA - August 2012

4020C-10
Air Conditioner
84551720B NA - August 2012

4020C-11
Lever Lock
Horn
Working lights
84551720B NA - August 2012

4020C-12
Option
84551720B NA - August 2012

4020C-13
Other
84551720B NA - August 2012

4020C-14
Electrical Symbol List

Symbol Name Symbol Name
Fuse Variable solenoid valve
Diode Resistor
LED Variable resistor
Toggle switch "a" contact Variable resistor
Push switch "a" contact Alarm
Limit switch "a" contact Buzzer
Limit switch "b" contact Horn
Relay coil Motor
Relay contact "a" contact Solar radiation sensor
84551720B NA - August 2012

4020C-15
Symbol Name Symbol Name
Relay contact "b" contact Speaker
Solenoid valve Lamp
84551720B NA - August 2012

4020C-16
Section
4021
Engine-side DTC List
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Engine-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


DTC code Description
P0016 Abnormally correlation between crankshaft position and camshaft position
P0045 Turbocharger boost pressure control system abnormality
P0087 Fuel rail system pressure low pressure error
P0088 Fuel rail system pressure high pressure error
P0089 Fuel rail pressure regulator characteristics error
P0091 Fuel rail pressure regulator control system low input
P0092 Fuel rail pressure regulator control system high input
P0093 Fuel system leak detection
P0102 Mass air flow sensor system law input
P0103 Mass air flow sensor system high input
P0112 Intake temperature sensor system low input
P0113 Intake temperature sensor system high input
P0117 Engine coolant temperature sensor system low input
P0118 Engine coolant temperature sensor system high input
P0122 Throttle sensor system low input
P0123 Throttle sensor system high input
P0182 Fuel temperature sensor system low input
P0183 Fuel temperature sensor system high input
P0192 Fuel rail pressure sensor system low input
P0193 Fuel rail pressure sensor system high input
P0201 Injector first cylinder system error
P0202 Injector second cylinder system error
P0203 Injector third cylinder system error
P0204 Injector fourth cylinder system error
P0205 Injector fifth cylinder system error
P0206 Injector sixth cylinder system error
P0217 Engine coolant high temperature error
P0219 Engine high rpm error
P0234 Turbocharger high boost pressure state
P0299 Turbocharger low boost pressure state
P0237 Boost sensor circuit low input
P0238 Boost sensor circuit high input
P0335 Crankshaft position sensor system error
P0336 Crankshaft position sensor system characteristics error
P0340 Camshaft position sensor system error
P0341 Camshaft position sensor characteristics error
P0404 EGR1 control system error
P0409 EGR1 position sensor system error
P041C IMT sensor system high input
P041D IMT sensor system low input
P0426 Pre-filtered exhaust gas high temperature error
P0427 Exhaust temperature sensor 1 system low input
P0428 Exhaust temperature sensor 1 system high input
P042B Exhaust gas high temperature error before oxidation catalyst
P042C Exhaust temperature sensor 2 system low input
P042D Exhaust temperature sensor 2 system high input
P0522 Oil pressure sensor system low input
P0523 Oil pressure sensor system high input
P0560 System voltage error
P0563 System voltage high input
P0601 Control module memory checksum error
P0602 Control module program error
P0604 Control module RAM error
P0606 Control module processing device error
P060B Control module A/D converter processing system characteristics error
P0638 Throttle actuator control system characteristics error
84551720B NA - August 2012
4021-3
DTC code Description

P0641 Sensor voltage system error
P0650 MIL control system error
P0685 ECM main relay control system low input
P0687 ECM main relay control system high input
P1093 Fuel rail pressure low pressure error
P1112 Boost temperature sensor system low input
P1113 Boost temperature sensor system high input
P1261 Injector group 1 voltage control system error
P1262 Injector group 2 voltage control system error
P1293 Fuel filter pressure sensor system low input
P1294 Fuel filter pressure sensor system high input
P1404 EGR close position characteristics error
P1455 DPD restriction 2
P1471 DPD regeneration error
P1621 Control module EEPROM error
P1669 DPD light control system error
P2122 Pedal position sensor 1 system low input
P2123 Pedal position sensor 1 system high input
P2127 Pedal position sensor 2 system low input
P2128 Pedal position sensor 2 system high input
P2146 Injector group 1 supplied voltage system error
P2149 Injector group 2 supplied voltage system error
P2228 Atmospheric pressure sensor system low input
P2229 Atmospheric pressure sensor system high input
P242F DPD restriction
P2452 DPD differential pressure sensor system error
P2453 DPD differential pressure sensor system characteristics error
P2454 DPD differential pressure sensor system low input
P2455 DPD differential pressure sensor system high input
P2456 DPD differential pressure sensor learning position error
P2458 DPD regeneration time error
U0001 CAN bus communication error
U0073 Control module communication error
U0101 TCM communication error
U0110 Turbocharger control module communication error
U0411 Turbocharger control module signal error
84551720B NA - August 2012

4021-4
Section
4022
Main Unit-side DTC List
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Main Unit-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DTC Trouble mode

7000 P1 Pressure Sensor Signal Abnormality
7001 P2 Pressure Sensor Signal Abnormality
7002 N1 Pressure Sensor Signal Abnormality
7003 N2 Pressure Sensor Signal Abnormality
7004 Overload Pressure Sensor Signal Abnormality
7005 Bottom Pressure Sensor Signal Abnormality
7006 Rod Pressure Sensor Signal Abnormality
7020 Upper Pressure Sensor Signal Abnormality
7021 Swing Pressure Sensor Signal Abnormality
7022 Travel Pressure Sensor Signal Abnormality
7023 Arm-in Pressure Sensor Signal Abnormality
7040 Fuel Level Sensor Signal Abnormality
7041 Oil Temperature Sensor Signal Abnormality
7045 Monitor Thermistor Signal Abnormality
7060 Boom Angle Sensor Signal Abnormality
7061 Arm Angle Sensor Signal Abnormality
7063 Return Filter Clogging Pressure Switch Signal Abnormality
7065 Boom-up Pilot Pressure Sensor Signal Abnormality
7067 Bucket-close Pilot Pressure Sensor Signal Abnormality
7200 Swing Brake Solenoid Signal Abnormality
7201 Travel High-speed Solenoid Signal Abnormality
7202 Pressure Boost Solenoid Signal Abnormality
7203 Travel Alarm Buzzer Signal Abnormality
7204 Power Save Solenoid Signal Abnormality
7205 Feed Pump Relay Signal Abnormality
7206 Option Line Switchover Solenoid Signal Abnormality
7207 Free Swing Solenoid Signal Abnormality
7210 Liftcrane Buzzer Signal Abnormality
7211 Rotating Light Relay and Bucket Lock Signal Abnormality
7240 Pump Horsepower Proportional Valve Signal Abnormality
7241 P1 Flow Control Proportional Valve Signal Abnormality
7242 Fan Proportional Valve Signal Abnormality
7246 2 Pumps Flow Solenoid Signal Abnormality
7247 Boom-down Proportional Valve Signal Abnormality
7248 Arm-in Proportional Valve Signal Abnormality
7250 Option Relief Pressure Proportional Valve Signal Abnormality
7251 Battery Control Relay Signal Abnormality
7252 Idle Stop Relay Signal Abnormality
7253 DPD Regeneration Request Output Signal Abnormality
7400 Abnormally High Coolant Temperature [ 105 °C ( 221.0 °F )or higher ]
7404 Abnormally High Oil Temperature [ 95 °C ( 203.0 °F )or higher ]
7405 Boost temperature is abnormally high [ 80 °C ( 176.0 °F )or more ]
7406 Boost temperature is abnormally high [ 90 °C ( 194.0 °F )or more ]
7420 Abnormally Low Alternator Voltage
7421 Coolant Level Reduction
7422 Abnormally Low Engine Oil Pressure
7423 Air Cleaner Clogging
7424 Return Filter Clogging (breaker specifications)
7425 Fuel Density Error Signal Abnormality
7600 CAN Bus Abnormality
7601 Monitor Communication Abnormality
7602 ECM Communication Abnormality
7603 Computer B Communication Abnormality
84551720B NA - August 2012
4022-3
DTC Trouble mode

7605 ECM Mismatch
7606 EEPROM Data Abnormality
7607 Computer C Communication Abnormality
84551720B NA - August 2012

4022-4
Section
4023B
Introduction to the trouble diagnosis
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS

1. Introduction to the trouble diagnosis The customer complaint is clear, but the fail-
ure conditions are unclear.
1) About trouble diagnosis Therefore, the person performing the diagno-
The following trouble diagnosis procedure is sis can reproduce the failure by understanding
extremely important to resolve problems of all its conditions.
electric/electronic systems. Intermittent failures, intermittent
Neglecting to implement these steps may re- Stage where failure is realistic
sult in requiring unnecessary repairs. The occurrence of the failure is set, and the
Read and understand the procedure carefully customer complaint is real and clear.
and proceed with the trouble diagnosis. Therefore, the person performing the diagno-
Also, use available functions and the trouble sis can reproduce the failure.
diagnosis scan tool to perform the trouble di- However, there may sometimes be more than
agnosis and system check. 2 causes for the failure.
2) Trouble diagnosis procedure Current malfunction, Current failures
Checking complaints from customer 3) Diagnosis
• Use the check sheet to organize the trouble Fully understand the description given by the
situation. customer using the Engine Control System
Check Sheet.
Performing preliminary inspection
ANNOTATION:
• Perform overall visual inspection.
• Check the past maintenance history. • When questioning, do not ask randomly but
• Detect any abnormality such as abnormal focus on the system that is inferred to be de-
noise, smell, etc. fective based on the malfunction phenome-
• Collect the failure trouble DTC information non.
to provide effective repair. Determine failure information accurately.
• Inspect for an abnormality by comparing to Have concrete understanding based on
the standard value. 5W1H.
Inspect the service information Low air temperature, at start or on a steady
basis, near the engine parts, metallic sound,
• Check the market service bulletin. etc.
Perform inspection for the displayed code. Check points
• Inspect the item shown by DTC. • Failure symptoms
• Month and Date, Time, Frequency of occur-
Perform an inspection for problems according rence
to symptoms • Road conditions
• Check the item that is not displayed in the • Working conditions, Operation conditions,
DTC. Weather
• Feeling of symptom
NOTE
System trouble diagnosis type Engine control system check sheet
The system diagnosis method is a standard- When receiving the actual unit from the cus-
ized method applied for repairing all electric/ tomer at the service factory, the failure symp-
electronic systems. toms and the data on occurrence of failure
Failures in electric/electronic systems often must be confirmed with the customer based
occur in the following steps unlike common on the engine control check sheet.
actual unit failures. • Failure symptoms may not be able to be
Initial stage of failure reproduced at the service factory.
The failure occurs sporadically and for a short • The customer's complaint may not always
time, often times the driver does not notice it. be a malfunction.
At this stage, the customer's complaint is un- • Notification of incorrect malfunction condi-
clear, and the malfunction cannot be repro- tions to the person in charge of repairs may
duced. result in unnecessary man-hours for repairs.
However, the ECM may have recorded the • The check sheet assists actual unit diagno-
failure. sis, repair, and repair confirmation at the ve-
Past malfunction, past failures hicle servicing station.
Middle stage of failure
The failure occurs sporadically and for a short
time, but may occur repeatedly at intervals,
and occurs under specific conditions.
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4023B-3
1 Failure symptoms
Failure frequency・failure con-
2
ditions
84551720B NA - August 2012

4023B-4
4) Preparatory check This inspection can often lead to solving a

Visual inspection of engine room problem without taking extra steps.
When implementing the diagnostic proce-
dures, carefully make a visual inspection of
the engine room.
84551720B NA - August 2012
4023B-5
• Visually inspect all air hoses for punched Do not attempt to diagnose a problem re-
holes, cuts, disconnections, and appropri- lated to the powertrain without having the
ate piping. basic knowledge.
• Visually inspect the hoses that are difficult A basic understanding of hand tools, such
to see behind other components. as the trouble diagnosis scan tools, is re-
• For every harness in the engine room, visu- quired to utilize the service manual effec-
ally inspect that all harnesses are properly tively.
connected.
About the diagnostic test performed on the
Inspect that there are no burned or worn
actual unit
areas, that the harnesses are properly fas-
Past failures
tened and that they are not in contact with
sharp edges or the hot exhaust manifold or • The diagnostic tests of the previous ignition
pipes. cycle have been completed.
Checking the machine maintenance status • The diagnostic tests of the current ignition
cycle have passed.
If the maintenance of the actual machine is
not performed correctly, the monitor may illu- • Problems identified in the diagnostic tests
currently do not exist.
minate.
Restricted oil filters, fuel filters, and crankcase Current failures
deposits due to lack of oil changes or improper
oil viscosity can trigger actual unit faults that • The diagnostic tests of the previous ignition
were not previously monitored prior to OBD. cycle have been completed.
Poor vehicle maintenance cannot be classi- • Problems identified in the diagnostic tests
fied as a non-machine failure, but since the currently exist.
sensitivity of OBD system checks is high, ac- • Problems exist in the current ignition cycle.
tual unit maintenance schedules must be fur- Glossary
ther closely followed. DTC
Non-OEM parts Every time the starter switch is turned ON,
All the OBD system checks are adjusted to the ECM performs the self-test on most of the
operate with the genuine parts. wiring and components, records any detected
Therefore, when a commercially sold sensor system failure in the memory of the ECM, and
or switch, etc. is installed, a wrong diagnosis performs the backup control, depending on
is made, and the monitor comes on. the DTC.
Accordingly, if general commercially-available Also, abnormalities that affect travel will cause
sensors or switches are installed, this will the monitor to show an abnormality display to
cause mistakes in diagnosis and the monitor inform the operator.
to show an abnormality display. Ignition cycle
If a commercially-available electronic device Because the actual unit activates with a
such as a mobile phone, stereo or anti-theft method to satisfy a predetermined diagno-
device is inappropriately installed, an EMI sis standard, an ignition cycle is defined as
may be emitted to the control system. turning the starter switch ON, running, then
As the result, false sensor information is gen- turning the starter switch OFF.
erated causing the monitor to come on. Monitor
When conducting a trouble diagnoses, either In general, the monitor shows an abnormal-
turn OFF the power for all commercially sold ity display when a malfunction occurs in elec-
parts or remove them, and then check the fail- tronic control such as the ECM and a DTC is
ure again. detected.
NOTE DLC
Related system failure The equipment for communicating with the
Many OBD system checks go into the backup control unit is the Data Link Connector (DLC).
operation mode based on the instruction from The DLC is also provided to establish a con-
the ECM which is given when the ECM de- nection with the scan tool.
tects a failure in the related systems or com- Identification of recorded
ponents. DTC Reading the serial data
When the backup operation mode is acti-
vated, the output is reduced to protect the ANNOTATION:
actual unit. • The installation position of the DLC and ex-
5) Trouble diagnosis istence or nonexistence of the DLC vary de-
Basic knowledge of tools required pending on the actual unit, so refer to the
ANNOTATION: manual of the actual unit.
• When performing the diagnostic procedure, ECM OFF

lack of basic knowledge regarding this pow- Turn the ECM off starter switch off and the
ertrain could result in an incorrect diagnosis ECM power supply completely tops in approx-
or damage to the powertrain components. imately 10 seconds to disable the ECM.
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4023B-6
General diagnostic operations of the compo- • Turn the starter switch ON, but the engine
nents monitor off.
To run the engine normally, a general diagno- • Connect the diagnostic switch.
sis of the components is required. For an actual unit with no diagnostic switch,
Input components short the DLC No. 1 and No. 4 or No. 5.
Inspect the input components to see whether • Read the blinking count of the monitor.
an open in the circuit or outside range value • The DTC determines the failure contents
exists. from the diagnostic trouble code list.
Crankshaft position sensor
If the trouble diagnostic scan tool is con-
Camshaft position sensor
nected, the diagnostic codes can be read by
Water temperature sensor
operating the trouble diagnostic scan tool.
Boost sensor
Fuel pressure sensor ANNOTATION:
Accelerator position sensor
Output components • As for the installation position of the monitor,
The output components are inspected to diag- refer to the manual of the actual unit.
nose whether responses to commands from Display code when no DTC is recorded
the control unit are appropriate. Code 1 (indicating the start of code display)
Inspect whether the circuits have disconnec- continues to be displayed.
tions and whether their values are within the Display when a DTC is recorded
range. The recorded trouble codes are displayed 3
Suction control valve times.
Light, Relay control If more than 2 or more trouble codes have
Magnetic valve been recorded, the DTCs will be output in as-
Monitor cending order with each DTC being displayed
6) DTC reading procedure three times.
Reading DTC with monitor After displaying all codes, the codes will be
Current and past DTCs recorded in the ECM displayed again starting with the smallest
can be displayed by connecting the diagnostic code number.
switch and blinking the monitor. This display continues while the diagnosis
• Switch the starter switch ON and check that connector is connected.
the monitor shows an abnormality display.
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4023B-7
a At code "23"
b At code "413"
*1 ON *3 Tens digit *5 Hundreds digit

*2 Goes off *4 Units digit
t1 Approx. 0.3 sec t3 Approx. 1.2 sec

t2 Approx. 0.6 sec t4 Approx. 2.4 sec
DTC indicated by monitor blinking display Verify the symptoms and conditions reported
The current and past DTCs are both displayed by the customer.
while the engine is being stopped. Use a check sheet or other method to check
While the engine is in operation, the light is the circuit or electronic system components.
turned on only when a current DTC exists. When no trouble is detected
Using the trouble display monitor to read the This status indicates that the actual unit is de-
DTC termined as operating properly.
When a DTC occurs, the DTC can be dis- The condition reported by the customer may
played on the trouble display monitor of the be normal.
actual unit. Check the customer complaint by comparing
Using the scan tool to read the DTC to other actual unit that is operating properly.
The DTC can be read using the trouble diag- However, depending on the condition, it may
nosis scan tool. be an intermittent.
Before returning the actual unit, check the
ANNOTATION: complaint under the conditions given by the
• For the work procedure, refer to the manual customer.
of the trouble diagnosis scan tool. Investigate the complaint again.
If the complaint cannot be adequately de-
When the DTC is recorded tected or confirmed , it is necessary to perform
Perform repairs accurately according to the the diagnosis again to verify the complaint.
specified DTC chart. As stated above in "Intermittent", the com-
If no DTC is available plaint may be an intermittent or normal con-
Select the symptom from "Diagnosis By dition.
Symptom". Repair and confirm.
Complete the repair according to the diagnos- Perform the repair when the cause has been
tic procedure. confirmed.
It is also possible to perform the inspection by Confirm that the operation is performed
referring to the functional diagnosis. properly, and that the symptom has been
When the appropriate symptom is not found; corrected.
Investigate the complaint in detail. This includes the confirmation test performed
Create a diagnosis plan. on the actual unit or other methods to confirm
Utilize the schematics and operation princi- that the complaint has been resolved.
ples. Confirm by testing under the conditions given
When repair history for similar cases are avail- by the customer.
able, request technical assistance. When a DTC is diagnosed, confirm that the
Combine technical knowledge and effective failure has been repaired by reproducing the
utilization of available service information. condition that appeared when the DTC was
Intermittent set while checking the scan tool data.
A failure condition that does not necessarily
always appear is referred to as intermittent.
Check the DTC information and the data dis-
play.
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4023B-8
7) Check after repair

Check repair on actual unit
When an repair has been performed for the
electronic control system, it is necessary to
check that the repair is accurate after repairing
the actual unit.
If this confirmation is not done thoroughly,
the monitor may show an abnormality dis-
play again or operability problems may occur
when the actual machine is handed over to
the customer.
It is especially necessary to recreate customer
complaint conditions and confirm repair for in-
termittent problems.
About confirmation of the actual unit repairs
It is effective to use the OBD system check for
confirming actual unit repairs.
After the repair is completed, the person who
have performed the actual unit diagnosis shall
review either the DTC that was diagnosed or
scan tool data, or both, and record it.
Clear the DTC.
Run the actual unit based on the scan tool
data.
Check the DTC status information of the spec-
ified DTC that was diagnosed until the diagno-
sis test related to that DTC is implemented by
the control unit.
The implementation of these steps is ex-
tremely important when checking the repair
status with the OBD system check.
Neglecting to implement these steps may re-
sult in unnecessary repairs.
8) Final check item list
Item Item Objective Method

Clear the previous DTCs.
Keep the engine idling to warm up, then perform
1 DTC check Confirm the DTC display after the repair.
a racing run to increase the engine rpm to No
Load Max to secure the test conditions.
Check whether the idling rotation speed is con-
Idling speed stant under the no load condition after engine is
To check whether the idling control is op-
2 check after warm- warmed up.
erating normally.
ing up the engine If a problem is detected, refer to Idling Unstable
in Diagnosis by Symptom.
Monitor the scan tool data list, and check the
Check the engine control, communica-
Confirm the scan values using a typical value sheet.
3 tion status error and abnormality under
tool data list Confirm the typical values of the scan tool data
the standard condition.
list.
After warming up the engine, confirm that the
Re-startability To check whether the starting control is cranking time is 5 seconds or less when restart-
4
check normal. ing the vehicle, and that the engine revolution is
stable after starting.
Check whether turning the electromagnetic
When electromagnetic transmitters such transmitter such as a transceiver ON and OFF
Check powerful
as a transceiver have been added to the causes the idling engine rpm to change.
5 electromagnetic
vehicle, confirm that no interfering waves If a problem is found, let the customer know that
transmitters
are being emitted. the installation position and output of the elec-
tromagnetic transmitter need to be changed.
Supplementary information regarding the If you discover a problem in this item, convey
check for powerful electromagnetic transmit- it to the customer as necessary.
ters
• Install the antenna to the a place distant
from the electronic control system of the ac-
84551720B NA - August 2012
4023B-9
tual unit such as the control units and sen- CAUTION

sors.
• Install the antenna cord at least 20 cm • When conditions such as the run-
(7.874 in.) away from the electronic sys- ning state of the actual unit or
tems of the actual unit, such as the control the engine, water temperature,
units and sensors. switches and gear position are not
• Do not wire other cables together with an- met, or when a DTC has been de-
tenna. tected, each test may possibly not
Also, locate the antenna cord as far away operate.
from other wiring as possible.
• Make sure to attach retrofitted equipment in ECM reflash
accordance with their respective installation The ECM can be updated by overwriting its
manuals. control program using the most recent control
• Do not install high-output mobile communi- data issued every 3 months.
cation devices. Normal reflash
The ECM is reflashed by automatically
CAUTION searching for the ECM part number compati-
• Follow the steps when performing ble with the part number currently reflashed.
the OBD system checks to confirm Forced reflash
the repair. The ECM is reflashed by specifying an arbi-
Failure to follow these steps may trary ECM part number.
result in performing unnecessary In this case, a password dedicated for forced
repair works. reflash is necessary.
• Review the scan tool data relating Campaign reflash The ECM is reflashed by
to the DTC that was diagnosed and selecting the part number during a campaign
make a record. carried out by the manufacturer.
• Clear the DTC. Rewriting injector QR code
• Operate the actual unit while check- The injector QR code that is required when
ing the related scan tool data. replacing the injector can be rewritten.
This allows fuel compensation to be per-
formed on each injector to optimize the engine
9) DTC clearing method
condition.
Clearing DTC
Engine replacement mode
If an error occurs in the system and the DTC is
This should be used when changing back to
recorded in the ECU, that DTC is not deleted
the old ECM part number which requires hard-
from the memory even when the malfunction-
ware changes such as addition of actual unit
ing part is repaired, so use the following mea-
wiring is performed along with engine replace-
sures to execute a forced deletion.
ment, etc.
Using the scan tool to delete the DTC
ECM replacement
If the trouble diagnosis scan tool is connected,
When replacing the ECM within the same
you can delete codes by performing turning off
model, the data can be updated from the cur-
of the trouble diagnosis scan tool.
rent ECM to a trouble diagnosis scan tool and
Erasure by ECM
then downloaded it from the trouble diagnosis
A DTC recorded in the ECM is erased if the
scan tool to the new ECM after replacement.
same DTC has not been satisfied for 40 con-
Factory shipment settings
secutive ignition cycles.
Based on the engine serial number, data such
About trouble diagnosis scan tool
as ECM injector QR code can be downloaded
This tool is effective for diagnosing electrical
to ECM.
failures in engine control units and performing
Actuator test
system checks.
The injector test, fuel injection test, rail pres-
If you connect the SAE 16/19 adapter to the
sure test, glow plug test, and EGR control test
DLC installed in the unit, it performs commu-
are performed to inspect the operation and
nication with the control units of the machine,
function of each target component.
and enables various diagnoses and tests to
be performed. CAUTION
Functions of the trouble diagnosis scan tool.
Data display • When conditions such as the run-
Snapshot ning state of the actual unit or
Programming the engine, water temperature,
Actuator test switches and gear position are not
met, or when a DTC has been de-
tected, each test may possibly not
operate.
Links with the HTML manual display
84551720B NA - August 2012

4023B-10
DTC to display the manual along with the fail- CAUTION

ure diagnosis procedure.
Reading saved data • When using the trouble diagnosis
Read in the saved snapshot data to display scan tool, refer to the separate in-
reproduction. struction manual for the trouble di-
agnosis scan tool.
10) Reference data value
84551720B NA - August 2012

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4023B-12
Section
4023D
Engine Control System
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal and Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Fuel filter pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filter pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filter pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine coolant temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine coolant temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine coolant temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Installation of CKP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal and Installation of CMP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation of Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal and Installation of Boost sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boost sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boost sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Boost temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boost temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boost temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal and Installation of IMT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IMT sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IMT sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal and Installation of Exhaust differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust differential pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust differential pressure sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust differential pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal and Installation of Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DPD temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DPD temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Exhaust gas temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Removal and Installation of 2) Remove the suction control valve from the fuel
supply pump.
Suction Control Valve
Removal of Suction Control Valve
battery.
2. Suction control valve Removal
CAUTION
• Before removing the suction control
valve, clean the surrounding area.
1 Relief valve
2 Union
3 Fuel temperature sensor
3. Remove the O-ring from the fuel supply pump.

suction control valve.
1 O-ring
84551720B NA - August 2012

4023D-3
Installation of Suction Control Valve 3. Fuel Air bleed

1. Suction control valve Installation CAUTION
1) Install the O-ring to the fuel supply pump. • To prevent engine failure, be sure to per-
1 O-ring
2) Apply the engine oil to the O-ring. 1 Priming pump

3) Temporarily tighten the suction control valve 2 Plug
to the fuel supply pump.
3 Drain plug
ANNOTATION: 4 Case
• Temporarily tighten by hand until it adheres 5 Fuel filter element
the supply pump.
1) Prepare the pan.
CAUTION 2) Turn ON the starter switch.
• Be careful not to allow the O-ring to ANNOTATION:
caught in.
• This is for the models with an electromag-
netic pump.
4) Securely tighten the suction control valve to
the fuel supply pump. 3) Loosen the plug using the wrench.
Tightening torque: 9 N・m { 0.9 kgf・m / 6.64 4) Operate the priming pump.
lbf・ft. } Number of times： 20 count(s) or more
5) Connect the harness connector to the suction
control valve. ANNOTATION:
plug.
ANNOTATION:
the priming pump.
ANNOTATION:
1 Relief valve
2 Union
3 Fuel temperature sensor Number of times： 10 count(s) or more
ANNOTATION:
2. Battery ground cable Connect • Wait for the specified time after operating
the priming pump.
tery. Specified time： 1 min
84551720B NA - August 2012
4023D-4
10) Loosen the plug using the wrench. Removal and Installation of Fuel
ANNOTATION: filter pressure
Fuel filter pressure sensor Removal
12) Operate the priming pump. 1. Fuel filter pressure sensor Removal
Number of times： 10 count(s) or more 1) Disengage the harness connector from the
ANNOTATION: fuel filter pressure sensor.
2) Remove the fuel filter pressure sensor from
• Wait for the specified time after operating the fuel filter.
the priming pump.
ANNOTATION:
7.38 lbf・ft. }
CAUTION
15) Operate the priming pump. 1 Fuel filter pressure sensor

Number of times the operation is performed:
10 - 15 times
CAUTION
Idling: 5 s
ANNOTATION:
ANNOTATION:
mum.
• Lower the rotation.S
84551720B NA - August 2012

4023D-5
Fuel filter pressure sensor Installation Removal and Installation of Engine

1. Fuel filter pressure sensor Installation coolant temperature sensor
1) Install the fuel filter pressure sensor to the fuel
filter. Engine coolant temperature sensor
Removal
CAUTION
1. Engine coolant temperature sensor Removal
• After cleaning the threaded portion
of the fuel filter body, install it. 1) Disengage the harness connector from the
engine coolant temperature sensor.
Tightening torque: 12 N・m { 1.3 kgf・m / 2) Remove the engine coolant temperature sen-
8.85 lbf・ft. } sor from the cylinder head assembly.
2) Connect the harness connector to the fuel fil-
ter pressure sensor.
1 Overheat switch
1 Fuel filter pressure sensor

ANNOTATION:
• Check that there is no fuel leaks.
• Confirm that DTC has not yet been de-
tected.
84551720B NA - August 2012

4023D-6
Engine coolant temperature sensor Engine coolant temperature sensor

Installation Inspection
1. Engine coolant temperature sensor Installation 1. Engine coolant temperature sensor Inspection
1) Install the engine coolant temperature sensor 1) Inspect the engine coolant temperature sen-
to the cylinder head assembly. sor using the circuit tester.
• Apply Loctite 572 to the threaded portion. • Confirm that the resistance value according
to water temperature matches the thermis-
tor characteristics.
18 lb・ft. }
1 Overheat switch GND terminal for engine con-

1
2 Water temperature sensor trol
Signal terminal for engine con-
2
2) Connect the harness connector to the engine trol
coolant temperature sensor. 3 Signal terminal for meters
Resistance (kΩ）
Temperature °C (°F)
84551720B NA - August 2012

4023D-7
Removal and Installation of CKP CKP sensor Installation

sensor 1. CKP sensor Installation
1) Install the CKP sensor to the flywheel housing.
CKP sensor Removal
1. Battery ground cable Disconnect CAUTION
1) Disengage the battery ground cable from the • Be careful not to subject the sensor
battery. to shock.
2. CKP sensor Removal ANNOTATION:

1) Disengage the harness connector from the • Tighten together with the clip.
CKP sensor.
2) Remove the CKP sensor from the flywheel Tightening torque： 6 N・m { 0.6 kgf・m /
housing. 4.43 lbf・ft. }
2) Connect the harness connector to the CKP
CAUTION sensor.

to shock.
1 CKP sensor
2 Flywheel housing

1 CKP sensor
2 Flywheel housing tery.
CKP sensor Inspection

1. Inspect the CKP sensor.
ANNOTATION:
• Condition of the sensor installation
• Grime on the sensor and connector
84551720B NA - August 2012

4023D-8
Removal and Installation of CMP CMP sensor Installation

sensor 1. CMP sensor Installation
CMP sensor Removal 2) Install the CMP sensor to the cylinder head
1. Battery ground cable Disconnect assembly.
1) Disengage the battery ground cable from the CAUTION

battery.
2. CMP sensor Removal to shock.
CMP sensor. ANNOTATION:
2) Remove the CMP sensor from the cylinder • Tighten together with the clip.
head assembly.
lbf・ft. }
3) Connect the harness connector to the CMP
sensor.
CAUTION
to shock. 2. Battery ground cable Connect
tery.
84551720B NA - August 2012

4023D-9
CMP sensor Inspection Removal and Installation of Oil

1. Inspect the CMP sensor. pressure sensor
ANNOTATION:
Oil pressure sensor Removal
• Condition of the sensor installation
• Grime on the sensor and connector 1. Oil pressure sensor Removal
1) Disconnect the harness connector from the oil
pressure sensor.
2) Remove the oil pressure sensor from the oil
port cover.

2 Oil port cover
3 Starter assembly
84551720B NA - August 2012

4023D-10
Oil pressure sensor Installation Oil pressure sensor Inspection

1. Oil pressure sensor Installation 1. Oil pressure sensor Inspection
1) Install the oil pressure sensor to the oil port 1) Turn OFF the starter switch.
cover. 2) Disconnect the harness connector from the oil
Tightening torque： 41 N・m { 4.2 kgf・m / pressure sensor.
30 lb・ft. } 3) Inspect the continuity using the circuit tester.
CAUTION
2) Connect the harness connector to the oil pres-

sure sensor.
CAUTION
• Replace the oil pressure sensor if
there is no continuity.

5) Inspect the circuit using the jumper wire.
2 Oil port cover
3 Starter assembly
6) Check lighting of the warning light.

ANNOTATION:
• If the warning light does not illuminate, in-
spect the circuit between the meter and the
oil pressure.
84551720B NA - August 2012

4023D-11
Removal and Installation of Boost Boost sensor Installation

sensor 1. Boost sensor Installation
1) Install the boost sensor to the inlet pipe.
Boost sensor Removal Tightening torque: 2 N・m { 0.2 kgf・m / 1.48
1. Battery ground cable Disconnect lbf・ft. }

battery.
2. Boost sensor Removal
boost sensor.
2) Remove the boost sensor from the inlet pipe.
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
2) Connect the harness connector to the boost

sensor.
1 Boost sensor 2. Battery ground cable Connect
2 IMT sensor
3 EGR valve 1) Connect the battery ground cable to the bat-
4 Harness clip tery.
5 Boost temperature sensor 3. Boost sensor Inspection
1) Inspect the boost sensor.
ANNOTATION:
• Stains on the unit
• Damage on the unit
• Malfunction of the terminal
CAUTION
• Do not clean the sensor unit since
damage may be caused inside the
sensor.
84551720B NA - August 2012

4023D-12
Removal and Installation of Boost Boost temperature sensor Installation

temperature sensor 1. Boost temperature sensor Installation
1) Install the boost temperature sensor to the in-
Boost temperature sensor Removal let pipe.
1. Boost temperature sensor Removal Tightening torque: 13 N・m { 1.3 kgf・m /
9.59 lbf・ft. }
1) Disconnect the harness connector from the 2) Connect the harness connector to the boost
boost temperature sensor. temperature sensor.
2) Remove the boost temperature sensor from
the inlet pipe.
1 Boost sensor
2 IMT sensor
1 Boost sensor 3 EGR valve
2 IMT sensor 4 Harness clip
3 EGR valve 5 Boost temperature sensor
4 Harness clip
84551720B NA - August 2012

4023D-13
Removal and Installation of IMT IMT sensor Installation

sensor 1. IMT sensor Installation
1) Install the IMT sensor to the bracket.
IMT sensor Removal tightening torque： 20 N・m {2.0 kgf・m / 14
1. IMT sensor Removal lb・ft.}
1) Disconnect the harness connector from the sensor.
IMT sensor.
2) Remove the IMT sensor from the bracket.
1 Boost sensor
2 IMT sensor
1 Boost sensor 3 EGR valve
2 IMT sensor 4 Harness clip
3 EGR valve 5 Boost temperature sensor
4 Harness clip
84551720B NA - August 2012

4023D-14
Removal and Installation of 1 Screw

Exhaust differential pressure 2. Exhaust differential pressure sensor Removal
sensor
CAUTION
Exhaust differential pressure sensor • Before performing work, be sure to
Removal check the DPD differential pressure sen-
sor precautions.
1. Exhaust differential pressure sensor Safety Infor-
mation 1) Disengage the differential pressure hose from
the exhaust differential pressure sensor.
CAUTION
• Do not use a tool which causes vibra- exhaust differential pressure sensor.
tions such as an impact wrench when in- 3) Remove the exhaust differential pressure sen-
stalling and removing the DPD differen- sor from the DPD assembly.
tial pressure sensor.
• Do not reuse a DPD differential pressure CAUTION
sensor which has been subjected to • Remove the DPD differential pres-
shock such as being dropped. sure sensor with the attached
• Install or remove the DPD differen- bracket.
bracket.
• Be sure not to loosen the 4 screws in-
sensor.
been loosened.

1
sor
84551720B NA - August 2012

4023D-15
Exhaust differential pressure sensor 2. Exhaust differential pressure sensor Installation

Installation CAUTION
1. Exhaust differential pressure sensor Safety
Information check the DPD differential pressure sen-
CAUTION sor precautions.
• Do not use a tool which causes vibra- 1) Install the exhaust differential pressure sensor
tions such as an impact wrench when in- to the DPD assembly.
stalling and removing the DPD differen- 2) Connect the harness connector to the exhaust
tial pressure sensor. differential pressure sensor.
• Do not reuse a DPD differential pressure 3) Connect the differential pressure hose to the
sensor which has been subjected to exhaust differential pressure sensor.
• Install or remove the DPD differen- CAUTION
bracket. • Be careful not to mistake the con-
necting position of the differential
• Be sure not to loosen the 4 screws in- pressure hose.
sensor. • Since the differential pressure sen-
sor may malfunction if exhaust gas
• Replace the DPD differential pressure leaks from the joint sections, con-
firm that there is no exhaust gas
DPD differential
leakage after the engine starts.
• pressure sensor have been loosened.

1
1 Screw sor
84551720B NA - August 2012

4023D-16
Exhaust differential pressure sensor Removal and Installation of

Inspection Exhaust gas temperature sensor
CAUTION
DPD temperature sensor Removal
• Perform 0-point correction when replacing 1. Exhaust gas temperature sensor Safety Information
the DPD differential pressure sensor.
• Perform 0-point correction when the DPD dif- CAUTION
ferential pressure sensor is at room temper-
ature. • Before removing, be sure to check the
• Do not perform 0-point correction within two DPD pressure difference, status, and in-
hours after regenerating DPD. spection/maintenance contents using a
scan tool.
ANNOTATION: • Do not reuse an exhaust gas tempera-
ture sensor which has been subjected to
• 0-point correction shock such as being dropped.
1. Turn OFF the starter switch.
2. Turn ON the starter switch. 2. Exhaust gas temperature sensor Removal
CAUTION 1) Disengage the harness connector from the

exhaust gas temperature sensor.
• Do not start the engine. ANNOTATION:
starter switch ON time： 40 s or more • To prevent incorrect assembling, make an
3. Turn OFF the starter switch. alignment mark on the connector before dis-
starter switch OFF time： 15 s or more connecting.
2) Remove the exhaust gas temperature sensor
from the DPD assembly.

1
sor 1
2
sor 2
84551720B NA - August 2012

4023D-17
DPD temperature sensor Installation 2) Securely tighten the exhaust gas temperature
sensor to the DPD assembly.
1. Exhaust gas temperature sensor Installation tightening torque： 30 N・m {3.1 kgf・m / 22
lb・ft.}
CAUTION
3) Connect the harness connector to the exhaust
• Do not subject the tip of the exhaust gas gas temperature sensor.
temperature sensor to shock when in-
stalling. CAUTION
• Remove the old anti-seize lubricant on • Be careful not to twist the harness.
the sleeve nut.
• Apply the anti-seize lubricant on the
threaded portion of the sleeve nut.
ture Stainless Grade: 5-87411-039-0
anti-seize lubricant, manufactured by
Bostik in the United states.
• Replace the oxidation catalyst assembly
if damage has been found in the sensor
installation section of the oxidation cata-
lyst assembly.
1) Temporarily tighten the exhaust gas tempera-

ture sensor to the DPD assembly.
CAUTION
• To avoid damaging the sensor in- Exhaust gas temperature sen-
1
stallation sections due to sensor sor 1
incorrect assembly, tighten it by Exhaust gas temperature sen-
2
hand. sor 2
• Exhaust gas temperature sensor identifica- • Start the engine after assembling each part,
tion and check for gas leaks from each joint and
for vibration.
Screw Connector
Sensor type
size color
Exhaust gas tempera- M12 x
Dark gray
ture sensor 1 1.75
Exhaust gas tempera- M12 x
Light gray
ture sensor 2 1.25
84551720B NA - August 2012

4023D-18
Exhaust gas temperature sensor

Inspection
1. Exhaust gas temperature sensor Inspection
1) Measure the resistance using the circuit
tester.
ANNOTATION:
• The reference values for the sensor
characteristics are indicated in the diagram.
temperature Resistance value

： 1000.0 °C
： 115.00 - 127.00 Ω
( 1832.00 °F )
： 950.0 °C
： 130.00 - 143.00 Ω
( 1742.00 °F )
： 900.0 °C
： 147.00 - 163.00 Ω
( 1652.00 °F )
： 850.0 °C
： 167.00 - 187.00 Ω
( 1562.00 °F )
： 800.0 °C
： 192.00 - 219.00 Ω
( 1472.00 °F )
： 750.0 °C
： 226.00 - 258.00 Ω
( 1382.00 °F )
： 700.0 °C
： 267.00 - 309.00 Ω
( 1292.00 °F )
： 650.0 °C
： 333.00 - 360.00 Ω
( 1202.00 °F )
： 600.0 °C
： 406.00 - 442.00 Ω
( 1112.00 °F )
： 550.0 °C
： 504.00 - 552.00 Ω
( 1022.00 °F )
： 500.0 °C
： 640.00 - 709.00 Ω
( 932.00 °F )
： 450.0 °C
： 835.00 - 937.00 Ω
( 842.00 °F )
： 400.0 °C
： 1130.00 - 1280.00 Ω
( 752.00 °F )
： 350.0 °C
： 1590.00 - 1850.00 Ω
( 662.00 °F )
： 300.0 °C
： 2360.00 - 2830.00 Ω
( 572.00 °F )
： 200.0 °C
： 6230.00 - 7830.00 Ω
( 392.00 °F )
： 150.0 °C
： 11900.00 - 16300.00 Ω
( 302.00 °F )
： 100.0 °C
： 27600.00 - 41200.00 Ω
( 212.00 °F )
： 50.0 °C
： 82000.00 - 137000.00 Ω
( 122.00 °F )
84551720B NA - August 2012

4023D-19
84551720B NA - August 2012

4023D-20
Section
4023G
Engine-side Trouble
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC U0001 (Flash Code 84) CAN-Bus Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DTC U0073 (Flash Code 84) Control Module Communication Bus Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DTC P0089 (Flash Code 151)Fuel Pressure Regulator Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DTC P0093 (Flash Code 227) Fuel System Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DTC U0101 (Flash Code 85) Lost Communication with TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC U0110 (Flash Code 87) Lost Communication with VNT System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance. . . . . . . . . . . . . . . . . . . . . . . 33
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance . . . . . . . . . . . . . . . . 34
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 . . . . . . . . . . . 36
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DTC P0560 (Flash Code 155) System Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DTC P0563 (Flash Code 35) System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DTC P0602 (Flash Code 154) Control Module Programming Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error . . . . . . . . . . . . . . . 43
DTC P0606 (Flash Code 51) ECM/PCM Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance . . . . . . . . . . . . . . . 56
DTC P1455 (Flash Code 132) PM Over Accumulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance . . . . . . . . . . . . . . . . 67
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
DTC P2458 (Flash Code 139) DPD Regeneration Duration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 . . . . . . . . . . . 70
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance . . . . . . . . . . . . . . . . . . . . . . . . 72
DTC P242F (Flash Code 131) DPD Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Engine-side Trouble
Engine-side Trouble
DTC U0001 (Flash Code 84) DTC P0016 (Flash Code 16)
CAN-Bus Malfunction Crankshaft Position - Camshaft
1. DTC U0001 Diagnostics Position Correlation
1) Turn OFF the starter switch. 1. DTC P0016 Priority DTC
2) Disconnect the harness connector from the DTC P0335
ECM. DTC P0336
3) Measure the resistance between the CAN- DTC P0340
High side terminal and CAN-Low side termi- 2. DTC P0016 Diagnostics
nal.
1) Inspect the CKP sensor.
ANNOTATION: Refer to "1.Engine 1B.Mechanical(4HK1X)
CKP sensor Inspection".
• Measure the resistance between the termi- 2) If a problem is discovered, replace the crank-
nals of the ECM harness connector.
shaft position sensor.
Resistance： about 120.0 Ω Refer to "1.Engine 1B.Mechanical(4HK1X)
4) If it is outside the standard range, inspect CKP sensor Removal".
the CANLow circuit and CAN-High circuit be- Refer to "1.Engine 1B.Mechanical(4HK1X)
tween the ECM and the control unit of the ac- CKP sensor Installation".
tual unit. 3) Inspect the CMP sensor.
Refer to "1.Engine 1B.Mechanical(4HK1X)
• There should be no short to the battery or CMP sensor Inspection".
ignition power supply. 4) If a problem is discovered, replace the
• There should be no open circuit or high re- camshaft position sensor.
sistance. Refer to "1.Engine 1B.Mechanical(4HK1X)
• There should be no short to GND. CMP sensor Removal".
5) If a problem is discovered, repair the CAN Refer to "1.Engine 1B.Mechanical(4HK1X)
circuit. CMP sensor Installation".
6) If the CAN circuit is normal, replace the control 5) Inspect the flywheel.
unit of the actual unit.
• The sensor rotor should not be damaged.
7) Connect the harness connector to the ECM.
• The ring gear should be installed correctly.
control unit of the actual unit. 6) If a problem is discovered, repair the flywheel.
9) Measure the resistance between the CAN- 7) Inspect the camshaft gear.
High side terminal and CAN-Low side termi-
nal. • The camshaft gear should not be damaged
• The camshaft gear should be installed cor-
ANNOTATION: rectly.
• Measure the resistance between the termi- 8) If a problem is discovered, repair the camshaft
nals of the ECM harness connector. gear.
Resistance： about 120.0 Ω 3. DTC P0016 Confirm Resolution
10) If it is outside the standard range, replace the
1) Clear the DTC using the trouble diagnosis
ECM.
scan tool.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
2) Turn the starter switch OFF for 30 seconds or
Removal".
longer.
Installation".
11) Set the injector ID code on the ECM. ANNOTATION:
supply pump to the ECM. • When the engine does not start, crank the
engine for 10 seconds.
2. DTC U0001 Confirm Resolution
4) Perform a test-run.
1) Clear the DTC using the trouble diagnosis 5) Use the trouble diagnosis scan tool to confirm
scan tool. that a DTC has not been detected.
longer.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
84551720B NA - August 2012

4023G-3
Engine-side Trouble
DTC P0045 (Flash Code 33) 14) If the voltage is outside the standard range,
inspect the position sensor power supply cir-
Turbocharger Boost Control cuit between the turbo actuator and the turbo
Solenoid Circuit control unit.
• There should be no open circuit or high re-
1. DTC P0045 Priority DTC
sistance.
DTC P0563
• There should be no short to the battery
2. DTC P0045 Diagnostics
power supply or ignition power supply cir-
1) Turn OFF the starter switch. cuit.
2) Inspect the turbocharger assembly. • There should be no short to GND.
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
15) If a problem is discovered, repair the position
bocharger assembly Inspection".
sensor power supply circuit.
3) If a problem is discovered, replace the tur-
16) If the circuit is normal, inspect to the turbo
bocharger assembly.
control unit harness connector for a contact
failure.
bocharger assembly Removal".
17) If a problem is discovered, repair the harness
connector.
bocharger assembly Installation".
18) If the harness connector is normal, replace the
turbo control unit.
turbo actuator.
19) If the voltage is within the standard range,
5) Connect the test light between the motor op-
measure the voltage between the position
eration terminal and GND of the turbo actuator
sensor signal terminal of the turbo actuator
harness connector.
harness connector and GND.
7) Check if the test light does not come on or ANNOTATION:
remains on.
• Measurement of voltage value should be
ANNOTATION: taken on each terminal.
• The inspection with a test light should be Voltage： 4.0 - 6.0 V
performed on each terminal. 20) If the voltage is outside the standard range,
• When it is normal, the test light comes on inspect the position sensor signal circuit be-
after the key switch is turned ON, and then tween the turbo actuator and the turbo control
goes out after a few seconds. unit.
8) If the test light does not come on or remains • There should be no open circuit or high re-
on, inspect the motor operation circuit be- sistance.
tween the turbo • There should be no short to the battery
actuator and turbo control unit. power supply or ignition power supply cir-
cuit.
• There should be no short to GND.
sistance.
• There should be no short to the battery 21) If a problem is discovered, repair the position
power supply or ignition power supply cir- sensor signal circuit.
cuit. 22) If the circuit is normal, inspect to the turbo
• There should be no short to GND. control unit harness connector for a contact
failure.
9) If a problem is discovered, repair the motor
operation circuit.
connector.
10) If the test light operates properly, inspect to
see if a short with other circuit exists in the
turbo control unit.
motor operation circuit between the turbo ac-
25) If the voltage is within the standard range, in-
tuator and turbo control unit.
spect to see if there is a short circuit with the
11) If a problem is discovered, repair the motor
position sensor.
operation circuit.
13) Measure the voltage between the position
sensor power supply terminal and GND of the
turbo actuator harness connector.
Voltage： 8.0 - 11.0 V
84551720B NA - August 2012

4023G-4
Engine-side Trouble
DTC U0073 (Flash Code 84) 12) Replace the ECM if the resistance value is
within the range of standard value.
Control Module Communication Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Bus Off Removal".
1. DTC U0073 Diagnostics Installation".
13) Set the injector ID code on the ECM.
1) Turn OFF the starter switch. 14) Perform the unit difference learning of the fuel
2) Measure the resistance between the termi- supply pump to the ECM.
nals of the termination resistor harness con- 15) Turn OFF the starter switch.
nector. 16) Connect the harness connector to the ECM.
ANNOTATION: 17) Turn ON the starter switch.
18) Measure the voltage between the CAN-High
• Make a measurement from the back with the terminal and GND of the termination resistor
harness connector connected. harness connector.
• Confirm that the parallel resistance of the 19) Measure the voltage between the CAN-Low
120 Ω resistor in the termination resistor and terminal and GND of the termination resistor
that of the 120 Ω resistor in the ECM are harness connector.
both 60Ω. Roltage： 1.5 - 3.5 V
Resistance： 50.0 - 70.0 Ω 20) If the voltage is outside the standard range,
3) Disconnect the harness connector from termi- replace the ECM.
nation resistor if the resistance value is out- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
side the standard range. Removal".
4) Measure the resistance of the termination re- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
sistor. Installation".
Resistance： 110.0 - 130.0 Ω 21) Set the injector ID code on the ECM.
5) If the resistance value is outside the standard 22) Perform the unit difference learning of the fuel
range, replace the termination resistor. supply pump to the ECM.
6) Connect the harness connector to the termi- 23) Turn OFF the starter switch.
nation resistor . 24) Connect the harness connector to the control
7) Disconnect the harness connector from the unit of the actual unit.
control unit of the actual unit. 25) Turn ON the starter switch.
8) Measure the resistance between the termi- 26) Measure the voltage between the CAN-High
nals of the termination resistor harness con- terminal and GND of the termination resistor
nector. harness connector.
27) Measure the voltage between the CAN-Low
ANNOTATION: terminal and GND of the termination resistor
• Make a measurement from the back with the harness connector.
harness connector connected. Voltage： 1.5 - 3.5 V
28) If the voltage is outside the standard range,
Resistance： 50.0 - 70.0 Ω replace the control unit of the actual unit.
9) If the resistance value is within the standard 29) If the voltage is within the standard range, re-
range, replace the control unit of the actual place the termination resistor.
unit.
10) Disconnect the harness connector from the 2. DTC U0073 Confirm Resolution
ECM. 1) Use the trouble diagnosis scan tool to clear
11) Measure the resistance between the termi- the DTC.
nals of the termination resistor harness con- 2) Turn the starter switch OFF for 30 seconds.
nector. 3) Start the engine.
ANNOTATION: 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to check
• Make a measurement from the back with the if a DTC has been detected.
harness connector connected.
Resistance： 110.0 - 130.0 Ω
84551720B NA - August 2012

4023G-5
Engine-side Trouble
DTC P0087 (Flash Code 225) Fuel 15) If the harness connector and each circuit are
normal, replace the fuel pressure sensor.
Rail/System Pressure - Too Low Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0088
Common rail assembly Installation".
DTC P0089
DTC P0091 ANNOTATION:
DTC P0092
DTC P0192 • Do not replace the fuel pressure sensor sep-
DTC P0193 arately. When a problem is found, replace
DTC P0201 the common rail assembly.
DTC P0202 16) If the fuel rail pressure sensor display is within
DTC P0203 the standard range, start the engine.
DTC P0204 17) Perform the injector stop test with the trouble
DTC P2146 diagnosis scan tool.
DTC P2149 18) Command each injector OFF, and confirm that
2. DTC P0087 Diagnostics the engine RPM changes on each injector.
1) Start the engine. 19) If any injector does not change the engine
2) Rev the engine a few times in neutral while RPM when OFF is instructed, replace the rel-
checking for a DTC with the trouble diagnosis evant injector.
scan tool. Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Check to see if the DTC P0087 is detected. Injector Removal".
4) If the DTC P0087 is not detected, replace the Refer to "1.Engine 1C.Fuel System(4HK1X)
fuel filter element. Injector Installation".
20) When the injector has been replaced, set the
ANNOTATION: injector ID code on the ECM.
21) Inspect to see if there is clogging with the fuel
• An intermittent problem due to foreign mat- system between the fuel tank and the fuel sup-
ter in the fuel is suspected.
ply pump.
Refer to "1.Engine 1C.Fuel System(4HK1X) 22) If a problem is discovered, repair the clogging
Fuel filter element Removal". of the fuel system.
Refer to "1.Engine 1C.Fuel System(4HK1X) 23) Inspect the fuel hose between the fuel tank
Fuel filter element Installation". and the fuel supply pump for a cut and crack.
5) Turn OFF the starter switch. 24) If a problem is discovered, replace the fuel
6) Wait for the specified period of time until the hose.
fuel pressure is released from the common
ANNOTATION:
rail.
Specified time： 2 min • The fuel hose between the fuel tank and the
7) Turn ON the starter switch. fuel supply pump becomes negative pres-
8) Check the fuel rail pressure sensor display sure state when the engine is running.
with the trouble diagnosis scan tool. • When the fuel hose is not connected se-
Voltage： 0.9 - 1.0 V curely, the air can enter.
9) If the fuel rail pressure sensor display is out- • When the engine RPM or the engine load
side the standard range, inspect the fuel pres- increases while the air has intruded in the
sure sensor harness connector for a contact fuel system, fluctuation in the common rail
failure. pressure is caused, and DTC P0087 may
10) If a problem is discovered, repair the harness be detected.
connector.
11) Inspect the ECM harness connector for a con- 25) Check that an appropriate clamp is used be-
tact failure. tween the fuel tank and the fuel supply pump.
12) If a problem is discovered, repair the harness 26) If a problem is discovered, replace the clamp.
connector. 27) Operate the priming pump until the handle be-
13) Inspect each circuit for high resistance. comes heavy.
14) Repair the circuit if a problem is discovered. ANNOTATION:
• When a leak exists in the fuel system be-
tween the priming pump and the fuel sup-
ply pump, the pressing weight of the priming
pump does not become heavy.
29) Inspect the high-pressure side of the fuel sys-
tem and check for fuel leak between the fuel
supply pump and common rail.
84551720B NA - August 2012

4023G-6
Engine-side Trouble
ANNOTATION: 39) If a problem is discovered, repair the fuel sys-

tem.
• The fuel may leak to the bottom section of 40) Inspect the fuel tank bent hose.
the cylinder head cover from the high pres- 41) If a problem is discovered, repair the bent
sure hose inlet. hose.
• The engine oil level increases when the fuel 42) Check to see if there is any foreign matter in
leaks to the bottom portion of the cylinder the fuel tank or any foreign matter which can
head cover. cause fuel clogging.
• Inspect for fuel leaks into the engine oil. 43) If a problem is discovered, repair it.
30) If fuel leak if found, fix the problem. 44) Replace the fuel filter element.
31) Turn OFF the starter switch. Refer to "1.Engine 1C.Fuel System(4HK1X)
32) Remove the fuel hose on the fuel supply pump Fuel filter element Removal".
side from the fuel filter. Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
ANNOTATION: 45) If the negative pressure is at or below the stan-
• Use a pan to catch the fuel from the re- dard value, pinch the fuel hose at a position as
moved fuel hose. close as possible to the fuel tank, so that the
• Clean the pressure gauge and connection fuel does not flow.
hose before connecting to the fuel pipe. ANNOTATION:
• The fuel supply pump may be damaged due
to foreign matter that has entered in the con- • The fuel pipe can be disconnected and
nection hose. clogged with a plug.
33) Connect the pressure gauge between the fuel 46) Start the engine and use the idling control
filter and the removed fuel hose. switch to increase the RPM to the highest
level.
ANNOTATION: 47) Check the pressure gauge.
• Confirm that the fuel system is connected Specified value： 27.0 kPa ( 3.916 psi ) {203
securely. mmHg / 8 inHg}
34) Remove the air using the priming pump, and ANNOTATION:
crank the engine for the specified period of • When the pressure gauge is likely to indi-
time or shorter. cate a value exceeding the standard value
Specified time： 5 s during inspection, release the fuel being
ANNOTATION: blocked.
• Air mixture is checked with the negative
• Repeat this until the engine starts. pressure amount while the fuel flow is being
35) Leave the engine idling for the specified pe- blocked.
riod of time or longer. 48) If the standard negative pressure cannot be
specified time： 1 min generated, inspect to see if there is a cut or
36) While keeping the engine rotating at the spec- crack with the fuel hose.
ified engine RPM for the specified period of 49) If a problem is discovered, replace the fuel
time, check the pressure gauge. hose.
specified time： 1 min 50) Inspect to see if appropriate clamp is used.
rotational speed： 2500 min-1 {2500 r/min} 51) If a problem is discovered, replace the clamp
37) Check if the pressure gauge shows a negative with an appropriate one.
pressure value at or above the standard value 52) Turn OFF the starter switch.
during inspection. 53) Inspect the suction control valve harness con-
Specified value： 17.0 kPa ( 2.466 psi ) {128 nector for a contact failure.
mmHg / 5 inHg} 54) If a problem is discovered, repair the harness
ANNOTATION: connector.
55) Inspect the ECM harness connector for a con-
• Fuel clogging is checked with the negative tact failure.
pressure amount in the fuel system. 56) If a problem is discovered, repair the harness
38) If the negative pressure is at or above the connector.
standard value, inspect to see if there is dam- 57) Inspect each circuit for high resistance.
age or twisting with the fuel system between 58) Repair the circuit if a problem is discovered.
the fuel supply pump and the fuel tank.
84551720B NA - August 2012

4023G-7
Engine-side Trouble
59) If the suction control valve harness connector DTC P0088 (Flash Code 118) Fuel
and the ECM harness connector are normal
and there is no high resistance in each circuit, Rail/System Pressure - Too High
replace the fuel supply pump and the fuel filter
element.
DTC P0089
DTC P0091
Fuel supply pump Removal".
DTC P0092
DTC P0192
Fuel supply pump Installation".
DTC P0193
DTC P0201
Fuel filter element Removal".
DTC P0202
DTC P0203
DTC P0204
ANNOTATION: DTC P2146
DTC P2149
• When replacing the fuel supply pump, it is 2. DTC P0088 Diagnostics
required to also replace the fuel filter ele-
ment at the same time. 1) Start the engine.
2) Rev the engine a few times in neutral while
60) Perform the unit difference learning of the fuel checking the actual fuel rail pressure display
supply pump to the ECM. with the trouble diagnosis scan tool.
3. DTC P0087 Confirm Resolution 3) Check the actual fuel rail pressure display with
1) Clear the DTC using the trouble diagnosis Standard value ：(-5) - 5 MPa ( (-725.26) -
scan tool. 725.27 psi )
2) Turn the starter switch OFF for 30 seconds or 4) If it is at or below the standard value, replace
longer. the fuel filter element.
4) Perform a test-run. ANNOTATION:
• An intermittent problem due to foreign mat-
that a DTC has not been detected. ter in the fuel is suspected.
6) Wait for the specified period of time until the
rail.
8) Check the fuel rail pressure sensor display
with the trouble diagnosis scan tool.
Voltage： 0.9 - 1.0 V
9) If the fuel rail pressure sensor display is out-
side the standard range, inspect the fuel pres-
sure sensor harness connector for a contact
failure.
connector.
tact failure.
connector.
13) Inspect each circuit for high resistance.
14) If a problem is discovered, repair the circuit.
84551720B NA - August 2012

4023G-8
Engine-side Trouble
15) If the harness connector and each circuit are ANNOTATION:

Refer to "1.Engine 1C.Fuel System(4HK1X) • The fuel may leak to the bottom section of
the cylinder head cover from the high pres-
sure hose inlet.
Common rail assembly Installation". • The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder
ANNOTATION: head cover.
• Inspect for fuel leaks into the engine oil.
• Do not replace the fuel pressure sensor sep-
arately. 30) If fuel leak if found, fix the problem.
When a problem is found, replace the com- 31) Turn OFF the starter switch.
mon rail assembly. 32) Remove the fuel hose on the fuel supply pump
side from the fuel filter.
17) Perform the injector stop test with the trouble ANNOTATION:
diagnosis scan tool.
18) Command each injector OFF, and confirm that • Use a pan to catch the fuel from the re-
moved fuel hose.
the engine RPM changes on each injector.
19) If any injector does not change the engine • Clean the pressure gauge and connection
hose before connecting to the fuel pipe.
RPM when OFF is instructed, replace the rel-
evant injector. • The fuel supply pump may be damaged due
to foreign matter that has entered in the con-
nection hose.
Injector Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X) 33) Connect the pressure gauge between the fuel
Injector Installation". filter and the removed fuel hose.
injector ID code on the ECM. ANNOTATION:
21) Inspect to see if there is clogging with the fuel • Confirm that the fuel system is connected
system between the fuel tank and the fuel sup- securely.
ply pump.
22) If a problem is discovered, repair the clogging 34) Remove the air using the priming pump, and
of the fuel system. crank the engine for the specified period of
23) Inspect the fuel hose between the fuel tank time or shorter.
and the fuel supply pump for a cut and crack. specified time： 5 s
24) If a problem is discovered, replace the fuel ANNOTATION:
hose.
• Repeat this until the engine starts.
ANNOTATION:
35) Leave the engine idling for the specified pe-
• The fuel hose between the fuel tank and the riod of time or longer.
fuel supply pump becomes negative pres- specified time： 1 min
sure state when the engine is running. 36) While keeping the engine rotating at the spec-
• When the fuel hose is not connected se- ified engine RPM for the specified period of
curely, the air can enter. time, check the pressure gauge.
• When the engine RPM or the engine load Specified time： 1 min
increases while the air has intruded in the Rotational speed： 2500 min-1 {2500 r/min}
fuel system, fluctuation in the common rail 37) Check if the pressure gauge shows a negative
pressure is caused, and DTC P0088 may pressure value at or above the standard value
be detected. during inspection.
25) Check that an appropriate clamp is used be- specified value： 17.0 kPa ( 2.466 psi ) {128
tween the fuel tank and the fuel supply pump. mmHg / 5 inHg}
26) If a problem is discovered, replace the clamp. ANNOTATION:
27) Operate the priming pump until the handle be-
comes heavy. • Fuel clogging is checked with the negative
pressure amount in the fuel system.
ANNOTATION:
38) If the negative pressure is at or above the
• When a leak exists in the fuel system be- standard value, inspect to see if there is dam-
tween the priming pump and the fuel sup- age or twisting with the fuel system between
ply pump, the pressing weight of the priming the fuel supply pump and the fuel tank.
pump does not become heavy. 39) If a problem is discovered, repair the fuel sys-
28) Start the engine. tem.
29) Inspect the high-pressure side of the fuel sys- 40) Inspect the fuel tank bent hose.
tem and check for fuel leak between the fuel 41) If a problem is discovered, repair the bent
supply pump and common rail. hose.
84551720B NA - August 2012

4023G-9
Engine-side Trouble
42) Check to see if there is any foreign matter in 53) Inspect the suction control valve harness con-
the fuel tank or any foreign matter which can nector for a contact failure.
cause fuel clogging. 54) If a problem is discovered, repair the harness
43) If a problem is discovered, repair it. connector.
44) Replace the fuel filter element. 55) Inspect the ECM harness connector for a con-
Refer to "1.Engine 1C.Fuel System(4HK1X) tact failure.
Fuel filter element Removal". 56) If a problem is discovered, repair the harness
Refer to "1.Engine 1C.Fuel System(4HK1X) connector.
Fuel filter element Installation". 57) Inspect each circuit for high resistance.
45) If the negative pressure is at or below the stan- 58) Repair the circuit if a problem is discovered.
dard value, pinch the fuel hose at a position as 59) If the suction control valve harness connector
close as possible to the fuel tank, so that the and the ECM harness connector are normal
fuel does not flow. and there is no high resistance in each circuit,
replace the fuel supply pump and the fuel filter
ANNOTATION: element.
• The fuel pipe can be disconnected and Refer to "1.Engine 1C.Fuel System(4HK1X)
clogged with a plug. Fuel supply pump Removal".
46) Start the engine and use the idling control Fuel supply pump Installation".
switch to increase the RPM to the highest Refer to "1.Engine 1C.Fuel System(4HK1X)
level. Fuel filter element Removal".
47) Check the pressure gauge. Refer to "1.Engine 1C.Fuel System(4HK1X)
Specified value： 27.0 kPa ( 3.916 psi ) {203 Fuel filter element Installation".
mmHg / 8 inHg}
ANNOTATION:
ANNOTATION:
• When replacing the fuel supply pump, it is
• When the pressure gauge is likely to indi- required to also replace the fuel filter ele-
cate a value exceeding the standard value ment at the same time.
during inspection, release the fuel being
blocked. 60) Perform the unit difference learning of the fuel
• Air mixture is checked with the negative supply pump to the ECM.
pressure amount while the fuel flow is being 3. DTC P0088 Confirm Resolution
blocked.
48) If the standard negative pressure cannot be scan tool.
generated, inspect to see if there is a cut or 2) Turn the starter switch OFF for 30 seconds or
crack with the fuel hose. longer.
49) If a problem is discovered, replace the fuel 3) Start the engine.
hose. 4) Perform a test-run.
50) Inspect to see if appropriate clamp is used. 5) Use the trouble diagnosis scan tool to confirm
51) If a problem is discovered, replace the clamp that a DTC has not been detected.
with an appropriate one.
84551720B NA - August 2012

4023G-10
Engine-side Trouble
DTC P0089 (Flash Code 151)Fuel 14) Inspect each circuit for high resistance.
Pressure Regulator Performance 16) Turn the starter switch OFF for 30 seconds or
longer.
DTC P0091
18) Rev the engine a few times in neutral while
DTC P0092
checking the actual fuel rail pressure display
DTC P0192
DTC P0193
DTC P0201
if the actual fuel rail pressure display shows a
DTC P0202
value within the standard range at a sufficient
DTC P0203
rate.
DTC P0204
Standard values: (-5) - 5 MPa ( (-725.26) -
DTC P2146
725.27 psi )
DTC P2149
2. DTC P0089 Diagnostics ANNOTATION:
1) Wait for the specified period of time until the • If possible, compare with other actual unit
fuel pressure is released from the common equipped with the same model engine.
rail.
Specified time： 2 min 20) If it is within the standard range, replace the
2) Check the fuel rail pressure sensor display fuel filter element.
with the trouble diagnosis scan tool. Refer to "1.Engine 1C.Fuel System(4HK1X)
Coltage： 0.9 - 1.0 V Fuel filter element Removal".
3) If the fuel rail pressure sensor display is out- Refer to "1.Engine 1C.Fuel System(4HK1X)
side the standard range, inspect the fuel pres- Fuel filter element Installation".
sure sensor harness connector for a contact 21) If it is outside the standard range, replace the
failure. fuel supply pump and the fuel filter element.
4) If a problem is discovered, repair the harness Refer to "1.Engine 1C.Fuel System(4HK1X)
connector. Fuel supply pump Removal".
5) Inspect the ECM harness connector for a con- Refer to "1.Engine 1C.Fuel System(4HK1X)
tact failure. Fuel supply pump Installation".
6) If a problem is discovered, repair the harness Refer to "1.Engine 1C.Fuel System(4HK1X)
connector. Fuel filter element Removal".
7) Inspect each circuit for high resistance. Refer to "1.Engine 1C.Fuel System(4HK1X)
8) Repair the circuit if a problem is discovered. Fuel filter element Installation".
9) If the harness connector and each circuit are ANNOTATION:
Refer to "1.Engine 1C.Fuel System(4HK1X) • When replacing the fuel supply pump, it is
Common rail assembly Removal". required to also replace the fuel filter ele-
Refer to "1.Engine 1C.Fuel System(4HK1X) ment at the same time.
Common rail assembly Installation". 22) Perform the unit difference learning of the fuel
ANNOTATION: supply pump to the ECM.
• Do not replace the fuel pressure sensor sep- 3. DTC P0089 Confirm Resolution
arately. 1) Clear the DTC using the trouble diagnosis
When a problem is found, replace the com- scan tool.
mon rail assembly. 2) Turn the starter switch OFF for 30 seconds or
10) Inspect the suction control valve harness con- longer.
nector for a contact failure. 3) Start the engine.
11) If a problem is discovered, repair the harness 4) Perform a test-run.
connector. 5) Use the trouble diagnosis scan tool to confirm
12) Inspect the ECM harness connector for a con- that a DTC has not been detected.
tact failure.
connector.
84551720B NA - August 2012

4023G-11
Engine-side Trouble
DTC P0091 (Flash Code 247) Fuel 12) If a problem is discovered, repair the High side
circuit.
Pressure Regulator Control Circuit 13) Turn the starter switch OFF for 30 seconds or
Low 14)
longer.
Connect the test light between the suction
1. DTC P0091 Diagnostics control valve Low side circuit and battery
power supply.
1) Check the rail pressure regulator feedback 15) Turn ON the starter switch.
current display with the trouble diagnosis scan 16) Check if the test light comes on and then goes
tool. off.
Current： 300 - 900 mA 17) If it does not turn off, inspect the Low side
2) If it is at or above the standard value, inspect circuit between the ECM and suction control
to see if there is a short circuit to the battery valve.
or ignition power supply with the High side cir-
cuit between the ECM and the suction control • There should be no open circuit or high re-
valve. sistance.
• There should be no short to the battery or
ANNOTATION: ignition power supply.
• When the High side circuit is shorted to the 18) If a problem is discovered, repair the Low side
voltage, the engine stalls and does not start. circuit.
3) If a problem is discovered, repair the High side 19) Inspect the suction control valve harness con-
circuit. nector for a contact failure.
4) If it is within the standard range, inspect to 20) If a problem is discovered, repair the harness
see if there is a short circuit to the GND with connector.
the Low side circuit between the ECM and the 21) If the harness connector is normal, replace the
suction control valve. suction control valve.
ANNOTATION: Suction control valve Removal".
• When the Low side circuit is shorted to Refer to "1.Engine 1C.Fuel System(4HK1X)
GND, DTC P0091 may not be detected. Suction control valve Installation".
• When the Low side circuit is shorted to 22) Inspect the ECM harness connector for a con-
GND, the engine stalls and does not start. tact failure.
5) If a problem is discovered, repair the Low side connector.
circuit. 24) If the harness connector is normal, replace the
6) Turn the starter switch OFF for 30 seconds or ECM.
longer. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
7) Disconnect the harness connector from the Removal".
suction control valve. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) Connect the test light between the suction Installation".
control valve High side circuit and a normal 25) Set the injector ID code on the ECM.
GND. 26) Perform the unit difference learning of the fuel
9) Turn ON the starter switch. supply pump to the ECM.
10) Check if the test light comes on and then goes
off. 2. DTC P0091 Confirm Resolution
11) If it does not turn off, inspect the High side cir- 1) Clear the DTC using the trouble diagnosis
cuit between the ECM and the suction control scan tool.
valve. 2) Turn the starter switch OFF for 30 seconds or
• There should be no open circuit or high re- longer.
sistance. 3) Start the engine.
• There should be no short to GND. 4) Perform a test-run.
• There should be no short to the LOW side 5) Use the trouble diagnosis scan tool to confirm
circuit. that a DTC has not been detected.
84551720B NA - August 2012

4023G-12
Engine-side Trouble
DTC P0092 (Flash Code 247) Fuel 12) If a problem is discovered, repair the High side
circuit.
Pressure Regulator Control Circuit 13) Turn the starter switch OFF for 30 seconds or
High 14)
longer.
Connect the test light between the suction
1. DTC P0092 Diagnostics control valve Low side circuit and battery
power supply.
1) Check the rail pressure regulator feedback 15) Turn ON the starter switch.
current display with the trouble diagnosis scan 16) Check if the test light comes on and then goes
tool. off.
Current： 300 - 900 mA 17) If it does not turn off, inspect the Low side
2) If it is at or above the standard value, inspect circuit between the ECM and suction control
to see if there is a short circuit to the battery valve.
or ignition power supply with the High side cir-
cuit between the ECM and the suction control • There should be no open circuit or high re-
valve. sistance.
ANNOTATION: ignition power supply.
• When the High side circuit is shorted to the 18) If a problem is discovered, repair the Low side
voltage, the engine stalls and does not start. circuit.
3) If a problem is discovered, repair the High side 19) Inspect the suction control valve harness con-
circuit. nector for a contact failure.
4) If it is within the standard range, inspect to 20) If a problem is discovered, repair the harness
see if there is a short circuit to the GND with connector.
the Low side circuit between the ECM and the 21) If the harness connector is normal, replace the
suction control valve. suction control valve.
ANNOTATION: Suction control valve Removal".
• When the Low side circuit is shorted to Refer to "1.Engine 1C.Fuel System(4HK1X)
GND, DTC P0092 may not be detected. Suction control valve Installation".
• When the Low side circuit is shorted to 22) Inspect the ECM harness connector for a con-
GND, the engine stalls and does not start. tact failure.
5) If a problem is discovered, repair the Low side connector.
6) Turn the starter switch OFF for 30 seconds or ECM.
longer. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
7) Disconnect the harness connector from the Removal".
suction control valve. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) Connect the test light between the suction Installation".
control valve High side circuit and a normal 25) Set the injector ID code on the ECM.
GND. 26) Perform the unit difference learning of the fuel
10) Check if the test light comes on and then goes
off. 2. DTC P0092 Confirm Resolution
11) If it does not turn off, inspect the High side cir- 1) Clear the DTC using the trouble diagnosis
cuit between the ECM and the suction control scan tool.
valve. 2) Turn the starter switch OFF for 30 seconds or
• There should be no open circuit or high re- longer.
sistance. 3) Start the engine.
• There should be no short to GND. 4) Perform a test-run.
• There should be no short to the LOW side 5) Use the trouble diagnosis scan tool to confirm
circuit. that a DTC has not been detected.
84551720B NA - August 2012

4023G-13
Engine-side Trouble
DTC P0093 (Flash Code 227) Fuel 6) If fuel leak is found, replace the corresponding
injector.
System Leak Detected Refer to "1.Engine 1C.Fuel System(4HK1X)
Injector Removal".
DTC P0087
Injector Installation".
DTC P0091
DTC P0092
injector ID code on the ECM.
DTC P0192
DTC P0193
9) Wait for the specified period of time until the
DTC P0201
DTC P0202
rail.
DTC P0203
DTC P0204
DTC P2146
11) Check the fuel rail pressure sensor display
DTC P2149
Voltage： 0.9 - 1.0 V
1) Inspect for fuel leaks on the high-pressure 12) If the fuel rail pressure sensor display is out-
side between the fuel supply pump and injec- side the standard range, inspect the fuel pres-
tor. sure sensor harness connector for a contact
failure.
• There should be no fuel leakage from the 13) If a problem is discovered, repair the harness
fuel supply pump. connector.
• There should be no fuel leakage from the 14) Inspect the ECM harness connector for a con-
common rail. tact failure.
• There should be no fuel leakage from the 15) If a problem is discovered, repair the harness
pressure limiter valve. connector.
• There should be no fuel leakage from the 16) Inspect each circuit for high resistance.
fuel pressure sensor. 17) Repair the circuit if a problem is discovered.
• There should be no fuel leakage from the 18) If the harness connector and each circuit are
fuel pipe between the fuel supply pump and normal, replace the fuel pressure sensor.
common rail. Refer to "1.Engine 1C.Fuel System(4HK1X)
• There should be no fuel leakage from the Common rail assembly Removal".
fuel pipe between the common rail and in- Refer to "1.Engine 1C.Fuel System(4HK1X)
jector. Common rail assembly Installation".
• There should be no fuel leakage from the
sleeve nut of the fuel pipe. ANNOTATION:
2) If fuel leak if found, fix the problem. • Do not replace the fuel pressure sensor sep-
arately.
ANNOTATION: When a problem is found, replace the com-
• The fuel may leak to the bottom section of mon rail assembly.
the cylinder head cover from the high pres-
sure pipe inlet. 19) If the fuel rail pressure sensor display is within
the standard range, start the engine.
• The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder 20) Perform the injector stop test with the trouble
head cover. diagnosis scan tool.
21) Command each injector OFF, and confirm that
• Inspect for fuel leaks into the engine oil.
the engine RPM changes on each injector.
• Remove and inspect the high pressure pipe
joint connected to the injector for a fuel leak- 22) If any injector does not change the engine
age from the sleeve nut. RPM when OFF is instructed, replace the rel-
evant injector.
• When foreign matter has been attached,
replace the injector and the high pressure Refer to "1.Engine 1C.Fuel System(4HK1X)
pipe. Injector Removal".
3) Remove each glow plug from the cylinder Injector Installation".
head assembly. 23) When the injector has been replaced, set the
Refer to "1.Engine 1B.Mechanical(4HK1X) injector ID code on the ECM.
Cylinder head assembly Removal". 24) Inspect to see if there is clogging with the fuel
4) Inspect for fuel leaks into the combustion system between the fuel tank and the fuel sup-
chamber. ply pump.
5) Inspect to see if there is a cylinder from which 25) If a problem is discovered, repair clogging.
fuel leaks into the combustion chamber. 26) Inspect to see if there is cut or crack with the
fuel hose in the fuel system between the fuel
tank and the fuel supply pump.
84551720B NA - August 2012

4023G-14
Engine-side Trouble
27) If a problem is discovered, replace the fuel 37) Remove the air using the priming pump, and
hose. crank the engine for the specified period of
time or shorter.
ANNOTATION: Specified time： 5 s
• The fuel hose between the fuel tank and ANNOTATION:
the supply pump becomes negative pres-
sure state when the engine is running. • Repeat this until the engine starts.
• When the fuel hose is not connected se-
38) Leave the engine idling for the specified pe-
curely, the air can enter.
riod of time or longer.
• When the engine RPM or the engine load
increases while the air has intruded in the
39) While keeping the engine rotating at the spec-
fuel system, fluctuation in the common rail
ified engine RPM for the specified period of
pressure is caused, and DTC P0093 may
time, check the pressure gauge.
be detected.
28) Check that an appropriate clamp is used be- Rotational speed： 2500 min-1 {2500 r/min}
tween the fuel tank and the fuel supply pump. 40) Check if the pressure gauge shows a negative
29) If a problem is discovered, replace the clamp pressure value at or above the standard value
with an appropriate one. during inspection.
30) Operate the priming pump until the handle be- Specified value： 17.0 kPa ( 2.466 psi ) {128
comes heavy. mmHg / 5 inHg}
• When a leak exists in the fuel system be- • Fuel clogging is checked with the negative
tween the priming pump and the fuel sup- pressure amount in the fuel system.
ply pump, the pressing weight of the priming
41) If the negative pressure is at or above the
pump does not become heavy.
standard value, inspect to see if there is dam-
31) Start the engine. age or twisting with the fuel system between
32) Inspect the high-pressure side of the fuel sys- the fuel supply pump and the fuel tank.
tem and check for fuel leak between the fuel 42) If a problem is discovered, repair the fuel sys-
supply pump and common rail. tem.
43) Inspect the fuel tank bent hose.
ANNOTATION: 44) If a problem is discovered, repair the bent
• The fuel may leak to the bottom section of hose.
the cylinder head cover from the high pres- 45) Check to see if there is any foreign matter in
sure hose inlet. the fuel tank or any foreign matter which can
• The engine oil level increases when the fuel cause fuel clogging.
leaks to the bottom portion of the cylinder 46) If a problem is discovered, repair it.
head cover. 47) Replace the fuel filter element.
• Inspect for fuel leaks into the engine oil. Refer to "1.Engine 1C.Fuel System(4HK1X)
33) If fuel leak if found, fix the problem. Refer to "1.Engine 1C.Fuel System(4HK1X)
34) Turn OFF the starter switch. Fuel filter element Installation".
35) Remove the fuel hose on the fuel supply pump 48) If the negative pressure is at or below the stan-
side from the fuel filter. dard value, pinch the fuel hose at a position as
ANNOTATION: close as possible to the fuel tank, so that the
fuel does not flow.
• Use a pan to catch the fuel from the re-
moved fuel hose. ANNOTATION:
• Clean the pressure gauge and connection • The fuel pipe can be disconnected and
hose before connecting to the fuel pipe. clogged with a plug.
• The fuel supply pump may be damaged due
to foreign matter that has entered in the con- 49) Start the engine and use the idling control
nection hose. switch to increase the RPM to the highest
level.
36) Connect the pressure gauge between the fuel 50) Check the pressure gauge.
filter and the removed fuel hose. Specified value： 27.0 kPa ( 3.916 psi ) {203
ANNOTATION: mmHg / 8 inHg}
• Confirm that the fuel system is connected ANNOTATION:
securely. • When the pressure gauge is likely to indi-
cate a value exceeding the standard value
during inspection, release the fuel being
blocked.
84551720B NA - August 2012

4023G-15
Engine-side Trouble
• Air mixture is checked with the negative DTC U0101 (Flash Code 85) Lost
pressure amount while the fuel flow is being
blocked. Communication with TCM
51) If the standard negative pressure cannot be 1. DTC U0101 Diagnostics
generated, inspect to see if there is a cut or
1) Inspect the CAN-Low circuit and CAN-High
crack with the fuel hose.
circuit between the ECM and the control unit
52) If a problem is discovered, replace the fuel
of the actual unit.
hose.
53) Inspect to see if appropriate clamp is used. • There should be no short to the battery or
54) If a problem is discovered, replace the clamp ignition power supply.
with an appropriate one. • There should be no open circuit or high re-
55) Turn OFF the starter switch. sistance.
56) Inspect the suction control valve harness con- • There should be no short to GND.
nector for a contact failure.
57) If a problem is discovered, repair the harness 2) If a problem is discovered, repair the CAN
connector. circuit.
58) Inspect the ECM harness connector for a con- 3) If the CAN circuit is normal, connect all har-
tact failure. nesses.
59) If a problem is discovered, repair the harness 4) Clear the DTC using the trouble diagnosis
connector. scan tool.
60) Inspect each circuit for high resistance. 5) Turn the starter switch OFF for 30 seconds or
61) Repair the circuit if a problem is discovered. longer.
62) If the suction control valve harness connector 6) Perform a test-run.
and the ECM harness connector are normal 7) Check the DTC.
and there is no high resistance in each circuit, 8) If a DTC has been detected, replace the con-
replace the fuel supply pump and the fuel filter trol unit of the actual unit.
element. 9) Connect all harnesses.
Refer to "1.Engine 1C.Fuel System(4HK1X) 10) Clear the DTC using the trouble diagnosis
Fuel supply pump Removal". scan tool.
Refer to "1.Engine 1C.Fuel System(4HK1X) 11) Turn the starter switch OFF for 30 seconds or
Fuel supply pump Installation". longer.
Refer to "1.Engine 1C.Fuel System(4HK1X) 12) Perform a test-run.
Fuel filter element Removal". 13) Check the DTC.
Refer to "1.Engine 1C.Fuel System(4HK1X) 14) If a DTC has been detected, replace the ECM.
Fuel filter element Installation". Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
ANNOTATION: Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
• When replacing the fuel supply pump, it is 15) Set the injector ID code on the ECM.
required to also replace the fuel filter ele-
ment at the same time.
supply pump to the ECM.
2. DTC U0101 Confirm Resolution
3. DTC P0093 Confirm Resolution
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
84551720B NA - August 2012

4023G-16
Engine-side Trouble
DTC P0102 (Flash Code 91) Mass DTC P0103 (Flash Code 91) Mass
Air Flow Circuit Low Input Air Flow Circuit High Input
1. DTC P0102 Priority DTC 1. DTC P0103 Priority DTC
DTC P0560 DTC P0560
2. DTC P0102 Diagnostics 2. DTC P0103 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
mass air flow sensor. mass air flow sensor.
3) Inspect to see if there is an open circuit or high 3) Check the mass air flow sensor display with
resistance in the 12 V power supply circuit be- the trouble diagnosis scan tool.
tween the ECM and the mass air flow sensor. Voltage： 0.1 V
4) If a problem is discovered, repair the 12 V 4) If it is at or above the standard value, inspect
power supply circuit. the signal circuit between the ECM and the
5) Connect the test cable with fuse between the mass air flow sensor.
12 V power supply circuit and the signal circuit
of the mass air flow sensor harness connector. • There should be no short to the battery or
6) Check the mass air flow sensor display with ignition power supply.
the trouble diagnosis scan tool. • There should be no short to the 12 V or 5 V
Voltage： 4.9 V power supply.
7) If it is at or above the standard value, inspect 5) If a problem is discovered, repair the Signal
to see if there is a contact failure with the mass circuit.
air flow sensor harness connector. 6) Inspect to see if there is an open circuit or
8) If a problem is discovered, repair the harness high resistance in the GND circuit between the
connector. ECM and the mass air flow sensor.
9) If the harness connector is normal, replace the 7) If a problem is discovered, repair the GND
mass air flow sensor. circuit.
10) Inspect the signal circuit between the ECM 8) Inspect the mass air flow sensor harness con-
and the mass air flow sensor. nector for a contact failure.
connector.
sistance.
mass air flow sensor.
11) If a problem is discovered, repair the Signal 11) Inspect the ECM harness connector for a con-
circuit. tact failure.
12) Inspect the ECM harness connector for a con- 12) If a problem is discovered, repair the harness
tact failure. connector.
13) If a problem is discovered, repair the harness 13) If the harness connector is normal, replace the
connector. ECM.
14) If the harness connector is normal, replace the Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ECM. Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". Installation".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 14) Set the injector ID code on the ECM.
Installation". 15) Perform the unit difference learning of the fuel
15) Set the injector ID code on the ECM. supply pump to the ECM.
scan tool.
scan tool. longer.
84551720B NA - August 2012

4023G-17
Engine-side Trouble
DTC U0110 (Flash Code 87) Lost DTC P0112 (Flash Code 22)
Communication with VNT System Intake Air Temperature Sensor
1. DTC U0110 Priority DTC Circuit Low
DTC P0045
DTC U0001 1. DTC P0112 Priority DTC
2. DTC U0110 Diagnostics DTC P0641
2) Remove the harness connector from the turbo 1) Turn OFF the starter switch.
control unit. 2) Disconnect the harness connector from the
3) Turn ON the starter switch. intake air temperature sensor.
4) Measure the voltage between the CAN-High 3) Check the intake air temperature sensor dis-
circuit and GND of the turbo control unit har- play with the trouble diagnosis scan tool.
ness connector. Voltage： 4.5 V
5) Measure the voltage between the CAN-High 4) If it is at or above the standard value, replace
circuit and GND of the turbo control unit har- the intake air temperature sensor.
ness connector. 5) Inspect to see if there is a short circuit to the
Voltage： 1.5 - 3.5 V GND with the signal circuit between the ECM
6) If it is outside the standard range, inspect to and the intake air temperature sensor.
see if there is an open circuit or high resis- 6) If a problem is discovered, repair the signal
tance with the CAN-High circuit between the circuit.
turbo control unit and the ECM. 7) Turn OFF the starter switch.
7) If a problem is discovered, repair the CAN- 8) Disconnect the harness connector from the
High circuit. ECM.
8) Inspect to see if there is an open circuit or high 9) Inspect the ECM harness connector for a con-
resistance with the CAN-Low circuit between tact failure.
the turbo control unit and the ECM. 10) If a problem is discovered, repair the harness
9) If a problem is discovered, repair the CAN- connector.
Low circuit. 11) If the harness connector is normal, replace the
10) Inspect the turbo control unit harness connec- ECM.
tor for a contact failure. Refer to "1.Engine 1J.Electrical(4HK1) ECM
11) If a problem is discovered, repair the harness Removal".
connector. Refer to "1.Engine 1J.Electrical(4HK1) ECM
12) Replace the turbo control unit. Installation".
3. DTC U0110 Confirm Resolution 13) Perform the unit difference learning of the fuel
scan tool. 3. DTC P0112 Confirm Resolution
longer. 1) Clear the DTC using the trouble diagnosis
3) Start the engine. scan tool.
4) Perform a test-run. 2) Turn the starter switch OFF for 30 seconds or
5) Use the trouble diagnosis scan tool to confirm longer.
that a DTC has not been detected. 3) Start the engine.
84551720B NA - August 2012

4023G-18
Engine-side Trouble
DTC P0113 (Flash Code 22) 15) Check the intake air temperature sensor dis-
play with the trouble diagnosis scan tool.
Intake Air Temperature Sensor Voltage： 0.1 V
Circuit High 16) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
1. DTC P0113 Priority DTC tance with the GND circuit between the ECM
DTC P0641 and the intake air temperature sensor.
ANNOTATION:
• The intake air temperature sensor shares
the GND circuit with other sensors.
intake air temperature sensor.
• The DTC set on a sensor which shares this
circuit may be detected.
4) Measure the voltage between the intake air
temperature sensor signal circuit and a nor- 17) If a problem is discovered, repair the GND
mal GND. circuit.
Voltage： 5.5 V 18) Inspect to see if there is an open circuit or
5) If it is at or above the standard value, inspect high resistance in the signal circuit between
the signal circuit between the ECM and the the ECM and the intake air temperature sen-
intake air temperature sensor. sor.
19) If a problem is discovered, repair the signal
• There should be no short to the battery or circuit.
ignition power supply
• There should be no short to the 12 V power tact failure.
supply.
6) If a problem is discovered, repair the signal connector.
7) Connect the test cable with fuse between the ECM.
intake air temperature sensor signal circuit Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and the GND circuit. Removal".
8) Check the intake air temperature sensor dis- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
play with the trouble diagnosis scan tool. Installation".
Voltage： 0.1 V 23) Set the injector ID code on the ECM.
9) If it is at or below the standard value, inspect to 24) Perform the unit difference learning of the fuel
see if there is a short circuit to the 5 V power supply pump to the ECM.
supply circuit with the signal circuit between
the ECM and the intake air temperature sen-
sor. 1) Clear the DTC using the trouble diagnosis
10) If a problem is discovered, repair the signal scan tool.
circuit. 2) Turn the starter switch OFF for 30 seconds or
11) Inspect the intake air temperature sensor har- longer.
ness connector for a contact failure. 3) Start the engine.
13) If the harness connector is normal, replace the that a DTC has not been detected.
intake air temperature sensor.
14) Connect the test cable with fuse between the
intake air temperature sensor signal circuit
and a normal GND.
84551720B NA - August 2012

4023G-19
Engine-side Trouble
DTC P0117 (Flash Code 23) DTC P0118 (Flash Code 23)
Engine Coolant Temperature Engine Coolant Temperature
Sensor Circuit Low Sensor Circuit High
DTC P0697 DTC P0697
water temperature sensor. water temperature sensor.
3) Check the coolant temperature sensor display 3) Turn ON the starter switch.
with the trouble diagnosis scan tool. 4) Measure the voltage between the water tem-
Voltage： 4.5 V perature sensor signal circuit and normal
4) If it is at or above the standard value, replace GND.
the water temperature sensor. Voltage： 5.5 V
Refer to "1.Engine 1D.Cooling(4HK1X) En- 5) If it is at or above the standard value, inspect
gine coolant temperature sensor Removal". to see if there is a short circuit to the battery
Refer to "1.Engine 1D.Cooling(4HK1X) En- or ignition power supply with the signal circuit
gine coolant temperature sensor Installation". between the ECM and the water temperature
5) Inspect to see if there is a short circuit to the sensor.
GND with the signal circuit between the ECM 6) If a problem is discovered, repair the signal
and water temperature sensor. circuit.
6) If a problem is discovered, repair the signal 7) Connect the test cable with fuse between the
circuit. water temperature sensor signal Circuit and
7) Inspect the ECM harness connector for a con- GND circuit.
tact failure. 8) Check the coolant temperature sensor display
8) If a problem is discovered, repair the harness with the trouble diagnosis scan tool.
connector. Voltage： 0.1 V
9) If the harness connector is normal, replace the 9) If it is at or below the standard value, inspect to
ECM. see if there is a short circuit to the 5 V power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM supply circuit with the signal circuit between
Removal". the ECM and the water temperature sensor.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 10) If a problem is discovered, repair the signal
Installation". circuit.
10) Set the injector ID code on the ECM. 11) Inspect to see if there is a contact failure with
11) Perform the unit difference learning of the fuel the water temperature sensor harness con-
supply pump to the ECM. nector.
3. DTC P0117 Confirm Resolution connector.
1) Clear the DTC using the trouble diagnosis 13) If the harness connector is normal, replace the
scan tool. water temperature sensor.
2) Turn the starter switch OFF for 30 seconds or Refer to "1.Engine 1D.Cooling(4HK1X) En-
longer. gine coolant temperature sensor Removal".
3) Start the engine. Refer to "1.Engine 1D.Cooling(4HK1X) En-
4) Perform a test-run. gine coolant temperature sensor Installation".
5) Use the trouble diagnosis scan tool to confirm 14) Connect the test cable with fuse between the
that a DTC has not been detected. water temperature sensor signal circuit and
normal GND.
15) Check the coolant temperature sensor display
Voltage： 0.1 V
16) If it is at or below the standard value, inspect
tance with the water temperature sensor GND
circuit.
ANNOTATION:
• The water temperature sensor shares the
GND circuit with other sensors.
17) If a problem is discovered, repair the GND
circuit.
84551720B NA - August 2012
4023G-20
Engine-side Trouble
18) Inspect to see if there is a breakage or high re- DTC P0122 (Flash Code 43)
sistance in the signal circuit of the water tem-
perature sensor. Throttle Position Sensor Circuit
circuit.
Low
20) Inspect the ECM harness connector for a con- 1. DTC P0122 Priority DTC
tact failure. DTC P1655
21) If a problem is discovered, repair the harness 2. DTC P0122 Diagnostics
connector.
22) If the harness connector is normal, replace the 1) Turn OFF the starter switch.
ECM. 2) Disconnect the harness connector from the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM intake throttle valve.
Removal". 3) Turn ON the starter switch.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 4) Measure the voltage between the intake throt-
Installation". tle position sensor 5 V power supply circuit
23) Set the injector ID code on the ECM. and a normal GND.
24) Perform the unit difference learning of the fuel Voltage： 4.9 V
supply pump to the ECM. 5) If it is at or below the standard value, inspect
to see if there is an open circuit or high re-
3. DTC P0118 Confirm Resolution sistance with the 5 V power supply circuit be-
tween the ECM and the intake throttle position
sensor.
scan tool.
2) Turn the starter switch OFF for 30 seconds or ANNOTATION:
longer.
3) Start the engine. • The intake throttle position sensor shares
4) Perform a test-run. the 5 V power supply circuit with other sen-
5) Use the trouble diagnosis scan tool to confirm sors.
that a DTC has not been detected. • The DTC set on a sensor which shares this
6) If a problem is discovered, repair the 5 V
power supply circuit.
intake throttle position sensor 5 V power sup-
ply circuit and the signal circuit.
8) Check the intake throttle position sensor dis-
Voltage： 4.9 V
9) If it is at or above the standard value, inspect
to see if there is a contact failure with the in-
take throttle valve harness connector.
connector.
intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
take throttle valve Installation".
12) Inspect the signal circuit between the ECM
and intake throttle position sensor.
sistance.
circuit.
tact failure.
connector.
84551720B NA - August 2012

4023G-21
Engine-side Trouble
16) If the harness connector is normal, replace the DTC P0123 (Flash Code 43)
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Throttle Position Sensor Circuit
Removal".
High
Installation". 1. DTC P0123 Priority DTC
17) Set the injector ID code on the ECM. DTC P1655
18) Perform the unit difference learning of the fuel 2. DTC P0123 Diagnostics
3. DTC P0122 Confirm Resolution 2) Disconnect the harness connector from the
3) Check the intake throttle position sensor dis-
scan tool.
Voltage： 0.1 V
longer.
the signal circuit between the ECM and the
intake throttle position sensor.
that a DTC has not been detected. • There should be no short to the battery or
ignition power supply.
• There should be no short to the 5 V power
supply.
circuit.
6) Inspect the intake throttle valve harness con-
connector.
9) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the intake throttle position sensor.
ANNOTATION:
• The intake throttle position sensor shares
the GND circuit with other sensors.
circuit.
11) Check the ECM harness connector for a con-
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
84551720B NA - August 2012

4023G-22
Engine-side Trouble
2) Turn the starter switch OFF for 30 seconds or DTC P0182 (Flash Code 211) Fuel
longer.
3) Start the engine. Temperature Sensor Circuit Low
DTC P1655
fuel temperature sensor.
3) Check the fuel temperature sensor display
Voltage： 4.5 V
4) If it is at or above the standard value, replace
the fuel temperature sensor.
Fuel supply pump Removal".
Fuel supply pump Installation".
ANNOTATION:
• Do not replace the fuel temperature sensor
separately.
If a problem is found, replace the fuel supply
pump.
5) Inspect to see if there is a short circuit to the
GND with the signal circuit between the ECM
and fuel temperature sensor.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012

4023G-23
Engine-side Trouble
DTC P0183 (Flash Code 211) Fuel 14) Connect the test cable with fuse between the
fuel temperature sensor signal circuit and nor-
Temperature Sensor Circuit High mal GND.
15) Check the fuel temperature sensor display
DTC P1655
Voltage： 0.1 V
1) Turn OFF the starter switch. to see if there is an open circuit or high resis-
2) Disconnect the harness connector from the tance with the GND circuit between the ECM
fuel temperature sensor. and fuel temperature sensor.
ANNOTATION:
4) Measure the voltage between the fuel temper-
ature sensor signal circuit and normal GND. • The fuel temperature sensor shares the
Voltage： 5.5 V GND circuit with other sensors.
5) If it is at or above the standard value, inspect • The DTC set on a sensor which shares this
to see if there is a short circuit to the battery circuit may be detected.
or ignition power supply with the signal circuit
between the ECM and the fuel temperature 17) If a problem is discovered, repair the GND
sensor. circuit.
6) If a problem is discovered, repair the signal 18) Inspect to see if there is an open circuit or
circuit. high resistance in the signal circuit between
7) Connect the test cable with fuse between the ECM and the fuel temperature sensor.
the fuel temperature sensor signal circuit and 19) If a problem is discovered, repair the signal
GND circuit. circuit.
8) Check the fuel temperature sensor display 20) Inspect the ECM harness connector for a con-
with the trouble diagnosis scan tool. tact failure.
Voltage： 0.1 V 21) If a problem is discovered, repair the harness
9) If it is at or below the standard value, inspect to connector.
see if there is a short circuit to the 5 V power 22) If the harness connector is normal, replace the
supply circuit with the signal circuit between ECM.
the ECM and the fuel temperature sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
10) If a problem is discovered, repair the signal Removal".
circuit. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
11) Inspect to see if there is a contact failure with Installation".
the fuel temperature sensor harness connec- 23) Set the injector ID code on the ECM.
tor. 24) Perform the unit difference learning of the fuel
12) If a problem is discovered, repair the harness supply pump to the ECM.
connector. 3. DTC P0183 Confirm Resolution
fuel temperature sensor. 1) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1C.Fuel System(4HK1X) scan tool.
Fuel supply pump Removal". 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1C.Fuel System(4HK1X) longer.
Fuel supply pump Installation". 3) Start the engine.
ANNOTATION:
ANNOTATION:
• Do not replace the fuel temperature sensor
separately. • Run the engine for 3 minutes or longer.
If a problem is found, replace the fuel supply 5) Use the trouble diagnosis scan tool to confirm
pump. that a DTC has not been detected.
84551720B NA - August 2012

4023G-24
Engine-side Trouble
DTC P0192 (Flash Code 245) Fuel 10) Inspect to see if there is an open circuit or high
resistance with the 5 V power supply circuit
Rail Pressure Sensor Circuit Low between the ECM and fuel pressure sensor.
1. DTC P0192 Priority DTC ANNOTATION:
DTC P0641
2. DTC P0192 Diagnostics • The fuel pressure sensor shares the 5 V
power supply circuit with other sensors.
1) Turn OFF the starter switch. • The DTC set on a sensor which shares this
2) Disconnect the harness connector from the circuit may be detected.
3) Check the fuel rail pressure sensor display 11) If a problem is discovered, repair the 5 V
with the trouble diagnosis scan tool. power supply circuit.
Voltage： 4.5 V 12) Inspect the ECM harness connector for a con-
4) If it is at or below the standard value, inspect to tact failure.
see if there is a short circuit to the GND with 13) If a problem is discovered, repair the harness
the signal circuit between the ECM and the connector.
fuel pressure sensor. 14) If the harness connector is normal, replace the
5) If a problem is discovered, repair the signal ECM.
6) Measure the voltage between the fuel pres- Removal".
sure sensor 5 V power supply circuit and nor- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
mal GND. Installation".
Voltage： 4.5 V 15) Set the injector ID code on the ECM.
7) If it is at or above the standard value, inspect 16) Perform the unit difference learning of the fuel
to see if there is a contact failure with the fuel supply pump to the ECM.
pressure sensor harness connector. 3. DTC P0192 Confirm Resolution
connector. 1) Clear the DTC using the trouble diagnosis
9) If the harness connector is normal, replace the scan tool.
fuel pressure sensor. 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1C.Fuel System(4HK1X) longer.
Common rail assembly Removal". 3) Start the engine.
Refer to "1.Engine 1C.Fuel System(4HK1X) 4) Perform a test-run.
Common rail assembly Installation". 5) Use the trouble diagnosis scan tool to confirm
ANNOTATION:
arately.
When a problem is found, replace the com-
mon rail assembly.
84551720B NA - August 2012

4023G-25
Engine-side Trouble
DTC P0193 (Flash Code 245) Fuel 15) Inspect to see if there is an open circuit or
Rail Pressure Sensor Circuit High ECM and the fuel pressure sensor.
1. DTC P0193 Priority DTC ANNOTATION:
DTC P0641
2. DTC P0193 Diagnostics • The fuel pressure sensor shares the GND
circuit with other sensors.
1) Turn OFF the starter switch. • The DTC set on a sensor which shares this
2) Disconnect the harness connector from the circuit may be detected.
3) Turn ON the starter switch. 16) If a problem is discovered, repair the GND
4) Measure the voltage between the fuel pres- circuit.
sure sensor signal circuit and normal GND. 17) Inspect to see if there is an open circuit or
Voltage： 5.5 V high resistance in the signal circuit between
5) If it is at or above the standard value, inspect the ECM and the fuel pressure sensor.
to see if there is a short circuit to the battery 18) If a problem is discovered, repair the signal
or ignition power supply with the signal circuit circuit.
between the ECM and the fuel pressure sen- 19) Inspect the ECM harness connector for a con-
sor. tact failure.
6) If a problem is discovered, repair the signal 20) If a problem is discovered, repair the harness
circuit. connector.
7) Measure the voltage between the fuel pres- 21) If the harness connector is normal, replace the
sure sensor signal circuit and normal GND. ECM.
Voltage： 4.5 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) If it is at or above the standard value, inspect Removal".
to see if there is a short circuit to the 5 V power Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply circuit with the signal circuit between Installation".
the ECM and the fuel pressure sensor. 22) Set the injector ID code on the ECM.
9) If a problem is discovered, repair the signal 23) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
10) Connect the test cable with fuse between the 3. DTC P0193 Confirm Resolution
fuel pressure sensor signal circuit and GND
circuit. 1) Clear the DTC using the trouble diagnosis
11) Check the fuel rail pressure sensor display scan tool.
with the trouble diagnosis scan tool. 2) Turn the starter switch OFF for 30 seconds or
Voltage： 0.1 V longer.
12) If it is at or below the standard value, inspect 3) Start the engine.
to see if there is a contact failure with the fuel 4) Perform a test-run.
pressure sensor harness connector. 5) Use the trouble diagnosis scan tool to confirm
13) If a problem is discovered, repair the harness that a DTC has not been detected.
connector.
Common rail assembly Installation".
ANNOTATION:
arately.
mon rail assembly.
84551720B NA - August 2012

4023G-26
Engine-side Trouble
DTC P0201 (Flash Code 271) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 1 19) If any foreign matter is attached to the injector
terminal, remove it.
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the first cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the first cylin- mediate connector.
der injector charge voltage circuit and normal
GND. • There should be no open circuit or high re-
sistance.
Voltage： 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 1 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the first cylinder injector circuit between the
6) If a problem is discovered, repair the control injector and the injector intermediate connec-
circuit. tor is normal, replace the first cylinder injector.
7) Measure the voltage between the solenoid Refer to "1.Engine 1C.Fuel System(4HK1X)
control circuit of the first cylinder injector and Injector Removal".
normal GND. Refer to "1.Engine 1C.Fuel System(4HK1X)
Voltage： 16.0 V Injector Installation".
8) If it is at or above the standard value, inspect 25) When the injector has been replaced, set the
to see if there is a short circuit to the battery injector ID code on the ECM.
or ignition power supply with the control circuit 26) Disconnect the harness connector from the
between the ECM and the injector harness ECM.
intermediate connector. 27) Inspect the ECM harness connector for a con-
9) If a problem is discovered, repair the control tact failure.
circuit. 28) If a problem is discovered, repair the harness
10) Measure the voltage between the solenoid connector.
control circuit of the first cylinder injector and 29) If the harness connector is normal, replace the
normal GND. ECM.
11) If it is at or below the standard value, inspect Removal".
to see if there is an open circuit or high resis- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
tance with the control circuit between the ECM Installation".
and injector harness intermediate connector. 30) Set the injector ID code on the ECM.
12) If a problem is discovered, repair the control 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con-
nector for a contact failure. 2. DTC P0201 Confirm Resolution
14) If a problem is discovered, repair the injector 1) Clear the DTC using the trouble diagnosis
harness intermediate connector. scan tool.
15) Remove the cylinder head cover. 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1B.Mechanical(4HK1X) longer.
Cylinder head cover Removal". 3) Start the engine.
16) Inspect the injector harness tightening nut for 4) Perform a test-run.
looseness. 5) Use the trouble diagnosis scan tool to confirm
17) If the injector harness tightening nut is loose, that a DTC has not been detected.
tighten it.
84551720B NA - August 2012

4023G-27
Engine-side Trouble
connector. 22) Inspect the second cylinder injector circuit be-
4) Measure the voltage between the second mediate connector.
cylinder injector charge voltage circuit and
normal GND. • There should be no open circuit or high re-
sistance.
Voltage： 1.0 V
cuits.
tor harness intermediate connector. 24) If the second cylinder injector circuit between
6) If a problem is discovered, repair the control the injector and the injector intermediate con-
circuit. nector is normal, replace the second cylinder
7) Measure the voltage between the solenoid injector.
control circuit of the second cylinder injector Refer to "1.Engine 1C.Fuel System(4HK1X)
and normal GND. Injector Removal".
Voltage： 16.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
8) If it is at or above the standard value, inspect Injector Installation".
to see if there is a short circuit to the battery 25) When the injector has been replaced, set the
or ignition power supply with the control circuit injector ID code on the ECM.
between the ECM and the injector harness 26) Disconnect the harness connector from the
intermediate connector. ECM.
9) If a problem is discovered, repair the control 27) Inspect the ECM harness connector for a con-
10) Measure the voltage between the solenoid 28) If a problem is discovered, repair the harness
control circuit of the second cylinder injector connector.
and normal GND. 29) If the harness connector is normal, replace the
Voltage： 12.0 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(4HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the control circuit between the ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and injector harness intermediate connector. Installation".
12) If a problem is discovered, repair the control 30) Set the injector ID code on the ECM.
circuit. 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con- supply pump to the ECM.
14) If a problem is discovered, repair the injector 2. DTC P0202 Confirm Resolution
harness intermediate connector. 1) Clear the DTC using the trouble diagnosis
15) Remove the cylinder head cover. scan tool.
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Turn the starter switch OFF for 30 seconds or
Cylinder head cover Removal". longer.
16) Inspect the injector harness tightening nut for 3) Start the engine.
looseness. 4) Perform a test-run.
17) If the injector harness tightening nut is loose, 5) Use the trouble diagnosis scan tool to confirm
tighten it. that a DTC has not been detected.
84551720B NA - August 2012

4023G-28
Engine-side Trouble
connector. 22) Inspect the third cylinder injector circuit be-
4) Measure the voltage between the third cylin- mediate connector.
sistance.
Voltage： 1.0 V
cuits.
tor harness intermediate connector. 24) If the third cylinder injector circuit between the
6) If a problem is discovered, repair the control injector and the injector intermediate connec-
circuit. tor is normal, replace the third cylinder injec-
7) Measure the voltage between the solenoid tor.
control circuit of the third cylinder injector and Refer to "1.Engine 1C.Fuel System(4HK1X)
normal GND. Injector Removal".
control circuit of the third cylinder injector and connector.
normal GND. 29) If the harness connector is normal, replace the
84551720B NA - August 2012

4023G-29
Engine-side Trouble
connector. 22) Inspect the fourth cylinder injector circuit be-
4) Measure the voltage between the fourth cylin- mediate connector.
sistance.
Voltage： 1.0 V
cuits.
tor harness intermediate connector. 24) If the fourth cylinder injector circuit between
6) If a problem is discovered, repair the control the injector and the injector intermediate con-
circuit. nector is normal, replace the fourth cylinder
7) Measure the voltage between the solenoid injector.
control circuit of the fourth cylinder injector Refer to "1.Engine 1C.Fuel System(4HK1X)
and normal GND. Injector Removal".
control circuit of the third cylinder injector and connector.
normal GND. 29) If the harness connector is normal, replace the
84551720B NA - August 2012

4023G-30
Engine-side Trouble
DTC P0237 (Flash Code 32) Turbo 11) If the harness connector is normal, replace the
boost sensor.
Charger Boost Sensor Circuit Low Refer to "1.Engine 1F.Induction(4HK1X)
Boost sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1X)
DTC P1655
Boost sensor Installation".
1) Turn OFF the starter switch. and the boost sensor.
boost sensor. • There should be no open circuit or high re-
sistance.
4) Measure the voltage between the 5 V power • There should be no short to GND.
supply circuit of the boost sensor harness con- 13) If a problem is discovered, repair the signal
nector and a normal GND. circuit.
Voltage： 4.5 V 14) Inspect the ECM harness connector for a con-
5) If it is at or below the standard value, inspect tact failure.
to see if there is an open circuit or high re- 15) If a problem is discovered, repair the harness
sistance with the 5 V power supply circuit be- connector.
tween the ECM and the boost sensor. 16) If the harness connector is normal, replace the
ECM.
ANNOTATION:
• The boost sensor shares the 5 V power sup- Removal".
ply circuit with other sensors. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• The DTC set on a sensor which shares this Installation".
circuit may be detected. 17) Set the injector ID code on the ECM.
6) If a problem is discovered, repair the 5 V supply pump to the ECM.
7) Connect the test cable with fuse between the 3. DTC P0237 Confirm Resolution
5 V power supply circuit and the signal circuit
of the boost sensor harness connector.
scan tool.
8) Check the boost pressure sensor display with
longer.
Voltage： 4.5 V
to see if there is a contact failure with the boost
sensor harness connector.
connector.
84551720B NA - August 2012

4023G-31
Engine-side Trouble
DTC P0238 (Flash Code 32) Turbo 8) Inspect the boost sensor harness connector
for a contact failure.
Charger Boost Sensor Circuit High 9) If a problem is discovered, repair the harness
connector.
DTC P1655
boost sensor.
1) Turn OFF the starter switch. Boost sensor Removal".
2) Disconnect the harness connector from the Refer to "1.Engine 1F.Induction(4HK1X)
boost sensor. Boost sensor Installation".
3) Check the boost pressure sensor display with 11) Inspect the ECM harness connector for a con-
the trouble diagnosis scan tool. tact failure.
Voltage： 0.1 V 12) If a problem is discovered, repair the harness
4) If it is at or above the standard value, inspect connector.
the signal circuit between the ECM and the 13) If the harness connector is normal, replace the
boost sensor. ECM.
• There should be no short to the battery or Removal".
ignition power supply. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• There should be no short to the 5 V power Installation".
supply. 14) Set the injector ID code on the ECM.
5) If a problem is discovered, repair the signal 15) Perform the unit difference learning of the fuel
6) Inspect to see if there is an open circuit or 3. DTC P0238 Confirm Resolution
ECM and the boost sensor. 1) Clear the DTC using the trouble diagnosis
scan tool.
ANNOTATION: 2) Turn the starter switch OFF for 30 seconds or
• The boost sensor shares the GND circuit longer.
with other sensors. 3) Start the engine.
• The DTC set on a sensor which shares this 5) Use the trouble diagnosis scan tool to confirm
circuit may be detected. that a DTC has not been detected.
circuit.
84551720B NA - August 2012

4023G-32
Engine-side Trouble
Crankshaft Position Sensor Circuit Camshaft Position Sensor Circuit
Range/Performance 1. DTC P0340 Priority DTC
DTC P0601
1. DTC P0336 Priority DTC DTC P0651
DTC P0335 2. DTC P0340 Diagnostics
DTC P0340
DTC P0641 1) Turn OFF the starter switch.
2. DTC P0336 Diagnostics 2) Disconnect the harness connector from the
camshaft position sensor.
1) Inspect the crankshaft position sensor circuit. 3) Turn ON the starter switch.
• There should be enough clearing from the 4) Measure the voltage between the 5 V
wiring or component of the fuel injection power supply circuit and normal GND of the
unit. camshaft position sensor harness connector.
• There should be enough clearing from addi- voltage： 4.5 V
tionally installed electronic components. 5) If it is at or below the standard value, inspect
• There should be enough clearing from the to see if there is an open circuit or high re-
solenoids and relays. sistance with the 5 V power supply circuit be-
tween the ECM and the camshaft position
2) If a problem is discovered, repair the crank- sensor.
shaft position sensor circuit. 6) If a problem is discovered, repair the 5 V
3) Turn OFF the starter switch. power supply circuit.
4) Disconnect the harness connector from the 7) Measure the voltage between the signal cir-
ECM. cuit and normal GND of the camshaft position
5) Inspect the ECM harness connector for a con- sensor harness connector.
tact failure. voltage： 5.5 V
6) If a problem is discovered, repair the harness 8) If it is at or above the standard value, inspect
connector. to see if there is a short circuit to the battery
7) Disconnect the harness connector from the or ignition power supply with the signal circuit
crankshaft position sensor. between the ECM and the camshaft position
8) Inspect the crankshaft position sensor har- sensor.
ness connector for a contact failure. 9) If a problem is discovered, repair the signal
9) If a problem is discovered, repair the harness circuit.
connector. 10) Measure the voltage between the signal cir-
10) Inspect the CKP sensor. cuit of the camshaft position sensor harness
Refer to "1.Engine 1B.Mechanical(4HK1X) connector and a
CKP sensor Inspection". normal GND again.
11) If a problem is discovered, replace the crank- voltage： 4.5 V
shaft position sensor. 11) If it is at or below the standard value, inspect
Refer to "1.Engine 1B.Mechanical(4HK1X) the signal circuit between the ECM and the
CKP sensor Removal". camshaft position sensor.
CKP sensor Installation". • There should be no open circuit or high re-
sistance.
3. DTC P0336 Confirm Resolution • There should be no short to GND.
1) Clear the DTC using the trouble diagnosis 12) If a problem is discovered, repair the signal
scan tool. circuit.
2) Turn the starter switch OFF for 30 seconds or 13) Connect the test light between the signal cir-
longer. cuit and normal GND of the camshaft position
3) Start the engine. sensor harness connector.
4) Perform a test-run. 14) Measure the voltage between the probe of the
5) Use the trouble diagnosis scan tool to confirm test light and a normal GND.
that a DTC has not been detected. voltage： 4.5 V
to see if there is a short circuit to the 5 V power
supply circuit with the signal circuit between
the ECM and the camshaft position sensor.
circuit.
17) Measure the voltage between the 5 V power
supply circuit and GND circuit of the camshaft
position sensor harness connector.
voltage： 4.5 V
84551720B NA - August 2012

4023G-33
Engine-side Trouble
18) If it is at or above the standard value, inspect DTC P0404 (Flash Code 45)
to see if there is a contact failure with the
camshaft position sensor harness connector. Exhaust Gas Recirculation Control
connector.
Circuit Range/Performance
20) If the harness connector is normal, inspect the 1. DTC P0404 Priority DTC
camshaft position sensor. DTC P0409
Refer to "1.Engine 1B.Mechanical(4HK1X) 2. DTC P0404 Diagnostics
CMP sensor Inspection".
21) If a problem is discovered, replace the 1) Remove the EGR valve assembly from the
camshaft position sensor. engine.
Refer to "1.Engine 1B.Mechanical(4HK1X) Refer to "1.Engine 1H.Aux. Emission Control
CMP sensor Removal". Devices(4HK1X) EGR valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Inspect the EGR valve.
CMP sensor Installation". • There should be nothing to limit flow inside
22) Inspect the camshaft gear. the EGR valve.
• The camshaft gear should not be damaged • There should be no excessive accumulates
• The camshaft gear should be installed cor- inside the EGR valve.
rectly. • There should be no bending with the valve
shaft or valve itself inside the EGR valve.
23) If a problem is discovered, repair the camshaft
gear. 3) Turn OFF the starter switch.
24) Inspect the GND circuit between the ECM and 4) Disconnect the harness connector from the
the camshaft position sensor for an open cir- EGR valve.
cuit and high resistance. 5) Inspect the EGR valve harness connector for
a contact failure.
ANNOTATION: 6) If a problem is discovered, repair the harness
connector.
• The camshaft position sensor shares the
ECM.
tact failure.
25) If a problem is discovered, repair the GND 9) If a problem is discovered, repair the harness
circuit. connector.
26) Inspect the ECM harness connector for a con- 10) Inspect to see if there is an open circuit or high
tact failure. resistance in the EGR control circuit.
27) If a problem is discovered, repair the harness 11) If a problem is discovered, repair the EGR
connector. control circuit.
28) If the harness connector is normal, replace the 12) Inspect the EGR solenoid circuit between the
ECM. ECM and EGR valve.
Removal". • There should be no short to GND.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM • There should be no short to the battery or
ignition power supply circuit.
Installation".
29) Set the injector ID code on the ECM. • There should be no short between the cir-
cuits.
supply pump to the ECM. • There should be no short to EGR position
sensor circuit.
13) If a problem is discovered, repair the EGR
1) Clear the DTC using the trouble diagnosis solenoid circuit.
scan tool. 14) If the EGR solenoid circuit is normal, replace
2) Turn the starter switch OFF for 30 seconds or the EGR valve.
longer. Refer to "1.Engine 1H.Aux. Emission Control
3) Start the engine. Devices(4HK1X) EGR valve Removal".
4) Perform a test-run. Refer to "1.Engine 1H.Aux. Emission Control
5) Use the trouble diagnosis scan tool to confirm Devices(4HK1X) EGR valve Installation".
that a DTC has not been detected. 15) Restore the actual unit.
scan tool.
longer.
84551720B NA - August 2012

4023G-34
Engine-side Trouble
21) Check the DTC using the trouble diagnosis DTC P0409 (Flash Code 44)
scan tool.
22) If the DTC P0404 has been detected, replace Exhaust Gas Recirculation Sensor
the ECM.
Circuit
Removal". 1. DTC P0409 Priority DTC
Refer to "1.Engine 1J.Electrical(4HK1X) ECM DTC P1655
Installation". 2. DTC P0409 Diagnostics
24) Perform the unit difference learning of the fuel 1) Turn OFF the starter switch.
supply pump to the ECM. 2) Disconnect the harness connector from the
EGR valve.
3. DTC P0404 Confirm Resolution 3) Turn ON the starter switch.
if any of the EGR position 1, EGR position 2,
scan tool.
and EGR position 3 shows ON.
5) If there is a data display showing ON, inspect
longer.
the signal circuit between the ECM and EGR
valve of the EGR showing ON.
5) Use the trouble diagnosis scan tool to confirm • There should be no short to the battery or
that a DTC has not been detected. ignition power supply.
supply.
circuit.
7) Measure the voltage between the EGR posi-
tion sensor 5 V power supply circuit and a nor-
mal GND.
Voltage： 4.5 V
to see if there is an open circuit or high re-
sistance with the 5 V power supply circuit be-
tween the ECM and the EGR position sensor.
ANNOTATION:
• The EGR position sensor shares the 5 V
power supply circuit with other sensors.
10) Measure the voltage between the EGR posi-
tion sensor 5 V power supply circuit and the
GND circuit.
voltage： 4.5 V
tance with the GND circuit between the ECM
and EGR position sensor.
ANNOTATION:
• The EGR position sensor shares the GND
circuit with other sensors.
circuit.
13) While momentarily disconnecting the test ca-
ble with fuse from the EGR position sensor
1 signal circuit and 5 V power supply circuit,
check the EGR position 1 display with the
trouble diagnosis scan tool.
84551720B NA - August 2012

4023G-35
Engine-side Trouble
14) While momentarily disconnecting the test ca- DTC P0426 (Flash Code 143)
2 signal circuit and 5 V power supply circuit, Catalyst Temperature Sensor
check the EGR position 2 display with the
Circuit Range/Performance
15) While momentarily disconnecting the test ca- Sensor 1
3 signal circuit and 5 V power supply circuit, 1. DTC P0426 Priority DTC
check the EGR position 3 display with the DTC P0093
trouble diagnosis scan tool. DTC P0427
16) Check to see if there is a data display which DTC P1093
does not display ON when the EGR position 2. DTC P0426 Diagnostics
sensor signal circuit and 5 V power supply 1) Inspect the exhaust gas temperature sensor
circuit are shorted. 1.
17) If there is a data display which does not dis- Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
play ON, inspect the EGR position sensor cir- haust gas temperature sensor Inspection".
cuit which does not display ON. 2) If a problem is discovered, replace the ex-
• There should be no open circuit or high re- haust gas temperature sensor 1.
sistance between ECM and EGR position Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
sensor. haust gas temperature sensor Removal".
• There should be no short to GND between Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
ECM and EGR position sensor. haust gas temperature sensor Installation".
3) Inspect the DPD filter for a damage.
18) If a problem is discovered, repair the EGR Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
position sensor circuit. assembly Inspection".
19) Inspect the EGR valve harness connector for 4) If a problem is discovered, replace the DPD
a contact failure. filter.
20) If a problem is discovered, repair the harness Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
connector. assembly Disassembly".
21) In the EGR solenoid circuit between the ECM Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
and EGR valve, inspect to see if there is a assembly Reassembly".
short circuit with the EGR position sensor. 5) Perform the DPD regeneration data reset with
22) If a problem is discovered, repair the EGR the trouble diagnosis scan tool.
solenoid circuit.
23) If the EGR solenoid circuit is normal, replace 3. DTC P0426 Confirm Resolution
the EGR valve. 1) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1H.Aux. Emission Control scan tool.
Devices(4HK1X) EGR valve Removal". 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1H.Aux. Emission Control longer.
Devices(4HK1X) EGR valve Installation". 3) Start the engine.
24) Inspect the ECM harness connector for a con- 4) Perform a test-run.
tact failure. 5) Use the trouble diagnosis scan tool to confirm
25) If a problem is discovered, repair the harness that a DTC has not been detected.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012

4023G-36
Engine-side Trouble
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Low Sensor 1 Circuit High Sensor 1
DTC P0697 DTC P0697
exhaust gas temperature sensor 1. exhaust gas temperature sensor 1.
3) Check the exhaust temperature sensor (be- 3) Turn ON the starter switch.
fore the filter) display with the trouble diagno- 4) Measure the voltage between the exhaust gas
sis scan tool. temperature sensor 1 signal circuit and nor-
Voltage： 4.5 V mal GND.
4) If it is at or above the standard value, replace Voltage： 5.5 V
the exhaust gas temperature sensor 1. 5) If it is at or above the standard value, inspect
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- to see if there is a short circuit to the battery
haust gas temperature sensor Removal". or ignition power supply with the signal circuit
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- between the ECM and the exhaust gas tem-
haust gas temperature sensor Installation". perature sensor 1.
5) Inspect to see if there is a short circuit to the 6) If a problem is discovered, repair the signal
GND with the signal circuit between the ECM circuit.
and the exhaust gas temperature sensor 1. 7) Connect the test cable with fuse between the
6) If a problem is discovered, repair the signal exhaust gas temperature sensor 1 signal cir-
circuit. cuit and GND circuit.
7) Inspect the ECM harness connector for a con- 8) Check the exhaust temperature sensor (be-
tact failure. fore the filter) display with the trouble diagno-
8) If a problem is discovered, repair the harness sis scan tool.
9) If the harness connector is normal, replace the 9) If it is at or below the standard value, inspect to
ECM. see if there is a short circuit to the 5 V power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM supply circuit with the signal circuit between
Removal". the ECM and the exhaust gas temperature
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sensor 1.
Installation". 10) If a problem is discovered, repair the signal
10) Set the injector ID code on the ECM. circuit.
11) Perform the unit difference learning of the fuel 11) Inspect to see if there is a contact failure with
supply pump to the ECM. the exhaust gas temperature sensor 1 har-
ness connector.
3. DTC P0427 Confirm Resolution 12) If a problem is discovered, repair the harness
1) Clear the DTC using the trouble diagnosis connector.
scan tool. 13) If the harness connector is normal, replace the
2) Turn the starter switch OFF for 30 seconds or exhaust gas temperature sensor 1.
longer. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
3) Start the engine. haust gas temperature sensor Removal".
4) Perform a test-run. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
5) Use the trouble diagnosis scan tool to confirm haust gas temperature sensor Installation".
that a DTC has not been detected. 14) Connect the test cable with fuse between the
exhaust gas temperature sensor 1 signal cir-
cuit and normal GND.
15) Check the exhaust temperature sensor (be-
fore the filter) display with the trouble diagno-
sis scan tool.
Voltage： 0.1 V
tance with the signal circuit between the ECM
and the exhaust gas temperature sensor 1.
circuit.
84551720B NA - August 2012

4023G-37
Engine-side Trouble
ECM and the exhaust gas temperature sensor DTC P0522 (Flash Code 294) Oil
1.
Pressure Sensor Circuit Low
ANNOTATION:
• The exhaust gas temperature sensor 1 DTC P0697
shares the GND circuit with other sensors. 2. DTC P0522 Diagnostics
• The DTC may be detected on a sensor
which shares this circuit. 1) Turn OFF the starter switch.
19) If a problem is discovered, repair the GND pressure sensor.
circuit. 3) Turn ON the starter switch.
20) Inspect the ECM harness connector for a con- 4) Measure the voltage between the 5 V power
tact failure. supply circuit and normal GND of the oil pres-
21) If a problem is discovered, repair the harness sure sensor harness connector.
22) If the harness connector is normal, replace the 5) If it is at or below the standard value, inspect
ECM. to see if there is an open circuit or high re-
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sistance with the 5 V power supply circuit be-
Removal". tween the ECM and the oil pressure sensor.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 6) If a problem is discovered, repair the 5 V
Installation". power supply circuit.
23) Set the injector ID code on the ECM. 7) Connect the test cable with fuse between the
24) Perform the unit difference learning of the fuel 5 V power supply circuit and signal circuit of
supply pump to the ECM. the oil pressure sensor harness connector.
3. DTC P0428 Confirm Resolution 8) Check the oil pressure sensor display with the
1) Clear the DTC using the trouble diagnosis Voltage： 4.5 V
scan tool. 9) If it is at or above the standard value, inspect
2) Turn the starter switch OFF for 30 seconds or to see if there is a contact failure with the oil
longer. pressure sensor harness connector.
3) Start the engine and warm it up until the 10) If a problem is discovered, repair the harness
coolant temperature exceeds the standard connector.
value. 11) If the harness connector is normal, replace the
Specified value： 70 °C {158 °F} oil pressure sensor.
4) Repeatedly rev the engine in neutral to in- Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
crease the engine rpm while checking the ex- pressure sensor Removal".
haust temperature sensor (in front of the filter) Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
display with the trouble diagnosis scan tool. pressure sensor Installation".
5) Use the trouble diagnosis scan tool to confirm 12) Inspect the signal circuit between the ECM
that the exhaust temperature sensor (before and the oil pressure sensor.
the filter) display does not exceed the stan-
dard value. • There should be no open circuit or high re-
Voltage： 4.8 V sistance.
6) Use the trouble diagnosis scan tool to confirm • There should be no short to GND.
that a DTC has not been detected. 13) If a problem is discovered, repair the signal
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012
4023G-38
Engine-side Trouble
3) Start the engine. DTC P0523 (Flash Code 294) Oil

5) Use the trouble diagnosis scan tool to confirm Pressure Sensor Circuit High
DTC P0697
pressure sensor.
3) Check the oil pressure sensor display with the
Voltage： 0.1 V
the signal circuit between the ECM and the oil
pressure
sensor.
supply.
circuit.
ECM and the oil pressure sensor.
ANNOTATION:
• The oil pressure sensor shares the GND cir-
cuit with other sensors.
circuit.
8) Inspect the oil pressure sensor harness con-
connector.
oil pressure sensor.
Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
pressure sensor Removal".
pressure sensor Installation".
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012

4023G-39
Engine-side Trouble
3) Start the engine. DTC P0560 (Flash Code 155)

5) Use the trouble diagnosis scan tool to confirm System Voltage
if a DTC is detected.
4) If a DTC has not been detected, inspect the
mass air flow sensor harness connector for a
contact failure.
connector.
8) Leave the mass air flow sensor harness con-
nector disconnected.
dropping register.
if a DTC is detected.
11) If a DTC has been detected, inspect the volt-
age supply circuit between the ECM and drop-
ping register.
12) If a problem is discovered, repair the voltage
supply circuit.
13) If the voltage supply circuit is normal, inspect
the 12 V power supply circuit between the
ECM and the mass air flow sensor.
15) Check the resistance value of the dropping
register.
Resistance： 45.0 - 55.0 Ω
16) If the resistance value is outside the standard
range, replace the dropping register.
18) Measure the voltage between the ignition
power supply circuit of the dropping register
and a normal GND.
Voltage： 18.0 V
the fuse.
20) If the fuse is faulty, replace the fuse.
21) If it is at or below the standard value, repair
an open circuit or high resistance in the igni-
tion power supply circuit between the fuse and
dropping register.
22) Measure the voltage between the voltage sup-
ply circuit of the dropping register and a nor-
mal GND.
Voltage： 13.0 V
84551720B NA - August 2012

4023G-40
Engine-side Trouble
23) If it is at or above the standard value, inspect DTC P0563 (Flash Code 35)
to see if there is a contact failure with the drop-
ping register harness connector. System Voltage High
connector.
25) Inspect to see if there is an open circuit or 1) Check if the battery charger has been recently
high resistance in the voltage supply circuit connected to the battery.
between the ECM and the dropping register. 2) Start the engine, and idle it.
26) If a problem is discovered, repair the voltage 3) Check the ignition voltage display with the
supply circuit. trouble diagnosis scan tool.
27) Inspect the ECM harness connector for a con- Voltage： 32.0 V
tact failure. 4) If it is at or above the standard value, inspect
28) If a problem is discovered, repair the harness the charging system.
connector. Refer to "1.Engine 1J.Electrical(4HK1X) Gen-
29) If the harness connector is normal, replace the erator Reassembly".
ECM. 5) If a problem is discovered, repair the charging
Refer to "1.Engine 1J.Electrical(4HK1X) ECM system.
Removal". 6) If the charging system is normal, replace the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM ECM.
Installation". Refer to "1.Engine 1J.Electrical(4HK1X) ECM
30) Set the injector ID code on the ECM. Removal".
31) Perform the unit difference learning of the fuel Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply pump to the ECM. Installation".
1) Clear the DTC using the trouble diagnosis supply pump to the ECM.
scan tool.
longer. 1) Clear the DTC using the trouble diagnosis
3) Start the engine. scan tool.
4) Perform a test-run. 2) Turn the starter switch OFF for 30 seconds or
5) Use the trouble diagnosis scan tool to confirm longer.
that a DTC has not been detected. 3) Start the engine, and idle it.
4) Check the ignition voltage display with the
trouble diagnosis scan tool, and confirm that
the value does not exceed the standard value.
voltage： 32.0 V
84551720B NA - August 2012

4023G-41
Engine-side Trouble
Internal Control Module Memory Control Module Programming
Check Sum Error Error
1) Replace the ECM. 1) Confirm that the connecting sections of all
Refer to "1.Engine 1J.Electrical(4HK1X) ECM tools are securely connected.
Removal". 2) Confirm that the programming device is oper-
Refer to "1.Engine 1J.Electrical(4HK1X) ECM ating normally.
Installation". 3) Use the trouble diagnosis scan tool to confirm
2) Set the injector ID code on the ECM. that the correct injector ID code has been en-
3) Perform the unit difference learning of the fuel tered to the ECM.
ANNOTATION:
• When the injector ID code has been cor-
1) Clear the DTC using the trouble diagnosis rectly input, clear the DTC using the trouble
scan tool. diagnosis scan tool.
longer.
3) Start the engine. longer.
5) Use the trouble diagnosis scan tool to confirm 6) Use the trouble diagnosis scan tool to check
that a DTC has not been detected. if a DTC has been detected.
7) If a DTC has been detected, replace the ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012

4023G-42
Engine-side Trouble
Internal Control Module Random ECM/PCM Processor
Access Memory (RAM) Error 1. DTC P0606 Diagnostics
1. DTC P0604 Diagnostics 1) Replace the ECM.
1) Replace the ECM. Removal".
Removal". Installation".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 2) Set the injector ID code on the ECM.
Installation". 3) Perform the unit difference learning of the fuel
2) Set the injector ID code on the ECM. supply pump to the ECM.
supply pump to the ECM. 2. DTC P0606 Confirm Resolution
2. DTC P0604 Confirm Resolution 1) Clear the DTC using the trouble diagnosis
scan tool.
scan tool. longer.
84551720B NA - August 2012

4023G-43
Engine-side Trouble
DTC P0638 (Flash Code 14) If a problem is discovered, repair the solenoid
circuit.
61) Throttle Actuator Control 15) If the solenoid circuit is normal, replace the
Range/Performance intake throttle valve.
1. DTC P0638 Priority DTC take throttle valve Removal".
DTC P0122 Refer to "1.Engine 1B.Mechanical(4HK1X) In-
DTC P0123 take throttle valve Installation".
2. DTC P0638 Diagnostics 16) Restore the actual unit.
1) Remove the air intake hose from the intake 18) Turn the starter switch OFF for 30 seconds or
throttle valve. longer.
take throttle valve Removal". ANNOTATION:
2) Inspect the intake throttle valve.
• The starter switch must be once turned ON
• The intake throttle valve flow should not be and then turned OFF before clearing the
limited. DTC.
• There should be no excessive deposit inside 19) Clear the DTC using the trouble diagnosis
the throttle bore of the intake throttle valve.
scan tool.
• There should be no bending with the butter- 20) Turn the starter switch OFF for 30 seconds or
fly valve of the intake throttle valve.
longer.
• The intake throttle valve should not be 21) Start the engine.
locked.
3) If a problem is discovered, replace the intake if a DTC has been detected.
throttle valve. 23) If a DTC has been detected, replace the ECM.
Refer to "1.Engine 1B.Mechanical(4HK1X) In- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
take throttle valve Removal". Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
take throttle valve Installation". Installation".
4) Turn OFF the starter switch. 24) Set the injector ID code on the ECM.
5) Disconnect the harness connector from the 25) Perform the unit difference learning of the fuel
intake throttle valve. supply pump to the ECM.
6) Inspect the intake throttle valve harness con-
7) If a problem is discovered, repair the harness 1) Turn ON the starter switch.
connector. 2) Turn the starter switch OFF for 30 seconds or
8) Disconnect the harness connector from the longer.
ECM.
9) Inspect the ECM harness connector for a con- ANNOTATION:
tact failure. • The starter switch must be once turned ON
10) If a problem is discovered, repair the harness and then turned OFF before clearing the
connector. DTC.
11) Inspect the intake throttle valve circuit for high
resistance. 3) Clear the DTC using the trouble diagnosis
12) Repair the circuit if a problem is discovered. scan tool.
13) Inspect the solenoid circuit between the ECM 4) Turn the starter switch OFF for 30 seconds or
and the intake throttle valve. longer.
• There should be no short to GND. 6) Perform a test-run with the intake throttle so-
• There should be no short to the battery or lenoid drive duty of 20 ％ or above.
ignition power supply. 7) Use the trouble diagnosis scan tool to confirm
• There should be no short between the sole- that a DTC has not been detected.
noid circuits.
• There should be no short to intake throttle
position sensor circuit.
84551720B NA - August 2012

4023G-44
Engine-side Trouble
DTC P0641 (Flash Code 55) 18) If it is at or below the standard value, turn the
starter switch OFF.
Sensor Reference Voltage 1 19) Disconnect the harness connector from the
Circuit 20)
Turn ON the starter switch.
1. DTC P0641 Diagnostics 21) Measure the voltage between the accelerator
position sensor 5 V power supply circuit and
1) Turn OFF the starter switch. GND of the accelerator position sensor har-
2) Disconnect the harness connector from the ness connector.
accelerator position sensor. Voltage： 4.5 V
3) Turn ON the starter switch. 22) If it is at or above the standard value, replace
4) Measure the voltage between the accelerator the fuel pressure sensor.
position sensor 5 V power supply circuit and Refer to "1.Engine 1C.Fuel System(4HK1X)
GND of the accelerator position sensor har- Common rail assembly Removal".
ness connector. Refer to "1.Engine 1C.Fuel System(4HK1X)
Voltage： 5.5 V Common rail assembly Installation".
to see if there is a short circuit to the battery or ANNOTATION:
ignition power supply with the accelerator po-
sition sensor 5 V power supply circuit between
arately.
the ECM and the accelerator position sensor.
6) If a problem is discovered, repair the acceler-
mon rail assembly.
ator position sensor 5 V power supply circuit.
7) Inspect to see if there is a short circuit to the 23) If it is at or below the standard value, inspect
battery or ignition power supply with the crank- to see if there is a short circuit to the GND with
shaft position sensor 5 V power supply circuit the accelerator position sensor 5 V power sup-
between the ECM and the crankshaft position ply circuit between the ECM and the acceler-
sensor. ator position sensor.
8) If a problem is discovered, repair the crank- 24) If a problem is discovered, repair the acceler-
shaft position sensor 5 V power supply circuit ator position sensor 5 V power supply circuit.
between the ECM and the crankshaft position 25) Inspect to see if there is a short circuit to the
sensor. GND with the crankshaft position sensor 5 V
9) Inspect to see if there is a short circuit to the power supply circuit between the ECM and the
battery or ignition power supply with the fuel crankshaft position sensor.
pressure sensor 5 V power supply circuit be- 26) If a problem is discovered, repair the crank-
tween the ECM and the fuel pressure sensor. shaft position sensor 5 V power supply circuit.
10) If a problem is discovered, repair the fuel pres- 27) Inspect to see if there is a short circuit to the
sure sensor 5 V power supply circuit. GND with the fuel pressure sensor 5 V power
11) If it is at or below the standard value, measure supply circuit between the ECM and the fuel
the voltage between the 5 V power supply cir- pressure sensor.
cuit and GND of the accelerator position sen- 28) If a problem is discovered, repair the fuel pres-
sor harness connector. sure sensor 5 V power supply circuit.
Voltage： 4.5 V 29) Replace the ECM.
12) If it is at or above the standard value, replace Refer to "1.Engine 1J.Electrical(4HK1X) ECM
the throttle accelerator switch assembly. Removal".
13) If it is at or below the standard value, turn the Refer to "1.Engine 1J.Electrical(4HK1X) ECM
starter switch OFF. Installation".
14) Disconnect the harness connector from the 30) Set the injector ID code on the ECM.
crankshaft position sensor. 31) Perform the unit difference learning of the fuel
16) Measure the voltage between the accelerator
position sensor 5 V power supply circuit and 2. DTC P0641 Confirm Resolution
GND of the accelerator position sensor har- 1) Clear the DTC using the trouble diagnosis
ness connector. scan tool.
Voltage： 4.5 V 2) Turn the starter switch OFF for 30 seconds or
17) If it is at or above the standard value, replace longer.
the crankshaft position sensor. 3) Start the engine.
Refer to "1.Engine 1B.Mechanical(4HK1X) 4) Perform a test-run.
CKP sensor Removal". 5) Use the trouble diagnosis scan tool to confirm
Refer to "1.Engine 1B.Mechanical(4HK1X) that a DTC has not been detected.
CKP sensor Installation".
84551720B NA - August 2012

4023G-45
Engine-side Trouble
DTC P0651 (Flash Code 56) 12) Disconnect the harness connector from the
atmospheric pressure sensor.
Sensor Reference Voltage 2 13) Turn ON the starter switch.
Circuit 14) Measure the voltage between the camshaft
position sensor 5 V power supply circuit and
1. DTC P0651 Diagnostics GND of the camshaft position sensor harness
connector.
1) Turn OFF the starter switch. Voltage： 4.5 V
2) Disconnect the harness connector from the 15) If it is at or above the standard value, replace
camshaft position sensor. the atmospheric pressure sensor.
3) Turn ON the starter switch. 16) If it is at or below the standard value, inspect
4) Measure the voltage between the camshaft to see if there is a short circuit to the GND with
position sensor 5 V power supply circuit and the camshaft position sensor 5 V power sup-
GND of the camshaft position sensor harness ply circuit between the ECM and the camshaft
connector. position sensor.
Voltage： 5.5 V 17) If a problem is discovered, repair the camshaft
5) If it is at or above the standard value, inspect position sensor 5 V power supply circuit.
to see if there is a short circuit to the battery or 18) Inspect to see if there is a short circuit to the
ignition power supply with the camshaft posi- GND with the atmospheric pressure sensor 5
tion sensor 5 V power supply circuit between V power supply circuit between the ECM and
the ECM and the camshaft position sensor. the atmospheric pressure sensor.
6) If a problem is discovered, repair the camshaft 19) If a problem is discovered, repair the atmo-
position sensor 5 V power supply circuit. spheric pressure sensor 5 V power supply cir-
7) Inspect to see if there is a short circuit to the cuit.
battery or ignition power supply with the atmo- 20) Replace the ECM.
spheric pressure sensor 5 V power supply cir- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
cuit between the ECM and atmospheric pres- Removal".
sure sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) If a problem is discovered, repair the atmo- Installation".
spheric pressure sensor 5 V power supply cir- 21) Set the injector ID code on the ECM.
cuit. 22) Perform the unit difference learning of the fuel
9) If it is at or below the standard value, mea- supply pump to the ECM.
sure the voltage between the camshaft posi-
tion sensor 5 V power supply circuit and GND 2. DTC P0651 Confirm Resolution
of the camshaft position sensor harness con-
nector.
scan tool.
Voltage： 4.5 V
longer.
the camshaft position sensor.
CMP sensor Removal".
CMP sensor Installation".
11) If it is at or below the standard value, turn the
starter switch OFF.
84551720B NA - August 2012

4023G-46
Engine-side Trouble
ECM/PCM Power Relay Control ECM/PCM Power Relay Control
Circuit/Open Circuit High
1) Turn the starter switch OFF for 30 seconds or 1) Turn OFF the starter switch.
longer. 2) Remove the main relay.
2) Replace the main relay with a glow relay or 3) Turn ON the starter switch.
normal relay. 4) Use the trouble diagnosis scan tool to see if
3) Turn ON the starter switch. DTC P0685 is detected.
4) Use the trouble diagnosis scan tool to check 5) If the DTC P0685 is not detected, repair the
if a DTC is detected. short circuit to the battery power supply of the
5) If a DTC has not been detected, replace the power supply circuit between the ECM and
main relay. main relay.
6) Inspect the body grounding terminal for a con- 6) Turn the starter switch OFF for 30 seconds or
tact failure. longer.
7) If a problem is discovered, repair the terminal. 7) Replace the main relay with a glow relay or
8) Inspect the slow blow fuse. normal relay.
9) If a problem is discovered, replace the slow 8) Turn ON the starter switch.
blow fuse. 9) Use the trouble diagnosis scan tool to check
if DTC P0687 has been detected.
ANNOTATION:
10) If the DTC P0687 is not detected, replace the
• When the fuse is blown again, repair the main relay.
cause of slow-blow fuse meltdown.
scan tool.
ECM.
longer.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012

4023G-47
Engine-side Trouble
DTC P0697 (Flash Code 57) 17) If it is at or above the standard value, replace
the oil pressure sensor.
Sensor Reference Voltage 3 Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
Circuit pressure sensor Removal".
1. DTC P0697 Diagnostics pressure sensor Installation".
1) Turn OFF the starter switch. starter switch OFF.
DPD differential pressure sensor. fuel filter pressure sensor.
3) Turn ON the starter switch. 20) Turn ON the starter switch.
4) Measure the voltage between the DPD differ- 21) Measure the voltage between the DPD differ-
ential pressure sensor 5 V power supply cir- ential pressure sensor 5 V power supply cir-
cuit and GND of the DPD differential pressure cuit and GND of the DPD differential pressure
sensor harness connector. sensor harness connector.
Voltage： 5.5 V Voltage： 4.5 V
5) If it is at or above the standard value, inspect 22) If it is at or above the standard value, replace
to see if there is a short circuit to the battery or the fuel filter pressure sensor.
ignition power supply with the DPD differential Refer to "1.Engine 1C.Fuel System(4HK1X)
pressure sensor 5 V power supply circuit be- Fuel filter pressure sensor Removal".
tween the ECM and the DPD differential pres- Refer to "1.Engine 1C.Fuel System(4HK1X)
sure sensor. Fuel filter pressure sensor Installation".
6) If a problem is discovered, repair the DPD 23) If it is at or below the standard value, inspect
differential pressure sensor 5 V power supply to see if there is a short circuit to the GND
circuit. with the DPD differential pressure sensor 5 V
7) Inspect to see if there is a short circuit to the power supply circuit between the ECM and the
battery or ignition power supply with the oil DPD differential pressure sensor.
pressure sensor 5 V power supply circuit be- 24) If a problem is discovered, repair the DPD
tween the ECM and oil pressure sensor. differential pressure sensor 5 V power supply
8) If a problem is discovered, repair the oil pres- circuit.
sure sensor 5 V power supply circuit. 25) Inspect to see if there is a short circuit to the
9) Inspect to see if there is a short circuit to the GND with the oil pressure sensor 5 V power
battery or ignition power supply with the fuel supply circuit between the ECM and oil pres-
filter pressure sensor 5 V power supply circuit sure sensor.
between the ECM and the fuel filter pressure 26) If a problem is discovered, repair the oil pres-
sensor. sure sensor 5 V power supply circuit.
10) If a problem is discovered, repair the fuel filter 27) Inspect to see if there is a short circuit to the
pressure sensor 5 V power supply circuit. GND with the fuel filter pressure sensor 5 V
11) If it is at or below the standard value, mea- power supply circuit between the ECM and
sure the voltage between the DPD differential fuel filter pressure sensor.
pressure sensor 5 V power supply circuit and 28) If a problem is discovered, repair the fuel filter
GND of the DPD differential pressure sensor pressure sensor 5 V power supply circuit.
harness connector. 29) Replace the ECM.
12) If it is at or above the standard value, replace Removal".
the DPD differential pressure sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- Installation".
haust differential pressure sensor Removal". 30) Set the injector ID code on the ECM.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 31) Perform the unit difference learning of the fuel
haust differential pressure sensor Installa- supply pump to the ECM.
tion".
13) If it is at or below the standard value, turn the 2. DTC P0697 Confirm Resolution
starter switch OFF.
scan tool.
pressure sensor.
longer.
16) Measure the voltage between the DPD differ-
ential pressure sensor 5 V power supply cir-
cuit and GND of the DPD differential pressure
Voltage： 4.5 V
84551720B NA - August 2012

4023G-48
Engine-side Trouble
DTC P1093 (Flash Code 227) Fuel • The fuel hose between the fuel tank and the
fuel supply pump becomes negative pres-
Rail Pressure (FRP) Too Low sure state when the engine is running.
1. DTC P1093 Priority DTC • When the fuel hose is not connected se-
curely, the air can enter.
DTC P0087
DTC P0091 • When the engine RPM or the engine load
increases while the air has intruded in the
DTC P0092
fuel system, fluctuation in the common rail
DTC P0192
pressure is caused, and DTC P1093 may
DTC P0193
be detected.
DTC P0201
DTC P0202 16) Check that an appropriate clamp is used be-
DTC P0203 tween the fuel tank and the fuel supply pump.
DTC P0204 17) If a problem is discovered, replace the clamp.
DTC P2146 18) Operate the priming pump until the handle be-
DTC P2149 comes heavy.
ANNOTATION:
2) Wait for the specified period of time until the • When a leak exists in the fuel system be-
fuel pressure is released from the common tween the priming pump and the fuel sup-
rail. ply pump, the pressing weight of the priming
Specified time: 2 min pump does not become heavy.
3) Turn ON the starter switch. 19) Start the engine.
4) Use the trouble diagnosis scan tool to check 20) Inspect the high-pressure side of the fuel sys-
if the fuel rail pressure sensor display is within tem and check for fuel leak between the fuel
the standard range. supply pump and common rail.
Voltage: 0.9 - 1.0 V
5) If the fuel rail pressure sensor display is out- ANNOTATION:
side the standard range, inspect the fuel pres- • The fuel may leak to the bottom section of
sure sensor harness connector for a contact the cylinder head cover from the high pres-
failure. sure hose inlet.
6) If a problem is discovered, repair the harness • The engine oil level increases when the fuel
connector. leaks to the bottom portion of the cylinder
7) Inspect the ECM harness connector for a con- head cover.
tact failure. • Inspect for fuel leaks into the engine oil.
connector. 21) If fuel leak if found, fix the problem.
9) Inspect each circuit for high resistance. 22) Turn OFF the starter switch.
10) Repair the circuit if a problem is discovered. 23) Remove the fuel hose on the fuel supply pump
11) If the harness connector and each circuit are side from the fuel filter.
normal, replace the fuel pressure sensor. ANNOTATION:
Common rail assembly Removal". • Use a pan to catch the fuel from the re-
Refer to "1.Engine 1C.Fuel System(4HK1X) moved fuel hose.
Common rail assembly Installation". • Clean the pressure gauge and connection
hose before connecting to the fuel pipe.
ANNOTATION: • The fuel supply pump may be damaged due
• Do not replace the fuel pressure sensor sep- to foreign matter that has entered in the con-
arately. nection hose.
When a problem is found, replace the com- 24) Connect the pressure gauge between the fuel
mon rail assembly. filter and the removed fuel hose.
12) Inspect to see if there is clogging with the fuel ANNOTATION:
system between the fuel tank and the fuel sup-
ply pump. • Confirm that the fuel system is connected
13) If a problem is discovered, repair the clogging securely.
of the fuel system. 25) Remove the air using the priming pump, and
14) Inspect the fuel hose between the fuel tank crank the engine for the specified period of
and the fuel supply pump for a cut and crack. time or shorter.
15) If a problem is discovered, replace the fuel Specified time: 5 s
hose.
ANNOTATION:
ANNOTATION:
• Repeat this until the engine starts.
84551720B NA - August 2012

4023G-49
Engine-side Trouble
26) Leave the engine idling for the specified pe- 40) If a problem is discovered, replace the fuel
riod of time or longer. hose.
specified time: 1 min 41) Inspect to see if appropriate clamp is used.
27) While keeping the engine rotating at the spec- 42) If a problem is discovered, replace the clamp
ified engine RPM for the specified period of with an appropriate one.
time, check the pressure gauge. 43) Turn OFF the starter switch.
Specified time: 1 min 44) Inspect the suction control valve harness con-
Rotational speed: 2500 min-1 {2500 r/min} nector for a contact failure.
28) Check if the pressure gauge shows a negative 45) If a problem is discovered, repair the harness
pressure value at or above the standard value connector.
during inspection. 46) Inspect the ECM harness connector for a con-
Specified value: 17.0 kPa ( 2.466 psi ) {128 tact failure.
mmHg / 5 inHg} 47) If a problem is discovered, repair the harness
connector.
ANNOTATION: 48) Inspect each circuit for high resistance.
• Fuel clogging is checked with the negative 49) Repair the circuit if a problem is discovered.
pressure amount in the fuel system. 50) If the suction control valve harness connector
and the ECM harness connector are normal
29) If the negative pressure is at or above the and there is no high resistance in each circuit,
standard value, inspect to see if there is dam- replace the fuel supply pump and the fuel filter
age or twisting element.
with the fuel system between the fuel supply Refer to "1.Engine 1C.Fuel System(4HK1X)
pump and the fuel tank. Fuel supply pump Removal".
30) If a problem is discovered, repair the fuel sys- Refer to "1.Engine 1C.Fuel System(4HK1X)
tem. Fuel supply pump Installation".
31) Inspect the fuel tank bent hose. Refer to "1.Engine 1C.Fuel System(4HK1X)
32) If a problem is discovered, repair the bent Fuel filter element Removal".
hose. Refer to "1.Engine 1C.Fuel System(4HK1X)
33) Check to see if there is any foreign matter in Fuel filter element Installation".
the fuel tank or any foreign matter which can
cause fuel clogging. ANNOTATION:
34) If a problem is discovered, repair it.
• When replacing the fuel supply pump, it is
35) Replace the fuel filter element. required to also replace the fuel filter ele-
Refer to "1.Engine 1C.Fuel System(4HK1X) ment at the same time.
Refer to "1.Engine 1C.Fuel System(4HK1X) 51) Perform the unit difference learning of the fuel
Fuel filter element Installation". supply pump to the ECM.
36) If the negative pressure is at or below the stan- 52) If the negative pressure is normal, turn OFF
dard value, pinch the fuel hose at a position as the starter switch.
close as possible to the fuel tank, so that the 53) Restore the fuel system.
fuel does not flow. 54) Start the engine.
55) Perform the injector stop test with the trouble
ANNOTATION: diagnosis scan tool.
• The fuel pipe can be disconnected and 56) Check to see if any injector does not change
clogged with a plug. the engine RPM when OFF is instructed.
57) If any injector does not change the engine
37) Start the engine and use the idling control RPM when OFF is instructed, replace the rel-
switch to increase the RPM to the highest evant injector.
level. Refer to "1.Engine 1C.Fuel System(4HK1X)
38) Check the pressure gauge. Injector Removal".
Specified value: 27.0 kPa ( 3.916 psi ) {203 Refer to "1.Engine 1C.Fuel System(4HK1X)
mmHg / 8 inHg} Injector Installation".
ANNOTATION: 58) When the injector has been replaced, set the
injector ID code on the ECM.
• When the pressure gauge is likely to indi- 59) If the engine RPM changes when OFF is in-
cate a value exceeding the standard value structed to all injectors, replace the pressure
during inspection, release the fuel being limiter valve.
blocked. Refer to "1.Engine 1C.Fuel System(4HK1X)
• Air mixture is checked with the negative Common rail assembly Removal".
pressure amount while the fuel flow is being Refer to "1.Engine 1C.Fuel System(4HK1X)
blocked. Common rail assembly Installation".
39) If the standard negative pressure cannot be ANNOTATION:
generated, inspect to see if there is a cut or
crack with the fuel hose.
84551720B NA - August 2012

4023G-50
Engine-side Trouble
• The pressure limiter valve may be fixed DTC P1112 (Flash Code 295)
open, or the operation pressure may de-
crease. Boost Temperature Sensor Circuit
• Do not replace the pressure limiter valve
separately. When a problem is found, re-
Low
place the common rail assembly. 1. DTC P1112 Priority DTC
DTC P0651
scan tool.
2) Remove the harness connector from the
longer.
3) Check the boost temperature sensor display
Voltage： 4.5 V
the boost temperature sensor.
Boost temperature sensor Removal".
Boost temperature sensor Installation".
and boost temperature sensor.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012

4023G-51
Engine-side Trouble
DTC P1113 (Flash Code 295) 15) Check the boost temperature sensor display
Boost Temperature Sensor Circuit Voltage: 0.1 V
High 16) If it is at or below the standard value, inspect
1. DTC P1113 Priority DTC tance with the GND circuit between the ECM
DTC P0651 and the boost temperature sensor.
ANNOTATION:
• The boost temperature sensor shares the
2) Remove the harness connector from the
4) Measure the voltage between the boost tem-
perature sensor signal circuit and a normal 17) If a problem is discovered, repair the GND
GND. circuit.
Voltage: 5.5 V 18) Inspect to see if there is an open circuit or
5) If it is at or above the standard value, inspect high resistance in the signal circuit between
to see if there is a short circuit to the battery the ECM and the boost temperature sensor.
or ignition power supply with the signal circuit 19) If a problem is discovered, repair the signal
between the ECM and the boost temperature circuit.
sensor. 20) Inspect the ECM harness connector for a con-
6) If a problem is discovered, repair the signal tact failure.
circuit. 21) If a problem is discovered, repair the harness
7) Connect the test cable with fuse between the connector.
boost temperature sensor signal circuit and 22) If the harness connector is normal, replace the
GND circuit. ECM.
8) Check the boost temperature sensor display Refer to "1.Engine 1J.Electrical(4HK1X) ECM
with the trouble diagnosis scan tool. Removal".
Voltage: 0.1 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
9) If it is at or below the standard value, inspect to Installation".
see if there is a short circuit to the 5 V power 23) Set the injector ID code on the ECM.
supply circuit with the signal circuit between 24) Perform the unit difference learning of the fuel
the ECM and the boost temperature sensor. supply pump to the ECM.
circuit. 3. DTC P1113 Confirm Resolution
11) Inspect boost temperature sensor harness 1) Clear the DTC using the trouble diagnosis
connector for a contact failure. scan tool.
12) If a problem is discovered, repair the harness 2) Turn the starter switch OFF for 30 seconds or
connector. longer.
13) If the harness connector is normal, replace the 3) Start the engine.
boost temperature sensor. 4) Perform a test-run.
Boost temperature sensor Removal". ANNOTATION:
Refer to "1.Engine 1F.Induction(4HK1X) • Run the engine for 3 minutes or longer.
Boost temperature sensor Installation".
14) Connect the test cable with fuse between the 5) Use the trouble diagnosis scan tool to confirm
boost temperature sensor signal circuit and a that a DTC has not been detected.
normal GND.
84551720B NA - August 2012

4023G-52
Engine-side Trouble
Injector Positive Voltage Control Injector Positive Voltage Control
Circuit Group 1 Circuit Group 2
1) Replace the ECM. 1) Replace the ECM.
Removal". Removal".
Installation". Installation".
2) Set the injector ID code on the ECM. 2) Set the injector ID code on the ECM.
3) Perform the unit difference learning of the fuel 3) Perform the unit difference learning of the fuel
supply pump to the ECM. supply pump to the ECM.
2. DTC P1261 Confirm Resolution 2. DTC P1262 Confirm Resolution
1) Clear the DTC using the trouble diagnosis 1) Clear the DTC using the trouble diagnosis
scan tool. scan tool.
2) Turn the starter switch OFF for 30 seconds or 2) Turn the starter switch OFF for 30 seconds or
longer. longer.
3) Start the engine. 3) Start the engine.
4) Perform a test-run. 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected. that a DTC has not been detected.
84551720B NA - August 2012

4023G-53
Engine-side Trouble
DTC P1293 (Flash Code 211) Fuel 11) If the harness connector is normal, replace the
fuel filter pressure sensor.
Pressure Sensor Circuit Low Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter pressure sensor Removal".
DTC P0697
Fuel filter pressure sensor Installation".
1) Turn OFF the starter switch. and the fuel filter pressure sensor.
fuel filter pressure sensor. • There should be no open circuit or high re-
sistance.
4) Measure the voltage between the 5 V power • There should be no short to GND.
supply circuit of the fuel filter pressure sensor 13) If a problem is discovered, repair the signal
harness connector and normal GND. circuit.
Voltage: 4.5 V 14) Inspect the ECM harness connector for a con-
5) If it is at or below the standard value, inspect tact failure.
to see if there is an open circuit or high re- 15) If a problem is discovered, repair the harness
sistance with the 5 V power supply circuit be- connector.
tween the ECM and the fuel filter pressure 16) If the harness connector is normal, replace the
sensor. ECM.
ANNOTATION:
Removal".
• The fuel filter pressure sensor shares the 5 Refer to "1.Engine 1J.Electrical(4HK1X) ECM
V power supply circuit with other sensors. Installation".
• The DTC set on a sensor which shares this 17) Set the injector ID code on the ECM.
circuit may be detected. 18) Perform the unit difference learning of the fuel
power supply circuit. 3. DTC P1293 Confirm Resolution
5 V power supply circuit and signal circuit of
scan tool.
the fuel filter pressure sensor harness con-
nector.
longer.
8) Check the fuel filter pressure sensor display
Voltage: 4.5 V
to see if there is a contact failure with the fuel
filter pressure sensor harness connector.
connector.
84551720B NA - August 2012

4023G-54
Engine-side Trouble
DTC P1294 (Flash Code 211) Fuel 8) Inspect to see if there is a contact failure with
the fuel filter pressure sensor harness con-
Pressure Sensor Circuit High nector.
connector.
DTC P0697
fuel filter pressure sensor.
1) Turn OFF the starter switch. Refer to "1.Engine 1C.Fuel System(4HK1X)
2) Disconnect the harness connector from the Fuel filter pressure sensor Removal".
fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Check the fuel filter pressure sensor display Fuel filter pressure sensor Installation".
with the trouble diagnosis scan tool. 11) Inspect the ECM harness connector for a con-
Voltage: 0.1 V tact ailure.
4) If it is at or above the standard value, inspect 12) If a problem is discovered, repair the harness
the signal circuit between the ECM and the connector.
fuel filter pressure sensor. 13) If the harness connector is normal, replace the
ECM.
• There should be no short to the battery or Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ignition power supply. Removal".
• There should be no short to the 5 V power Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply. Installation".
5) If a problem is discovered, repair the signal 14) Set the injector ID code on the ECM.
6) Inspect to see if there is an open circuit or supply pump to the ECM.
high resistance in the GND circuit between the 3. DTC P1294 Confirm Resolution
ECM and the fuel filter pressure sensor.
ANNOTATION: scan tool.
• The fuel filter pressure sensor shares the 2) Turn the starter switch OFF for 30 seconds or
GND circuit with other sensors. longer.
• The DTC set on a sensor which shares this 3) Start the engine.
circuit may be detected. 4) Perform a test-run.
7) If a problem is discovered, repair the GND that a DTC has not been detected.
circuit.
84551720B NA - August 2012

4023G-55
Engine-side Trouble
DTC P1404 (Flash Code 45) 9) Inspect the ECM harness connector for a con-
tact failure.
Exhaust Gas Recirculation (EGR) 10) If a problem is discovered, repair the harness
Closed Position Performance 11)
connector.
Inspect the EGR valve circuit between the
1. DTC P1404 Priority DTC ECM and the EGR valve for an open circuit
DTC P0404 and high resistance.
DTC P0409 12) If a problem is discovered, repair the EGR
2. DTC P1404 Diagnostics valve circuit.
13) Inspect the solenoid circuit between the ECM
1) Remove the EGR valve assembly from the and EGR valve.
engine.
Refer to "1.Engine 1H.Aux. Emission Control • There should be no short to GND.
Devices(4HK1X) EGR valve Removal". • There should be no short to the battery or
2) Inspect the EGR valve. ignition power supply.
• There should be no short to other circuits.
• There should be nothing to limit flow inside • There should be no short to EGR position
the EGR valve. sensor circuit.
• There should be no excessive accumulates
inside the EGR valve. 14) If a problem is discovered, repair the solenoid
• There should be no bending with the valve circuit.
shaft or valve itself inside the EGR valve. 15) If the circuit is normal, replace the EGR valve.
Refer to "1.Engine 1H.Aux. Emission Control
3) If a problem is discovered, repair or replace Devices(4HK1X) EGR valve Removal".
the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control
Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1X) EGR valve Installation".
Devices(4HK1X) EGR valve Removal".
Refer to "1.Engine 1H.Aux. Emission Control 3. DTC P1404 Confirm Resolution
Devices(4HK1X) EGR valve Installation".
scan tool.
EGR valve.
longer.
6) Inspect the EGR valve harness connector for
a contact failure.
connector.
ECM.
84551720B NA - August 2012

4023G-56
Engine-side Trouble
DTC P1455 (Flash Code 132) PM 15) Use the trouble diagnosis scan tool to check if
the boost pressure and atmospheric pressure
Over Accumulation are operating properly.
16) Inspect the air cleaner element.
Refer to "1.Engine 1F.Induction(4HK1X) Air
1) Check with the operator if the DPD light has cleaner element Inspection".
blinked before. 17) If a problem is discovered, replace the air
2) If necessary, explain DPD regeneration. cleaner element.
18) Check the intake duct for a clogging, hole, and
• Check with the operator if the engine oper- leakage.
ating time was short. 19) If a problem is discovered, replace the intake
• Ckeck with the operator if the idling time was duct.
too long. 20) Inspect the intake throttle valve for fixing.
3) Inspect the DPD differential pressure sensor 21) If a problem is discovered, replace the intake
hose. throttle valve.
• There should be no incorrect piping or dis- take throttle valve Removal".
connection. Refer to "1.Engine 1B.Mechanical(4HK1X) In-
4) If a problem is discovered, repair the hose. take throttle valve Installation".
5) Inspect the DPD differential pressure sensor. 22) Inspect the turbocharger assembly.
• DPD differential pressure sensor unit should bocharger assembly Inspection".
not be damaged. 23) If a problem is discovered, replace the tur-
• There should be no dirt or foreign matter bocharger assembly.
blocking the DPD differential pressure sen- Refer to "1.Engine 1F.Induction(4HK1X) Tur-
sor entrance. bocharger assembly Removal".
• There should be no detection error or slow Refer to "1.Engine 1F.Induction(4HK1X) Tur-
response from the DPD differential pressure bocharger assembly Installation".
sensor. 24) Inspect the quality of fuel.
6) If a problem is discovered, replace the DPD ANNOTATION:
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- • An appropriate fuel is used.
haust differential pressure sensor Removal". 25) Turn the starter switch ON for 30 seconds.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa- ANNOTATION:
tion".
• Do not start the engine.
7) When the DPD differential pressure sensor
• This is for the DPD differential pressure sen-
has been replaced, perform the 0-point cor- sor to relearn.
rection.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 26) Clear the DTC using the trouble diagnosis
haust differential pressure sensor Inspection". scan tool.
8) Inspect the exhaust system. 27) Perform the DPD regeneration data reset with
• There should be no absence or damage of 28) Turn the starter switch OFF for 30 seconds or
the exhaust pipe gasket. longer.
• There should be no exhaust gas leak from 29) Start the engine.
the exhaust system. 30) Check the exhaust temperature (before the
• The exhaust system should not be modified. filter) display with the trouble diagnosis scan
• There should be no damage or excessive tool.
deposits on the oxidation catalyst. 31) Confirm that the exhaust temperature is at or
9) If a problem is discovered, repair or replace below the standard value.
the exhaust system. Specified value: 130 °C {266 °F}
10) Inspect the DPD assembly. 32) If it is at or above the standard value, idle the
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD engine until it falls to or below the standard
assembly Inspection". value.
11) If a problem is discovered, replace the DPD 33) Check the exhaust differential pressure dis-
assembly. play when the exhaust temperature (in front
12) If the DPD assembly has been replaced, use of the filter) display has reached the standard
the trouble diagnosis scan tool to perform value with the engine revolution increased to
DPD regeneration data reset. the maximum revolution speed without load.
13) Inspect the mass air flow sensor with the trou- Specified value: 150 °C {302 °F}
ble diagnosis scan tool.
14) If a problem is discovered, replace the mass
air flow sensor.
84551720B NA - August 2012

4023G-57
Engine-side Trouble
34) Use the trouble diagnosis scan tool to check if DTC P1471 (Flash Code 149)
the exhaust differential pressure data display
is at or below the standard value. DPD Insufficient Regeneration
Specified value: 7.5 kPa {0.08 kgf/cm2 / 1.1
psi}
35) If it is at or above the standard value, replace 1) Inspect the DPD differential pressure sensor
the DPD filter. hose.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Disassembly". • There should be no incorrect piping or dis-
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD connection.
assembly Reassembly". 2) If a problem is discovered, repair the hose.
36) If the DPD filter has been replaced, use the 3) Inspect the DPD differential pressure sensor.
trouble diagnosis scan tool to perform DPD
regeneration data reset. • DPD differential pressure sensor unit should
37) When a DTC has been detected, clear it using not be damaged.
the trouble diagnosis scan tool. • There should be no dirt or foreign matter
38) Turn the starter switch OFF for 30 seconds or blocking the DPD differential pressure sen-
longer. sor entrance.
39) Perform the DPD forced slow regeneration • There should be no detection error or slow
with the trouble diagnosis scan tool. response from the DPD differential pressure
sensor.
ANNOTATION:
4) If a problem is discovered, replace the DPD
• After the DPD forced slow regeneration is differential pressure sensor.
completed, replace the engine oil. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
40) Check the exhaust temperature (before the haust differential pressure sensor Removal".
filter) display with the trouble diagnosis scan Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
tool. haust differential pressure sensor Installa-
41) Confirm that the exhaust temperature is at or tion".
below the standard value. 5) When the DPD differential pressure sensor
Specified value: 130 °C {266 °F} has been replaced, perform the 0-point cor-
42) If it is at or above the standard value, idle the rection.
engine until it falls to or below the standard Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
value. haust differential pressure sensor Inspection".
43) Check the exhaust differential pressure dis- 6) Inspect the exhaust system.
play when the exhaust temperature (in front • There should be no absence or damage of
of the filter) display has reached the standard the exhaust pipe gasket.
value with the engine revolution increased to • There should be no exhaust gas leak from
the maximum revolution speed without load. the exhaust system.
Specified value: 150 °C {302 °F} • The exhaust system should not be modified.
44) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at 7) If a problem is discovered, repair or replace
or below the standard value. the exhaust system.
Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3 8) Inspect the exhaust gas temperature sensor.
psi} Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
45) If it is at or above the standard value, perform haust gas temperature sensor Inspection".
ash removal. 9) If a problem is discovered, replace the ex-
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD haust gas temperature sensor.
assembly Inspection". Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust gas temperature sensor Removal".
2. DTC P1455 Confirm Resolution Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
1) Turn ON the starter switch. haust gas temperature sensor Installation".
2) Use the trouble diagnosis scan tool to confirm 10) Inspect the air cleaner element.
that a DTC has not been detected. Refer to "1.Engine 1F.Induction(4HK1X) Air
cleaner element Inspection".
11) If a problem is discovered, replace the air
cleaner element.
12) Inspect the air intake system.
• There should be no crush, limited flow, or
damage of the duct between the air cleaner
and intake manifold.
• The intake system should not be modified.
• There should be no air leak with the intake
system.
84551720B NA - August 2012

4023G-58
Engine-side Trouble
13) If a problem is discovered, repair the intake 20) If the situation falls in the area C or D, use
system. the trouble diagnosis scan tool to perform the
14) Use the trouble diagnosis scan tool to inspect DPD forced slow regeneration.
the mass air flow sensor.
15) If a problem is discovered, replace the mass ANNOTATION:
air flow sensor. • When a DTC has been detected, clear it
16) Turn the starter switch ON for 30 seconds. using the trouble diagnosis scan tool.
ANNOTATION: • After the DPD forced slow regeneration is
completed, replace the engine oil.
21) Check the exhaust temperature (before the
• This is for the DPD differential pressure sen-
sor to relearn. filter) display with the trouble diagnosis scan
tool.
17) Start the engine. 22) Confirm that the exhaust temperature is at or
18) Use the trouble diagnosis scan tool to check below the standard value.
the DPD accumulation status and the DPD Specified value： 130 °C {266 °F}
time status, and confirm the corresponding 23) If it is at or above the standard value, idle the
area from the DPD status table. engine until it falls to or below the standard
value.
24) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum revolution speed without load.
Specified value： 150 °C {302 °F}
25) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at
DPD Ac- or below the standard value.
cumula- Specified value： 1.8 kPa {0.02 kgf/cm2 / 0.3
tion Sta- psi}
tus 26) If it is at or above the standard value, perform
ash removal.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Inspection".
DPD Time Status that a DTC has not been detected.
19) If the situation falls in the area A or B, use

the trouble diagnosis scan tool to perform the
DPD forced regeneration.
ANNOTATION:
• When a DTC has been detected, clear it
using the trouble diagnosis scan tool.
84551720B NA - August 2012

4023G-59
Engine-side Trouble
Control Module Long Term Sensor Reference Voltage Circuit
Memory Performance 1. DTC P1655 Diagnostics
1. DTC P1621 Diagnostics 1) Turn OFF the starter switch.
1) Confirm that the connecting sections of all boost sensor.
tools are securely connected. 3) Turn ON the starter switch.
2) Confirm that the programming device is oper- 4) Measure the voltage between the boost sen-
ating normally. sor 5 V power supply terminal and GND of the
3) Turn the starter switch OFF, and wait for 30 boost sensor harness connector.
seconds. Voltage： 5.5 V
4) Turn ON the starter switch. 5) If it is at or above the standard value, inspect
5) Use the trouble diagnosis scan tool to check to see if there is a short circuit to the battery or
if a DTC has been detected. ignition power supply with the boost sensor 5
6) If a DTC has been detected, replace the ECM. V power supply circuit between the ECM and
Refer to "1.Engine 1J.Electrical(4HK1X) ECM the boost sensor.
Removal". 6) If a problem is discovered, repair the boost
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sensor 5 V power supply circuit.
Installation". 7) Inspect to see if there is a short circuit to the
7) Set the injector ID code on the ECM. battery or ignition power supply with the intake
8) Perform the unit difference learning of the fuel throttle position sensor 5 V power supply cir-
supply pump to the ECM. cuit between the ECM and the intake throttle
2. DTC P1621 Confirm Resolution valve.
8) If a problem is discovered, repair the intake
1) Clear the DTC using the trouble diagnosis throttle position sensor 5 V power supply cir-
scan tool. cuit.
2) Turn the starter switch OFF for 30 seconds or 9) Inspect to see if there is a short circuit to the
longer. battery or ignition power supply with the EGR
3) Start the engine. valve position sensor 5 V power supply circuit
4) Use the trouble diagnosis scan tool to confirm between the ECM and EGR valve.
that a DTC has not been detected. 10) If a problem is discovered, repair the EGR
valve position sensor 5 V power supply circuit.
11) If it is at or below the standard value, mea-
sure the voltage between the boost sensor 5
V power supply terminal and GND of the boost
Voltage： 4.5 V
the boost sensor.
Boost sensor Removal".
Boost sensor Installation".
starter switch OFF.
14) Remove the harness connector from the in-
16) Measure the voltage between the boost sen-
sor 5 V power supply terminal and GND of the
boost sensor harness connector.
Voltage： 4.5 V
the intake throttle valve.
starter switch OFF.
EGR valve.
84551720B NA - August 2012
4023G-60
Engine-side Trouble
21) Measure the voltage between the boost sen- DTC P1669 (Flash Code 75) DPD
sor 5 V power supply terminal and GND of the
boost sensor harness connector. Lamp Control Circuit
Voltage： 4.5 V
the EGR valve. 1) Confirm that the monitor panel operates prop-
Refer to "1.Engine 1H.Aux. Emission Control erly.
Devices(4HK1X) EGR valve Removal". 2) Turn OFF the starter switch.
Refer to "1.Engine 1H.Aux. Emission Control 3) Inspect the fuse.
Devices(4HK1X) EGR valve Installation". 4) If a problem is discovered, replace the fuse.
to see if there is a short circuit to the GND ANNOTATION:
with the boost sensor 5 V power supply circuit • When the fuse is blown again, repair the
between the ECM and the boost sensor. cause of fuse meltdown.
24) If a problem is discovered, repair the boost
sensor 5 V power supply circuit.
ECM.
GND with the intake throttle position sensor 5
V power supply circuit between the ECM and
8) Check to see if the DPD light is off.
the intake throttle valve.
9) If the DPD light is not turned off, repair the
26) If a problem is discovered, repair the intake
short circuit to GND in the DPD light con-
throttle position sensor 5 V power supply cir-
trol circuit between the ECM and the monitor
cuit.
panel.
GND with the EGR valve position sensor 5
11) Remove the fuse.
V power supply circuit between the ECM and
EGR valve.
13) Measure the voltage between the DPD light
28) If a problem is discovered, repair the EGR
control circuit and GND of the ECM harness
valve position sensor 5 V power supply circuit.
connector.
29) Replace the ECM.
Voltage： 1.0 V
14) If it is at or above the standard value, repair
Removal".
the short circuit to the battery or ignition power
supply circuit in the DPD light control circuit
Installation".
between the ECM and the monitor panel.
16) Install the fuse.
2. DTC P1655 Confirm Resolution DPD light control circuit and GND of the ECM
harness connector.
1) Clear the DTC using the trouble diagnosis 18) Turn ON the starter switch.
scan tool. 19) If the DPD light turns on, inspect the ECM
2) Turn the starter switch OFF for 30 seconds or harness connector for a contact failure.
longer. 20) If a problem is discovered, repair the harness
3) Start the engine. connector.
4) Perform a test-run. 21) If the harness connector is normal, replace the
5) Use the trouble diagnosis scan tool to confirm ECM.
that a DTC has not been detected. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Installation".
24) If the DPD light does not turn on, remove the
DPD light bulb from the monitor panel.
25) Inspect the DPD light bulb.
26) Replace the valve if a problem is discovered.
27) Inspect to see if there is an open circuit or high
resistance in the ignition power supply circuit
between the fuse and the monitor panel.
28) If a problem is discovered, repair the ignition
84551720B NA - August 2012

4023G-61
Engine-side Trouble
29) Inspect to see if there is an open circuit or DTC P2146 (Flash Code 158) Fuel
high resistance in the DPD light control circuit
between the ECM and the monitor panel. Injector Group 1 Supply Voltage
30) If a problem is discovered, repair the control
circuit.
Circuit
31) Inspect the monitor panel harness connector 1. DTC P2146 Diagnostics
32) If a problem is discovered, repair the harness 1) Turn the starter switch OFF.
connector. 2) Disconnect the harness connector from the
33) When the harness connector is normal, re- cylinder head injector harness intermediate
place the monitor panel. connector.
3) Turn the starter switch ON.
2. DTC P1669 Confirm Resolution 4) Measure the voltage between the solenoid
control circuit and GND.
scan tool. ANNOTATION:
longer. • Solenoid control circuit and GND of the first
3) Turn the starter switch ON, and wait for 40 cylinder injector
seconds. • Solenoid control circuit and GND of the
4) Start the engine. fourth cylinder injector
5) Use the trouble diagnosis scan tool to confirm Voltage： 12.0 V
that a DTC has not been detected. 5) If it is at or below the standard value, inspect
to see if there is a short circuit to the GND
with the control circuit between the ECM and
injector harness intermediate connector.
6) If a problem is discovered, repair the control
circuit.
7) Inspect the charge voltage circuit between the
ECM and the injector harness intermediate
connector.
ANNOTATION:
• No short circuit to the battery or ignition
power is present.
• No short circuit to GND is present.
8) If a problem is discovered, repair the charge
voltage circuit.
9) If the charge voltage circuit between the ECM
and the injector harness intermediate connec-
tor is normal, replace the ECM.
Removal".
Installation".
13) If a problem is discovered, repair the injector
harness intermediate connector.
ECM.
tact failure.
connector.
high resistance with the charge voltage circuit
between the ECM and the injector harness
intermediate connector.
voltage circuit.
84551720B NA - August 2012

4023G-62
Engine-side Trouble
19) Remove the cylinder head cover. DTC P2149 (Flash Code 159) Fuel
Cylinder head cover Removal". Injector Group 2 Supply Voltage
20) Inspect the injector harness tightening nut for
looseness.
Circuit
21) If the injector harness tightening nut is loose, 1. DTC P2149 Diagnostics
tighten it.
22) Inspect to see if any foreign matter is attached 1) Turn the starter switch OFF.
to the injector terminal. 2) Disconnect the harness connector from the
23) If any foreign matter is attached to the injector cylinder head injector harness intermediate
terminal, remove it. connector.
24) Inspect the injector harness intermediate har- 3) Turn the starter switch ON.
ness connector for a contact failure. 4) Measure the voltage between the solenoid
25) If a problem is discovered, repair the interme- control circuit and GND.
diate harness connector. ANNOTATION:
26) Check if insulation resistance of the first cylin-
der and fourth cylinder injector is at or above • Solenoid control circuit and GND of the sec-
the standard value. ond cylinder injector
Resistance： 1.0 Ω • Solenoid control circuit and GND of the third
27) If it is at or below the standard value, replace cylinder injector
the relevant injector. Voltage: 12.0 V
Refer to "1.Engine 1C.Fuel System(4HK1X) 5) If it is at or below the standard value, inspect
Injector Removal". to see if there is a short circuit to the GND
Refer to "1.Engine 1C.Fuel System(4HK1X) with the control circuit between the ECM and
Injector Installation". injector harness intermediate connector.
28) Set the injector ID code on the ECM. 6) If a problem is discovered, repair the control
29) If it is at or above the standard value, repair or circuit.
replace the injector harness. 7) Inspect the charge voltage circuit between the
2. DTC P2146 Confirm Resolution ECM
1) Clear the DTC using the trouble diagnosis tor.
scan tool.
2) Turn the starter switch OFF for 30 seconds or ANNOTATION:
longer. • No short circuit to the battery or ignition
3) Start the engine. power is present.
4) Use the trouble diagnosis scan tool to confirm • No short circuit to GND is present.
voltage circuit.
9) If the charge voltage circuit between the ECM
tor is normal, replace the ECM.
Removal".
Installation".
13) If a problem is discovered, repair the injector
harness intermediate connector.
ECM.
tact failure.
connector.
high resistance with the charge voltage circuit
between the ECM and the injector harness
intermediate connector.
voltage circuit.
84551720B NA - August 2012

4023G-63
Engine-side Trouble
19) Remove the cylinder head cover. DTC P2228 (Flash Code 71)
Cylinder head cover Removal". Barometric Pressure Circuit Low
20) Inspect the injector harness tightening nut for
looseness.
DTC P0651
21) If the injector harness tightening nut is loose,
tighten it.
22) Inspect to see if any foreign matter is attached 1) Turn OFF the starter switch.
to the injector terminal. 2) Disconnect the harness connector from the
23) If any foreign matter is attached to the injector atmospheric pressure sensor.
terminal, remove it. 3) Turn ON the starter switch.
24) Inspect the injector harness intermediate har- 4) Measure the voltage between the atmo-
ness connector for a contact failure. spheric pressure sensor 5 V power supply
25) If a problem is discovered, repair the interme- circuit and GND.
diate harness connector. Voltage: 4.5 V
26) Check if insulation resistance of the first cylin- 5) If it is at or below the standard value, inspect
der and fourth cylinder injector is at or above to see if there is an open circuit or high re-
the standard value. sistance with the 5 V power supply circuit be-
Resistance: 1.0 MΩ tween the ECM and the atmospheric pressure
27) If it is at or below the standard value, replace sensor.
the relevant injector. 6) If a problem is discovered, repair the 5 V
Refer to "1.Engine 1C.Fuel System(4HK1X) power supply circuit.
Injector Removal". 7) Connect the test cable with fuse between the
Refer to "1.Engine 1C.Fuel System(4HK1X) atmospheric pressure sensor 5 V power sup-
Injector Installation". ply circuit and the signal circuit.
28) Set the injector ID code on the ECM. 8) Check the atmospheric pressure sensor dis-
29) If it is at or above the standard value, repair or play with the trouble diagnosis scan tool.
replace the injector harness. Voltage: 4.5 V
to see if there is a contact failure with the at-
1) Clear the DTC using the trouble diagnosis mospheric pressure sensor harness connec-
scan tool. tor.
2) Turn the starter switch OFF for 30 seconds or 10) If a problem is discovered, repair the harness
longer. connector.
3) Start the engine. 11) If the harness connector is normal, replace the
4) Use the trouble diagnosis scan tool to confirm atmospheric pressure sensor.
that a DTC has not been detected. 12) If it is at or below the standard value, inspect
sistance.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012
4023G-64
Engine-side Trouble
4) Perform a test-run. DTC P2229 (Flash Code 71)

that a DTC has not been detected. Barometric Pressure Circuit High
DTC P0651
3) Check the atmospheric pressure sensor dis-
Voltage: 0.1 V
supply.
circuit.
6) Connect the test light between the atmo-
spheric pressure sensor GND circuit and
battery power supply.
7) If the test light comes on, inspect the atmo-
spheric pressure sensor harness connector
connector.
10) If the test light does not come on, inspect to
see if there is an open circuit or high resis-
tance with the GND circuit between the ECM
and the atmospheric pressure sensor.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84551720B NA - August 2012

4023G-65
Engine-side Trouble
DTC P2452 (Flash Code 142) 17) If a problem is discovered, repair the harness
connector.
DPD Differential Pressure Sensor 18) Inspect the signal circuit between the ECM
Circuit and the DPD differential pressure sensor for
a high resistance.
1. DTC P2452 Priority DTC 19) If a problem is discovered, repair the signal
DTC P2456 circuit.
2. DTC P2452 Diagnostics 20) If the harness connector and circuit are nor-
mal, replace the DPD differential pressure
1) Inspect the DPD differential pressure sensor sensor.
hose. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
• There should be no incorrect piping or dis- haust differential pressure sensor Removal".
connection. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
2) If a problem is discovered, repair the hose. tion".
3) Inspect the DPD differential pressure sensor. 21) When the DPD differential pressure sensor
• DPD differential pressure sensor unit should has been replaced, perform the 0-point cor-
not be damaged. rection.
• There should be no dirt or foreign matter Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
blocking the DPD differential pressure sen- haust differential pressure sensor Inspection".
sor entrance. 22) Restore the actual unit.
• There should be no detection error or slow 23) Turn the starter switch ON for 30 seconds.
response from the DPD differential pressure ANNOTATION:
sensor.
4) If a problem is discovered, replace the DPD • This is for the DPD differential pressure sen-
differential pressure sensor. sor to relearn.
haust differential pressure sensor Removal". 24) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- scan tool.
haust differential pressure sensor Installa- 25) Perform the DPD regeneration data reset with
tion". the trouble diagnosis scan tool.
5) When the DPD differential pressure sensor 26) Turn the starter switch OFF for 30 seconds or
has been replaced, perform the 0-point cor- longer.
rection. 27) Perform the DPD forced regeneration with the
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- trouble diagnosis scan tool.
haust differential pressure sensor Inspection". ANNOTATION:
6) Inspect the exhaust system.
• When the DPD filter is replaced by a new
• There should be no absence or damage of one, do not perform the DPD forced regen-
the exhaust pipe gasket. eration.
• There should be no exhaust gas leak from
the exhaust system. 28) Use the trouble diagnosis scan tool to confirm
• The exhaust system should not be modified. that the exhaust temperature (before the filter)
display is at or below the standard value.
7) If a problem is discovered, repair or replace Specified value: 130 °C {266 °F}
the exhaust system. 29) If it is at or above the standard value, idle the
8) Inspect the DPD assembly. engine until it falls to or below the standard
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD value.
assembly Inspection". 30) Check the exhaust differential pressure dis-
9) If a problem is discovered, replace the DPD play when the exhaust temperature (in front
assembly. of the filter) display has reached the standard
10) If the DPD assembly has been replaced, use value with the engine revolution increased to
the trouble diagnosis scan tool to perform the maximum Revolution speed without load.
DPD regeneration data reset. Specified value: 150 °C {302 °F}
11) Turn OFF the starter switch. 31) Use the trouble diagnosis scan tool to check if
12) Disconnect the harness connector from the the exhaust differential pressure display is at
DPD differential pressure sensor. or above the standard value.
13) Inspect the DPD differential pressure sensor Specified value: 0.5 kPa {0.01 kgf/cm2 / 0.1
harness connector for a contact failure. psi}
connector. 3. DTC P2452 Confirm Resolution
ECM.
tact failure.
84551720B NA - August 2012

4023G-66
Engine-side Trouble
DTC P2453 (Flash Code 141) 13) Inspect the ECM harness connector for a con-
tact failure.
DPD Differential Pressure Sensor 14) If a problem is discovered, repair the harness
Circuit Range/Performance 15)
connector.
Inspect the signal circuit between the ECM
1. DTC P2453 Priority DTC and the DPD differential pressure sensor for
DTC P2456 a high resistance.
2. DTC P2453 Diagnostics 16) If a problem is discovered, repair the signal
circuit.
1) Inspect the DPD differential pressure sensor 17) If the harness connector and signal circuit are
hose. normal, replace the DPD assembly.
• There should be no incorrect piping or dis- 18) If the DPD assembly has been replaced, use
connection. the trouble diagnosis scan tool to perform
DPD regeneration data reset.
2) If a problem is discovered, repair the hose. 19) Restore the actual unit.
3) Inspect the DPD differential pressure sensor. 20) Turn the starter switch ON for 30 seconds.
• DPD differential pressure sensor unit should ANNOTATION:
not be damaged.
• There should be no dirt or foreign matter • Do not start the engine.
blocking the DPD differential pressure sen- • This is for the DPD differential pressure sen-
sor entrance. sor to relearn.
• There should be no detection error or slow 21) Clear the DTC using the trouble diagnosis
response from the DPD differential pressure scan tool.
sensor. 22) Perform the DPD regeneration data reset with
4) If a problem is discovered, replace the DPD the trouble diagnosis scan tool.
differential pressure sensor. 23) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- longer.
haust differential pressure sensor Removal". 24) Perform the DPD forced regeneration with the
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- trouble diagnosis scan tool.
haust differential pressure sensor Installa- 25) Use the trouble diagnosis scan tool to confirm
tion". that the exhaust temperature (before the filter)
5) When the DPD differential pressure sensor display is at or below the standard value.
has been replaced, perform the 0-point cor- Specified value: 130 °C {266 °F}
rection. 26) If it is at or above the standard value, idle the
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- engine until it falls to or below the standard
haust differential pressure sensor Inspection". value.
6) Inspect the exhaust system. 27) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
• There should be no missing or damage with of the filter) display has reached the standard
the gasket of the exhaust pipe. value with the engine revolution increased to
• There should be no exhaust gas leak from the maximum revolution speed without load.
the exhaust system. Specified value: 150 °C {302 °F}
• The exhaust system should not be modified. 28) Use the trouble diagnosis scan tool to check if
• There should be no flow limitation or crush the exhaust differential pressure display is at
of the exhaust system. or below the standard value.
7) If a problem is discovered, repair or replace Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
the exhaust system. psi}
8) Turn OFF the starter switch. 29) If it is at or above the standard value, perform
9) Disconnect the harness connector from the ash removal.
DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
10) Inspect the DPD differential pressure sensor haust differential pressure sensor Inspection".
harness connector for a contact failure. 3. DTC P2453 Confirm Resolution
connector. 1) Turn ON the starter switch.
12) Disconnect the harness connector from the 2) Use the trouble diagnosis scan tool to confirm
ECM. that a DTC has not been detected.
84551720B NA - August 2012

4023G-67
Engine-side Trouble
DTC P2454 (Flash Code 47) 11) If the harness connector is normal, replace the
DPD differential pressure sensor.
DPD Differential Pressure Sensor Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
Circuit Low haust differential pressure sensor Removal".
1. DTC P2454 Priority DTC haust differential pressure sensor Installa-
DTC P0697 tion".
2. DTC P2454 Diagnostics 12) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
1) Turn OFF the starter switch. rection.
2) Disconnect the harness connector from the Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
DPD differential pressure sensor. haust differential pressure sensor Inspection".
3) Turn ON the starter switch. 13) If it is at or below the standard value, inspect
4) Measure the voltage between the DPD differ- the signal circuit between the ECM and the
ential pressure sensor 5 V power supply cir- DPD differential pressure sensor.
cuit and GND.
Voltage: 4.5 V • There should be no open circuit or high re-
5) If it is at or below the standard value, inspect sistance.
to see if there is an open circuit or high re- • There should be no short to GND.
sistance with the 5 V power supply circuit be-
tween the ECM and the DPD differential pres-
circuit.
sure sensor.
ANNOTATION: tact failure.
• The DPD differential pressure sensor connector.
shares the 5 V power supply circuit with 17) If the harness connector is normal, replace the
other sensors. ECM.
• The DTC set on a sensor which shares this Refer to "1.Engine 1J.Electrical(4HK1X) ECM
circuit may be detected. Removal".
6) If a problem is discovered, repair the 5 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
power supply circuit. Installation".
7) Connect the test cable with fuse between the 18) Set the injector ID code on the ECM.
5 V power supply circuit and signal circuit of 19) Perform the unit difference learning of the fuel
the DPD differential pressure sensor. supply pump to the ECM.
8) Check the exhaust differential pressure dis- 3. DTC P2454 Confirm Resolution
Voltage: 4.5 V 1) Clear the DTC using the trouble diagnosis
9) If it is at or above the standard value, inspect scan tool.
to see if there is a contact failure with the DPD 2) Turn the starter switch OFF for 30 seconds or
differential pressure sensor harness connec- longer.
tor. 3) Start the engine.
84551720B NA - August 2012

4023G-68
Engine-side Trouble
DTC P2455 (Flash Code 47) 10) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
DPD Differential Pressure Sensor rection.
Circuit High Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
1. DTC P2455 Priority DTC 11) If the test light does not come on, inspect to
DTC P0697 see if there is an open circuit or high resis-
2. DTC P2455 Diagnostics tance with the GND circuit between the ECM
and the DPD differential pressure sensor.
2) Disconnect the harness connector from the ANNOTATION:
DPD differential pressure sensor.
• The DPD differential pressure sensor
3) Check the exhaust differential pressure dis-
shares the GND circuit with other sensors.
• The DTC may be detected on a sensor
Voltage: 0.1 V
which shares this circuit.
the signal circuit between the ECM and the 12) If a problem is discovered, repair the GND
DPD differential pressure sensor. circuit.
• There should be no short to the battery or tact failure.
• There should be no short to the 5 V power connector.
supply.
5) If a problem is discovered, repair the signal ECM.
6) Connect the test light between the GND circuit Removal".
and battery power supply of the DPD differen- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
tial pressure sensor. Installation".
7) If the test light comes on, inspect DPD differ- 16) Set the injector ID code on the ECM.
ential pressure sensor harness connector for 17) Perform the unit difference learning of the fuel
a contact failure. supply pump to the ECM.
connector.
9) If the harness connector is normal, replace the 1) Clear the DTC using the trouble diagnosis
DPD differential pressure sensor. scan tool.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 2) Turn the starter switch OFF for 30 seconds or
haust differential pressure sensor Removal". longer.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 3) Start the engine.
haust differential pressure sensor Installa- 4) Perform a test-run.
tion". 5) Use the trouble diagnosis scan tool to confirm
84551720B NA - August 2012

4023G-69
Engine-side Trouble
DTC P2458 (Flash Code 139) DTC P042B (Flash Code 145)
DPD Regeneration Duration Catalyst Temperature Sensor
1. DTC P2458 Description of DTC Circuit Range/Performance
The ECM detects PM accumulation failures from the
DPD differential pressure sensor installed near the
Sensor 2
DPD itself. 1. DTC P042B Description of DTC
When it is reached to a certain amount of PM accu- The exhaust temperature sensor 2 is installed on
mulations or a certain length of operating time, the the DPD housing.
automatic regeneration of the DPD starts. The exhaust temperature sensor 2 is a variable re-
If the automatic regeneration cannot be completed sistor, and measures the temperature of the ex-
by some reason, the manual regeneration is re- haust gas before entering the oxidation catalyst.
quested to the operator by blinking the orange DPD The DTC is set when the ECM detects an abnor-
indicator light on the display. mally high exhaust temperature.
Once the DPD filter regeneration starts, it must be 2. DTC P042B Condition for setting the DTC
finished within a certain time. DTC P042C and P042D are not set
When DPD regeneration continues for longer than The starter switch is ON
the specified period of time, it sets DTC. When the ECM has detected that the exhaust tem-
2. DTC P2458 Condition for setting the DTC perature
The starter switch is ON 2 has been 870 °C (1600 °F) or higher for 5 seconds
The DPD filter regeneration has been completed 3. DTC P042B Action taken when the DTC sets
When the ECM detected that the DPD filter regener- Failure is indicated in the monitor on the actual unit,
ation process took time longer than a certain period or the monitor is turned on.
of time for 3 consecutive times
3. DTC P2458 Action taken when the DTC sets ANNOTATION:
Failure is indicated in the monitor on the actual unit, • Depending on the manufacturer of the actual unit,
or the monitor is turned on. the failure indication may not be shown.
ANNOTATION: Restricts the fuel injection amount.
• Depending on the manufacturer of the actual unit,
the failure indication may not be shown.
Restricts the fuel injection amount.
84551720B NA - August 2012

4023G-70
Engine-side Trouble
DTC P042C (Flash Code 49) DTC P042D (Flash Code 49)
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Low Sensor 2 Circuit High Sensor 2
1. DTC P042C Priority DTC 1. DTC P042D Description of DTC
DTC P0697 The exhaust temperature sensor 2 is installed on
2. DTC P042C Diagnostics the DPD housing.
The exhaust temperature sensor 2 is a variable re-
sistor, and measures the temperature of the ex-
2) Disconnect the harness connector from the haust gas before entering the oxidation catalyst.
exhaust gas temperature sensor 2.
This sensor has a signal circuit and GND circuit.
3) Check the exhaust temperature sensor (be- The ECM supplies 5 V to the signal circuit, and the
fore the oxidation catalyst) display with the
GND circuit connects to GND.
trouble diagnosis scan tool. When the exhaust temperature sensor 2 is cold, the
Voltage： 4.5 V
resistance of the sensor is high.
4) If it is at or above the standard value, replace When the exhaust temperature rises, the resistance
the exhaust gas temperature sensor 2.
of the sensor decreases.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- The ECM detects a high voltage when the sensor
haust gas temperature sensor Removal".
resistance is high.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- The ECM detects a low voltage when the sensor
haust gas temperature sensor Installation".
resistance is low.
5) Inspect to see if there is a short circuit to the The DTC is set when the ECM detects an abnor-
mally low signal voltage.
and the exhaust gas temperature sensor 2.
2. DTC P042D Condition for setting the DTC
DTC P0112, P0113, P0117, P0118, P060B, P2228,
circuit.
and P2229 are not set
The battery voltage is between 18 and 32 V The
tact failure.
starter switch is ON
The engine coolant temperature is 70 °C (158 °F)
connector.
or higher.
The fuel injection amount is a certain value or more
ECM.
The engine operating time is 0.5 - 10 minutes or
longer
Removal".
When the ECM has detected that the signal voltage
of the exhaust temperature sensor 2 has been 4.85
Installation".
V or higher for 5 seconds.
3. DTC P042D Action taken when the DTC sets
Failure is indicated in the monitor on the actual unit,
or the monitor is turned on.
3. DTC P042C Confirm Resolution
ANNOTATION:
scan tool.
longer. Restrict the fuel injection amount.
3) Start the engine. Stop the EGR control.
84551720B NA - August 2012

4023G-71
Engine-side Trouble
DTC P060B (Flash Code 36) DTC P242F (Flash Code 131)
Internal Control Module A/D DPD Restriction
Processing Performance 1. DTC P242F Description of DTC
The ECM detects PM accumulation failures from the
1. DTC P060B Diagnostics DPD differential pressure sensor installed near the
1) Replace the ECM. DPD it self.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM When it is reached to a certain amount of PM accu-
Removal". mulations or a certain length of operating time, the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM automatic regeneration of the DPD starts.
Installation". If the automatic regeneration cannot be completed
2) Set the injector ID code on the ECM. by some reason, the manual regeneration is re-
3) Perform the unit difference learning of the fuel quested to the operator by blinking the orange DPD
supply pump to the ECM. indicator light on the display.
If the ECM detects that learned exhaust differential
2. DTC P060B Confirm Resolution pressure is not within a predetermined range, it sets
1) Clear the DTC using the trouble diagnosis DTC.
scan tool. 2. DTC P242F Condition for setting the DTC
2) Turn the starter switch OFF for 30 seconds or The starter switch is ON
longer. The DPD differential pressure has been above the
3) Start the engine. calculated range for 30 seconds or longer.
4) Perform a test-run. 3. DTC P242F Action taken when the DTC sets
5) Use the trouble diagnosis scan tool to confirm Failure is indicated in the monitor on the actual unit,
that a DTC has not been detected. or the monitor is turned on.
ANNOTATION:
Restrict the fuel injection amount.
Stop the EGR control.
Stop the DPD regeneration.
84551720B NA - August 2012

4023G-72
Section
4023H
Main Unit-side Trouble
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Main Unit-side Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Diagnostic Trouble Code: 7063 Return Filter Clogging Pressure Switch Signal Abnormality. . . . . . . . . . . . . . . . . . 34
(Breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
(Other than breaker specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . 36
Diagnostic Trouble Code: 7067 Bucket-close Pilot Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 38
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . 54
Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock Signal Abnormality . . . . . . . . . . . . . . . . . . . 58
Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . 59
Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . 61
Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . 66
Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . 70
Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Diagnostic Trouble Code: 7253 DPD Regeneration Request Output Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 75
Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature [ 105 °C ( 221.0 °F )or higher ] . . . . . . . . 77
Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature [ 95 °C ( 203.0 °F )or higher ]. . . . . . . . . . . . . . 78

4023H-1 PRINTED IN FRANCE
Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature [ 80 °C ( 176.0 °F )or higher ], 7406 Abnormally
High Boost Temperature [ 90 °C ( 194.0 °F )or higher ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Diagnostic Trouble Code: 7421 Coolant Level Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnostic Trouble Code: 7423 Air Cleaner Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Diagnostic Trouble Code: 7600 CAN Bus Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Diagnostic Trouble Code: 7601 Monitor Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Diagnostic Trouble Code: 7602 ECM Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Diagnostic Trouble Code: 7604 Computer B Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Diagnostic Trouble Code: 7605 ECM Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Diagnostic Trouble Code: 7606 EEPROM Data Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Diagnostic Trouble Code: 7607 Computer C Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94


Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7000 is displayed. Go to Step 2
Is diagnostic trouble code: 7000 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7000 is displayed.
1. Check the P1 pressure sensor voltage
on the service support screen. 4.75 V or When 0.25 V or
3 Go to Step 4
higher lower, go to Step 8
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. D45.
2. Turn the key switch ON. W400 harness defect
4 About 5 V Go to Step 5
3. Measure the voltage between the (short). Replace
ground and terminal 1 of the CN. D45
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D45 4.75 V or Y410 harness defect
5 harness side. Go to Step 6
lower (short). Replace
Is it 4.75 V or lower?
ground and terminal 3 of the CN. D45 0.25 V or BW420 harness de-
lower fect (short). Replace
Judge as a computer A defect.
7
…Replace computer A
1. Inspect the P1 pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D45.
8 4. Measure the resistance between termi- About 10 Go to Step 9 P1 pressure sensor
nals 1 and 3 of the CN. D45 P1 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. D45 W400 or Y410 har-
9 harness side. ness defect (short). Go to Step 10
2. Inspect for continuity between the Replace
harness side.
Is there continuity?
ground and terminal 3 of the CN. D45 BW420 harness de-
10 harness side. Go to Step 11 fect (disconnection).
Repair or replace
84551720B NA - August 2012

4023H-3
Standard
Step Action Yes No
value
2. Measure the voltage between the W400 or W401 har-
ground and terminal 1 of the CN. D45 About 5 V ness defect (discon-
11 Go to Step 12
harness side. nection). Repair or
replace
Is it about 5 V?
ground and terminal 2 of the CN. D45 0.25 V or Computer A defect. Y410 harness defect
12 harness side. (disconnection). Re-
higher Replace
place
1 COMPUTER A
2 PRESS. SENSOR (P1)
84551720B NA - August 2012

4023H-4
Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7001 is displayed.
1. Check the P2 pressure sensor voltage
3 Go to Step 4
CN. D46.
W400 or W401 har-
4 About 5 V Go to Step 5 ness defect (short).
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D46 4.75 V or L411 harness defect
ground and terminal 3 of the CN. D46 0.25 V or Computer A defect. BW420 or BW421
6 harness side. harness defect
lower Replace
(short). Replace
7 4. Measure the resistance between termi- About 10 Go to Step 8 P2 pressure sensor
nals 1 and 3 of the CN. D46 P2 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D46 W400, W401, or
8 harness side. L411 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
harness side.
1. Inspect for continuity between the BW420 or BW421
ground and terminal 3 of the CN. D46 harness defect (dis-
connection). Repair
Is there continuity? or replace
84551720B NA - August 2012

4023H-5
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D46 0.25 V or Computer A defect. L411 harness defect
higher Replace
place
1 COMPUTER A
2 PRESS. SENSOR (P1)
84551720B NA - August 2012

4023H-6
Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7002 is displayed.
1. Check the N1 pressure sensor voltage
3 Go to Step 4
CN. D47.
W400 or W402 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D47 4.75 V or Lg412 harness de-
lower Replace
(short). Replace
7 4. Measure the resistance between termi- About 10 Go to Step 8 N1 pressure sensor
nals 1 and 3 of the CN. D47 N1 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
tions.
8 harness side. Lg412 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
harness side.
connection). Repair
84551720B NA - August 2012

4023H-7
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D47 0.25 V or Computer A defect. Lg412 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
1 COMPUTER A
2 PRESS. SENSOR (N1)
84551720B NA - August 2012

4023H-8
Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7003 is displayed.
1. Check the N2 pressure sensor voltage
3 Go to Step 4
CN. D48.
W400 or W403 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D48 4.75 V or G413 harness defect
lower Replace
(short). Replace
1. Inspect the N2 pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 N2 pressure sensor
nals 1 and 3 of the CN. D48 N2 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
tions.
8 harness side. G413 harness defect Go to Step 9
harness side.
connection). Repair
84551720B NA - August 2012

4023H-9
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D48 0.25 V or Computer A defect. G413 harness defect
higher Replace
pair or replace
1 COMPUTER A
2 PRESS. SENSOR (N2)
84551720B NA - August 2012

4023H-10
Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7004 is displayed.
1. Check the overload pressure sensor
3 voltage on the service support screen. 4.75 V or Go to Step 4 When 0.25 V or
CN. D52-1.
W400 or W409 har-
Replace
ground and terminal 1 of the CN. D52-1
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D52-1 4.75 V or Gr419 harness de-
ground and terminal 3 of the CN. D52-1 0.25 V or Computer A defect. BW420 or BW429
lower Replace
(short). Replace
1. Inspect the overload pressure sensor.
3. Disconnect CN. D52-1. Overload pressure
7 4. Measure the resistance between termi- About 10 Go to Step 8 sensor defect. Re-
nals 1 and 3 of the CN. D52-1 overload kΩ place
pressure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D52-1 W400, W409, or
8 harness side. Gr419 harness de- Go to Step 9
harness side.
ground and terminal 3 of the CN. D52-1 harness defect (dis-
connection). Repair
84551720B NA - August 2012

4023H-11
Standard
Step Action Yes No
value
ground and terminal 1 of the CN. D52-1 About 5 V ness defect (discon-
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D52-1 0.25 V or Computer A defect. Gr419 harness de-
higher Replace
Repair or replace
1 COMPUTER A
2 PRESS. SENSOR (HBCV)
84551720B NA - August 2012

4023H-12
Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7005 is displayed.
1. Check the bottom pressure sensor volt-
age on the service support screen. 4.75 V or When 0.25 V or
3 Go to Step 4
CN. CR9.
2. Turn the key switch ON. W414 harness defect
4 About 5 V Go to Step 5
3. Measure the voltage between the (short). Replace
ground and terminal 1 of the CN. CR9
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR9 4.75 V or Y434 harness defect
ground and terminal 3 of the CN. CR9 0.25 V or Computer B defect. BW454 harness de-
6 harness side. lower Replace fect (short). Replace
Inspect the bottom pressure sensor.
2. Disconnect CN. CR9.
About 10 Bottom pressure sen-
7 3. Measure the resistance between termi- Go to Step 8
kΩ sor defect. Replace
nals 1 and 3 of the CN. CR9 bottom sen-
sor.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. CR9 W414 or Y434 har-
8 harness side. ness defect (short). Go to Step 9
2. Inspect for continuity between the Replace
harness side.
ground and terminal 3 of the CN. CR9 BW454 harness de-
Repair or replace
84551720B NA - August 2012

4023H-13
Standard
Step Action Yes No
value
2. Measure the voltage between the W414 harness defect
10 ground and terminal 1 of the CN. CR9 About 5 V Go to Step 11 (disconnection). Re-
harness side. pair or replace
Is it about 5 V?
ground and terminal 2 of the CN. CR9 0.25 V or Computer B defect. Y434 harness defect
higher Replace
pair or replace
84551720B NA - August 2012

4023H-14
Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7006 is displayed.
1. Check the rod pressure sensor voltage
3 Go to Step 4
CN. CR10.
W414 or W415 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR10 4.75 V or L435 harness defect
ground and terminal 3 of the CN. CR10 0.25 V or Computer B defect. BW454 or BW455
lower Replace
(short). Replace
Inspect the rod pressure sensor.
About 10 Rod pressure sensor
kΩ defect. Replace
nals 1 and 3 of the CN. CR10 rod pres-
sure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. CR10 W414, W415, or
8 harness side. L435 harness defect Go to Step 9
harness side.
ground and terminal 3 of the CN. CR10 harness defect (dis-
connection). Repair
84551720B NA - August 2012

4023H-15
Standard
Step Action Yes No
value
ground and terminal 1 of the CN. CR10 About 5 V ness defect (discon-
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. CR10 0.25 V or Computer B defect. L435 harness defect
higher Replace
pair or replace
84551720B NA - August 2012

4023H-16
Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7020 is displayed.
1. Check the upper pressure sensor volt-
3 Go to Step 4
CN. D50.
W400 or W405 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D50 4.75 V or V415 harness defect
lower Replace
(short). Replace
1. Inspect the upper pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Upper pressure sen-
nals 1 and 3 of the CN. D50 upper pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
8 harness side. V415 harness defect Go to Step 9
harness side.
connection). Repair
84551720B NA - August 2012

4023H-17
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D50 0.25 V or Computer A defect. V415 harness defect
higher Replace
pair or replace
1 COMPUTER A
PRESS. SENSOR (PILOT UP-
2
PER)
84551720B NA - August 2012

4023H-18
Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7021 is displayed.
1. Check the swing pressure sensor volt-
3 Go to Step 4
CN. D49.
W400 or W404 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D49 4.75 V or GR414 harness de-
lower Replace
(short). Replace
1. Inspect the swing pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Swing pressure sen-
nals 1 and 3 of the CN. D49 swing pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
8 harness side. GR414 harness de- Go to Step 9
harness side.
connection). Repair
84551720B NA - August 2012

4023H-19
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D49 0.25 V or Computer A defect. GR414 harness de-
higher Replace
Repair or replace
1 COMPUTER A
PRESS. SENSOR (PILOT
2
SWING)
84551720B NA - August 2012

4023H-20
Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7022 is displayed.
1. Check the travel pressure sensor volt-
3 Go to Step 4
CN. D51.
W400 or W406 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D51 4.75 V or YG416 harness de-
lower Replace
(short). Replace
1. Inspect the travel pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Travel pressure sen-
nals 1 and 3 of the CN. D51 travel pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
8 harness side. YG416 harness de- Go to Step 9
harness side.
connection). Repair
84551720B NA - August 2012

4023H-21
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D51 0.25 V or Computer A defect. YG416 harness de-
higher Replace
Repair or replace
1 COMPUTER A
2
TRAVEL)
84551720B NA - August 2012

4023H-22
Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7023 is displayed.
1. Check the arm-in pressure sensor volt-
3 Go to Step 4
CN. D54.
3. Measure the voltage between the About 5 V WL430 harness de-
4 Go to Step 5
ground and terminal 1 of the CN. D54 fect (short). Replace
harness side.
-
Is it about 5 V?
1. 1. Measure the voltage between the
harness side. 4.75 V or YG445 harness de-
5 Go to Step 6
-
1. 1. Measure the voltage between the
harness side. 0.25 V or Computer B defect. BL450 harness de-
6
lower Replace fect (short). Replace
-
1. Inspect the arm-in pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Arm-in pressure sen-
nals 1 and 3 of the CN. D54 arm-in pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D54 WL430 or YG445
8 harness side. harness defect Go to Step 9
harness side.
ground and terminal 3 of the CN. D54 BL450 harness de-
Repair or replace
84551720B NA - August 2012
4023H-23
Standard
Step Action Yes No
value
2. Measure the voltage between the WL430 harness de-
10 ground and terminal 1 of the CN. D54 About 5 V Go to Step 11 fect (disconnection).
harness side. Repair or replace
Is it about 5 V?
ground and terminal 2 of the CN. D54 0.25 V or Computer B defect. YG445 harness de-
higher Replace
Repair or replace
84551720B NA - August 2012

4023H-24
Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector and ground.
7040 is displayed.
1. Check the fuel level sensor resistance
on the service support screen. 100 Ω or When 2 Ω or lower,
3 Go to Step 4
higher go to Step 7
Is it 100 Ω or higher?
Inspect for disconnection.
CN. D57.
2. Measure the resistance between termi- Fuel level sensor de-
4 Go to Step 5
nals 1 and 2 of the CN. D57 fuel level fect. Replace
sensor side.(See the Float position and
resistance table.)
Is it the standard value?
1. Inspect for continuity between the BG660 or BG601
connection). Repair
2. Measure the voltage between the GL492 harness de-
ground and terminal 2 of the CN. D57 About 5 V Computer A defect.
6 fect (disconnection).
harness side. Replace
Repair or replace
Is it about 5 V?
Inspect for shorts.
2. Connect CN. D57.
GL492 harness de-
7 3. Inspect for continuity between the Go to Step 8
fect (short). Replace
harness side.
2. Measure the voltage between the BG660 or BG601
ground and terminal 1 of the CN. D57 0 V Computer A defect.
8 harness defect
(short). Replace
Is it 0 V?
84551720B NA - August 2012

4023H-25
1 COMPUTER A
2 FUEL LEVEL SENSOR
84551720B NA - August 2012

4023H-26
Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7040 is displayed.
1. Check the oil temperature sensor resis-
tance (or voltage) on the service support 67200 Ω (or When 111 Ω (or 0.5
3 screen. 4.93 V) or Go to Step 4 V) or lower, go to
higher Step 7
Is it 67200 Ω (or 4.93 V) or higher?
CN. D56.
2. Measure the resistance between termi- Oil temperature sen-
4 Go to Step 5
nals 1 and 2 of the CN. D56 oil temper- sor defect. Replace
ature sensor side.(See the Oil tempera-
ture and resistance table.)
Is it the standard value?
connection). Repair
2. Measure the voltage between the YB490 harness de-
Repair or replace
Is it about 5 V?
Inspect for shorts.
2. Connect CN. D56.
YB490 harness de-
harness side.
2. Measure the voltage between the BW491 or BW420
8 harness defect
(short). Replace
Is it 0 V?
84551720B NA - August 2012

4023H-27
1 COMPUTER A
2 HYD. OIL TEMP SENSOR
84551720B NA - August 2012

4023H-28
Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality

Standard
Step Action Yes No
value
Monitor defect. Replace
CAUTION
Contrast correction is
performed when the
1. Turn the key switch ON. monitor thermistor is
2. On the service support DIAG at an extremely high
screen, or low temperature.
check whether diagnostic trouble Even if the monitor
1
code: 7045 (●) is displayed. thermistor has a de-
fect, there is a correc-
Is diagnostic trouble code: 7045 (●) dis- tion function inside
played? the monitor, so the
monitor thermistor
does not need to be
replaced if the moni-
tor contrast is not sig-
nificantly affected.
84551720B NA - August 2012

4023H-29
Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7060 is displayed.
1. Check the boom angle sensor voltage
on the service support screen. 4.8 V or When 0.2 V or lower,
3 Go to Step 4
higher go to Step 7
CN. CR11.
W414 or W416 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR11 4.8 V or Lg436 harness de-
ground and terminal 1 of the CN. CR11 0.2 V BW454 or BW456
or Computer B defect.
lower Replace
(short). Replace
Inspect the boom angle sensor.
About 10 Boom angle sensor
kΩ defect. Replace
nals 1 and 3 of the CN. CR11 boom an-
gle sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 3 of the CN. CR11 W414, W416, or
8 harness side. Lg436 harness de- Go to Step 9
harness side.
ground and terminal 1 of the CN. CR11 harness defect (dis-
connection). Repair
84551720B NA - August 2012

4023H-30
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. CR11 0.2 V Lg436 harness de-
higher Replace
Repair or replace
84551720B NA - August 2012

4023H-31
Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7061 is displayed.
1. Check the arm angle sensor voltage on
the service support screen. 4.8 V or When 0.2 V or lower,
3 Go to Step 4
higher go to Step 7
CN. CR12.
BW457 or W414 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR12 4.8 V or Br437 harness defect
ground and terminal 3 of the CN. CR12 0.2 V BW454 or W417 har-
6 harness side. ness defect (short).
lower Replace
Replace
Inspect the arm angle sensor.
About 10 Arm angle sensor de-
kΩ fect. Replace
nals 1 and 3 of the CN. CR12 arm angle
sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. CR12 BW457, W414, or
8 harness side. Br437 harness defect Go to Step 9
harness side.
1. Inspect for continuity between the BW454 or W417 har-
ground and terminal 3 of the CN. CR12 ness defect (discon-
nection). Repair or
Is there continuity? replace
84551720B NA - August 2012

4023H-32
Standard
Step Action Yes No
value
2. Measure the voltage between the BW457 or W414 har-
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. CR12 0.2 V Br437 harness defect
higher Replace
pair or replace
84551720B NA - August 2012

4023H-33
Diagnostic Trouble Code: 7063

Return Filter Clogging Pressure
Switch Signal Abnormality
(Breaker specifications)
Standard
Step Action Yes No
value
7063 is displayed.
Inspect the return filter clog pressure switch.
CN. D81. Return filter clog
3 2. Inspect for continuity between terminals Go to Step 4 pressure switch de-
1 and 2 of the CN. D81 return filter clog fect. Replace
pressure switch side.
1. Inspect for continuity between the BG652 harness de-
4 ground and terminal 1 of the CN. D81 Go to Step 5 fect (disconnection).
harness side. Repair or replace
2. Measure the voltage between the YL538 harness de-
Repair or replace
Is it about 5 V?
1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)
84551720B NA - August 2012

4023H-34
(Other than breaker specifications)

Standard
Step Action Yes No
value
7063 is displayed.
CN. D81. Jump harness defect
3 2. Inspect for continuity between terminals Go to Step 4 (disconnection). Re-
1 and 2 of the CN. D81 jump harness pair or replace
side.
ground and terminal 1 of the CN. D81 BG652 harness de-
Repair or replace
2. Measure the voltage between the YL538 harness de-
Repair or replace
Is it about 5 V?
1 COMPUTER A
84551720B NA - August 2012

4023H-35
Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7065 is displayed.
1. Check the boom-up pilot pressure sen-
sor voltage on the service support 4.75 V or When 0.25 V or
3 screen. Go to Step 4
CN. D53.
WL432 or WL430
4 About 5 V Go to Step 5 harness defect
(short). Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D53 4.75 V or GW444 harness de-
ground and terminal 3 of the CN. D53 0.25 V or Computer B defect. BL452 or BL450 har-
lower Replace
Replace
1. Inspect the boom-up pilot pressure sen-
sor.
3. Disconnect CN. D53. Boom-up pilot pres-
About 10
7 4. Measure the resistance between termi- kΩ Go to Step 8 sure sensor defect.
nals 1 and 3 of the CN. D53 boom-up Replace
pilot pressure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D53 WL432, WL430, or
8 harness side. GW444 harness de- Go to Step 9
harness side.
1. Inspect for continuity between the BL452 or BL450 har-
ground and terminal 3 of the CN. D53 ness defect (discon-
nection). Repair or
84551720B NA - August 2012

4023H-36
Standard
Step Action Yes No
value
2. Measure the voltage between the WL432 or WL430
ground and terminal 1 of the CN. D53 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
ground and terminal 2 of the CN. 120 0.25 V or Computer B defect. GW444 harness de-
higher Replace
Repair or replace
84551720B NA - August 2012

4023H-37
Diagnostic Trouble Code: 7067 Bucket-close Pilot Pressure Sensor

Signal Abnormality
Standard
Step Action Yes No
value
connector.
7067 is displayed.
1. Check the bucket-close pilot pressure
sensor voltage on the service support 4.75 V or When 0.25 V or
3 screen. Go to Step 4
CN. D55.
WL431 or WL430
4 About 5 V Go to Step 5 harness defect
(short). Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D55 4.75 V or LR446 harness de-
ground and terminal 3 of the CN. D55 0.25 V or Computer B defect. BL451 or BL450 har-
lower Replace
Replace
Inspect the bucket-close pilot pressure sen-
sor.
Bucket-close pilot
2. Disconnect CN. D55. About 10
7 Go to Step 8 pressure sensor de-
3. Measure the resistance between termi- kΩ
fect. Replace
nals 1 and 3 of the CN. D55 bucket-
close pilot pressure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D55 WL431, WL430, or
8 harness side. LR446 harness de- Go to Step 9
harness side.
1. Inspect for continuity between the BL451 or BL450 har-
ground and terminal 3 of the CN. D55 ness defect (discon-
nection). Repair or
84551720B NA - August 2012

4023H-38
Standard
Step Action Yes No
value
2. Measure the voltage between the WL431 or WL430
ground and terminal 1 of the CN. D55 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
ground and terminal 2 of the CN. D55 0.25 V or Computer B defect. LR446 harness de-
higher Replace
Repair or replace
84551720B NA - August 2012

4023H-39
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
2. Inspect the fusible link F1 (65 A) fuse
and fuse box F13 (10 A) fuse to see if
2 either is blown. Go to Step 3
7200 is displayed.
Inspect the swing brake solenoid.
CN. D60.
Swing brake solenoid
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4
defect. Replace
nals 1 and 2 of the CN. D60 swing brake
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the W800 harness defect
4 0V Go to Step 5
ground and terminal 2 of the CN. D60 (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the R181, GR180, R105,
5 ground and terminal 1 of the CN. D60 or R104 harness de- Go to Step 6
harness side. fect (short). Replace
W800 harness defect
Inspect for continuity between the ground
6 Go to Step 7 (disconnection). Re-
and terminal 2 of the CN. D60 harness side.
pair or replace
2. Measure the voltage between the R181, GR180, R105,
ground and terminal 1 of the CN. D60 24 V Computer A defect. or R104 harness de-
7
harness side. Replace fect (disconnection).
Repair or replace
Is it 24 V?
84551720B NA - August 2012

4023H-40
1 COMPUTER A 6 FUSE CONT 11 RELAY KEY ON

2 ENGINE COMPUTER 7 SWING BRAKE 12 FUSIBLE LINK FUSE BOX
3 8 RELAY BATTERY 13 KEY SWITCH
SWING)
4 9 BATTERY (24 V)
PER)
5 CRANK ANGLE SENSOR 10 FUSIBLE LINK BACK UP
a CAN COMMUNICATION
84551720B NA - August 2012

4023H-41
Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7201 is displayed.
Inspect the travel high-speed solenoid.
CN. D61. Travel high-speed
3 2. Measure the resistance between ter- 34 Ω - 47 Ω Go to Step 4 solenoid defect. Re-
minals 1 and 2 of the CN. D61 travel place
high-speed solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the L801 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
2. Inspect for continuity between the R183, GR180,
ground and terminal 1 of the CN. D61 R105a, R104, or
5 Go to Step 6
harness side. R105 harness defect
(short). Replace
L801 harness defect
pair or replace
1. Turn the key switch ON. R183, GR180,
2. Measure the voltage between the R105a, R104, or
7 R105 harness defect
(disconnection). Re-
Is it 24 V? pair or replace
84551720B NA - August 2012

4023H-42
1 COMPUTER A 5 FUSE CONT 9 FUSE KEY

2 ENGINE COMPUTER 6 2 STAGE TRAVEL 10 RELAY KEY ON
3 7 RELAY BATTERY 11 FUSIBLE LINK FUSE BOX
TRAVEL)
4 CRANK ANGLE SENSOR 8 BATTERY (24 V) 12 KEY SWITCH
a CAN COMMUNICATION
84551720B NA - August 2012

4023H-43
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7202 is displayed.
Inspect the pressure boost solenoid.
CN. D62.
Pressure boost sole-
noid defect. Replace
nals 1 and 2 of the CN. D62 pressure
boost solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the Y802 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
Y802 harness defect
pair or replace
7
Repair or replace
Is it 24 V?
84551720B NA - August 2012

4023H-44
84551720B NA - August 2012

4023H-45

1 COMPUTER A 7 13 BATTERY (24 V)
TRAVEL)
PRESS. SWITCH (1ST OP-
2 ENGINE COMPUTER 8 14 BACK UP FUSIBLE LINK
TION)
PRESS. SWITCH (2ND OP-
3 THROTTLE VOL. 9 15 RELAY KEY ON
TION)
4 PRESS. SENSOR (P1) 10 FUSE CONT 16 MONITOR DISPLAY
5 PRESS. SENSOR (P2) 11 2 STAGE RELIEF 17 FUSIBLE LINK FUSE BOX
PER)
a CAN COMMUNICATION
84551720B NA - August 2012

4023H-46
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality

Standard
Step Action Yes No
value
2. On the service support DIAG screen,
check whether diagnostic trouble code:
1 7203 (●) is displayed. Go to Step 2
Is diagnostic trouble code: 7203 (●) dis-
played?
connector.
2 and fuse box F21 (10 A) fuse to see if Go to Step 3
either is blown.
Are 1 and 2 above both OK?
Inspect the travel alarm.
CN. D69.
2. Connect terminal 1 of the CN. D69 travel
Travel alarm defect.
3 alarm side to the negative terminal of Go to Step 4
Replace
the battery and terminal 2 to the positive
terminal, and inspect the operation of
the travel alarm.
Does the travel alarm sound?
Inspect for shorts.
2. Measure the voltage between the WL807 harness de-
4 0V Go to Step 5
ground and terminal 1 of the CN. D69 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the GW215, R105, or
5 ground and terminal 2 of the CN. D69 R104 harness defect Go to Step 6
harness side. (short). Replace
Inspect whether there is continuity between
WL807 harness de-
the ground and terminal 1 of the CN. D69
6 Go to Step 7 fect (disconnection).
harness side for 0.4 sec. after the key switch
Repair or replace
is turned ON.
2. Measure the voltage between the GW215, R105, or
ground and terminal 2 of the CN. D69 24 V Computer A defect. R104 harness defect
7
harness side. Replace (disconnection). Re-
pair or replace
Is it 24 V?
84551720B NA - August 2012

4023H-47
1 COMPUTER A 5 BACK UP FUSIBLE LINK 9 FUSIBLE LINK FUSE BOX

TRAVEL)
3 FUSE CONT 7 RELAY KEY ON
4 TRAVEL ALARM 24 V, 107 dB 8 BATTERY (24 V)
84551720B NA - August 2012

4023H-48
Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality

Standard
Step Action Yes No
value
connector.
7204 is displayed.
Inspect the power save solenoid.
CN. D60.
Power save solenoid
defect. Replace
nals 1 and 2 of the CN. D60 power save
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the G812 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
G812 harness defect
pair or replace
7
Repair or replace
Is it 24 V?
84551720B NA - August 2012

4023H-49
84551720B NA - August 2012

4023H-50
1 COMPUTER A 6 CRANK ANG (MRE) SENSOR 11 RELAY BATTERY

2 ENGINE COMPUTER 7 FUSE CONT 12 FUSIBLE LINK BACK UP
3 8 POWER SAVE 13 FUSIBLE LINK FUSE BOX
SWING)
PER)
5 10 BATTERY (24 V) 15 COMPUTER B
TRAVEL)
a CAN COMMUNICATION
84551720B NA - August 2012

4023H-51
Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormality

Standard
Step Action Yes No
value
connector.
2. Inspect the fusible link F (65 A) fuse and
2 fuse box F19 (30 A) fuse to see if either Go to Step 3
is blown.
Inspect the feed pump relay.
CN. D83-1.
Feed pump relay de-
3 2. Inspect for continuity between terminals Go to Step 4
fect. Replace
1 and 2 of the CN. D83-1 feed pump
relay side.
Inspect for shorts.
VR845, W250,
1. Install CN. D83-1.
VR894, L846, or
4 R105 harness defect Go to Step 5
(short). Replace
harness side.
VR845, W250,
VR894, L846, or
2. Inspect for continuity between the Computer B defect.
5 R105 harness defect
ground and terminal 1 of the CN. D83-1 Replace
(disconnection). Re-
harness side.
pair or replace
84551720B NA - August 2012

4023H-52
1 RELAY BATTERY 4 RELAY STOP 7 REFUEL PUMP

2 FUSIBLE LINK FUSE BOX 5 MANUAL/AUTO 8 MONITOR DISPLAY
3 RELAY PUMP 6 ALARM 24V,107dB
84551720B NA - August 2012

4023H-53
Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
fuse box F20 (10 A) fuse to see if either
2 is blown. Go to Step 3
7206 is displayed.
Inspect the option line switchover solenoid.
CN. 162. Option line
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4 switchover solenoid
nals 1 and 2 of the CN. 162 option line defect. Replace
switchover solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the LY806 harness de-
4 0V Go to Step 5
ground and terminal 2 of the CN. 162 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the WL260 or SR105
5 ground and terminal 1 of the CN. 162 harness defect Go to Step 6
LY806 harness de-
and terminal 2 of the CN. 162 harness side.
Repair or replace
2. Measure the voltage between the WL260 or SR105
ground and terminal 1 of the CN. 162 24 V Computer A defect. harness defect (dis-
7
harness side. Replace connection). Repair
or replace
Is it 24 V?
84551720B NA - August 2012

4023H-54
1 RELAY BATTERY 3 OPTION SELECT

2 FUSIBLE LINK FUSE BOX 4 CONTROLLER A
84551720B NA - August 2012

4023H-55
Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality

Standard
Step Action Yes No
value
connector.
7207 is displayed.
Inspect the free swing solenoid.
CN. D64.
Free swing solenoid
defect. Replace
nals 1 and 2 of the CN. D64 free swing
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the Br803 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
2. Inspect for continuity between the R187, GR180, or
5 ground and terminal 1 of the CN. D64 SR105 harness de- Go to Step 6
Br803 harness defect
pair or replace
2. Measure the voltage between the R187, GR180, or
ground and terminal 1 of the CN. D64 24 V Computer A defect. SR105 harness de-
7
Repair or replace
Is it 24 V?
84551720B NA - August 2012

4023H-56
Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality

Standard
Step Action Yes No
value
connector.
either is blown.
Inspect the liftcrane buzzer.
CN. CR5 and CN. CR6.
2. Connect the terminal of the CN. CR6
liftcrane buzzer side to the negative ter-
Liftcrane buzzer de-
3 minal of the battery and the terminal of Go to Step 4
fect. Replace
the CN. CR5 liftcrane buzzer side to the
positive terminal, and inspect the oper-
ation of the liftcrane buzzer.
Does the liftcrane buzzer sound?

Inspect for shorts.
2. Measure the voltage between the VG815 harness de-
4 0V Go to Step 5
ground and the terminal of the CN. CR6 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the BrW237, BrW236,
ground and the terminal of the CN. CR5 R111, R106, or
5 Go to Step 6
harness side. R105 harness defect
(short). Replace
Inspect for disconnection. BrW237, BrW236,
Turn the key switch ON and measure the R111, R106, or R105
6 voltage between the ground and the terminal About 24 V Go to Step 7 harness defect (dis-
of the CN. CR5 harness side. connection). Repair
Is it about 24 V? or replace
CN. CR4.
2. Inspect whether there is continuity be- VG815 harness de-
tween the terminal of the CN. CR6 har- Computer B defect.
ness side and terminal 6 of the CN. CR4 Replace
Repair or replace
harness side.
84551720B NA - August 2012

4023H-57
Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock
Signal Abnormality
Standard
Step Action Yes No
value
connector.
either is blown.
Inspect the rotating light relay.
CN. 19.
Rotating light relay
defect. Replace
1 and 2 of the CN. 19 rotating light relay
side.
Inspect for shorts.
1. Install CN. 19. VW858, GW226,
2. Inspect for continuity between the GW227, R106, or
4 Go to Step 5
ground and terminal 1 of the CN. 19 R105 harness defect
VW816, VW817,
1. Turn the key switch ON. GW227, GW226,
2. Inspect for continuity between the Computer B defect. GW225, R106, or
5
ground and terminal 1 of the CN. 19 Replace R105 harness defect
harness side. (disconnection). Re-
pair or replace
84551720B NA - August 2012

4023H-58
Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
connector.
7240 is displayed.
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7240 is displayed.
Inspect for shorts.
CN. D39.
Y900 harness defect Computer A defect.
4 2. Inspect for continuity between the
(short). Replace Replace
harness side.
Inspect the pump horsepower proportional
valve.
Pump horsepower
5 Go to Step 6 proportional valve
3. Inspect for continuity between terminals
defect. Replace
1 and 2 of the CN. D39 pump horse-
power proportional valve side.
YR940 harness de-
1. Disconnect CN. A56.
fect (disconnection)
2. Inspect for continuity between terminal
6 Go to Step 7 between CN. D39
1 of the CN. D39 female side and termi-
and CN. A56. Repair
nal 1 of the CN. A56 male side.
or replace
BY901 harness de-
Inspect for continuity between terminal 2 of
the CN. D39 female side and terminal 9 of
the CN. A56 male side.
and CN. A56. Repair
or replace
1. Disconnect CN. A4. Y900 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 1 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
3 of the CN. A4 female side. CN. A4. Repair or re-
Is there continuity? place
1. Inspect for continuity between terminal BY901 harness de-
9 of the CN. A56 male side and terminal fect (disconnection)
Computer A defect.
9 6 of the CN. A4 female side. between CN. A56
Replace
and CN. A4. Repair
84551720B NA - August 2012

4023H-59

1 COMPUTER A 4 7 ENGINE COMPUTER
PER)
2 PRESS. SENSOR (P1) 5 CRANK ANGLE SENSOR
3 PRESS. SENSOR (P2) 6 PUMP POWER
a CAN COMMUNICATION
84551720B NA - August 2012

4023H-60
Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
connector.
7241 is displayed.
7241 is displayed.
Inspect for shorts.
CN. D40.
L904 harness defect Computer A defect.
harness side.
Inspect the P1 flow control proportional
valve.
P1 flow control pro-
5 Go to Step 6 portional valve de-
fect. Replace
1 and 2 of the CN. D40 flow control
proportional valve side.
Y904 harness defect
(disconnection) be-
6 Go to Step 7 tween CN. D40 and
1 of the CN. D40 male side and terminal
CN. A56. Repair or
3 of the CN. A56 female side.
replace
BL905 harness de-
the CN. D40 male side and terminal 11 of the
CN. A56 female side.
and CN. A56. Repair
or replace
1. Disconnect CN. A3. Y904 harness defect
BL905 harness de-
the CN. A56 male side and terminal 5 of the Computer A defect.
9 between CN. A56
CN. A3 female side. Replace
and CN. A3. Repair
or replace
84551720B NA - August 2012

4023H-61

1 COMPUTER A 4 7 ENGINE COMPUTER
TRAVEL)
2 5 CRANK ANGLE SENSOR
SWING)
3 6 P1 FLOW
PER)
a CAN COMMUNICATION
1 COMPUTER A 3 WATER TEMP. SENSOR

2 ENGINE COMPUTER
84551720B NA - August 2012

4023H-62
Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7242 is displayed.
7242 is displayed.
Inspect for shorts.
CN. H1.
YG944 harness de- Computer B defect.
fect (short). Replace Replace
ground and terminal 1 of the CN. H1
harness side.
Inspect the fan proportional valve.
2. Disconnect CN. H1. Fan proportional
5 3. Inspect for continuity between terminals Go to Step 6 valve defect. Re-
1 and 2 of the CN. H1 fan proportional place
valve side.
YG494 harness de-
6 Go to Step 7 between CN. H1 and
1 of the CN. H1 female side and terminal
CN. A54. Repair or
5 of the CN. A54 female side.
replace
BY495 harness de-
1. Inspect for continuity between terminal fect (disconnection)
2 of the CN. H1 female side and terminal between CN. H1 and
7 15 of the CN. A54 female side. Go to Step 8
CN. A54. Repair or
1. Disconnect CN. A7. W908 harness defect

1. Inspect for continuity between terminal WB909 harness de-
15 of the CN. A54 male side and termi- fect (disconnection)
Computer B defect.
9 nal 4 of the CN. A7 female side. between CN. A54
Replace
and CN. A7. Repair
84551720B NA - August 2012

4023H-63
Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7246 is displayed.
Inspect the 2 pumps flow solenoid.
CN. 163.
2 pumps flow sole-
noid defect. Replace
nals 1 and 2 of the CN. 163 2 pumps
flow solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the YR805 harness de-
4 0V Go to Step 5
ground and terminal 3 of the CN. 163 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the WL260, WL261, or
5 ground and terminal 1 of the CN. 163 SR105 harness de- Go to Step 6
YR805 harness de-
and terminal 3 of the CN. 163 harness side.
Repair or replace
2. Measure the voltage between the WL260, WL261, or
ground and terminal 1 of the CN. 163 24 V Computer A defect. SR105 harness de-
7
Repair or replace
Is it 24 V?
84551720B NA - August 2012

4023H-64
1 RELAY BATTERY 3 OPTION 2SPEED

2 FUSIBLE LINK FUSE BOX 4 CONTROLLER A
84551720B NA - August 2012

4023H-65
Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7247 is displayed.
7247 is displayed.
Inspect for shorts.
CN. D41.
O902 harness defect Computer A defect.
harness side.
Inspect the boom-down proportional valve.
2. Disconnect CN. D41. Boom-down propor-
5 3. Inspect for continuity between terminals Go to Step 6 tional valve defect.
1 and 2 of the CN. D41 boom-down pro- Replace
portional valve side.
O902 harness defect
(disconnection) be-
6 Go to Step 7 tween CN. A56 and
CN. D41. Repair or
nal 2 of the CN. A56 female side.
replace
O903 harness defect
(disconnection) be-
the CN. A56 female side.
CN. D41. Repair or
replace
1. Disconnect CN. A3. O902 harness defect
O903 harness defect
(disconnection) be-
the CN. A56 male side and terminal 4 of the Computer A defect.
9 tween CN. A56 and
CN. A3. Repair or re-
place
84551720B NA - August 2012

4023H-66
1 CONTROLLER A
2 BOOM DOWN
84551720B NA - August 2012

4023H-67
Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7248 is displayed.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5.
7248 is displayed.
Inspect for shorts.
CN. D42.
G906 harness defect Computer B defect.
harness side.
Inspect the arm-in proportional valve.
2. Disconnect CN. D42. Arm-in proportional
5 3. Inspect for continuity between terminals Go to Step 6 valve defect. Re-
1 and 2 of the CN. D42 arm-in propor- place
tional valve side.
G906 harness defect
(disconnection) be-
CN. D42. Repair or
nal 4 of the CN. A56 female side.
replace
GB907 harness de-
7 Go to Step 8 between CN. A56
the CN. A56 female side.
and CN. D42. Repair
or replace
1. Disconnect CN. A7. G906 harness defect
GB907 harness de-
the CN. A56 male side and terminal 6 of the Computer B defect.
9 between CN. A56
and CN. A7. Repair
or replace
84551720B NA - August 2012

4023H-68
1 CONTROLLER B
2 ARM CLOSE
84551720B NA - August 2012

4023H-69
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional

Valve Signal Abnormality
Standard
Step Action Yes No
value
connector.
7250 is displayed.
7250 is displayed.
Inspect for shorts.
CN. D44-1.
V910 harness defect Computer B defect.
harness side.
Inspect the option relief pressure propor-
tional valve.
Option relief pressure
2. Disconnect CN. D44-1.
5 Go to Step 6 proportional valve
defect. Replace
1 and 2 of the CN. D44-1 option relief
pressure proportional valve side.
V910 harness defect
(disconnection) be-
6 Go to Step 7 tween CN. D44-1 and
1 of the CN. D44-1 female side and ter-
CN. D44. Repair or
minal 1 of the CN. D44 male side.
replace
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44-1 female side and ter- fect (disconnection)
7 minal 2 of the CN. D44 male side. Go to Step 8 between CN. D44-1
and CN. D44. Repair
1. Disconnect CN. A7. V910 harness defect
1 of the CN. D44 female side and termi- tween CN. D44 and
8 Go to Step 9
nal 2 of the CN. A7 female side. CN. A7. Repair or re-
place
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44 female side and termi- fect (disconnection)
Computer B defect.
9 nal 5 of the CN. A7 female side. between CN. D44
Replace
and CN. A7. Repair
84551720B NA - August 2012

4023H-70
1 CONTROLLER B
2 PROPORTIONAL S/V
3 OPT PRESS
84551720B NA - August 2012

4023H-71
Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality

Standard
Step Action Yes No
value
connector.
2 Inspect the computer fuse (15 A) to see Go to Step 3
if it is blown.
Inspect the battery control relay.
CN. A11.
Battery control relay
defect. Replace
1 and 2 of the CN. A11 battery control
relay side.
Inspect for shorts.
1. Install CN. A11.
W113, W112, W107,
4 or W106 harness de- Go to Step 5
ground and terminal 1 of the CN. A11
harness side.
W113, W112, W107,
W106, or OG804 har-
2. Inspect for continuity between the Computer A defect.
5 ness defect (discon-
ground and terminal 1 of the CN. A11 Replace
nection). Repair or
harness side.
replace
1 RELAY BATTERY 3 RELAY BATTERY RL

2 FUSE CONT 4 CONTROLLER A
84551720B NA - August 2012

4023H-72
Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality

Standard
Step Action Yes No
value
connector.
2 and computer (15 A) fuse to see if either Go to Step 3
is blown.
Inspect the idle stop relay.
CN. A12.
Idle stop relay defect.
Replace
1 and 2 of the CN. A12 idle stop relay
side.
Inspect for shorts.
1. Install CN. A12. W115, W114, W112,
2. Inspect for continuity between the W113, or W107 har-
4 Go to Step 5
ground and terminal 1 of the CN. A12 ness defect (short).
W106, W107, W112,
W113, W114, W115,
2. Inspect for continuity between the Computer B defect.
5 or LY824 harness de-
fect (disconnection).
harness side.
Repair or replace
84551720B NA - August 2012

4023H-73
1 RELAY BATTERY 3 RELAY IDLE STOP 5 KEY SWITCH

2 FUSE CONT 4 RELAY KEY ON 6 MONITOR DISPLAY
84551720B NA - August 2012

4023H-74
Diagnostic Trouble Code: 7253 DPD Regeneration Request Output

Signal Abnormality
Standard
Step Action Yes No
value
connector.
2 fuse box F4 (10 A) fuse to see if either Go to Step 3
is blown.
Inspect the DPD relay.
CN. A10. DPD relay defect.
3 Go to Step 4
2. Inspect for continuity between terminals Replace
1 and 2 of the CN. A10 DPD relay side.
Inspect for shorts.
1. Install CN. A10.
WR147, WR141, or
4 WR140 harness de- Go to Step 5
harness side.
WR147, WR141,
WR140, or YL806
2. Inspect for continuity between the Computer A defect.
5 harness defect (dis-
connection). Repair
harness side.
or replace
84551720B NA - August 2012

4023H-75
1 FUSIBLE LINK BACK UP 3 RELAY DPD 5 ENGINE CONTROLLER

2 RELAY ECM 4 CONTROLLER A 6 RELAY BATTERY
84551720B NA - August 2012

4023H-76
Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature [

105 °C ( 221.0 °F )or higher ]
Standard
Step Action Yes No
value
1. Start the engine and perform a warm-up
operation until the engine is fully
warmed up.
1 check whether diagnostic trouble code: Go to Step 2
7400 (●) is displayed.
played?
2 Inspect the engine unit.

110 °C ( 230.0 °F )or higher ]
Standard
Step Action Yes No
value
warmed up.
played?

120 °C ( 248.0 °F )or higher ]
Standard
Step Action Yes No
value
warmed up.
played?
84551720B NA - August 2012

4023H-77
Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature [ 95

°C ( 203.0 °F )or higher ]
Standard
Step Action Yes No
value
warmed up.
played?
2 Inspect the hydraulic oil temperature.
1 COMPUTER A
2 HYD. OIL TEMP SENSOR
84551720B NA - August 2012

4023H-78
Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature [ 80

°C ( 176.0 °F )or higher ], 7406 Abnormally High Boost Temperature [ 90
°C ( 194.0 °F )or higher ]
Standard
Step Action Yes No
value
warmed up.
1 check whether diagnostic trouble code Go to Step 2.
7405 (●) or 7406 (●) is displayed.
Is diagnostic trouble code 7405 (●) or 7406
(●) displayed?
84551720B NA - August 2012

4023H-79
Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage

Standard
Step Action Yes No
value
played?
2 connector. Go to Step 3
Is 1 above OK?
Inspect for shorts.
CN. D14.
Br515 harness defect
(short). Replace
harness side.
Inspect the alternator.
1. Start the engine.
2. Measure the voltage between the 10 V or Alternator defect.
4 Go to Step 5
ground and terminal 2 of the CN. D14 lower Replace
alternator side.
Is it 10 V or lower?
2. Connect CN. D14.
3. Disconnect CN. A1. Br515 harness defect
10 V or Computer A defect.
5 4. Start the engine. (disconnection). Re-
lower Replace
5. Measure the voltage between the pair or replace
harness side.
Is it 10 V or lower?
84551720B NA - August 2012

4023H-80
84551720B NA - August 2012

4023H-81
1 COMPUTER A 6 FUSIBLE LINK FUSE BOX 11 STARTER MOTOR

2 RELAY STARTER CUT 7 FUSIBLE LINK BACK UP 12 ALTERNATOR
3 BATTERY (24 V) 8 FUSIBLE LINK SAFETY RL 13 RELAY STARTER
4 RELAY BATTERY 9 RELAY KEY ON
5 FUSE CONT 10 KEY SWITCH
84551720B NA - August 2012

4023H-82
Diagnostic Trouble Code: 7421 Coolant Level Reduction

Standard
Step Action Yes No
value
1. Check that the "LOW COOLANT" dis-
play appears.
2. Fill with coolant.
1 4. On the service support DIAG screen, Go to Step 2
played?
connector.
played?
Inspect the coolant level switch.
CN. D79.
Coolant level switch Computer A defect.
3 2. Inspect for continuity between terminals
defect. Replace Replace
1 and 2 of the CN. D79 coolant level
switch side.
1 COMPUTER A
LEVEL SWITCH (RESERVE
2
TANK)
84551720B NA - August 2012

4023H-83
Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure

Standard
Step Action Yes No
value
1. Start the engine and wait for 30 sec.
played?
1 COMPUTER A
2 ENGINE COMPUTER
3 OIL PRESS SENSOR
84551720B NA - August 2012

4023H-84
Diagnostic Trouble Code: 7423 Air Cleaner Clogging

Standard
Step Action Yes No
value
1. Check that the "AIR FILTER" display ap-
pears.
2. Clean or replace the air cleaner ele-
ment.
3. Start the engine and wait for 10 sec.
1 4. On the service support DIAG screen, Go to Step 2
played?
connector.
played?
Inspect the air cleaner clog pressure switch.
CN. D80. Air cleaner clog pres-
3 Inspect for continuity between terminals sure switch defect. Go to Step 4
1 and 2 of the CN. D80 air cleaner clog Replace
pressure switch side.
Inspect for shorts.
LW533 harness de- Computer A defect.
4 ground and terminal 2 of the CN. D80
fect (short). Replace Replace
harness side.
1 COMPUTER A
PRESS. SWITCH (AIR
2
CLEANER)
84551720B NA - August 2012

4023H-85
Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker

specifications)
Standard
Step Action Yes No
value
1. Check that the "HYD. OIL FILTER" dis-
play appears.
2. Replace the return filter.
1 3. Turn the key switch ON. Go to Step 2
7424 is displayed.
7424 is displayed.
Inspect the return filter clog switch.
CN. D81. Return filter clog
Computer A defect.
3 2. Inspect for continuity between terminals pressure switch de-
Replace
1 and 2 of the CN. D81 return filter clog fect. Replace
switch side.
1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)
84551720B NA - August 2012

4023H-86
Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality

Standard
Step Action Yes No
value
1. View the fuel density data on the service
support CHK-MAIN-11 screen.
2. Turn the key switch OFF, but just before
doing so, record the fuel density data.
3. Turn the key switch OFF. The fuel is not appro-
4. Turn the key switch ON, and record the priate. Go to Step 4
2 fuel density data at this time. If the fuel density is a Go to Step 3
5. Compare the data from 2 and 4 above to borderline value, per-
check whether the difference between form fuel analysis.
the values has dropped by 0.01 g/cm3
or more.
Has the value dropped by 0.01 g/cm3 or
more?
1. While the diagnostic trouble code is dis-
played, turn the key switch OFF.
2. After checking that the display has
turned off, turn the key switch ON again.
3. When the diagnostic trouble code is dis- Check again from the
3 played, wait for at least 5 min. End
beginning of the step.
4. Turn the key switch OFF, turn the igni-
tion key ON again, and check whether
the error code is displayed.
Has the error code disappeared?
1. Check whether the customer has
changed gas station or fuel manufac- Have the customer If the fuel density is
turer. return to the previous clearly outside the
4
gas station or fuel standard, go to Step
Has the customer changed gas station or manufacturer. 5
fuel manufacturer?
1. Drain the fuel.
2. Check whether the fuel density sensor Check for fuel density
5 is dirty. Clean
sensor trouble.
Is the fuel density sensor dirty?
84551720B NA - August 2012

4023H-87
Diagnostic Trouble Code: 7600 CAN Bus Abnormality

Standard
Step Action Yes No
value
connector.
7600 is displayed.
Inspect for shorts.
P040, P042, P044,
CN. 50.
P046, P048, or
P050 harness defect
ground and terminal A of the CN. 50
(short). Replace
harness side.
1. Inspect for continuity between the PG041, PG043,
ground and terminal B of the CN. 50 PG045, PG047,
4 harness side. PG049, or P051 har- Go to Step 5
ness defect (short).
Is there continuity? Replace
P040, P042, P044,
P046, P048, P050,
1. Inspect for continuity between terminals PG041, PG043,
5 A and B of the CN. 50 harness side. PG045, PG047, Go to Step 6
Is there continuity? PG049, or P051 har-
ness defect (short).
Replace
Inspect the ECM, computer A, computer B,
and computer S units.
1. Connect CN. 50.
2. Disconnect CN. A0 and turn the key ECM defect. Re-
6 Go to Step 7
switch ON. place
7600 is displayed.
1. Turn the key switch OFF and connect
CN. A0.
2. Disconnect CN. C2 and turn the key
switch ON. Computer S defect. Computer A defect.
7
3. Check whether diagnostic trouble code: Replace Replace
7600 is displayed.
84551720B NA - August 2012

4023H-88
Diagnostic Trouble Code: 7601 Monitor Communication Abnormality

Standard
Step Action Yes No
value
connector.
7601 is displayed.
CN. A2 and CN. C1. WL061 harness de-
3 2. Inspect for continuity between terminal Go to Step 4 fect (disconnection).
10 of the CN. A2 harness side and ter- Repair or replace
minal 8 of the CN. C1 harness side.
3 of the CN. A2 harness side and termi- W060 harness defect
4 nal 9 of the CN. C1 harness side. Go to Step 5 (disconnection). Re-
pair or replace
2. Check whether diagnostic trouble code: Computer A defect. Monitor defect. Re-
5 7601 is displayed. Replace place
1 COMPUTER A
2 MONITOR
a CAN COMMUNICATION
84551720B NA - August 2012

4023H-89
Diagnostic Trouble Code: 7602 ECM Communication Abnormality

Standard
Step Action Yes No
value
connector.
7602 is displayed.
1. Check whether diagnostic trouble codes
7603 and 7604 are displayed at the
same time. Inspect the connec-
3 Go to Step 4
tion status of CN. C2.
Are diagnostic trouble codes 7603 and 7604
displayed at the same time?
P040 or P042 har-
CN. C2 and CN. A0.
ness defect (discon-
4 2. Inspect for continuity between terminal Go to Step 5
nection). Repair or
6 of the CN. C2 harness side and termi-
replace
nal 18 of the CN. A0 harness side.
1. Inspect for continuity between terminal PG041 or PG043
14 of the CN. C2 harness side and ter- ECM defect. Re- harness defect (dis-
5 minal 37 of the CN. A0 harness side. place connection). Repair
84551720B NA - August 2012

4023H-90
Diagnostic Trouble Code: 7604 Computer B Communication Abnormality

Standard
Step Action Yes No
value
connector.
7602 and 7603 are displayed at the Inspect the connec-
2 Go to Step 3
same time. tion status of CN. C2.
Are diagnostic trouble codes 7602 and 7603
displayed at the same time?
P040 or P048 har-
CN. C2 and CN. C7.
nection). Repair or
6 of the CN. C2 harness side and termi-
replace
nal 8 of the CN. C7 harness side.
1. Inspect for continuity between terminal PG041 or PG049
14 of the CN. C2 harness side and ter- Computer S defect. harness defect (dis-
4 minal 16 of the CN. C7 harness side. Replace connection). Repair
84551720B NA - August 2012

4023H-91
Diagnostic Trouble Code: 7605 ECM Mismatch

Standard
Step Action Yes No
value
1. Check for an error on the service sup-
port model selection screen. Correctly set the
2 Go to Step 3
model selection.
Is the model selection screen correct?
1. Check that the ECM which matches the Replace with an ECM
model is installed. ECM defect. Re-
3 that matches the
place
Does the ECM match the model? model.
1 COMPUTER A
2 ENGINE COMPUTER
a CAN COMMUNICATION
84551720B NA - August 2012

4023H-92
Diagnostic Trouble Code: 7606 EEPROM Data Abnormality

Standard
Step Action Yes No
value
played?
Rewriting of the com-
1. Check whether rewriting was performed puter changed the
on computer A before the diagnostic used space of the
trouble code was displayed. EEPROM. Computer A defect.
2
Was rewriting performed on computer A be- Turn the key switch Replace
fore the diagnostic trouble code was dis- OFF, and then turn
played? the key switch ON
again.
84551720B NA - August 2012

4023H-93
Diagnostic Trouble Code: 7607 Computer C Communication Abnormality

Standard
Step Action Yes No
value
connector.
7602, 7603, 7604 are displayed at the Inspect the connec-
2 Go to Step 3
same time. tion status of CN. A2.
Are diagnostic trouble codes 7602, 7603,
7604 displayed at the same time?
P040 or V050 har-
CN. A2 and CN. A23.
nection). Repair or
6 of the CN. A2 harness side and termi-
replace
nal 7 of the CN. A23 harness side.
1. Inspect for continuity between terminal PG041 or VG051
14 of the CN. A2 harness side and ter- Computer C defect. harness defect (dis-
4 minal 8 of the CN. A23 harness side. Replace connection). Repair
84551720B NA - August 2012

4023H-94
Section
4023K
Data Reference Values
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Non-operational P rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Two pump relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4023K-1 PRINTED IN FRANCE
4023K-2 PRINTED IN FRANCE
The purpose of data list is for checking the status of the whether the vehicle data is temporarily or always differ-
machine and each equipment. ent from the reference values.
This data is used in trouble diagnosis by comparing the This display menu is subject to change without notice.
each machine data with standard values, and checking
Non-operational P rotation
Non operation P rotation reference value
Data display items Units It varies depending on the actual machine con-
dition
Battery voltage V 28.3 - 28.5
min-1
Target engine rpm 500
( rpm )
min-1
Engine speed 1797 - 1801
( rpm )
Accelerator pedal position sensor 1 (APP1) V 0.0
Accelerator pedal position (APP) % 0
Fuel rail pressure sensor V 2.0 - 2.1
Fuel rail pressure feedback - Feedback mode
Coolant temperature sensor V 0.4 - 0.5
Coolant temperature °C ( °F ) 80 - 83
Intake temperature sensor V 2.4
Intake air temperature °C ( °F ) 27
Fuel temperature sensor V 1.3
Fuel temperature °C ( °F ) 44
Atmospheric pressure sensor V 1.9
Atmospheric pressure kPa ( psi ) 100
Boost temperature sensor voltage V 4.4
Boost pressure sensor kPa ( psi ) 118 - 119
First cylinder fuel correction amount mm3/st -
Second cylinder fuel correction amount mm3/st -
Third cylinder fuel correction amount mm3/st -
Fourth cylinder fuel correction amount mm3/st -
Engine mode - Fuel mode
EGR valve 1 drive duty % EGR valve 1 drive duty
Reverse the polarity of either 1, 2, or 3
EGR position 1 ON/OFF
(Example：1=ON, 2=ON, 3=OFF, etc)
Ignition switch ON/OFF ON
Starter switch ON/OFF ON
OFF
Glow relay ON/OFF
ON immediately after the starter switch ON
Q adjustment compensation data 1 - -
84551720B NA - August 2012

4023K-3
Two pump relief

TTwo Pump Relief reference value
Data display items Units
It varies depending on the actual machine
Battery voltage V 28.4 - 28.5
min-1
Target engine rpm 500 (500)
( rpm )
min-1
Engine speed 1898 - 1901 (1898 - 1901)
( rpm )
Accelerator pedal position (APP) % 0
Fuel rail pressure difference (actual – target) MPa ( psi ) -
Fuel rail pressure sensor V 3.3 - 3.5
Fuel rail pressure feedback - Feedback mode
Coolant temperature sensor V 0.4
Coolant temperature °C ( °F ) 83 - 85 (181.4 - 185.0)
Intake temperature sensor V 2.2
Intake air temperature °C ( °F ) 27 (80.6)
Fuel temperature sensor V 1.3
Fuel temperature °C ( °F ) 43 - 44 (109.4 - 111.2)
Atmospheric pressure sensor V 1.9
Atmospheric pressure kPa ( psi ) Approx. 100 (14.51)
Boost temperature sensor voltage V 4.3
Boost pressure sensor kPa ( psi ) 203 - 210 (29.45 - 30.46)
First cylinder fuel correction amount mm3/st -
Second cylinder fuel correction amount mm3/st -
Third cylinder fuel correction amount mm3/st -
Fourth cylinder fuel correction amount mm3/st -
Engine mode Fuel mode Fuel mode
EGR valve 1 drive duty % 19
Ignition switch ON/OFF ON
Starter switch ON/OFF OFF
OFF
Glow relay ON/OFF
ON immediately after the starter switch ON
84551720B NA - August 2012

4023K-4
Section
4040
Electrical Wiring Diagram
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CX210C LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CX210C LC NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine and Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine and Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CX210C LC NLC
Main Frame
84551720B NA - August 2012

4040-2
Detail of engine controller connec- CN.D10M Engine harness: D CN.D57F Fuel level sensor
1 Red adhesive tape 4 Green adhesive tape 7
tor CN.D11M Engine harness: H CN.D58F Solenoid valve joint connector
2 Blue adhesive tape 5 Yellow adhesive tape CN.D12 Starter motor: S CN.D59F Lock lever SOL. V
3 White adhesive tape 6 Nameplate CN.D13 Alternator: B CN.D60F Swing brake SOL. V
CN.D14F Alternator: L/R CN.D61F 2-stage travel SOL. V
CN.D15 Alternator: E CN.D62F 2-stage relief SOL. V
a CN.D76F must be fastened with red CN.D58F must be fastened with red g CN.D68,D82 must be fastened with
d CN.D16 Alternator: GND CN.D63F Power save SOL. V
tape. tape. red tape.
CN.D17 Battery relay: B *CN.D64F Free swing solenoid valve
CN.D52F must be fastened with red e CN.D38F must be fastened with red CN.D69F must be fastened with red
b h CN.D18 Battery relay: IGN1 CN.D65F Housing lamp
tape. tape. tape.
CN.D44F must be fastened with red CN.D75F must be fastened with red CN.D4F must be fastened with red CN.D19 Battery relay: IGN2 CN.D66F Boom lamp harness
c f i CN.D20 Battery relay: Coil1 CN.D67F Washer motor
tape. tape. tape.
CN.D21 Battery relay: Coil2 CN.D68F Diode: Washer
CN.D22M Battery relay: GND *CN.D69F Travel alarm
CN.A50F Cab main harness: A CN.D41F Reducing valve: Boom CN.D23M Fusible link: 50A +B CN.D70F Horn: L+
CN.A51F Cab main harness: B CN.D42F Reducing valve: Arm CN.D24M Fusible link: 50A ST CN.D71F Horn: L-
CN.A52F Cab main harness: C CN.D43F Reducing valve: Bucket CN.D25M Fusible link: 65A IGN CN.D72F Horn: H+
Option proportional valve har- CN.D26F Fusible link: 15A CONT CN.D73F Horn: H-
CN.A53F Cab main harness: D CN.D44F
ness CN.D27F Starter relay: B/C *CN.D74F Beacon harness
CN.A54F Cab main harness: E CN.D45F P1 pressure sensor CN.D28F Starter relay: S/E *CN.D76F Feed pump harness
CN.A55F Cab main harness: F CN.D46F P2 pressure sensor CN.D29F Glow relay: Coil CN.D77F Receiver dryer
CN.A56F Cab main harness: G CN.D47F N1 pressure sensor CN.D30F Glow relay: 1 CN.D78F Air conditioner compressor
CN.D1F ECM: 1 CN.D48F N2 pressure sensor CN.D31F Glow relay: 2 CN.D79F Reserve tank switch
CN.D2F ECM: 2 CN.D49F Swing pressure sensor CN.D35F MAF sensor CN.D80 Ground G1
CN.D3F Turbo computer CN.D50F Upper pressure sensor CN.D36F Fuel filter sensor CN.D80M Air cleaner sensor
CN.D4M Connector: CAN CN.D51F Travel pressure sensor CN.D37F Charge fuel pump CN.D81 Ground G2
CN.D5F Barometric pressure sensor *CN.D52F HBCV pressure sensor CN.D38F Diode: Pump CN.D81F Pressure switch: Filter
CN.D6F MAF register CN.D53F Boom-up pressure sensor Proportional valve; Horse-
CN.D7F Engine harness: A CN.D54F Arm-in pressure sensor CN.D39F CN.D82F Diode: Starter
power control
CN.D8M Engine harness: B CN.D55F Bucket-close pressure sensor Proportional valve: Flow con-
CN.D40F CN.D85F DPD sub harness
CN.D9M Engine harness: C CN.D56F Oil temperature sensor trol
84551720B NA - August 2012

4040-3
Cab Main Harness
84551720B NA - August 2012

4040-4
*1 White adhesive tape *3 Blue ID tape CN. A11F Battery relay CN. A37M Memory clear: GND
*2 Red ID tape *4 Fuse box CN. A12F Idle stop relay CN. A38F ECM joint connector
CN. A13F Key ON relay CN. A39F Joint connector: CONT
CN. A33M and A33F must be fas- CN. A24 must be fastened with red CN. A32F, 32M and 29F must be CN. A14F Neutral start relay CN. A40F Joint connector: GND
a e i
tened with red tape. tape. fastened with red tape. CN. A15F Starter cut relay CN. A41F Joint connector: A
CN. A31M and A31F must be con- CN. A26F must be fastened with CN. A58 must be fastened with red CN. A16F Horn relay CN. A42F Joint connector: B
b f j
nected, then fastened with red tape. red tape. tape. CN. A17F Lamp relay: Upper CN. A43 Ground: Cab
c CN. A30 and A38 must be fastened g CN. A34F and 35F must be fas- CN. A40F, 41F and 42F must be CN. A18F Lamp relay: CAB CN. A44F Cab harness: A
k
with red tape. tened with red tape. tied together with red tape. CN. A19F Beacon relay CN. A45F Cab harness: B
CN. A23 must be fastened with red CN. A25M and CN. A25F must be CN. A20F Room lamp relay CN. A46F Console harness: A
d h l Nameplate position
tape. connected. CN. A21F Speaker relay: R CN. A47F Console harness: B
CN. A22F Speaker relay: L CN. A48F Console harness: C
CN. A1F Computer A: 1 CN. A31M Hour meter: - CN. A23F Computer C harness CN. A49F Console harness: D
CN. A2F Computer A: 2 CN. A32F Option power supply: IGN CN. A24F Computer T harness CN. A50M Frame main harness: A
CN. A3F Computer A: 3 CN. A32M Option power supply: GND CN. A25F EST-B connector (M) CN. A51M Frame main harness: B
CN. A4F Computer A: 4 CN. A33F Immobilizer CN. A25M EST-B connector (F) CN. A52M Frame main harness: C
CN. A5F Computer B: 1 CN. A33M Immobilizer: GND CN. A26F EST-A harness CN. A53M Frame main harness: D
CN. A6F Computer B: 2 CN. A34F CAN-H CN. A27F Diagnostic connector CN. A54M Frame main harness: E
CN. A7F Computer B: 3 CN. A35F CAN-L CN. A28F DC/DC converter CN. A55M Frame main harness: F
CN. A8F Computer B: 4 CN. A36F Diagnostic switch CN. A29F FMS harness CN. A56M Frame main harness: G
CN. A9F ECM relay CN. A36M Diagnostic switch: GND CN. A30F Diode CN. A57M Option line harness
CN. A10F DPF relay CN. A37F Memory clear CN. A31F Hour meter: + CN. A58F Horn jumper
84551720B NA - August 2012

4040-5
Engine Harness
84551720B NA - August 2012

4040-6
*1 SENSOR:WATER *7 SENSOR:OIL PRESSURE *13 SENSOR:FUEL TEMP *4 INJECTOR *10 SENSOR:IMT *16 SENSOR:NE.CRANK
*2 SWITCH:O/H *8 SENSOR:BOOST PRESSURE *14 SCV *5 INTAKE THROTTLE *11 EGR VALVE
*3 GLOW PLUG(CYL#2) *9 TURBO *15 SENSOR:CAM ANGLE(G) *6 SENSOR:COM.RAIL *12 SENSOR:BOOST TEMP
84551720B NA - August 2012

4040-7
Frame
84551720B NA - August 2012

4040-8
a Marking position; Align white tape of harness. c ID: H Pressure sensor: Bucket
CN.A55 Cab main harness: F (18-pin) CN.D55
b ID: L d Fasten pilot control line together. (3-pin)
CN.A56 Cab main harness: G (20-pin) CN.D57 Fuel level sensor (2-pin)
*1 Round terminal M8 (floor ground) CN.D1 ECM: 1 (60-pin) CN.D64 SV; Free swing (2-pin)
*2 Round terminal M8 CN.D2 ECM: 2 (94-pin) CN.D65 Lamp: Housing (2-pin)
*3 KHR11160 Wire harness; Light (frame main) CN.D3 Turbo computer (16-pin) CN.D66 Boom lamp harness (2-pin)
Barometric pressure sensor
CN.D5 CN.D67 Washer motor (2-pin)
(3-pin)
Code Part name Q'ty Code Part name Q'ty
Travel alarm (2-pin) (secured to
1 Battery cable; Relay (starter) 1 6 Sensor; Pressure [5 MPa (725.27 psi)] G1/4 7 CN.D6 Register (2-pin) CN.D69
harness with red tape)
2 Harness; Wire (frame main) 1 7 Bracket; Lamp 1 CN.D16 Alternator ground CN.D70,71 Horn (left)
3 Wire; Ground (floor) 1 8 Light; Working 24 V × 70 W 1 CN.D35 Suction air sensor (5-pin) CN.D72,73 Horn (right)
4 Horn; Electric (LOW) 1 9 Alarm; Travel 1 Proportional valve: BOOM Feed pump harness (3-pin) (se-
5 Horn; Electric (HIGH) 1 10 Bracket; Alarm 1 CN.D41 CN.D76
(2-pin) ID tape: None cured to harness with red tape)
Proportional valve: Arm (2-pin)
CN.D42 CN.D77 Receiver dryer (2-pin)
CN.A50 Cab main harness: A (2-pin) CN.D50 Pressure sensor: Upper (3-pin) ID tape: Red
CN.A51 Cab main harness: B (8-pin) CN.D51 Pressure sensor: Travel (3-pin) Proportional valve: Bucket
CN.D43 CN.D79 LLC tank (2-pin)
HBCV harness (3-pin) (secured (2-pin) ID tape: Blue
CN.A52 Cab main harness: C (8-pin) CN.D52 Option proportional valve har-
to harness with red tape)
Pressure sensor: BOOM CN.D44 ness (2-pin) (secured to har- CN.D80 Floor ground G1
CN.A53 Cab main harness: D (14-pin) CN.D53 ness with red tape)
(3-pin)
Pressure sensor: Arm (3-pin) CN.D47 Pressure sensor: N1 (3-pin) CN.D81 Ground G2
CN.A54 Cab main harness: E (22-pin) CN.D54 CN.D49 Pressure sensor: Swing (3-pin) CN.D84 Filter indicator (2-pin)
ID tape: Red
84551720B NA - August 2012

4040-9
Engine and Pump
84551720B NA - August 2012

4040-10
ANNOTATION: Pressure sensor P1 (3-pin) ID Proportional valve: Flow con-
CN.45 CN.D40
tape: None trol (2-pin)
1. When assembling the ground terminals marked with a ※, it should be confirmed that the frame seating surface is not
Pressure sensor P2 (3-pin) ID
coated. If the surface is coated, assembly should be performed after removing the coating. *CN.D7 Engine harness: A (32-pin) CN.D46
tape: None
2. Clean the terminal of the connectors marked with a * using cleaning agent before mating, and then coat with an anti-rust
agent. *CN.D8 Engine harness: B (16-pin) CN.D48 Pressure sensor N2 (3-pin)
3. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does *CN.D9 Engine harness: C (14-pin) CN.D56 Sensor; Oil temperature (2-pin)
not form sharp rounded shapes. (Radius of curve = 10 mm (0.394 in.) or more) Joint connector (8-pin) (se-
*CN.D10 Engine harness: D (16-pin) CN.D58
cured to red tape harness)
Be careful to assemble the bat- SV; Lever lock (2-pin) ID tape:
*CN.D11 Engine harness: H (1-pin) CN.D59
a tery cable in the correct direc- Blue
tion. SV; Swing brake (2-pin) ID
CN.D12 Starter motor: S CN.D60
tape: White
Starter motor (attached to engine main unit) Round terminal M6 SV; 2-stage travel (2-pin) ID
*1 *4 CN.D14 Alternator: L/R (2-pin) CN.D61
tape: Red
*2 Engine ground (attached to engine main unit) *5 Round terminal M5
Pressure sensor; Exhaust gas SV; 2-stage relief (2-pin) ID
*3 Engine harness (attached to engine main unit) *6 KRR20010 Harness; Wire (frame main) CN.D32 CN.D62
(3-pin) tape: Yellow
Temperature sensor DPD
Code Part name Q'ty SV; Power save (2-pin), ID
CN.D33 (CENTER) (2-pin) Connector CN.D63
tape: Green
1 Sensor; Pressure [50 MPa (7252.68 psi)] M18 × 1.5 2 color: Light gray
2 Sensor; Pressure [5 MPa (725.27 psi)] G1/4 1 Temperature sensor DPD
3 Sensor; Thermo 1 CN.D34 (FRONT) (2-pin) Connector CN.D78 Compressor (1-pin)
color: Dark gray
Alternator: B Electrical wiring CN.D36 Fuel filter (3-pin) CN.D85 DPD sub harness (8-pin)
CN.13 CN.D37 Charge fuel pump (2-pin)
color: Red
Alternator: E Electrical wiring Proportional valve; Horse-
CN.15 CN.D39
color: Black power control (2-pin)
84551720B NA - August 2012

4040-11
Attachments
84551720B NA - August 2012

4040-12
a Secure harness to the boom

seating with a wire band
Harness length from connector
b to wire band: 700 mm (27.559
in.)
c CN.D66 Connect to frame main
harness
Code Part name Q'ty

1 Wire harness; Light (frame main) 1
2 Light; Working 1
84551720B NA - August 2012

4040-13
Battery
84551720B NA - August 2012

4040-14
ANNOTATION: CN.D24 Fuse 50 A ST (2-pin) CN.D77 Receiver dryer (2-pin)
CN.D25 Fuse 65 A IGN (2-pin) CN.D79 Switch; LLC tank (2-pin)
coated. CN.D26 Fuse 15 A CONT (2-pin) CN.D80 Pressure switch; Air cleaner (2-pin)
If the surface is coated, assembly should be performed after removing the coating.
2. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does
not form sharp rounded shapes. (Radius of curve = 10 mm (0.394 in.) or more)
a Align indicator of battery with

hole position.
Fasten the air conditioner hose
b
and harness together.
c Marking position; Align white
tape of harness.
*1 Glow relay (engine accessory) *5 Round terminal M8

*2 Starter relay (engine accessory) *6 Round terminal M4
*3 M10 (battery accessory) *7 KRR20010 Harness; Wire (frame main)
*4 M8 (battery accessory)

1 Holder; Battery 1 6 Cable; Battery ground 1
2 Fuse; High current (model A3 50 A) 2 7 Battery 130E41R (with terminal) 2
3 Fuse (fusible link) 65 A 1 8 Cable; Battery bridge 1
4 Bracket; Battery relay 1 9 Cable; Battery B+ relay 1
5 Relay; Battery 1
CN.D17 Battery relay B ID tape: Red CN.D27 Starter relay B/C (2-pin)
CN.D18 Battery relay IGN Electrical wiring color: Red CN.D28 Starter relay S/E (2-pin)
CN.D19 Battery relay IGN Electrical wiring color: White CN.D29 Glow relay coil (2-pin)
Glow relay1 (1-pin) Electrical wiring color: White
CN.D20 Battery relay coil1 Electrical wiring color: Green CN.D30
stripe on red background
Battery relay coil 2 Electrical wiring color: Red
CN.D21 CN.D31 Glow relay2 (1-pin) Electrical wiring color: Blue
stripe on white background
CN.D22 Battery relay GND (1-pin) CN.D67 Washer motor (2-pin)
Fuse 50 A +B (2-pin) Electrical wiring color: White
CN.D23 CN.D74 Beacon harness (2-pin)
84551720B NA - August 2012

4040-15
Cab
84551720B NA - August 2012

4040-16
Remove only CN.A31 F from CN.A9 ECM CN.A52 Frame main harness: C: 8-pin
a Marking position (align white the red tape and fasten it again g For HBCV specifications ma- CN.A10 DPF; White marking CN.A53 Frame main harness: D: 14-pin
d
tape of harness) with the red tape after connect- chines CN.A11 Battery relay CN.A54 Frame main harness: E: 22-pin
ing it with the joint harness (45). Frame main harness: F: 20-pin Connect with joint
Connect with the supplied cab e Tighten the harness and the an- CN.A12 Idle stop; White marking CN.A55
b harness (45)
antenna line. tenna together. CN.A13 Key ON CN.A56 Frame main harness: G: 18-pin
Connect the (45) CN.A32M Fasten the harness with the CN.A14 Neutral start; White marking CN.A57 Frame main harness: G: 18-pin
c and the cab main harness f clip. The clip (KHN17050) is a CN.A15 Starter cut CN.A58 Jumper harness: 2-pin
CN.A32F. console accessory.
CN.A16 Horn; White marking CN.A60 ECM: GND
CN.A17 Relay lamp: Upper CN.B1 Starter switch: 6-pin
*1 Monitor; System *5 Cover; Top (console right) *9 Air conditioner panel CN.A18 CAB lamp; White marking CN.B2 Throttle volume: 3-pin
*2 Trim; Side (upper) *6 Cover; Top (console left) *10 Switch rocker; Overload warning CN.A19 Relay beacon CN.B3 Limit switch: 2-pin
Engine controller (engine acces- CN.A20 Room lamp; White marking CN.B4 Knob right switch: 8-pin
*3 *7 Register (engine accessory) *11 Switch rocker; Free swing
sory) CN.A21 Speaker: R CN.B5 Knob left switch: 8-pin
Barometric pressure sensor (en- Box; Fuse (cab main harness ac- CN.A22 Speaker: L; White marking CN.B7 Engine stop SW: 10-pin ID: None
*4 *8
gine accessory) cessory) Computer C: 14-pin (fastened with
CN.A23 CN.B8 Fan reverse SW: 10-pin ID: Red tape
red tape)
Code Part name Q'ty Code Part name Q'ty Computer T: 10-pin (fastened with
CN.A24 CN.B9 Free swing SW: 10-pin ID: Blue tape
1 Switch; Rocker (horn switchover) 1 7 Switch; Starter assembly 1 red tape)
2 Harness; Wire (console) 3 8 Switch; Rocker (E. STOP) 1 CN.A25 EST-B: 12-pin CN.B10 SW beacon: 10-pin ID: Red tape
3 Harness; Wire (cab; main) 4 9 Radio; Car (12/24 V) (with AUX; NA) 1 CN.A26 EST-A harness: 6-pin CN.B11 SW alarm switchover: 10-pin ID: Blue tape
4 Changeover relay; 24V 5 10 Switch; Rocker (warning switchover) 1 CN.A27 Diagnostic: 16-pin CN.B12 SW liftcrane: 10-pin ID: None
5 CN.B14,B15,
Harness; Wire (EST-A) 1 11 Switch; Rocker (beacon) 1 CN.A28 DC converter: 7-pin Knob terminal (12 V power socket)
B16
6 Code; Antenna 1 12 Harness; Wire (joint) 1
Option power supply: 4-pin (fas-
CN.A29 CN.B17 Seat suspension: 2-pin (fastened with red tape)
tened with red tape)
CN.52 EST: A: 9-pin CN.A43 Cab: GND Option power supply (fastened Air conditioner unit A: 6-pin Connect with supplied
CN.A32 CN.B19
Cab; Harness: A: 14-pin Connect with supplied cab with red tape) air conditioner harness
CN.A1 Computer A: 1: 26-pin CN.A44
harness Air conditioner unit B: 22-pin Connect with supplied
CN.A34 CAN H CN.B20
Cab; Harness: B: 18-pin Connect with supplied cab air conditioner harness
harness CN.A35 CAN L CN.B21 Air conditioner panel: A: 20-pin
CN.A3 Computer A: 3: 12-pin CN.A46 Console harness: A: 10-pin CN.A36 Diagnostic SW CN.B22 Air conditioner panel: B: 16-pin
CN.A4 Computer A: 4: 22-pin CN.A47 Console harness: B: 18-pin CN.A37 Memory clear SW CN.B26 Knob right option switch: 6-pin
CN.A5 Computer B: 1: 26-pin CN.A48 Console harness: C: 14-pin CN.A39 Joint: Controller: 6-pin CN.B27 Knob left option switch: 6-pin
CN.A6 Computer B: 2: 16-pin CN.A49 Console harness: D: 18-pin CN.A40 Joint: GND: 6-pin CN.B28 Knob right option switch: 4-pin
CN.A7 Computer B: 3: 12-pin CN.A50 Frame main harness: A: 2-pin CN.A41 Joint: A: 20-pin CN.B29 Knob left option switch: 4-pin
CN.A8 Computer B: 4: 22-pin CN.A51 Frame main harness: B: 8-pin CN.A42 Joint: B: 20-pin
84551720B NA - August 2012

4040-17
CX210C LR
Main Frame
84551720B NA - August 2012

4040-18
Detail of engine controller connec- CN.D8M Engine harness: B CN.D55F Bucket-close pressure sensor
*1 Red adhesive tape *4 Green adhesive tape *7
tor CN.D9M Engine harness: C CN.D56F Oil temperature sensor
*2 Blue adhesive tape *5 Yellow adhesive tape CN.D10M Engine harness: D CN.D57F Fuel level sensor
*3 White adhesive tape *6 Nameplate CN.D11M Engine harness: H CN.D58F Solenoid valve joint connector
CN.D12 Starter motor: S CN.D59F Lock lever SOL. V
CN.D81F must be fastened with red CN.D4F must be fastened with red CN.D58F must be fastened with red CN.D13 Alternator: B CN.D60F Swing brake SOL. V
a e i CN.D14F Alternator: L/R CN.D61F 2-stage travel SOL. V
tape. tape. tape.
CN.D76F must be fastened with red CN.D69F must be fastened with red CN.D38F must be fastened with red CN.D15 Alternator: E CN.D62F 2-stage relief SOL. V
b f j
tape. tape. tape. CN.D16 Alternator: GND CN.D63F Power save SOL. V
CN.D44F must be fastened with red CN.D68, D82 must be fastened CN.D17 Battery relay: B *CN.D64F Free swing solenoid valve
c g
tape. with red tape. CN.D18 Battery relay: IGN 1 CN.D67F Washer motor
CN.D52F must be fastened with red CN.D75F must be fastened with red CN.D19 Battery relay: IGN 2 CN.D68F Diode: Washer
d h
tape. tape. CN.D20 Battery relay: Coil 1 *CN.D69F Travel alarm
CN.D21 Battery relay: Coil 2 CN.D70F Horn: L+
Proportional valve: Flow con- CN.D22M Battery relay: GND CN.D71F Horn: L-
CN.A50F Cab main harness: A CN.D40F CN.D23M Fusible link: 50A + B CN.D72F Horn: H+
trol
CN.A51F Cab main harness: B CN.D41F Reducing valve: Boom CN.D24M Fusible link: 50A ST CN.D73F Horn: H-
CN.A52F Cab main harness: C CN.D42F Reducing valve: Arm CN.D25M Fusible link: 65A IGN *CN.D74F Beacon harness
CN.A53F Cab main harness: D CN.D43F Reducing valve: Bucket CN.D26F Fusible link: 15A CONT *CN.D75F Signal lamp harness
Option proportional valve har- CN.D27F Starter relay: B/C *CN.D76F Refuel pump harness
CN.A54F Cab main harness: E CN.D44F
ness CN.D28F Starter relay: S/E CN.D77F Receiver dryer
CN.A55F Cab main harness: F CN.D45F P1 pressure sensor CN.D29F Glow relay: Coil CN.D78F Air conditioner compressor
CN.A56F Cab main harness: G CN.D46F P2 pressure sensor CN.D30F Glow relay: 1 CN.D79F Reserve tank switch
CN.D1F ECM: 1 CN.D47F N1 pressure sensor CN.D31F Glow relay: 2 CN.D80M Air cleaner sensor
CN.D2F ECM: 2 CN.D48F N2 pressure sensor CN.D35F MAF sensor CN.D81 Ground G2
CN.D3F Turbo computer CN.D50F Upper pressure sensor CN.D36F Fuel filter sensor CN.D81F Hydraulic filter switch
CN.D4M Connector: CAN CN.D51F Travel pressure sensor CN.D37F Charge fuel pump CN.D82F Diode: Starter
CN.D5F Barometric pressure sensor *CN.D52F HBCV harness CN.D38F Diode: Pump *CN.D84F Hydraulic filter pressure sensor
CN.D6F MAF register CN.D53F Boom-up pressure sensor Proportional valve; Horse-
CN.D39F CN.D85M DPD sub harness
CN .D7F Engine harness: A CN.D54F Arm-in pressure sensor power control
84551720B NA - August 2012

4040-19
Cab Main Harness
84551720B NA - August 2012

4040-20
*1 White adhesive tape *3 Blue ID tape CN.A11F Battery relay CN.A38F Joint connector: ECM
*2 Red ID tape *4 Fuse box CN.A12F Idle stop relay CN.A39F Joint connector: CONT
CN.A13F Key ON relay CN.A40F Joint connector: GND
CN.A14F Neutral start relay CN.A41F Joint connector: A
a CN.A33M and A33F must be fas- e CN.A30, 38 and A59 must be fas- CN.A32F, 32M and 29F must be CN.A15F Starter cut relay CN.A42F Joint connector: B
i
tened with red tape. tened with red tape. fastened with red tape. Horn relay
CN.A16F CN.A43 Ground: Cab
CN.A40F, 41F and 42F must be tied CN.A23 must be fastened with red CN.A34F and A35F must be fas- Lamp relay: Upper
b f j CN.A17F CN.A44F Cab harness: A
together with red tape. tape. tened with red tape.
CN.A18F Lamp relay: CAB CN.A45F Cab harness: B
c CN.A31M and A31F must be con- g CN.A24 must be fastened with red CN.A25M and CN.A25F must be
k CN.A19F Beacon relay CN.A46F Console harness: A
nected, then fastened with red tape. tape. connected.
CN.A58 must be fastened with red CN.A26 must be fastened with red CN.A20F Room lamp relay CN.A47F Console harness: B
d h l Nameplate position CN.A21F Speaker relay: R CN.A48F Console harness: C
tape. tape.
CN.A22F Speaker relay: L CN.A49F Console harness: D
CN.A23F Computer C harness CN.A50M Frame main harness: A
CN.A1F Computer A: 1 CN.A32F Option power supply: IGN CN.A24F Computer T harness CN.A51M Frame main harness: B
CN.A2F Computer A: 2 CN.A32M Option power supply: GND CN.A25F EST-B connector (M) CN.A52M Frame main harness: C
CN.A3F Computer A: 3 CN.A33F Immobilizer CN.A25M EST-B connector (F) CN.A53M Frame main harness: D
CN.A4F Computer A: 4 CN.A33M Immobilizer: GND CN.A26F EST-A harness CN.A54M Frame main harness: E
CN.A5F Computer B: 1 CN.A34F CAN-H CN.A27F Diagnostic connector CN.A55M Frame main harness: F
CN.A6F Computer B: 2 CN.A35F CAN-L CN.A28F DC/DC converter CN.A56M Frame main harness: G
CN.A7F Computer B: 3 CN.A36F Diagnostic switch CN.A29F FMS harness CN.A57M Option line harness
CN.A8F Computer B: 4 CN.A36M Diagnostic switch: GND CN.A30F Diode CN.A58F Horn jumper
CN.A9F ECM relay CN.A37F Memory clear CN.A31F Hour meter: + CN.A59F Diode 2
CN.A10F DPF relay CN.A37M Memory clear: GND CN.A31M Hour meter: -
84551720B NA - August 2012

4040-21
Engine Harness
84551720B NA - August 2012

4040-22
*1 SENSOR:WATER *7 SENSOR:OIL PRESSURE *13 SENSOR:FUEL TEMP *4 INJECTOR *10 SENSOR:IMT *16 SENSOR:NE.CRANK
*2 SWITCH:O/H *8 SENSOR:BOOST PRESSURE *14 SCV *5 INTAKE THROTTLE *11 EGR VALVE
*3 GLOW PLUG(CYL#2) *9 TURBO *15 SENSOR:CAM ANGLE(G) *6 SENSOR:COM.RAIL *12 SENSOR:BOOST TEMP
84551720B NA - August 2012

4040-23
Frame
84551720B NA - August 2012

4040-24
a Marking position; Align white c CN.A53 Cab main harness: D (14-pin) CN.D53 Pressure sensor: BOOM (3-pin)
ID: H
tape of harness. CN.A54 Cab main harness: E (22-pin) CN.D54 Pressure sensor: Arm (3-pin) ID tape: Red
Fasten pilot control line to- CN.A55 Cab main harness: F (20-pin) CN.D55 Pressure sensor: Bucket (3-pin)
b ID: L d
gether. CN.A56 Cab main harness: G (18-pin) CN.D57 Fuel level sensor (2-pin)
CN.D1 ECM: 1 (60-pin) CN.D64 SV; Free swing (2-pin)
*1 Round terminal M8 (floor ground) CN.D2 ECM: 2 (94-pin) CN.D65 Lamp: Housing (2-pin)
*2 Round terminal M8 CN.D3 Turbo computer (16-pin) CN.D66 Boom lamp harness (2-pin)
*3 KHR11160 Wire harness; Light (frame main) CN.D5 Barometric pressure sensor (3-pin) CN.D67 Washer motor (2-pin)
Travel alarm (2-pin) (secured to harness with red
CN.D6 Register (2-pin) CN.D69
tape)
CN.D16 Alternator ground CN.D70,71 Horn (left)
1 Battery cable; Relay (starter) 1 5 Horn; Electric (HIGH) 1
CN.D35 Suction air sensor (5-pin) CN.D72,73 Horn (right)
2 Harness; Wire (frame main) 1 6 Sensor; Pressure [5 MPa (725.27 psi)] G1/4 7
Feed pump harness (3-pin) (secured to harness
3 Wire; Ground (floor) 1 7 Light; Working 24 V × 70 W 1 CN.D41 Proportional valve: BOOM (2-pin) ID tape: None CN.D76
with red tape)
4 Horn; Electric (LOW) 1 8 Alarm; Travel 1 CN.D42 Proportional valve: Arm (2-pin) ID tape: Red CN.D77 Receiver dryer (2-pin)
CN.D43 Proportional valve: Bucket (2-pin) ID tape: Blue CN.D79 LLC tank (2-pin)
CN.A50 Cab main harness: A (2-pin) CN.D50 Pressure sensor: Upper (3-pin) Option proportional valve harness (2-pin) (se-
CN.D44 CN.D80 Floor ground G1
CN.A51 Cab main harness: B (8-pin) CN.D51 Pressure sensor: Travel (3-pin) cured to harness with red tape)
HBCV harness (3-pin) (secured to harness with CN.D47 Pressure sensor: N1 (3-pin) CN.D84 Filter indicator (3-pin)
CN.A52 Cab main harness: C (8-pin) CN.D52
red tape) CN.D49 Pressure sensor: Swing (3-pin) CN.D85 Ground G2
84551720B NA - August 2012

4040-25
Engine and Pump
84551720B NA - August 2012

4040-26
ANNOTATION: Pressure sensor P1 (3-pin) ID Pressure sensor P2 (3-pin) ID
CN.45 CN.D46
tape: None tape: Blue
*CN.D7 Engine harness: A (25-pin) CN.D48 Pressure sensor N2 (3-pin)
coated. If the surface is coated, assembly should be performed after removing the coating.
2. Clean the terminal of the connectors marked with a * using cleaning agent before mating, and then coat with an anti-rust *CN.D8 Engine harness: B (16-pin) CN.D56 Sensor; Oil temperature (2-pin)
agent. Joint connector (8-pin) (se-
*CN.D9 Engine harness: C (14-pin) CN.D58
3. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does cured to red tape harness)
not form sharp rounded shapes. (Radius of curve = 10 mm (0.394 in.) or more) SV; Lever lock (2-pin) ID tape:
*CN.D10 Engine harness: D (16-pin) CN.D59
Blue
Be careful of the direction of SV; Swing brake (2-pin) ID
a *CN.D11 Engine harness: H (1-pin) CN.D60
battery cable. tape: White
SV; 2-stage travel (2-pin) ID
CN.D12 Starter motor: S CN.D61
tape: Red
*1 Starter motor (attachment for engine) *4 Ring terminal M6
SV; 2-stage relief (2-pin) ID
*2 Engine earth (attachment for engine) *5 Ring terminal M5 CN.D14 Alternator: L/R (2-pin) CN.D62
tape: Yellow
*3 Engine harness (attachment for engine) *6 KRR20400 Harness; Wire (frame main) Pressure sensor; Exhaust gas SV; Power save (2-pin), ID
CN.D32 CN.D63
(3-pin) tape: Green
Code Part name Q'ty Temperature sensor DPD
1 Sensor; Pressure [50 MPa (7252.68 psi)] M18 × 1.5 2 CN.D33 (FRONT) (2-pin) Connector CN.D71 Compressor (1-pin)
2 Sensor; Pressure [5 MPa (725.27 psi)] G1/4 1 color: Dark gray
3 Sensor; Thermo 1 Temperature sensor DPD
Beacon harness (2-pin) (se-
CN.D34 (CENTER) (2-pin) Connector CN.D75
cured to harness with red tape)
color: Light gray
Alternator: B Electrical wiring Proportional valve; Horse-
CN.13 CN.D39 CN.D36 Fuel filter (3-pin) CN.D85 Sub harness DPD (2-pin)
color: Red power control (2-pin)
Alternator: E Electrical wiring Proportional valve: Flow con- CN.D37 Charge fuel pump (2-pin)
CN.15 CN.D40
color: Black trol (2-pin)
84551720B NA - August 2012

4040-27
Attachments
84551720B NA - August 2012

4040-28
a Secure harness to the boom

seating with a wire band
Harness length from connector
b to wire band: 700 mm (27.559
in.)
c CN.D66 Connect to frame main
harness
Code Part name Q'ty

1 Wire harness; Light (frame main) 1
2 Light; Working 1
84551720B NA - August 2012

4040-29
Battery
84551720B NA - August 2012

4040-30
ANNOTATION: CN.D22 Battery relay GND (1-pin) CN.D77 Receiver dryer (2-pin)
Fuse 50 A +B (2-pin) Electrical wiring color:
1. When assembling the ground terminals marked with a ※, it should be confirmed that the frame seating surface is not CN.D23 CN.D79 Switch; LLC tank (2-pin)
White stripe on red background
coated.
If the surface is coated, assembly should be performed after removing the coating.
2. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does
not form sharp rounded shapes. (Radius of curve = 10 mm (0.394 in.) or more)
a Align indicator of battery with

hole position.
Fasten the air conditioner hose
b
and harness together.
c Marking position; Align white
tape of harness.
*1 Glow relay (engine accessory) *5 Round terminal M8

*2 Starter relay (engine accessory) *6 Round terminal M4
*3 M10 (battery accessory) *7 KRR20400 Harness; Wire (frame main)
*4 M8 (battery accessory)

1 Holder; Battery 1 6 Cable; Battery ground 1
2 Fuse; High current (model A3 50 A) 2 7 Battery 130E41R (with terminal) 2
3 Fuse (fusible link) 65 A 1 8 Cable; Battery bridge 1
4 Bracket; Battery relay 1 9 Cable; Battery B+ relay 1
5 Relay; Battery 1
CN.19 Fuse 20 A CONT (2-pin) CN.D25 Fuse 65 A IGN (2-pin)

CN.80 Pressure switch; Air cleaner (2-pin) CN.D27 Starter relay B/C (2-pin)
CN.D10 Battery relay B ID tape: Red CN.D28 Starter relay S/E (2-pin)
CN.D17 Fuse 50 A ST (2-pin) Electrical wiring color: Red CN.D29 Glow relay coil (2-pin)
Glow relay1 (1-pin) Electrical wiring color: White
CN.D18 Battery relay IGN Electrical wiring color: Red CN.D30
CN.D19 Battery relay IGN Electrical wiring color: White CN.D31 Glow relay2 (1-pin) Electrical wiring color: Blue
CN.D20 Battery relay coil1 Electrical wiring color: Green CN.D67 Washer motor (2-pin)
Battery relay coil 2 Electrical wiring color: Red
CN.D21 CN.D74 Beacon harness (2-pin)
stripe on white background
84551720B NA - August 2012

4040-31
Cab
84551720B NA - August 2012

4040-32
Fasten the harness with the CN.A8 Computer B: 4: 22-pin CN.A49 Console harness: D: 18-pin
a Marking position (align white c clip. CN.A9 ECM CN.A50 Jumper harness: 2-pin (LBX)
tape of harness) The clip (KHN17050) is a con- CN.A10 DPF; White marking CN.A50 Frame main harness: A: 2-pin
sole accessory. CN.A11 Battery relay CN.A51 Frame main harness: B: 8-pin
Connect with the supplied cab For HBCV specifications ma- CN.A12 Idling start; White marking CN.A52 Frame main harness: C: 8-pin
b d
antenna line. chines CN.A13 Key ON CN.A53 Frame main harness: D: 14-pin
CN.A14 Neutral start; White marking CN.A55 Frame main harness: F: 20-pin
*1 Monitor; System *5 Cover; Top (console right) *9 Air conditioner panel CN.A15 Starter cut CN.A56 Frame main harness: G: 18-pin
*2 Trim; Side (upper) *6 Cover; Top (console left) *10 Radio external input terminal CN.A16 Horn; White marking CN.A57 Option line harness: 10-pin
Engine controller (engine acces- Switch rocker; Overload warning CN.A17 Relay lamp: Upper CN.B1 Starter switch: 6-pin
*3 *7 Register (engine accessory) *11 CN.A18 CAB lamp; White marking CN.B2 Throttle volume: 3-pin
sory) (KHR15490)
Barometric pressure sensor (en- Box; Fuse (cab main harness ac- CN.A19 Relay beacon CN.B3 Limit switch: 2-pin
*4 *8 CN.A20 Room lamp; White marking CN.B4 Knob right switch: 8-pin
gine accessory) cessory)
CN.A21 Speaker: R CN.B5 Knob left switch: 8-pin
CN.A22 Speaker: L; White marking CN.B7 Engine stop SW: 10-pin ID: None
Code Part name Q'ty Code Part name Q'ty Computer C: 14-pin (fastened with
1 Switch; Rocker (horn switchover) 1 7 Code; Antenna (NA) 1 CN.A23 CN.B8 Fan reverse SW: 10-pin ID: Red tape
red tape)
2 Plastic plug (25) 1 8 Switch; Starter assembly 1 Computer T: 8-pin (fastened with
CN.A24 CN.B9 Free swing SW: 10-pin ID: Blue tape
3 Harness; Wire (console) 1 9 Switch; Rocker (E. STOP) 1 red tape)
4 Harness; Wire (cab; main) 1 10 Radio; Car (12/24 V) (with AUX; NA) 1 CN.A25 EST-B: 12-pin CN.B10 SW beacon: 10-pin ID: Red tape
5 Changeover relay; 24V 14 11 Switch; Rocker (warning switchover) 1 CN.A26 EST-A harness: 8-pin CN.B11 SW alarm switchover: 10-pin ID: Blue tape
6 Harness; Wire (EST-A) 1 12 Switch; Rocker (beacon) 1 CN.A27 Diagnostic: 16-pin CN.B12 SW liftcrane: 10-pin ID: None
CN.A28 DC converter: 7-pin CN.B12 Radio: 9-pin
Fuel identification: 4-pin (fastened CN.B14,B15,
CN.52 EST: A: 9-pin CN.A39 Joint: Controller: 6-pin CN.A29 Knob terminal (12 V power socket)
with red tape) B16
CN.54 Frame main harness: E: 22-pin CN.A40 Joint: GND: 6-pin Option power supply (fastened
CN.A1 Computer A: 1: 26-pin CN.A41 Joint: A: 20-pin CN.A32 CN.B17 Seat suspension: 2-pin (fastened with red tape)
with red tape)
CN.A2 Computer A: 2: 16-pin CN.A42 Joint: B: 20-pin Immobilizer (fastened with red Air conditioner unit A: 8-pin Connect with supplied
CN.A33 CN.B19
Cab; Harness: A: 14-pin Connect with supplied cab tape) air conditioner harness
harness Air conditioner unit B: 22-pin Connect with supplied
CN.A34 CAN H CN.B20
Cab; Harness: B: 18-pin Connect with supplied cab air conditioner harness
harness CN.A35 CAN L CN.B21 Air conditioner panel: A: 20-pin
CN.A5 Computer B: 1: 26-pin CN.A46 Console harness: A: 10-pin CN.A36 Diagnostic SW CN.B22 Air conditioner panel: B: 16-pin
CN.A6 Computer B: 2: 16-pin CN.A47 Console harness: B: 8-pin CN.B23,B24,
CN.A37 Memory clear SW Controller DRM (fastened with red tape)
CN.A7 Computer B: 3: 12-pin CN.A48 Console harness: C: 14-pin B25
84551720B NA - August 2012

4040-33
84551720B NA - August 2012

4040-34
Section
5001A
Removal and Installation of Shoe Assembly
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING Removal of Shoe Assembly

• When loosening the grease cylinder check 1. Rotate the shoe and align it so that the master pin
valve, loosen it a little bit at a time. (1) is next to the idler.
• The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off.
The check valve adjustment procedure
should not be done in front of the check
valve.
• Do not get under the main unit when it is
jacked up.
Make sure to place the main unit on crossties
to prevent falling.
CAUTION
• Make sure to stop the engine for loosening
shoes and when removing master pins. 2. Use a box wrench [ 19 mm ( 0.748 in. ) ] to
loosen the check valve (1) to release grease, and
Items to prepare then loosen the track shoe tension.
• Wrenches [ 17 mm ( 0.669 in. ), 19 mm ( 0.748 in. ) ] WARNING
• Box wrench [ 19 mm ( 0.748 in. ) ]
• Hammer • If the check valve (1) is too loose, it may
• Wood planks, etc. fly off.
• Striking jig • Do not place your body in front.
• Crowbar
• Rag Do not loosen the check valve all at once.
• Lifting equipment (with the required breaking load) Loosen it slowly while monitoring the grease output
• Liftcrane (with the required lifting capacity) and shoe loosening.
Use a rag to catch grease that trickles out of the
check valve.
84551720B NA - August 2012

5001A-3
3. Use a wrench [ 17 mm ( 0.669 in. ) ] to remove the 6. Remove the track shoe (1).
bolt (1), and then remove the check valve (2) and At this time, support with a wood plank (2) so the
stopper (3). bottom track shoe (1) does not fall.
• If the check valve (2) is removed, it is easier to
loosen the track shoe tension.
7. Start the engine, raise the lower side frame of the

track shoe removal side about 20 cm ( 7.874 in. ),
slowly set the travel lever to backwards, and move
4. Put wood planks (1) underneath the track shoe. the track shoe (1) to remove it from the lower frame.
Straighten out the S-pin (3) attached to the master
pin (2) by striking one side of it with a hammer, and
use a crowbar, etc. to remove it.
5. Use a hammer (2) and striking rod (3) to push the

master pin (1) out.
84551720B NA - August 2012

5001A-4
Installation of Shoe Assembly 3. Wrap the edge of the track shoe (1) onto the take-up
roller (2).
1. Raise the lower side frame about 20 cm ( 7.874 in. Place a wood plank (3) on the ground and lift the
). bottom-side link to align the position where the mas-
Lift the track shoe (1) and align it with the sprocket ter pin is inserted.
(2).
Pay attention to the backwards and forward direc-
tion of the track shoe.
4. Insert the master pin (1).

Insert the S-pin (2) and bend it so that it cannot slip
out.
5. Tighten the check valve (1).

2. Slowly set the travel lever to forward and feed the While monitoring the track shoe tension, inject
track shoe to the take-up roller side as shown in the grease into the grease cylinder.
diagram.
In the middle of this procedure when the track shoe
passes the upper roller, use a crowbar, etc. to lift
the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.
84551720B NA - August 2012

5001A-5
6. To adjust the track shoe tension, raise the lower 7. Adjust the tension so that the distance indicated
side frame with a wood plank (1) as shown in the with A between the frame bottom (1) of the center
diagram. area of the lower side frame and the lowest hanging
part of the top of the shoe plate (2) is 290 - 310 mm
( 11.418 - 12.204 in. ).
84551720B NA - August 2012

5001A-6
Section
5001B
Removal and Installation of Shoe Plate
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CAUTION Installation of Shoe Plate

• Be sure to stop the engine before beginning 1. Install the shoe plate (1).
work.
Items to prepare
• Box wrench [ 30 mm ( 1.181 in. ) ]
• Grease
• Rag
• Cleaning fluid
Removal of Shoe Plate

1. Use a box wrench [ 30 mm ( 1.181 in. ) ] to remove
the 4 shoe bolts (1).
2. Use a box wrench [ 30 mm ( 1.181 in. ) ] to install

the 4 shoe bolts (1).
Bolt (1) tightening torque: 751 - 849 N・m ( 554.00
- 626.30 lbf・ft. )
2. Remove the shoe plate (1).
84551720B NA - August 2012

5001B-3
84551720B NA - August 2012

5001B-4
Section
5003A
Removal and Installation of Upper Roller
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Upper Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 48138AB21 Removal of Upper Roller

1. Use a box wrench [ 19 mm ( 0.748 in. ) ] to
WARNING loosen the check valve (1) to release grease, and
then loosen the track shoe tension.
• When loosening the check valve, loosen it a
little at a time and stop when any grease ap- WARNING
pears.
The pressure inside the cylinder is very high, • If the check valve (1) is too loose, it may
so there is the danger of grease being ex- fly off.
pelled and the plug flying off if the check • Do not place your body in front.
valve is loosened too much.
The check valve adjustment procedure Do not loosen the check valve all at once.
should not be done in front of the check Loosen it slowly while monitoring the grease output
valve. and shoe loosening.
Use a rag to catch grease that trickles out of the
CAUTION check valve.

work.
Items to prepare
• Box wrenches [ 19 mm ( 0.748 in. ), 30 mm ( 1.181 in.
) ]
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
2. Use a jack (3) to lift the top of the shoe, and then
insert wood planks (4) to separate the shoe (2) and
upper roller (1) by about 10 mm ( 0.394 in. ).
84551720B NA - August 2012

5003A-3
3. Use a box wrench [ 30 mm ( 1.181 in. ) ] to remove Installation of Upper Roller

the 2 bolts (2), and then remove the upper roller (1).
1. Use a jack (2) to lift the top of the shoe (1), and then
insert wood planks (3).
2. Use a box wrench [ 30 mm ( 1.181 in. ) ] to attach

the 2 bolts (2), and then install the upper roller (1).
• Apply Loctite.
• Bolt (2) tightening torque: 521 - 608 N ・ m (
384.34 - 448.51 lbf·ft. )

While monitoring the track shoe tension, inject
grease into the grease cylinder.
84551720B NA - August 2012

5003A-4
4. To adjust the track shoe tension, raise the lower side 5. Adjust the tension so that the distance indicated
frame as shown in the diagram. with A between the frame bottom (1) of the center
Place a wood plank (1) under the lower frame to area of the lower side frame and the lowest hanging
prevent falling. part of the top of the shoe plate (2) is 290 - 310 mm
( 11.417 - 12.205 in. ).
84551720B NA - August 2012

5003A-5
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5003A-6
Section
5003B
Assembly and Disassembly of Upper Roller
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Job code 48138AB30
CAUTION
• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a qualified
operator.
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling touching parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect
dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
parts from rusting or collecting dust.
Items to prepare
• Hexagon wrench 6 mm ( 0.236 in. )
• Hammer
• Box wrench [ 17 mm ( 0.669 in. ) ]
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite 262
• Special fiber cloth (Kimwipe)
• Marking pen
• Micrometer caliper
• Caliper
84551720B NA - August 2012

5003B-3
Configuration Diagram
Part name Part number Q'ty Part name Part number Q'ty
High-strength bolt 7 Thrust plate KRA1123 1
1 102R010Y016N 2
M10 x 16 8 Shaft KRA1252 1
Reqd. 9 Bushing KRA1248 1
2 Loctite #262 KRC5007
amount 10 Bushing KRA1249 1
Cover (bolt stop- 11 Roller KRA1718 1
3 KRA1719 1
per) 12 Floating seal KBA0783 1
Plug with seal ny- 13 Bracket KRA13740 1
4 KHJ0300 1
lon
5 O-ring UHA0049 1
High-strength bolt
6 102R008Y025R 3
M8 x 25
84551720B NA - August 2012

5003B-4
Dimension Diagram
*1 Press fit length
84551720B NA - August 2012

5003B-5
Jig Dimension Diagram
84551720B NA - August 2012

5003B-6
A Bushing removal jig Disassembly Procedures

B1 Bushing press-fit jig (10)
B2 Bushing press-fit jig (9) 1. Stand the roller vertically and use a hexagon
C Floating seal installation jig wrench [ 6 mm ( 0.236 in. ) ] (1) to remove the
plug (2).
• The plug is coated with seal nylon, which comes
off when the plug is removed. To reuse the plug,
using seal tape is necessary.
2. Face down the part of the roller from which the

plug was removed and empty the oil from within the
roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) under the roller to catch the
oil.

3 bolts (2) from the cover (1), and then remove the
cover.
84551720B NA - August 2012

5003B-7
4. Remove the cover (1). 6. Lift the roller (1) and remove the shaft (2).
If the cover is difficult to remove, it is acceptable to
use an air hose (2) with an adapter or to pry it open
by inserting a flathead screwdriver into either end of
the cover.
• When using compressed air, be careful of flying
parts.
7. Remove the floating seal (2) on the roller (1).

Check whether the sliding surface has rusted or is
damaged. Also make sure the O-ring (3) on the seal
ring (4) is not twisted.

the 2 bolts (2) inside the roller, and then remove the
thrust plate (1).
84551720B NA - August 2012

5003B-8
8. Remove the floating seal (2) on the shaft (1). 10. Use a micrometer caliper (4), caliper (5), cylinder
gauge (6), to measure the roller (with bushing) (1),
• The shaft and bracket (5) cannot be removed. bracket (2), and shaft (3) for wear and deformation.
Check whether the sliding surface has rusted or
Replace with new parts as necessary.
is damaged. Also make sure the O-ring (4) on the
seal ring (3) is not twisted.
11. When replacing bushings (1) (2), use jig A (4) to

restrain it from the side where the shaft (3) was re-
9. Remove the O-ring (2) on the cover (1) side. moved and press it out with a pressing machine (5).
• Check whether the O-ring is twisted. If it is
twisted, replace it with a new one.
84551720B NA - August 2012

5003B-9
Assembly Procedures 4. Invert the roller (1) and insert the bushing (2).
Restraining from above using jig B1 (3), push in with
1. Clean all parts. the pressing machine (4).
Push in all the way to the position where jig B1
• Find a clean location.
stops.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.
5. Insert the floating seal (3) into the roller (1) and
bracket (2).
Use jig C (4) to press it into position.
2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.
6. Use a special fiber cloth to wipe the surfaces of the

floating seals so as to increase adhesion and pre-
vent dust from entering.
3. If the bushing (2) was removed during disassembly,

put it into the roller (1).
Face up the thrust plate installation side, restrain
from above using jig B2 (3), and push in with the
pressing machine (4).
84551720B NA - August 2012

5003B-10
7. Apply hydraulic oil to the floating seal (1). 10. Install the thrust plate (1) with 2 bolts (2).
Degrease the bolts well, apply Loctite (3) to the bolt
openings, and tighten the bolts.
After tightening the bolts, mark them (4).
Bolt (2) tightening torque: 62.8 - 72.6 N・m ( 46.327
- 53.556 lbf・ft. )
8. Attach the shaft (2) to the roller (1).
11. Install the cover (1) with 3 bolts (2).

Degrease the bolts, apply Loctite (3) to the bolt
openings, and tighten the bolts.
- 27.442 lbf・ft. )
9. Use a special fiber cloth to thoroughly wipe the sur-

face of the thrust plate (1) to prevent any dust or
scratches.
12. Rotate the roller in the direction of the arrow and

check that it rotates smoothly.
84551720B NA - August 2012

5003B-11
13. Inject compressed air [ 0.2 MPa ( 29.011 psi ) ] from 14. Inject engine oil (50 - 55 cc) into the roller. After
the oil fill port and immerse in water to check that filling the engine oil, use a hexagon wrench (1) to
there are no leaks. tighten the plug (2) (coated with seal nylon).
• To reuse a plug, wrap it with seal tape.
Plug (2) tightening torque: 24.5 N・m ( 18.073
lbf・ft. )
This completes the assembly.
84551720B NA - August 2012

5003B-12
Section
5003C
Removal and Installation of Lower Roller
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Lower Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING Removal of Lower Roller

• Do not get under the main unit when it is 1. Use a box wrench [ 19 mm ( 0.748 in. ) ] to loosen
jacked up. the check valve (1), and then loosen the shoe ten-
Make sure to place the main unit on wood sion.
planks to prevent falling. Do not loosen the check valve all at once.
• When loosening the grease cylinder check Loosen it slowly while monitoring the grease output
valve, loosen it a little at a time and stop when and shoe loosening.
any grease appears.
• Grease drains out, so provide rag (2) close to the
The pressure inside the cylinder is very high, drain port.
pelled and the plug flying off if the check
CAUTION
work.
Items to prepare
) ]
• Rag
• Cleaning fluid
2. Jack up the side frame on the side where the roller

is being replaced, as shown in the diagram.
Jack up so that the shoe is floating about 5 cm (
1.969 in. ), and insert wood plank (1) under the
lower frame to prevent falling.
84551720B NA - August 2012

5003C-3
3. If it is impossible to insert wood planks (3) under Installation of Lower Roller

the lower frame, insert wood planks (3) between the
side frame and the link shoe (2) to separate the link 1. Insert wood planks (4) between the side frame and
shoe and lower roller (1) by about 15 mm ( 0.591 in. the link show (3), use a box wrench [ 27 mm ( 1.063
). in. ) ] to install 4 bolts (2) and then install the lower
roller (1).
• Bolt (2) tightening torque: tightening torque: 371
- 432 N·m ( 273.69 - 318.68 lbf·ft. )

the 4 bolts (2), then remove the lower roller (1).

While monitoring the track shoe tension, inject
3. When adjusting the track shoe tension, raise the

lower side frame as shown in the diagram.
Place a wood plank (1) under the lower frame to
prevent falling.
84551720B NA - August 2012

5003C-4
4. Adjust the tension so that the distance indicated

with A between the lower frame (1) of the center
area of the lower side frame and the lowest hanging
part of the shoe plate (2) is 290 - 310 mm ( 11.417
- 12.205 in. ).
84551720B NA - August 2012

5003C-5
84551720B NA - August 2012

5003C-6
Section
5003D
Assembly and Disassembly of Lower Roller
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CAUTION
precautions.
ing the load.
• The liftcrane must be operated by a qualified
operator.
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
roll.
in advance.
• When assembling sliding parts, be sure to
<General cautions>
to speed up operations.
Pay careful attention and proceed slowly so
as not to damage any parts, create any oil
leaks, or compromise the efficiency of the
equipment, etc.
dust.
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.
Items to prepare
• Hexagon wrench [6 mm (0.236 in.)]
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Loctite
• Caliper
• Cylinder gauge
84551720B NA - August 2012

5003D-3
Part name Part name

1 Roller 6 Collar (with plug)
2 Shaft 7 Wire clip
3 Bushing 8 Plug
4 Floating seal 9 Collar (without plug)
5 O-ring
84551720B NA - August 2012

5003D-4
Dimension Diagram
84551720B NA - August 2012

5003D-5
A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig
84551720B NA - August 2012

5003D-6
Disassembly Procedures
1. Stand the roller vertically and use a hexagon
wrench [6 mm (0.236 in.)] (1) to remove the plug
(2).
off when the plug is removed.
To reuse the plug, using seal tape is necessary.
4. Use pliers (2) to remove the pushed out wire clip (1).

roller.
oil.
• Place an oil pan (1) underneath to catch the oil.
5. Use a gear puller (2) to remove the collar (1).
• Securely fasten so that the roller does not fall
over. If the collar is difficult to remove, hook the collar on
the bolt and catch the puller on that part.
• If the collar has rusted or is difficult to remove due
to an accumulation of debris, subject it to a shock,
for example by hitting it with a hammer, to make
it easier to move.
• When hitting it with a hammer, be careful not to
dent it.
3. Tap another wire (2) with the hammer (3) from the
outside to push out the wire clip that is already in
the roller.
• Place the roller horizontally and secure it so it
does not roll before doing this work.
• The wire in the roller is very securely fixed, so
prepare several wire clips.
Also be sure to coat with lubricant.
84551720B NA - August 2012

5003D-7
6. Check whether the surface of the floating seal (2) 9. Remove the shaft (1).
sliding against the removed collar (1) has rusted or
is damaged.
Also make sure the O-ring (3) on the seal ring (4) is
not twisted.
• The O-ring cannot be reused.
Replace it with new part.
10. As described in step 7, remove the floating seal (1)

on the opposite side.
7. Remove the floating seal (1) on the roller.

As described in step 6, check whether the sliding
surface has rusted or is damaged.
Also make sure the O-ring is not twisted.
11. Use a caliper (6), micrometer caliper (5), and cylin-

der gauge (7) to measure the roller (with bushing)
(1), collars (2) (3), and shaft (4) for wear and defor-
mation.
8. Remove the O-ring (2) on the shaft (1).

84551720B NA - August 2012

5003D-8
12. When replacing a bushing, insert jig A (3) into the Assembly Procedures
bushing (1), and use a cylindrical object (such as a
shaft) (2) to push from the top. 1. Clean all parts by immersing them in cleaning fluid
The bushing comes off. (1).
• Select a clean location.


put it into the roller (1).
Restraining from above using jig B (3), push in with
the pressing machine (4).
Invert the roller and insert the bushing on the oppo-
site side in the same manner.
84551720B NA - August 2012

5003D-9
4. Use jig C (5) to push the floating seal (4) into the 7. Attach O-rings (3) to the shaft (2) and mount into the
collars (2) (3) and roller (1) by hand. roller (1).
5. Use a special fiber cloth to wipe the surfaces of the 8. Install the collars (1) (2) on both sides.
floating seals so as to increase adhesion and pre-
vent dust from entering.
9. Attach the wire clip (1).
6. Apply gear oil to the floating seals (3) on the collars • When attaching the wire clip, secure the roller
main unit so that it does not roll.
(1) (2).
84551720B NA - August 2012

5003D-10
10. Turn the main unit and check that the roller rotates 12. Fill gear oil (125 cc) into the roller.
properly. Use a hexagon wrench [6 mm (0.236 in.)] (2) to
tighten the plug (1) with the nylon seal applied.
• Mobile Gear Oil SHC320 is recommended for
use.
Plug (1) tightening torque: 24.5 N·m (18.073
lbf·ft.)
11. Inject compressed air [0.2 MPa (29.011 psi)] from

the oil fill port and immerse in water to check that
there are no leaks.
84551720B NA - August 2012

5003D-11
84551720B NA - August 2012

5003D-12
Section
5004
Removal and Installation of the Sprocket
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING 2. Slowly rotate the shoe so that the shoe joint section
(1) is aligned as in the diagram on the right.
• When loosening the check valve, loosen it a Place wood plank (2) under the shoe and return the
little at a time and stop when any grease ap- bucket to its original position.
pears. Perform air bleeding for the hydraulic line.
The pressure inside the cylinder is very high, For details, see Air Bleed Procedures.
CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
load.
Items to prepare
• Box wrenches [ 19 mm ( 0.748 in. ) ]
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Loctite #262
• Wood plank
• Rag
• Cleaning fluid
Removal of Sprocket
1. Allow the bucket (1) to touch the ground so as to
elevate the shoe (2) of the side to be removed as in
the diagram on the right.
84551720B NA - August 2012

5004-3
3. Use a box wrench [ 19 mm ( 0.748 in. ) ] to rotate 5. Place a striking jig (2) against the master pin (1) and
the grease cylinder check valve (1) and loosen the hit it with a hammer (3) to push the master pin out.
shoe tension.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off.
Be careful not to work in front of the check valve.
6. Open the shoe (1) to the rear.

22 bolts (1).
4. Pull out the S-pin (1) from the rear of the joint sec-
tion.
8. Use a wire rope (1) to lift the drive sprocket (2) and
remove it from the travel motor (3).
84551720B NA - August 2012

5004-4
Installation of Sprocket • Tightening torque M16: 267 - 312 N・m ( 196.96 -

230.16 lbf・ft. )
To install, perform the reverse of the removal procedure.
84551720B NA - August 2012

5004-5
84551720B NA - August 2012

5004-6
Section
5005A
Removal and Installation of Take-up Roller
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING Removal of Take-up Roller

• When loosening the grease cylinder check 1. Remove the shoe assembly.
valve, loosen it a little at a time. See the "Removal and Installation of Shoe Assem-
• The pressure inside the cylinder is very high, bly".
so there is a danger of grease being expelled 2. Use a crowbar (3) to pull off the take-up roller (1)
and the plug flying off. and recoil spring assembly from the side frame (2).
The check valve adjustment procedure
should not be done in front of the check
valve.
• Do not get under the machine when the main
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.
Items to prepare
• Wrench [ 24 mm ( 0.945 in. ) ]
• Hammer
• Lifting equipment 3. Install the lifting equipment (4) on the take-up roller
• Loctite #262 (1) and recoil spring assembly (3) and hang them
• Striking jig from the side frame (2) with the liftcrane.
• Liftcrane
• Crowbar
• Rag
4. Place the take-up roller (1) and recoil spring assem-

bly (2) onto wood planks (4) as in the diagram.
Use a wrench [ 24 mm ( 0.945 in. ) ] to remove the
take-up roller bolt (3) and separate the roller and the
recoil spring assembly.
84551720B NA - August 2012

5005A-3
Installation of Take-up Roller 2. Install the lifting equipment (4) on the take-up roller
(1) and recoil spring assembly (3) as in the diagram,
1. Place the take-up roller (1) and recoil spring assem- lift them up with the liftcrane, and insert them into
bly (2) onto wood planks (4) as in the diagram. Use the side frame (2).
a wrench [ 24 mm ( 0.945 in. ) ] to fasten the Push in with the crowbar until the recoil spring as-
take-up roller (1) and recoil spring assembly (2) with sembly contacts the grease cylinder.
the bolt (3).
At this time, be sure to coat the bolt with Loctite
#262.
Installation bolt tightening torque: 267 - 312 N・m
( 196.96 - 230.16 lbf・ft. )
3. Install the shoe assembly.

For details on installation, see the "Removal and
Installation of Shoe Assembly" procedure.
84551720B NA - August 2012

5005A-4
Section
5005B
Assembly and Disassembly of Take-up Roller
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CAUTION • Seal tape

• Oil pan (drip pan)
• To ensure safe operations, wear protective • Water container for inspection
precautions.
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
load.
• Check the weight of the roller to deter-
mine whether it can be carried by hand or
whether a liftcrane must be used.
roll.
in advance.
• When assembling sliding (5) parts, be sure to
• The take-up roller is a heavy object and re-
quires at least 2 workers to handle.
<General cautions>
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
dust. Therefore, immediately after disassem-
parts from rusting or collecting dust.
Items to prepare
• Hammer
• Pliers
• Gear puller
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Loctite
• Caliper
• Cylinder gauge
84551720B NA - August 2012

5005B-3
Part name Q'ty Part name Q'ty

1 Roller 1 6 Hub pin 2
2 Bushing 2 7 Shaft 1
3 Floating seal 2 Plug with seal ny-
8 1
4 Hub (without plug) 1 lon
5 O-ring 1A-G50 2 9 Hub 1
84551720B NA - August 2012

5005B-4
Dimension Diagram
84551720B NA - August 2012

5005B-5
A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig
84551720B NA - August 2012

5005B-6
Disassembly Procedures 3. Remove the hub pin (2) from the hub (1), and re-
move the hub (1) from the shaft (3).
1. After cleaning the roller with kerosene, use the
hexagon wrench (1) to remove the plug (2) from • Only remove on one side.
the hub (3).
off when the plug is removed. Seal tape is neces-
sary for reusing.
4. Check whether the surface of the floating seal (1)

sliding against the removed hub has rusted or is
damaged. Also make sure the O-ring (2) on the seal
ring (3) is not twisted.
• The O-ring cannot be reused. Replace it with new
part.

roller.
oil.
• Place an oil pan (1) underneath to catch the oil.
84551720B NA - August 2012

5005B-7
5. Remove the floating seal (1) on the roller. As de- 7. As described in step 3, remove the hub (1) on the
scribed in step 4, check whether the sliding sur- opposite side and check that the sliding surface of
face has rusted or is damaged. Also make sure the the floating seal is not rusted and that the O-ring is
O-ring is not twisted. not twisted.
6. Remove the O-ring (2) on the shaft (1) and then pull 8. As described in step 5, remove the floating seal (1)
the shaft (1) out. on the opposite side.
• The O-ring cannot be reused. Replace it with new
part.
84551720B NA - August 2012

5005B-8
9. Use a micrometer caliper (4), cylinder gauge (5), • Do not disassemble the bushing (1) unless it has
and caliper (6) to measure the roller (with bushing) become unusable due to wear, etc.
(1), hub (2), and shaft (3) for wear and deformation. • Be careful not to scratch the inside of the roller
Replace with new parts as necessary. when striking the end of the bushing.
11. Invert the roller (1), use jig A (4) to push up against
the bushing (2), and press with a rod-shaped object
(3) (such as a shaft). The bushing comes off.
10. When replacing the bushing (1), remove it by plac-

ing a striking rod (2) against the end surface and
striking that with a hammer (3) uniformly left and
right as in the diagram.
84551720B NA - August 2012

5005B-9
Assembly Procedures 4. Use the jigs (2) (3) attached to the pressing machine
to attach the bushing (1). Use the pressing machine
1. Clean all parts. to press from the opposite side. Next, use a special
fiber cloth to remove all dust and debris.
• Find a clean location.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.

• If the parts are to be left as is for a long time after
drying them, apply engine oil.
5. Attach the floating seal (2) to the hub (1). Use jig C
(3) to press it into position.

put it into the roller (1). Use a pressing machine (3)
to press in both the left and right sides.
84551720B NA - August 2012

5005B-10
6. Use jig C (3) to attach the floating seal (2) to the 9. After attaching the O-ring (4) to the shaft (1), attach
roller (1) side. the shaft to the hub (2) and fasten it with the hub pin
(3).
7. Use a special fiber cloth to thoroughly wipe the slid-

ing surface of the floating seal to prevent any dust 10. Attach the shaft (2) to the roller (1).
or scratches.
11. Install the opposite side hub (1) on the roller (2) and
8. Apply engine oil to the floating seals (1) on the hubs fasten with the hub pin (3).
(2) (3).
84551720B NA - August 2012

5005B-11
12. Inject compressed air [ 0.2 MPa ( 29.011 psi ) ] from 14. After filling the oil, use a hexagon wrench [ 6 mm (
the oil fill port and immerse in water to check that 0.236 in. ) ] (2) to tighten the plug (1) with the nylon
there are no leaks. seal applied.
13. Fill engine oil (120 cc) into the roller main unit.
• The roller main unit can be very unstable, so be
careful in securing it.
84551720B NA - August 2012

5005B-12
Section
5005C
Removal and Installation of Grease Cylinder
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of grease cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of grease cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING Removal of grease cylinder

• When loosening the grease cylinder check 1. Remove the shoe assembly.
valve, loosen it a little at a time. See the "Removal and Installation of Shoe Assem-
• The pressure inside the cylinder is very high, bly" procedure.
so there is a danger of grease being expelled 2. Use a crowbar (3) to pull off the take-up roller (1)
and the plug flying off. and recoil spring assembly about 100 mm ( 3.937
The check valve adjustment procedure in. ) from the side frame (2).
should not be done in front of the check When removing the grease cylinder, use a wood
valve. plank or the like (4) to prevent the take-up roller (1)
• Do not get under the machine when the main and recoil spring assembly from coming out.
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.
Items to prepare
• Wrench [ 24 mm ( 0.945 in. ), 27 mm ( 1.063 in. ) ]
• Hammer
• Lifting equipment
• Loctite #262
• Striking jig
• Striking jig
• Crowbar 3. Jack up the side frame on the side where the grease
• Wood planks, etc. cylinder is being removed as shown in the diagram.
• Rag Jack up so that the shoe is floating about 5 cm (
1.969 in. ), and insert wood plank (1) under the
lower frame to prevent falling.
4. Use a wrench [ 27 mm ( 1.063 in. ) ] to remove

the bolts (1) and washers (2), and then remove the
track guard (3).
84551720B NA - August 2012

5005C-3
5. Install the wire (2) on the grease cylinder assem- Installation of grease cylinder
bly (1), and then lift it with the liftcrane so that it is
slightly tensed. To install, perform the reverse of the removal procedure.
Grease cylinder installation bolt tightening torque: 267 -
312 N・m ( 196.96 - 230.16 lbf・ft. )
When installing bolts, coat the threaded sections with
Loctite #262.
6. Use a wrench or box wrench [ 24 mm ( 0.945 in. )

] to remove the bolt (1) and washer (2), and then
remove the grease cylinder (3).
Lower the liftcrane as is to lower to under the frame,
and then take out from between the lower rollers.
84551720B NA - August 2012

5005C-4
Section
5005D
Assembly and Disassembly of Tension Shock Absorber
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Configuration diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Jig dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CAUTION
precautions.
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
load.
• Check the weight of the grease cylinder to
determine whether it can be carried by hand
or whether a liftcrane must be used.
in advance.
• When assembling touching parts, be sure to
General cautions
to speed up operations.
Pay careful attention and proceed with cau-
tion so as not to damage any parts, create any
oil leaks, or compromise the efficiency of the
equipment.
dust.
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.
Items to prepare
• Hammer
• Wrenches [ 19 mm ( 0.748 in. ) ]
• Box wrench [ 19 mm ( 0.748 in. ) ]
• Screwdriver
• Specialty jigs
• Marking pen
84551720B NA - August 2012

5005D-3
Configuration diagram
Co- Co-
de de
1 Dust seal 1 6 High-strength bolt 2
2 Piston rod 1 7 Spring washer 2
3 U-packing 1 8 Bracket 1
4 Retaining ring 1 9 Check valve assembly 1
5 Grease cylinder 1
84551720B NA - August 2012

5005D-4
Dimension diagram
Jig dimension diagram
84551720B NA - August 2012

5005D-5
A Dust seal press-fit jig Disassembly procedures

B Removal jig
1. Clean the grease cylinder with kerosene, remove
the bolt (1) and washer (2), and remove the bracket
(3).
Remove the check valve (5) from the grease cylin-
der (4).
2. Pull out the piston rod (2) from the grease cylinder
(1).
3. Use the removal jig (B) to remove the dust seal (2)
from the grease cylinder (1).
84551720B NA - August 2012

5005D-6
4. Remove the retaining ring (2) from the piston rod Assembly procedures
(1), and then use the removal jig (B) to remove the
U-packing (3). 1. Place parts in a rough cleaning container filled with
kerosene to clean off any adhered matter that can
form sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.
2. Place parts in a finish cleaning container filled with
kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
3. Install the U-packing (1) coated with grease onto the
piston rod (2), and then install the retaining ring (3).
• Use a new U-packing (1).
• Be careful that the U-packing (1) faces correctly.
84551720B NA - August 2012

5005D-7
4. Use the jig (A) and hammer (C) to install the dust 5. Coat the surface of the piston rod (1) with grease
seal (2) on the grease cylinder (1). and insert into the grease cylinder (2).
Apply grease to the lip section of the dust seal (2).
• Use a new dust seal (2).
6. Tighten the check valve (1) to the grease cylinder

(2) to the specified tightening torque.
Install the bracket (3) and secure it with the spring
washer (4) and the bolt (5).
Check valve tightening torque: 48.99 - 68.61 N•m
(36.1394 - 50.6128 lbf・ft.)
84551720B NA - August 2012

5005D-8
Section
6001
Removal and Installation of Travel Motor
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WARNING Removal of Travel Motor

• When loosening the check valve, loosen it a 1. Allow the bucket (1) to touch the ground so as to
little at a time and stop when any grease ap- elevate the shoe (2) of the side to be removed as in
pears. the diagram on the right.
The pressure inside the cylinder is very high,
CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
load.
Items to prepare 2. Slowly rotate the shoe so that the shoe joint section
(3) is aligned as in the diagram on the right.
• Box wrenches [ 19 mm ( 0.748 in. ), 24 mm ( 0.945 in. 3. Place wood planks (4) under the shoe and return
) ] the bucket to its original position.
• Wrenches [ 19 mm ( 0.748 in. ), 27 mm ( 1.063 in. ), 4. Perform air bleeding for the hydraulic line.
41 mm ( 1.614 in. ) ] For details, see Air Bleed Procedures.
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Loctite #262
• Rag
• Cleaning fluid
84551720B NA - August 2012

6001-3
5. Use a box wrench [ 19 mm ( 0.748 in. ) ] to rotate 7. Place a striking jig (9) against the master pin (7) and
the grease cylinder check valve (5) and loosen the hit it with a hammer (8) to push the master pin out.
shoe tension.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off. Be careful not to work in front
of the check valve.
8. Open the shoe (2) to the rear.

4 bolts (10), then remove the cover (11).
6. Pull out the S-pin (6) from the rear of the joint sec-
tion.
84551720B NA - August 2012

6001-4
10. Use wrenches [ 27 mm ( 1.063 in. ) for drain hose, 12. Attach the wire rope (17) to the travel motor (16) as
41 mm ( 1.614 in. ) for high-pressure hose ] to in the diagram.
remove the drain hose (13) and 3 high-pressure Adjust the wire rope so that it is located at the center
hoses (12). of mass and lift it with the liftcrane so that it is slightly
tensed.
• Be sure to use plugs on the removed drain and
high-pressure hoses.

all 28 bolts (18).
pilot hoses (15) (14) shown in the diagram.
14. Remove the travel motor (16).
84551720B NA - August 2012

6001-5
Installation of Travel Motor 3. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove

the elbow joint (3) and pilot hose (4) shown in the
1. Attach the travel motor to the lower frame as in the diagram.
diagram.
• Be careful of the installation angles.
2. Apply Loctite #262 to the installation bolt (2)

threaded sections and temporarily tighten all 28
bolts.
Use a wrench [ 24 mm ( 0.945 in. ) ] to tighten the
top and bottom alternately to the specified torque so
that an even tightening force acts on the opposing
sides.
4. Use wrenches [ 27 mm ( 1.063 in. ) for drain hose,

41 mm ( 1.614 in. ) for high-pressure hose ] to install
the drain hose (6) and high-pressure hose (5).
Tightening torque M16: 267 - 312 N・m ( 196.97 -
230.15 lbf・ft. )
84551720B NA - August 2012

6001-6
5. Use a wrench [ 19 mm ( 0.748 in. ) ] to install the 8. Tighten the check valve (12).
cover (8) with the 4 bolts (7). While monitoring the track shoe tension, inject
6. Wrap the shoe (9).

9. When adjusting the track shoe tension, raise the
lower side frame as shown in the diagram.
Place a wood plank (13) under the lower frame to
prevent falling.
Adjust the tension so that the distance indicated
with A between the frame bottom (14) of the center
area of the lower side frame and the lowest hang-
ing part of the top of the shoe plate (15) is 290 - 310
mm ( 11.417 - 12.205 in. ).
7. Insert the master pin (11).

Insert the S-pin (10) and bend it so that it cannot slip
out.
84551720B NA - August 2012

6001-7
84551720B NA - August 2012

6001-8
Section
6002
Assembly and Disassembly of Travel Motor
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Tools for Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Secondary Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special Tool (jig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Measurement Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Precautions before Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Parts Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reduction Gear Parts Maintenance Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Precautions before Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Initial Pre-conditioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Tools for Assembly and Disassembly

Use the tools indicated below for the assembly and disassembly of the motor.
Standard Tools
The standard tools required for the assembly and disassembly of this motor are indicated in Table 1.
Standardized
No.
No. Tool name Type and dimensions Part used with
Manufacturer
name
1 Nominal size 60 1-2-19
3 Nominal size 230
5 Preset-type torque wrench JIS B4650 Nominal size 900 24, 28
6 Nominal size 1800 1-2-2-4, 1-2-11, 1-2-14, 29
7 Nominal size 2800 11
9 Nominal size 5600 8, 14
10 Rachet handle for socket wrench JIS B4641
Bolt width 2.5 mm
11 1-2-19
( 0.0984 in. )
Bolt width 4 mm
12 1-2-8
( 0.157 in. )
Bolt width 6 mm
13 1-2-20
( 0.236 in. )
Bolt width 8 mm
14 Hexagon bit for socket wrench 28
( 0.315 in. )
Bolt width 10 mm
15 1-2-11
( 0.394 in. )
Bolt width 12 mm
16 11、29
( 0.472 in. )
Bolt width 14 mm
17 1-2-2-4
( 0.551 in. )
18 Size T50 24
Torx T-shaped bit JASO F116-89
19 Size T90 8, 14
Bolt width 10 mm
20 1-2-14
( 0.394 in. )
Socket for socket wrench JIS B4636
Bolt width 27 mm
21 1-2-7
( 1.063 in. )
Bolt width 2.5 mm
22 1-2-19
( 0.0984 in. )
Bolt width 4 mm
23 1-2-8
( 0.157 in. )
Bolt width 6 mm
24 1-2-20
( 0.236 in. )
Bolt width 8 mm
25 Hexagon wrench JIS B4648 28
( 0.315 in. )
Bolt width 10 mm
26 1-2-11
( 0.394 in. )
Bolt width 12 mm
27 11, 29
( 0.472 in. )
Bolt width 14 mm
28 1-2-2-4
( 0.551 in. )
Bolt width 10 mm
29 1-2-14
( 0.394 in. )
Wrench JIS B4630
Bolt width 27 mm
30 1-2-7
( 1.063 in. )
31 Longnose pliers JIS B4631 1-2-7
32 Snap ring pliers S-2 type 1-4-5
84551720B NA - August 2012
6002-3
Standardized
No.
No. Tool name Type and dimensions Part used with
Manufacturer
name
33 Flathead screwdriver JIS B4609 6 x 100 2, 1-27, 1-2, 1-21
34 Plastic hammer OF-05 Nominal size #3
Length of about 10 mm
35 Punch
( 0.394 in. )
36 Press 200 kgf or higher
For 400 kg
37 Liftcrane
( 881.854 lb )
38 For M20
Eyebolt
39 For M12 1-2
40 Chain string (wire)
84551720B NA - August 2012

6002-4
Secondary Materials
The secondary materials required for the assembly and disassembly of this motor are indicated in Table 2.
Standardized
No. Type and dimen-
No. Secondary materials name Part used with
Manufacturer sions
name
1 Seal tape 1-2-8
2 Adhesive Loctite 271 8, 14
1-1, 1-7, 1-6, 1-2-1, 1-2-2, 1-2-9,
GL-4#90
3 Gear oil 1-4-1, 1-4-2, 1-21, 1-4-4, 1-4-3, 1-5,
equivalent
1-4-2, 1-6
ISO VG46
4 Hydraulic oil
equivalent
1-2-2-5, 1-2-6-2, 1-2-6-4, 1-2-12, 1-2-
5 Grease Lithium-series
21, 1-16, 1-17, 1-23, 1-12, 1-15, 1-21
No.2 equiva-
6 White kerosene
lent oil
7 Liquid packing ThreeBond 1211 4, 27
For sliding sur-
8 Lapping plate 1-4-1, 1-4-2, 1-5、1-21
face repair
For sliding sur-
9 Lapping agent #1000
face repair
10 Copper plate
11 Tube brush For cleaning 1-2-1, 1-4-1
12 Bamboo brush For cleaning
13 Oil pan Oil pan
14 Plastic container For filling grease
15 Rag
84551720B NA - August 2012

6002-5
Special Tool (jig)

The special tools required for the assembly and disassembly of this motor are indicated in Table 3 (For dimensions,
refer to Section 1003).
Standard-
Type and
ized No. Part used
No. Tool name dimen-
Manufac- with
sions
turer name
1 Pulley remover 1-8, 1-9
2 Bearing press-fit jig 1-8
3 Bearing press-fit jig 1-9
4 Floating seal mounting jig 2
5 Rod 3
6 Angular bearing press-fit jig 3
7 Shim thickness adjustment jig 5
8 Rod 1-2-2
10 Thrust plate selection jig 26
11 Oil seal press-fit jig 1-12
12 Brake piston positioning jig 1-15
13 Snap ring removal jig 1-4-5
14 Poppet seat removal jig 1-2-7-3
84551720B NA - August 2012

6002-6
Measurement Device
The measurement devices required for assembly of this motor are indicated in Table 4.
Standard-
Type and
ized No. Part used
No. Tool name dimen-
Manufac- with
sions
turer name
1 Dial gauge JIS B7503 5, 26
Micrometer
2 JIS B7502 5, 26
caliper
84551720B NA - August 2012

6002-7
Motor Disassembly Procedures 5. When removing lines connected to the motor, hy-
draulic oil from inside the lines will spray out.
Precautions before Motor Disassembly For this reason, remove these lines only after re-
moving pressure from inside the lines and prepar-
Begin motor disassembly only after thoroughly reading ing an oil pan.
the precautions below. To prevent injuries due to the motor falling when
1. When performing disassembly, always wear pro- transporting it by lifting the motor with a liftcrane,
tective gear such as a helmet, goggles and safety lift the machine with the eyebolts mounted in the
shoes. positions indicated in the diagram below.
2. Use the specified tools when performing disassem- 6. The motor is filled with hydraulic oil.
bly. Before disassembling the motor, prepare an oil pan
3. Remove all lines connected to the motor and re- and drain the hydraulic oil from the motor.
move the motor from the machine only after mak- 7. To prevent injuries during disassembly, prepare a
ing sure that the machine is on a level surface and waist-high, stable work platform to perform work on.
there are no external forces acting on rotating parts, 8. The motor comprises high-precision parts.
so that the machine does not operate uncontrollably For this reason, foreign matter adhering to parts can
when the motor is removed. be damaging.
4. To prevent foreign matter from entering the lines Motor disassembly should be done in an inside
and motor when removing the motor from the ma- space without dust, and mud and dirt should be
chine, sufficiently clean off mud and dirt adhered prevented from adhering to parts.
around the motor before removing lines connected 9. The motor comprises high-precision parts.
to the motor. For this reason, dents and scratches on part sur-
faces can be damaging.
Be very careful when handling parts during disas-
sembly and do not create any dents or scratching.
10. To prevent personal injury and damage to parts dur-
ing disassembly, do not force disassembly of parts
which are especially tight to disassemble.
*1 Eyebolt
*2 Lifting
84551720B NA - August 2012

6002-8
Tightening Torque
Table 5 indicates tightening torque for each fastening section.
Refer-
ence Part name Screw size Bolt width Tightening torque
number
127 - 147 N・m
1-2-2-4 Plug M24 x 1.5 14 (0.551)
(93.69 - 108.44 lbf・ft.)
98 - 118 N・m
1-2-6-4 Hexagon socket head bolt M12 x 1.75 x 40 (1.575) L 10 (0.394)
(72.30 - 87.04 lbf・ft.)
353 - 393 N・m
1-2-7 Relief valve assembly 1-5/16 12UNF 27 (1.063)
(260.41 - 289.91 lbf・ft.)
8.8 - 10.8 N・m
1-2-8 Plug NPTF1/16 4 (0.157)
(6.492 - 7.967 lbf・ft.)
112 - 124 N・m
1-2-11 Plug G1/2 10 (0.394)
(82.63 - 91.47 lbf・ft.)
112 - 124 N・m
1-2-14 Plug G1/2 10 (0.394)
(82.63 - 91.47 lbf・ft.)
1.96 - 2.94 N・m
1-2-17 Orifice M5 x 0.8 x 5 (0.197) L 2.5 (0.0984)
(1.4459 - 2.1688 lbf・ft.)
1.96 - 2.94 N・m
1-2-18 Orifice M5 x 0.8 x 5 (0.197) L 2.5 (0.0984)
(1.4459 - 2.1688 lbf・ft.)
1.96 - 2.94 N・m
1-2-19 Orifice M5 x 0.8 x 5 (0.197) L 2.5 (0.0984)
(1.45 - 2.16 lbf・ft.)
34.3 - 39.3 N・m
1-2-20 Plug G1/4 6 (0.236)
(25.303 - 28.991 lbf・ft.)
195 - 215 N・m
1-11 Hexagon socket head bolt M14 x 2.0 x 35 (1.378) L 12 (0.472)
(143.85 - 158.60 lbf・ft.)
512 - 566 N・m
8 Bolt M20 x 2.0 x 70 (2.756) L Torx T90
(377.70 - 417.53 lbf・ft.)
512 - 566 N・m
14 Bolt M20 x 2.0 x 130 (5.118) L Torx T90
(377.70 - 417.53 lbf・ft.)
53.9 - 63.7 N・m
24 Screw M10 x 1.5 Torx T50
(39.762 - 46.990 lbf・ft.)
69.77 - 77.03 N・m
28 Hexagon socket head bolt M10 x 1.5 x 16 (0.630) L 8 (0.315)
(51.4686 - 56.8241 lbf・ft.)
149 - 165 N・m
29 Plug G3/4 12 (0.472)
(109.92 - 121.71 lbf・ft.)
84551720B NA - August 2012

6002-9
Disassembly Procedure CAUTION

Perform disassembly by observing the precautions listed
The plunger assembly and base plate are
in Section 1 and following the procedure indicated below.
fit together with a very small gap.
1. Removal of cap assembly For this reason, observe the following pre-
Secure the motor on top of the stable work platform, cautions when working.
loosen the 8 hexagon socket head bolts (1-2-6-4),
1) Do not try to force out the plunger
and remove the 2 cap assemblies (1-2-6).
assembly if it becomes stuck when
Next, remove the springs (1-2-4) and spring seats
being removed.
(1-2-3).
If it is forced out, this could scratch
CAUTION the inner diameter surface of the base
plate hole or the outer diameter sur-
The cap assemblies are pushed out by the face of the plunger assembly.
spring. If the plunger assembly becomes
For this reason, observe the following pre- stuck, lightly hit the end surface of
cautions when working. it with a plastic hammer to insert it
once into the base plate.
1) Loosen the hexagon socket head After this, check that the plunger as-
bolts evenly. sembly moves smoothly and remove
2) Loosen the hexagon socket head it again while rotating it.
bolts while pressing down the cap 2) Do not perform disassembly of the
assemblies. plunger assembly if it is not neces-
sary.
Disassembly can cause scratching
on the outside diameter surface of
the plunger assembly.
When disassembly is necessary, con-
tact our company.
2. Removal of plunger assembly

Lightly press the end of the plunger assembly
(1-2-2) to partially eject the plunger assembly from
the base plate (1-2-1).
Next, hold the end of the plunger assembly by hand
and remove the plunger assembly from the base
plate while rotating it. 3. Removal of relief valve assembly
Loosen the plug (1-2-7-6) and remove the relief
valve assembly (1-2-7).
At this time, each poppet seat (1-2-7-3) remains in
the base plate (1-2-1).
84551720B NA - August 2012

6002-10
CAUTION 5. Removal of spool assembly

Loosen the plugs (1-2-11) (1-2-14) and remove the
The relief valve assemblies are at a set plugs and spring (1-2-10).
pressure. Lightly press the end of the spool assembly (1-2-9)
The motor driving force and braking force to partially eject the spool assembly from the base
are both determined by this set pressure. plate (1-2-1).
For this reason, do not perform the follow- Next, hold the end of the spool assembly by hand
ing actions. and remove the spool assembly from the base plate
while rotating it.
1) Loosen the nut (1-2-7-16) and do not
tamper with the locking screw (1-2-7- CAUTION
15).
If this part is tampered with, the The spool assembly and base plate fit to-
set pressure of the relief valve will gether with a very small gap.
change and the machine will no For this reason, observe the following pre-
longer display prescribed capabili- cautions when working.
ties.
1) Do not try to force out the spool as-
2) Do not perform disassembly of the
sembly if it becomes stuck when be-
relief valve assemblies.
ing removed.
The set pressure will change and the
If it is forced out, it could scratch
machine will no longer display pre-
the inner diameter surface of the base
scribed capabilities.
plate hole or the outer diameter sur-
face of the spool assembly.
If the spool assembly becomes stuck,
lightly hit its end surface with a plas-
tic hammer to insert it temporarily
into the base plate.
After this, check that the spool as-
sembly moves smoothly and remove
it again while rotating it.
2) Do not disassemble the spool assem-
bly unless it is necessary.
When disassembly is necessary, con-
tact our company.
4. Poppet seat removal

Use the poppet seat removal jig to remove each
poppet seat (1-2-7-3) from the base plate (1-2-1).
CAUTION
Do not perform disassembly if it is not nec-
essary.
6. Do not remove the plugs (1-2-8) unnecessarily.

Each orifice (1-2-22) (1-2-23) (1-2-19) is caulked to
prevent loosening.
Do not perform disassembly.
7. Removal of base plate
Loosen the hexagon socket head bolts (1-11) and
remove the base plate (1-2-1).
84551720B NA - August 2012

6002-11
CAUTION 8. Removal of valve plate

Use a flathead screwdriver to remove the valve
When removing the base plate, observe plate (1-21) from the base plate (1-2-1).
the following precautions.
CAUTION
1) The base plate is pushed upwards by
the springs (1-18). When removing the valve plate, observe
For this reason, loosen the hexagon the following precaution.
socket head bolts evenly when loos-
1) The valve plate sliding surface is eas-
ening. ily scratched.
2) Positioning pins (1-19) are mounted
If the sliding surface is scratched,
between the base plate and main unit. prescribed capabilities will disap-
For this reason, pull the base plate
pear, so prevent scratching from
(1-2-1) straight off in alignment with occurring.
the center axis of the motor when re-
moving it so that it does not become
stuck with the pins.
If it becomes stuck, lightly strike the
base plate with a plastic hammer to
put the pins in the correct position,
and then remove the base plate.
3) When removing the base plate, the
valve plate (1-21) is attached to the
base plate.
The valve plate sliding surface is eas-
ily scratched, so be careful not to let
the valve plate fall.
9. Removal of O-rings, pin and spring

Remove the O-rings (1-22) (1-23), pin (1-19), and
spring (1-18).
10. Removal of brake piston

Attach a pressured air nozzle to the flange (1-1) oil
path for the parking brake, and inject compressed
air to the parking brake cylinder chamber to raise
the brake piston (1-15) and remove it.
After removing the brake piston, remove the disk
plates (1-13) and friction plates (1-14), and remove
the D-rings (1-16) (1-17) from the brake piston.
84551720B NA - August 2012

6002-12
CAUTION
When removing the cylinder block assem-
bly, observe the following precautions.
1) Hold the cylinder block assembly
with both hands and lightly rotate it
left and right to slowly remove it.
2) Be careful not to scratch the sur-
face of the cylinder block (1-4-1) that
slides against the valve plate (1-21).
If this surface is scratched, the ma-
chine will no longer display pre-
scribed capabilities.
3) Be careful not to scratch the piston
CAUTION assembly (1-4-2) shoe sliding sur-
faces.
When removing the brake piston, observe If this surface is scratched, the ma-
the following precautions. chine will no longer display pre-
1) When injecting compressed air from scribed capabilities.
the flange oil path for the parking
brake, do not let any compressed air
leak out.
2) When injecting compressed air from
the flange oil path for the parking
brake, the brake piston may fly off if
the pressure of the compressed air is
high, and this may cause injury.
For this reason, set the air pressure
at 0.29 MPa ( 42.07 psi ) or below,
and hold down the brake piston while
performing work so that it does not
fly off.
12. Disassembly of cylinder block assembly

1) Mark the piston assemblies (1-4-2) and cylin-
der block (1-4-1) with permanent ink so that
parts can be reassembled in the exact same
configuration, and remove the piston assem-
blies and retainer plate (1-4-3) from the cylin-
der block.
11. Removal of cylinder block assembly

Remove the cylinder block assembly (1-4) from the
flange (1-1).
84551720B NA - August 2012

6002-13
2) Mark the piston assemblies (1-4-2) and re- 4) Secure the cylinder block (1-4-1) on the man-
tainer plate (1-4-3) with permanent ink so that ual press platform with the sliding surface fac-
parts can be reassembled in the exact same ing up, remove the snap ring (1-4-5), press the
configuration, and remove the piston assem- collar (1-4-8) with the jig to make the spring
blies from the retainer plate. (1-4-7) bend, and use snap ring pliers to re-
move the snap ring.
CAUTION
When removing the snap ring, ob-
serve the following precaution to pre-
vent injuries.
1) The snap ring is stiff and may
come off from the snap ring pli-
ers when the snap ring is being
removed, which could cause in-
jury.
When removing the snap ring,
make sure to use a disassembly
3) Remove the retainer holder (1-4-4) from the jig and check that the nails of
cylinder block (1-4-1) and remove the pins the snap ring pliers are in the
(1-4-9) from the cylinder block. snap ring hole before removal.
5) Remove the collar (1-4-8), spring (1-4-7), and

spring seat (1-4-6) from the cylinder block
(1-4-1).
13. Removal of swash plate

Remove the swash plate (1-5) from the flange (1-1).
84551720B NA - August 2012

6002-14
CAUTION CAUTION
When removing the swash plate, observe When removing the shaft, observe the fol-
the following precautions. lowing precautions.
1) Be careful not to scratch the swash 1) Be careful not to scratch the splines
plate sliding surface. on the shaft.
If this surface is scratched, the ma- 2) Be careful not to scratch the sliding
chine will no longer display pre- section of the shaft oil seal (1-12).
scribed capabilities. Scratching this surface may cause oil
2) Piston assemblies (1-7) and steel leaking.
balls (1-6) may be attached to the
swash plate.
When these are attached, be careful
not to let them fall.
16. Draining reduction gear lubricating oil

Before disassembling the reduction gear section,
use the tap for securing the flange (1-1) and mount
two eyebolts in opposing positions to lift the reduc-
14. Removal of piston assembly and steel ball tion gear with a liftcrane.
Remove the piston assemblies (1-7) from the flange Remove the plugs (29) in the 2 locations and drain
(1-1) and remove the springs (1-20). the reduction gear lubricating oil.
Remove the steel balls (1-6) from the flange.
CAUTION
CAUTION
1) Prepare an oil pan before performing
The steel balls are difficult to remove, so work.
use the following procedure to do this. 2) Do not lift to too high position when
lifting with the liftcrane. Perform
1) With the steel balls mounted on the
work with the reduction gear at the
flange, use white kerosene or thinner
lowest possible position (at about
to degrease.
knee height).
2) Use a magnet to remove the steel
balls from the flange.
17. Removal of cover

Loosen and remove the hexagon socket head bolts
15. Removal of shaft
(28).
Remove the shaft (1-3) and ball bearing (1-8) from
After this, remove the cover (27).
the flange (1-1).
84551720B NA - August 2012

6002-15
CAUTION 20. Removal of 1st stage holder assembly

Remove the 1st stage holder assembly comprising
Use the following procedure when remov- the holder B (17), planetary gears B (21), needle
ing the cover. bearings (20), inner races (19), thrust plates (18),
thrust plates (22), thrust plate (23), and screws (24).
1) Liquid packing has been applied be-
tween the cover and housing (4). CAUTION
For this reason, it is difficult to re-
move the cover. When removing the 1st stage holder as-
Loosen the socket head bolt and sembly, observe the following precaution.
strike the top and side of the cover When removing the assembly, be careful of
with a plastic hammer after removing fingers getting caught.
the bolt.
2) Insert a flathead screwdriver in the
gap between the cover and housing
and remove the cover.
21. Disassembly of 1st stage holder assembly

Secure the 1st stage holder assembly with a vise
and warm the screws (24) with a dryer to loosen
them.
18. Removal of thrust plate Remove the screws, thrust plate (23), thrust plates
Remove the thrust plate (26) from the thrust plate (22), planetary gears B (21), needle bearings (20),
(23) top surface. inner races (19) and thrust plates (18) from holder
B (17), in that order.
CAUTION
When loosening the screws, observe the
following precautions.
Loctite has been applied to the screws.
For this reason, they do not loosen easily.
If they are scratched due to being forcibly
loosened, they cannot be used again.
Before loosening, warm the screws suffi-
ciently with a dryer.
19. Removal of drive gear

Remove the driver gear (25).
84551720B NA - August 2012

6002-16
22. Removal of sun gear C CAUTION

Remove sun gear C (15).
When loosening bolts, observe the follow-
ing precautions.
1) Loctite has been applied to the bolts
to prevent loosening.
For this reason, securely fix the
flanges.
2) When loosening bolts, use a tool
such as a steel pipe to reach the
bolts.
Straining excessively may cause
back pain or injury.
23. Removal of planetary gear C

Secure the flange (1-1) and loosen the bolts (14) to
remove them.
Next, remove the thrust plates (13), planetary gears
C (12), needle bearings (11), inner races (10), and
thrust plates (9), in that order.
CAUTION
When loosening bolts, observe the follow-
ing precautions.
1) Loctite has been applied to the bolts
to prevent loosening.
For this reason, securely fix the
flanges.
2) When loosening bolts, use a tool
such as a steel pipe to reach the
bolts.
Straining excessively may cause
back pain or injury.
25. Separation of flange and housing

Mount the jig on the outer circumference brim end
surface of the housing (4), and then press the flange
(1-1) with the press to separate the housing and
flange.
24. Disassembly of holder C

Secure the flange (1-1) and loosen and remove the
bolts (8).
Holder C (6) is secured to the flange with the pins
(31).
Mount the removal jig from the motor side and use
the press to remove holder C.
84551720B NA - August 2012

6002-17
26. Removal of floating seal 27. Parts storage

Raise the outer circumference of the floating seals This completes the disassembly.
(2) with a flathead screwdriver and remove the float- When storing disassembled parts, place parts in
ing seals. plastic bags in a cool, dark and dry location after
cleaning the parts and applying anti-rust oil.
If parts are stored in a hot, moist location, rust will
develop even if anti-rust oil is applied.
Also store them in a way so that dust does not col-
lect on them.
84551720B NA - August 2012

6002-18
Motor Parts Maintenance Standards
Table 6 indicates maintenance standards for motor parts.
Check each part according to the motor parts maintenance standards in Table 6. When a permissible limit has been
exceeded or is near being exceeded, perform part repair or replacement according to repair and solution procedures.
Inspection and measure- Repair, solution proce-

Applicable part Permissible limit value
ment location dure
Lap the shoe sliding surface
0.8 a degree of roughness
(#1000)
Or the surface is rough or there
1. Shoe sliding surface If the scratching cannot be
is scratching at least 0.02 mm (
removed, replace the cylin-
0.00079 in. ) deep.
der block assembly (1-4).
1.2a degree of roughness
Piston Assembly
(1-4-2) 2. Piston outer diameter
0.00079 in. ) deep. Replace the cylinder block
3. Piston outer diameters assembly (1-4).
and cylinder block (4-1) Gap 0.060 mm ( 0.002362 in. )
bore inner diameters
4. Shoe ball backlash 0.4 mm ( 0.0157 in. ) of backlash
Lap the sliding surface
(#1000)
1. Sliding surface against Or the surface is rough or there
If the scratching cannot be
the valve plate is scratching at least 0.02 mm (
removed, replace the cylin-
0.00079 in. ) deep.
der block assembly (1-4).
Cylinder block 1.6 a degree of roughness
(1-4-1) Or the surface is rough or there
2. Bore inner diameter
Replace the cylinder block
0.00079 in. ) deep.
assembly (1-4).
3. Bore inner diameter and
piston assembly (4-2) outer Gap 0.060 mm ( 0.002362 in. )
diameter
Diameter between parts
38.749 mm ( 1.525551 in. )
Cylinder block 1. Shaft bonding section Diameter of measurement pin Replace the cylinder block
(1-4-1) spline D3.333 ( 0.131220 in. ) [ V1 = 2.80 assembly (1-4).
( 0.11024 in. ) ] mm
Or breaking damage is occurring.
There is scratching at least 0.02 Lap the sliding surface
mm ( 0.00079 in. ) deep on the (#1000)
Valve plate
1. Sliding surface sliding surface. If the scratching cannot be
(1-21)
Or seizing is occurring. removed, replace the valve
There is abnormal wear on the plate (1-21).
sliding surface.
Retainer plate
There is scratching at least 0.02
(1-4-3) Replace the retainer plate
1. Sliding surface mm ( 0.00079 in. ) deep on the
Retainer holder and retainer holder.
sliding surface.
(1-4-4)
Or seizing is occurring.
84551720B NA - August 2012

6002-19

ment location dure
Lap the sliding surface
(#1000)
There is abnormal wear or scratch-
1. Sliding surface If the scratching cannot be
ing least 0.02 mm ( 0.00079 in. )
removed, replace the valve
deep on the sliding surface.
plate (1-21).
Swash plate
(1-5)
2. Steel ball mounting sec- There is scratching at least 0.02
tion spherical hole mm ( 0.00079 in. ) deep on the ball
surface or the surface is rough. Replace the swash plate.
3. Steel ball mounting sec-
Ball depth 14.5 mm ( 0.5709 in. )
tion spherical hole
Aside from the oil seal lip sliding
1. Oil seal sliding section
imprint, there is scratching at least
outer diameter
0.02 mm ( 0.00079 in. ) deep or
the surface is rough.
Over-pin diameter
47.380 mm ( 1.865354 in. )
Shaft 2. Cylinder block bonding
Diameter of measurement pin Replace the shaft.
(1-3) section spline
D3.00 mm ( 0.11811 in. )
30.498 mm ( 1.200709 in. )
3. Drive gear bonding sec-
Diameter of measurement pin
tion spline
D3.33 mm ( 0.13110 in. )
1. Exterior dimensions Height 38.2 mm n( 1.5039 in. )
2. Sliding surface 2.5 a degree of roughness
Brake piston
(1-15) There is scratching at least 0.02 Replace the brake piston.
3. Exterior mm ( 0.00079 in. ) deep. Or the
surface is rough.
1. Exterior dimensions Thickness 3.2 mm ( 0.1260 in. )
Disk plate
(1-139) There is deep scratching or friction Replace the disk plate.
2. Exterior
material is peeling off.
Flaking or pressure imprinting is
Ball bearing 1. Rotation surface
occurring.
(1-8)
Ball bearing There are rotation abnormalities Replace the ball bearing.
(1-9) 2. Operation (abnormal noises, rotation un-
evenness).
Lap the shoe sliding surface
(#1000)
1. Shoe sliding surface If the scratching cannot be
removed, replace using the
0.00079 in. ) deep.
flange holder kit.
Piston Assembly
(1-7) 2. Piston outer diameter
0.00079 in. ) deep. Replace using the flange
3. Piston outer diameters holder kit.
and flange holder (1-1) in- Gap 0.040 mm ( 0.001575 in. )
ner diameters
4. Shoe ball backlash 1.0 mm ( 0.0394 in. ) of backlash
1. Plunger outer diameter
mm ( 0.00079 in. ) deep. Or the
Plunger assembly Replace using the base
surface is rough.
(1-2-2) plate kit.
2. Plunger outer diameter
and base plate inner diam- Gap 0.060 mm ( 0.002362 in. )
eter
84551720B NA - August 2012

6002-20

ment location dure
1. Plunger assembly (2-2) There is scratching at least 0.02
mounting hole mm (0.00079 in.) deep. Or the
surface is rough.
2. Base plate inner diame-
ter and plunger outer diam- Gap 0.060mm ( 0.002362 in. )
eter
Base plate 0.8 a degree of roughness Replace using the base
(1-2-1) 3. Spool assembly (2-11) There is scratching at least 0.02 plate kit.
mounting hole mm ( 0.00079 in. ) deep. Or the
surface is rough.
4. Base plate inner diame-
Gap 0.060 mm ( 0.002362 in. )
ter and spool outer diameter
5. Relief valve assembly There is scratching at least 0.02
free piston sliding and seat mm ( 0.00079 in. ) deep. Or the
sections surface is rough.
1. Spool outer diameter
Spool assembly mm ( 0.00079 in. ) deep. Or the Replace using the base
(1-2-9) surface is rough. plate kit.
2. Spool outer diameter and
Gap 0.060 mm ( 0.002362 in. )
base plate inner diameter
1. Sliding section against There is scratching at least 0.02
Free piston
the base plate and seat sec- mm ( 0.00079 in. ) deep. Or the
(1-2-7-9)
tion surface is rough.
1. Sliding section against There is scratching at least 0.02
Relief housing
the free piston (outer diam- mm ( 0.00079 in. ) deep. Or the
(1-2-7-1)
eter) surface is rough.
1. Exterior dimensions Free length 61.0 mm ( 2.4016 in. )
Spring
(1-4-7) There is deformation and scratch-
2. Exterior
ing on the coil surface.
Spring Replace using the relief
(1-18) There is deformation and scratch-
2. Exterior valve assembly.
Spring
(1-20) There is deformation and scratch-
2. Exterior
Spring
2. Exterior
Spring
2. Exterior
Each O-ring and oil Replace each O-ring and oil
During disassembly
seal seal.
84551720B NA - August 2012

6002-21
Reduction Gear Parts Maintenance Standards

Table 7 indicates maintenance standards for reduction gear parts.
Check each part according to the reduction gear parts maintenance standards in Table 7. When a permissible limit
has been exceeded or is near being exceeded, perform part repair or replacement according to repair and solution
procedures.
Inspection and mea- Repair, solution proce-

surement location dure
Across 6 teeth
Tooth thickness
66.649 mm ( 2.623976 in. )
There is pitching on 10 % or Replace planetary gear B.
Planetary gear B (21) Tooth surface more of the tooth surface or
breaking damage is occurring.
Flaking is occurring on the in-
Inner diameter
ner diameter surface.
Replace the planetary gear,
Flaking is occurring on the sur-
Needle bearing (20) Roller rotation surfaces needle bearing and inner
face.
race.
Inner race (19) Outer diameter surface
face.
Across 3 teeth
Tooth thickness
29.908 mm ( 1.177480 in. )
There is pitching on 10 % or Replace the drive gear.
Tooth surface more of the tooth surface or
Drive gear (25) Over-pin diameter
38.989 mm ( 1.535000 in. )
If replacing the drive gear,
Spline section inspect the shaft at the
D3.00 mm ( 0.11811 in. )
same time.
Or breaking damage is occur-
ring.
66.742 mm ( 2.627637 in. )
Tooth thickness of inter- Diameter of measurement pin
Holder B (17) Replace holder B.
nal tooth D7.00 mm ( 0.27559 in. )
Or breaking damage is occur-
ring.
Across 4 teeth
Tooth thickness
41.371 mm ( 1.628779 in. )
Sun gear C (I5) There is pitching on 10 % or Replace sun gear C.
Across 6 teeth
Tooth thickness
65.662 mm ( 2.585118 in. )
There is pitching on 10 % or Replace planetary gear C.
Planetary gear C (12) Tooth surface more of the tooth surface or
Flaking is occurring on the in-
Inner diameter
ner diameter surface.
Replace the planetary gear,
Needle bearing (11) Roller rotation surfaces needle bearing and inner
face.
race.
Inner race (10) Outer diameter surface
face.
330.449 mm ( 13.009803 in. )
Tooth thickness
Housing (4) D7.000 mm ( 0.275590 in. ) Replace the housing.
There is pitching on 10 % or
Shim (5) During disassembly Replace the shim.
84551720B NA - August 2012

6002-22
Inspection and mea- Repair, solution proce-

surement location dure
2-speed piston hole in-
ner diameter and piston Gap 0.040 mm ( 0.001574 in. )
assembly outer diameter
Flange (1-1) 1.2 a degree of roughness Replace using the flange kit.
2-speed piston hole in- Or the surface is rough or there
ner diameter is scratching at least 0.02 mm (
0.00078 in. ) deep.
Plate thickness
3.3 mm ( 0.1299 in. )
Plate thickness
2.5 mm ( 0.0984 in. )
Plate thickness
2.9 mm ( 0.1141 in. )
Thrust plate (26) Thickness Replace the thrust plate.
Plate thickness
2.0 mm ( 0.0787 in. )
Plate thickness
2.7 mm ( 0.1062 in. )
Or there is deep scratching on
the sliding surface.
Ball rotation surfaces Flaking is occurring.
Replace the angular bear-
Angular bearing (3) Abnormal noise or unsmooth
Operation ing.
rotation occurs with rotation.
There is deep scratching that Replace the floating seal.
Sliding surface
may cause oil leaking. When doing more disas-
sembly beyond this, be-
cause oil leaking may oc-
cur due to the seal ring
Floating seal (2)
Cracking is occurring on the slide imprints not matching
O-ring up of reused seals when
surface.
reassembly is done, re-
place these seals before
reassembly.
Each O-ring During disassembly Replace each O-ring.
84551720B NA - August 2012

6002-23
Motor Assembly Procedures Assembly Procedure

Perform assembly by observing the precautions listed in
Precautions before Motor Assembly Section 1 and following the procedure indicated below.
Begin motor assembly only after thoroughly reading the 1. Assembly of reduction gear section
precautions below.
1) Attachment of floating seal to flange
1. When performing assembly, always wear protective After confirming the items below concerning
gear such as a helmet, goggles and safety shoes. the floating seals (2), use the floating seal in-
2. Use the specified tools when performing assembly. stallation jig to attach the floating seals to the
3. To prevent injuries during disassembly, prepare a flange (1-1).
waist-high, stable work platform to perform work on.
4. The motor comprises high-precision parts. Confirmation items:
For this reason, foreign matter adhering to parts can 1) Check that there is no dirt adhered to
be damaging. the floating seal mounting surfaces on
Motor assembly should be done in an inside space the flange.
without dust, and mud and dirt should be prevented 2) Thoroughly degrease the floating seal
from adhering to parts. mounting surfaces on the flange.
5. The motor comprises high-precision parts. 3) Check that there is no dirt adhered
For this reason, dents and scratching on part sur- to the O-ring surfaces on the floating
faces can be damaging. seals.
Be very careful when handling parts during assem- 4) Thoroughly degrease the O-ring sur-
bly and do not create any dents or scratching. faces on the floating seals.
6. Be sure to repair any damage discovered during
disassembly and prepare replacement parts before
beginning assembly.
7. Remove metal fragments and foreign matters from
all parts and check that there are no burrs or dents
on parts before beginning assembly.
If there are burrs or dents, use a whetstone to re-
move them.
8. When performing assembly, apply clean hydraulic
oil to each sliding and rotating sections before as-
sembly.
9. Thoroughly degrease areas where Loctite and liquid
packing is used and remove oil and water before
assembly.
10. Replace all seal parts such as O-rings and backup
rings with new parts. 2) Attachment of angular bearing to housing
11. Be careful not to damage O-rings and backup rings Use the press-fit jig or press to press fit the
during assembly. angular bearings (3) to the housing (4).
When assembling O-rings and backup rings, apply
a small amount of grease for assembly.
12. It is recommended that petroleum jelly or grease be
used to prevent parts from falling during assembly.
13. Tighten the bolts and other fastening sections to the
specified tightening torque indicated in "Tightening
Torque".
Tightening torque should be controlled with a torque
wrench.
14. After assembly is complete, plug all ports leading
into the motor to prevent dirt from entering.
3) Attachment of floating seal to housing

After confirming the items below concerning
the floating seals (2), use the floating seal in-
stallation jig to attach the floating seals to the
housing (4).
Confirmation items:
1) Check that there is no dirt adhered to
the floating seal mounting surface on
the housing.
84551720B NA - August 2012

6002-24
2) Thoroughly degrease the floating seal 1) Use the shim thickness adjustment jig to
mounting surface on the housing press the inner ring end sections of the
3) Check that there is no dirt adhered angular bearings (3) with a load of 2.94
to the O-ring surfaces on the floating kN ( 661.0514 lbf ).
seals. 2) Measure the H level dimensions at this
4) Thoroughly degrease the O-ring sur- time for the angular bearings inner ring
faces on the floating seals. end surfaces and flange (1-1) end sur-
face.
3) Measure the h level dimensions of
holder C (6).
4) Select a shim and install it so that the
shim thickness is appropriate to the di-
mensions (H-h).
CAUTION
1) Do not reuse shims.
2) Be sure to perform this
procedure properly.
If precompression adjust-
ment is not done properly,
reduction gear damage
4) Attachment of the housing to the flange could occur during opera-
After confirming the items below, use a tion.
liftcrane to attach the housing to the flange so 3) Clean the measurement
that the floating seal (2) section of the flange surfaces.
(1-1) is aligned with the floating seal section
of the housing (4).
Confirmation items:
1) Check that there is no dirt adhered to
the seal ring sliding surfaces of the
floating seals.
2) Apply reduction gear lubricating oil or
hydraulic oil all around the seal ring
sliding surfaces of the floating seals.
3) When attaching the flange and hous-
ing, attach them after checking that
the axis center is aligned.
Press load of 2.94 kN (

*1
661.0514 lbf )
*2 H dimensions
*3 h dimensions
6) Holder attachment
Secure the flange (1-1) and stand the pins
(31) straight up on the flange in 4 locations.
Use grease to attach the shim selected in 5)
to holder C (6), and press fit the shim while it
5) Shim thickness selection is aligned with the pin holes on the holder.
Select the precompression adjustment shim Mount the washers (7) on the holder, apply
(5) thickness according to the following pro- Loctite to the threaded sections, and tighten
cedure. the bolts (8) to the specified torque.
84551720B NA - August 2012

6002-25
CAUTION Be careful to attach the wash-

ers (7) in the correct direction.
*
1) Check that the pins (31) have Attach them in the direction
not fallen. shown in the diagram above.
2) The loosening stop spikes *1 Holder side
should be attached to the wash- *2 Bolt seating surface side
ers.
Put the spikes on the holder 7) Planetary gear attachment
seating surface side to mount Attach the thrust plates (9) to planetary gear
them. C (12).
3) Thoroughly clean the bolt Next, attach the needle bearings (11) to the
threaded sections and apply planetary gears.
Loctite after degreasing. Finally, after attaching the inner races (10),
4) Also thoroughly clean the inter- join the flange trunnion sections (4 locations)
nal areas of the screw holes of with the internal diameter sections of the inner
the flange, and thoroughly de- races to attach the planetary gears.
grease them.
CAUTION
1) When attaching the thrust
plates to the planetary gears,
make sure the shear droop on
the thrust plates created by the
press is facing the 1-1 flange
side.
2) When finally attaching the plan-
etary gears to the flange, attach
them so that the internal teeth of
the housing (4) engage with the
planetary gear teeth.
3) Be careful with the attach-
ment directions of the planetary
gears.
84551720B NA - August 2012

6002-26
Make the shear droop side face Mount so that the C2 chamfer
*1
the holder C (6) side. side is the seating surface side
*1
Thrust plate (9) attachment di- for the hexagon socket head
*2 bolts.
rection
9) Sun gear C attachment

8) Thrust plate attachment
After checking that the snap ring (16) is
Mount the thrust plates (13) on the planetary
mounted on sun gear C (15), mount sun gear
gears (12) in such a way that the chamfers
C in the middle of the 4 planetary gears C
of the bolt hole sections are the neck bottom
(12).
section of the bolts (14).
After mounting, mount the bolts that have had CAUTION
Loctite applied to the threaded sections and
tighten them to the specified torque. Mount the sun gear C so that the teeth
engage with the teeth of the planetary
CAUTION gears.
1) Be careful with the mounting di-
rection of the thrust plates.
Mistakes could cause scratch-
ing on the bolt neck sections
and this could result in damage.
2) Thoroughly clean the bolt
threaded sections and apply
Loctite after degreasing.
3) Also thoroughly clean the inter-
nal areas of the screw holes of
the flange (1-1), and thoroughly
degrease them.
10) Holder attachment

Engage the internal teeth of holder B (17) with
the teeth of sun gear C (15) and attach the
holder to sun gear C.
11) Planetary gear attachment

Attach the thrust plates (18) to planetary gear
B (21).
Next, attach the needle bearings (20) to the
planetary gears.
Finally, after attaching the inner races (19),
join the holder B (17) trunnion sections (3 lo-
cations) with the internal diameter sections of
the inner races to attach the planetary gears
to the holder.
84551720B NA - August 2012

6002-27
CAUTION CAUTION
1) When attaching the thrust 1) Be careful with the attachment
plates to the planetary gears, direction of the thrust plates.
make sure the shear droop on 2) Thoroughly clean and degrease
the thrust plates created by the the screw holes and threaded
press is facing the holder side. sections of holder B (17).
2) When finally attaching the plan-
etary gears to the holder, attach
so that the internal teeth of the
housing (4) engage with the
planetary gear teeth.
3) Be careful with the attach-
ment directions of the planetary
gears.
Make the shear droop side face

*1
the planetary gear C (12) side.
Thrust plate (13) attachment di-
*2
rection
13) Thrust plate attachment

Measure the level difference between the
housing (4) end surface and the thrust plate
Make the shear droop side face (23) end surface with the thrust plate selec-
*1 tion jig, and select and attach a thrust plate
the holder B (17) side.
Thrust plate (18) attachment di- (26) according to the table below.
*2
rection
Level difference dimensions Appropriate
[ mm ( in. ) ] thrust plate
12) Drive gear attachment 1.20 - 0.67
Attach the thrust plates (22) to planetary gear 20941-62306
( 0.04724 - 0.02638 )
B (21), and attach the thrust plate (23). 0.66 - 0.04
Insert the screws (24) with Loctite applied in 20941-62307
( 0.02598 - 0.00157 )
the threaded sections and tighten them to the
specified torque. 0.03 - (-0.16)
20941-62308
Make the spline-side of the drive gear (25) ( 0.00118 - (-0.00629) )
face the motor section attachment side and (-0.17) - (-0.41)
20941-62309
attach the drive gear in the middle of the 3 ( (-0.00668) - (-0.01613) )
planetary gears. Also engage the teeth of the (-0.42) - (-0.80)
B0841-23017
planetary gears with the drive gear teeth. ( (-0.01653) - (-0.03149) )
84551720B NA - August 2012

6002-28
CAUTION 15) Plug attachment

Remove the O-rings (30) attached to the plugs
Align the center hole of the thrust (29), and replace them with new O-rings.
plate with the protruding section of Next, attach plugs to the oil fill, oil drain and
the drive gear (25) and attach. oil check ports (3 total) on the cover (27) and
tighten them to the specified torque.
This completes assembly of the reduction

gear parts.
Next is assembly of motor parts.
Perform assembly while referring to "[2] As-
sembly of motor section".
2. Assembly of motor section
1) Oil seal attachment
Check whether the oil seal is mounted on the
flange (1-1), and use an oil seal press-fit jig to
press fit the oil seal (1-12) to the flange if it is
not mounted already.
CAUTION
1) Press fit the oil seal after ap-
*1 Measure the level difference plying grease to the internal di-
ameter surface of flange oil seal
14) Cover attachment press-fit section and the oil seal
Thoroughly clean off any foreign matter from outside diameter section.
the housing (4) end surface and cover (27) 2) Press fit the oil seal after apply-
matching surface. ing grease to the lip section of
Next, thoroughly degrease the housing end the oil seal inner diameter.
surface and cover matching surface. 3) When press fitting the oil seal,
Additionally, apply liquid packing to the cen- push it vertically with the press.
tering location corners on the housing attach- Slanting will cause damage to
ment surface-side of the cover, and align the the oil seal outer diameter sur-
housing screw holes and bolt openings on the face.
cover to mount the cover on the housing. 4) When press fitting the oil seal,
Finally, mount the hexagon socket head bolts be careful not to scratch the lip
(28) and tighten them to the specified torque. section of the oil seal internal
diameter.
Scratching may cause oil leak-
ing and reduction gear internal
damage could occur during mo-
tor operation.
84551720B NA - August 2012

6002-29
3) Steel ball attachment

Attach steel balls (1-6) to the spherical hole
sections of the flange (1-1).
CAUTION
Before attaching the steel balls, ap-
ply hydraulic oil to the inner diameter
surface of the spherical holes of the
flange.
2) Piston assembly attachment

Attach the springs (1-20) to the flange (1-1)
holes for attaching the piston assemblies
(1-7).
Next, attach the piston assemblies to the
flange.
CAUTION
1) Attach springs in the center of
the hole when attaching.
2) When attaching the piston as- 4) Shaft attachment
semblies, have the cylinder sec- Use the bearing press-fit jig to press fit the ball
tions facing down. bearing (1-8) to the shaft (1-3).
3) Before attaching the piston as- Next, attach the shaft to the center of the
semblies, apply hydraulic oil to flange (1-1).
the internal diameter surface of
the flange mounting holes and CAUTION
the outer diameter of the piston
assembly cylinder sections. 1) When attaching the ball bearing,
4) After attaching the piston as- attach it vertically.
semblies, check that the piston 2) After attaching the shaft, check
assemblies move smoothly. that it rotates smoothly.
84551720B NA - August 2012

6002-30
5) Swash plate attachment

Point the slanted surface of the swash plate
(1-5) upwards and attach the swash plate to
the flange (1-1).
CAUTION
1) Attach by matching the rear
surface spherical holes of the
swash plate with the steel balls
(1-6).
2) Attach the swash plate after ap-
plying hydraulic oil to the sur-
face of the steel balls.
3) After attaching the swash plate,
check that it moves smoothly.
Cylinder block attachment di-
*1
rection
2) Use the jig to press the top surface of

the collar (1-4-8) to attach the snap ring
(1-4-5).
CAUTION
1) The snap ring is stiff and
may come off from the
snap ring pliers when
the snap ring is being at-
tached, which could cause
6) Assembly of cylinder block assembly injury.
1) Point the surface of the cylinder block Make sure to use a jig
(1-4-1) that slides against the valve plate when attaching the snap
(1-21) upwards and place the cylinder ring, and check that the
block on the work platform of the hand nails of the snap ring pli-
press. ers are in the snap ring
Point the slanted surface of the spring hole before attachment.
seat (1-4-6) down and attach it to the 2) When retracting the snap
cylinder block. Place both the spring ring is difficult, use the
(1-4-7) and collar (1-4-8) on top of spring snap ring pliers that are
seat with the collar on top. one size bigger.
3) When pressing in the col-
lar (1-4-8), make the cen-
ters of the cylinder block
and press align with each
other.
3) Point the surface of the cylinder block

(1-4-1) that slides against the valve plate
(1-21) down and place the cylinder block
on the work platform.
84551720B NA - August 2012
6002-31
Insert the 3 pins (1-4-9) into the diagonal 5) Place the side of the retainer plate
holes of the cylinder block (1-4-1). (1-4-3) with a taper on the outer circum-
ference down, and attach the 9 piston
CAUTION assemblies (1-4-2) to the retainer plate.
1) When placing the cylinder
block on the work plat-
form, check that there is
no foreign matter on the
work platform.
2) Be careful not to scratch
the surface of the cylinder
block that slides against
the valve plate.
Scratching may cause a
reduction in motor perfor-
mance and early damage
to the motor.
3) Apply grease to the pin
holes before attaching the 6) Attach the piston assemblies (1-4-2) to
pins. the cylinder block (1-4-1).
CAUTION
1) Apply hydraulic oil to the
9 cylinder block piston at-
tachment holes before at-
taching the piston assem-
blies.
spherical surface of the re-
tainer holder (1-4-4) before
attaching it.
4) Attach the retainer holder (1-4-4) to the

cylinder block (1-4-1).
7) Cylinder block assembly attachment

Place the valve plate (1-21) sliding surface
side of the cylinder block assembly (1-4) up-
wards, engage the internal teeth splines of
the retainer holder (1-4-4) and cylinder block
(1-4-1) with the external teeth splines of the
shaft (1-3), and attach the cylinder block as-
sembly to the inside of the flange (1-1).
84551720B NA - August 2012

6002-32
CAUTION 9) Brake piston attachment

Attach the D-rings (1-16) (1-17) to the brake
1) When performing attachment, piston (1-15).
check that the piston assem- Next, place the large bore side of the brake
blies (1-4-2), retainer plate piston upwards and attach it to the flange
(1-4-3) and retainer holder do (1-1).
not come off from the cylinder
block assembly. CAUTION
2) Before performing attachment, 1) Thoroughly apply grease when
apply hydraulic oil to the swash
attaching the D-rings.
plate (1-5) surface and sliding 2) Attach the brake piston after
surfaces of the piston assem- using a positioning jig to align
blies. the flange base plate (1-2-1)
knock pin hole and brake piston
knock pin hole so that they are
arranged in a straight line.
3) When attaching the brake pis-
ton, apply grease to the outer
circumference of the brake pis-
ton and inner diameter section
of the flange.
4) Push and attach the brake pis-
ton evenly all around so that it
does not become slanted.
If the brake piston is attached at
a slant, this could cause opera-
tional problems or the D-rings to
8) Disk plate attachment break.
Engage the internal teeth of the disk plates
(1-13) with the external teeth of the cylinder
block (1-4-1) and attach the disk plates to the
flange (1-1).
Also, align the arc sections on the external
circumference of the friction plates (1-14) with
the notch sections of the flange and attach the
friction plates to the flange.
Attach in this manner, attaching the disk
plates before the friction plates.
CAUTION
The disk plates are wet type disk.
Before attachment, immerse the fric-
tion material parts in hydraulic oil and
have the friction materials thoroughly
absorb the hydraulic oil.
84551720B NA - August 2012

6002-33
10) Spring attachment CAUTION

Insert the springs (1-18) into the 8 spring
mounting holes on the brake piston (1-15). Caution:
1) Apply grease to the O-ring
(1-23).
2) Do not apply grease to the
O-rings (1-22).
3) Attach the pins with their ta-
pered sections up.
4) Attach the base plate after ap-
plying hydraulic oil to the valve
plate surface and cylinder block
(1-4-1) surface.
5) Be careful that the valve plate
does not fall because the valve
plate mounting surface of the
base plate is pointing down
11) Valve plate attachment
when the base plate is attached.
Place the base plate (1-2-1) on top of the work
6) Check the mounting position of
platform and press fit the ball bearing (1-9) in
the O-rings on the flange and
the center of the base plate using the bearing
the position of the holes for the
press-fit jig.
oil path on the base plate to at-
Attach the valve plate (1-21) to the base
tach the base plate.
plate after checking that the pins (1-19) are
7) Check the position of the knock
mounted to the base plate.
pins mounted to the base plate,
CAUTION the spring (1-18) mounting
holes on the base plate and the
1) Place the copper alloy side of flange-side pin holes, and the
the valve plate up to attach it. spring positions, and then at-
2) Thoroughly apply grease to the tach the base plate.
matching surface between the 8) When tightening the socket
base plate and valve plate to head bolts, screw in all of the
prevent the valve plate from bolts around the circumference
falling. evenly.
3) Be careful not to scratch the
copper alloy surface of the valve
plate.
13) Spool assembly attachment

Attach the spring (1-2-10) to the spool as-
sembly (1-2-9) and attach the assembly to the
12) Base plate attachment base plate (1-2-1).
Attach O-ring (1-23) and the 4 O-rings (1-22) After attaching the spool assembly, check that
to the top surface of the flange (1-1). the O-rings (1-2-12) are mounted to the plug
Attach the pins (1-19) to the base plate (1-2- (1-2-11), attach the plug to the base plate, and
1). tighten it to the specified torque.
Place the valve plate (1-21) mounting surface Next, check that the O-rings (1-2-12) are
of the base plate downwards and tighten it to mounted to the plug (1-2-14), attach the
the flange with the hexagon socket head bolts spring guide (1-2-13), and then attach the
(1-11). plug to the base plate and tighten it to the
specified torque.
84551720B NA - August 2012

6002-34
CAUTION
1) Attach the spool assembly to
the base plate so that the base
plate line port side is on the
front and the spool assembly
spring mounting side is on the
right.
Attaching in the opposite direc-
tion may cause problems such
as switching errors.
2) Attach the spool assembly af-
ter applying hydraulic oil to the
outer circumference.
3) After attaching the spool as- 15) Plunger assembly attachment
sembly, check that it moves Attach the base plate (1-2-1) to the plunger
smoothly. assembly (1-2-2).
CAUTION
plunger assembly outer circum-
ference before attachment.
2) Attach the plunger assembly
slowly and in a straight line
while rotating it.
3) If the plunger assembly be-
comes stuck, do not force it too
much and lightly strike it with a
hammer.
14) Relief valve assembly attachment

Attach the relief valve assemblies (1-2-7) to
the base plate (1-2-1) and tighten to the spec-
ified torque after checking that poppet seat
(1-2-7-3) is mounted on the end of each re-
lief valve assemblies.
CAUTION
1) Replace the O-ring (1-2-7-7) with
new one before attaching the re-
lief valve assemblies.
2) Check that the O-ring (1-2-7-17)
and backup rings (1-2-7-18) are 16) Cap assembly attachment
mounted on the each poppet Attach the spring seats (1-2-3) and springs
seat (1-2-7-3). (1-2-4) to the plunger assembly (1-2-2) in that
3) Apply grease to the O-rings and order.
backup rings before attaching Check that the O-ring (1-2-6-2) is mounted
the relief valve assemblies. to the cap assembly (1-2-6), and then mount
the spring seat (1-2-5) on the cap assembly
and attach the cap assembly to the base plate
(1-2-1).
Finally, tighten the hexagon socket head bolts
(1-2-6-4) to the specified torque.
84551720B NA - August 2012

6002-35
CAUTION
1) Apply grease to the O-ring.
2) The cap assemblies are pushed
by the springs.
Push the cap assemblies down
by hand when tightening the
socket head bolts.
3) When tightening the hexagon
socket head bolts, evenly
tighten the 4 bolts.
If the cap assemblies are tight-
ened at a slant, this could cause
damage O-rings and cause oil
leaking. This completes assembly of the motor.
84551720B NA - August 2012

6002-36
Motor Installation
Before placing the motor in the hydraulic shovel, perform inspection for the following items. If there is a problem,
perform the given procedure.
Solution for solving problem

Inspection item before installation When installing a motor stored af-
When installing a new motor
ter maintenance inspection
Contact our company's service plant
concerning damage that occurred
Are there any damaged areas? during shipping. Replace damaged parts.
Replace parts that have been dam-
aged during storage.
concerning parts lost during shipping.
Are there any missing parts? Purchase lost parts.
Purchase parts that have been lost
during storage.
If there is looseness in bolts just af-
ter delivery of the motor, contact our
company's service plant for instruc-
tions on tightening bolts to the spec- When there is looseness with bolts,
Is there any looseness in the tighten-
ified torque. disassemble again and inspect the
ing sections of the bolts?
If there is bolt loosening on a stored motor for rust on the inside.
motor, contact our company's service
plant as there is a chance that rust has
formed internally.
When ports for lines are dirty, per- When ports for lines are dirty, per-
form air blowing with compressed air, form air blowing with compressed air,
Dirt around ports
or cleaning with water vapor or high- or cleaning with water vapor or high-
pressure jet to remove dirt. pressure jet to remove dirt.
When checking just after delivery
When the plugs for each of the ports
When the plugs for each of the ports
are loose, use after removing dirt ad-
are loose or there are no plugs on the
hered to the ports.
ports, perform disassembly for confir-
When there are no plugs on the ports,
mation that dirt has not entered the
Are all of the port areas completely contact our company's service plant motor or there is no rust.
air-tight? as dirt has probably entered the mo-
tor.
When checking after storage
as rust has probably formed inside the
motor.
Is there any rust on the port sections If there is light rusting, use the motor
or the installation sections on the ma- after removing the rust.
after confirming the presence of rust.
chine? If rusting is severe, replace parts.
If oil leaking is discovered, there is
probably a problem with air-tightness
Oil leaking from ports and connection Contact our company's service plant if
and rust may have formed inside the
surfaces oil leaking is discovered.
motor, so perform disassembly again
to check for rust.
84551720B NA - August 2012

6002-37
1. Fill the inside of the piston motor case with hydraulic oil
Before performing a driving check, fill the inside of the piston motor case with about 500 cc of hydraulic oil from
the piston motor drain port to prevent problems at the start of driving in sliding sections of the piton motor.
When using a hand pump or a small-quantity electric pump for oil filling, make the internal case pressure of the
piston motor 0.3 MPa (43.516 psi) or less.
2. Reduction gear lubricating oil check
Use the oil fill, oil drain and oil check ports for reduction gear lubricating oil shown in Diagram 8 to check that the
reduction gear case contains the stipulated level of lubricating oil.
How to check the quantity of reduction gear lubricating oil in a new motor
Remove the lubricating oil check port plug and check that lubricating oil flows out.
If lubricating oil seems to be flowing out, return the oil check port plug to its original position and tighten it to the
specified torque.
If lubricating oil does not flow out even though the oil check port is open, open the oil fill port and fill with oil until
reduction gear lubricating oil flows out from the oil check port.
After filling with oil, return the plugs for the oil fill port and oil check port and tighten them to the specified torque.
CAUTION
When motors are shipped from the plant they are filled with Nippon Oil Hypoid Gear Oil 90 lubricating
oil to the stipulated volume [5.0 L (1.32gal.)].
Diagram 8. Oil fill, oil drain and oil check ports for reduction gear lubricating oil and stipulated oil volume
Reduction gear lubricating oil

*1
fill port
Reduction gear lubricating oil
*2
check port
*3 Lubricating oil level
84551720B NA - August 2012

6002-38
Initial Pre-conditioning Operation

Slowly operate the machine and perform air-bleeding for inside the motor circuit and inside the line according the
Operator's Manual for the Machine Main Unit.
First, perform an operation check by repeating "C direction rotation and stopping and A direction rotation and stopping"
a number of times at low-speed rotation.
At this time, remaining air inside the circuit may cause abnormal noises from the valves, etc. The abnormal noises
will stop as air is bled out while operation is done repeatedly at low speed.
If abnormal noises go away through repeated operation over a while, there is no problem with the motor and it can
be used as is.
If operation is done repeatedly and abnormal noises do not stop, there is an abnormality within the motor and it should
be replaced.
Check for the presence of oil leaking from the motor, line port sections, each line and each piece of equipment.
When oil leaking has been confirmed, retighten the bolts and line joints at the location where the leak is occurring to
the specified torque.
After checking is completed, raise the pressure and perform load operation, and check that no abnormal noises or
vibrations, etc. are occurring in the motor.
IMPORTANT:
• When tightening lines, etc. after confirming oil leaking, make sure to have operation of hydraulic devices stopped.
• Make sure that the operating pressure on the motor is low when checking for oil leaking.
If the operating pressure is high and there is oil leaking, there is the danger of oil spraying out.
84551720B NA - August 2012

6002-39
Troubleshooting
See the troubleshooting section below to perform checking, countermeasures and to solve problems when any kind
of problem occurs in the motor during operation.
1. Piston motor troubleshooting
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pressure is reaching
There is an operation problem in a piece of
the motor inlet side, investigate the causes of
equipment other than the piston motor or reduc-
problems and countermeasures for each piece
tion gear.
of equipment and perform inspection and repair.
Perform disassembly and clean and remove dirt
If the cause is in the motor itself, there is dirt
from parts before reassembling the motor.
clogging an operation section or there is an op-
If parts are damaged due to dirt, replace the
eration problem.
parts.
Operate the main relief valve of the circuit and
Motor inlet side pressure is low.
raise the set pressure.
The motor does
not rotate Perform disassembly and replace abnormally
There is abnormal wear on the sliding sections worn parts.
of the piston motor and pressure oil is escaping. After completely removing surface scratching,
burrs, etc. and cleaning, perform reassembly.
Damage is occurring with the main parts of the
Perform disassembly and replace damaged
piston motor.
parts.
In this instance, abnormal noise is coming from
Perform reassembly after cleaning parts.
the piston motor.
Investigate the load conditions and adjust the
The load on the piston motor is too large and
load to an amount appropriate to the set pres-
the relief valve is operating.
sure of the relief valve.
After investigating whether the required flow is
The cause resides in the hydraulic pump, pres-
being supplied to the piston motor inlet side, in-
sure control valve, flow control valve, etc. Re-
vestigate the causes of problems and counter-
quired oil flow is not being supplied to the piston
measures for each piece of equipment and per-
motor and rotation is insufficient.
form inspection and repair.
Motor rotation
Pressure oil is moving from the high-pressure Perform disassembly, investigate the status of
speed is insuffi-
side to the low-pressure side due to wear on wear on the sliding sections of the piston motor,
cient
the sliding sections of the piston motor (volume and perform repair or replacement according to
efficiency reduction) and speed is insufficient. the maintenance standards.
There is looseness in the piston motor base
Retighten the base plate fastening bolts to the
plate fastening bolts. Internal leaking is in-
specified torque.
creased and speed is insufficient.
There is wear on the sliding sections of the pis-
Perform disassembly, check the status of wear
ton motor and high-pressure oil is leaking and
on the sliding sections, and perform repair or re-
flowing out from the drain port, which is causing
placement according to the maintenance stan-
speed to greatly decrease and causing rotation
Motor rotation dards.
variation.
variation is high
When going down an incline, the double counter
on the double counter balance valve, and per-
balance valve is causing hunting and rotation
form repair or replacement according to the
variation.
maintenance standards.
The shaft is touching driven parts due to prob-
lems with shaft core alignment, and this is pro- Make the shaft core alignment accurate.
ducing noise.
Noise is high
There is wear or damage on the piston motor Perform disassembly and replace damaged
bearings or damage has occurred on springs, parts such as bearings or springs.
etc. and noise is being produced. Perform reassembly after cleaning parts.
84551720B NA - August 2012

6002-40
Trouble phe-
nomenon
There is looseness in bolts on matching sur- Retighten the fastening bolts to the specified
faces, etc. and oil leaking is occurring. torque.
Perform disassembly and replace seals.
Check the hydraulic oil temperature.
Oil leaking is occurring due to damage to oil When the temperature of the hydraulic oil is
seals, O-rings, packings, etc. 80 °C ( 176.0 °F ) or higher during operation,
recheck the cooler and reduce the temperature
of the hydraulic oil to below 80 °C ( 176.0 °F ).
Oil leak The amount of drain oil is high due to wear on on the sliding sections, and perform repair or re-
the sliding sections of the piston motor and oil placement according to the maintenance stan-
leaking is occurring due to damage to the oil dards.
seals. Replace oil seals.
Perform disassembly and replace oil seals.
Drain pressure has increased due to clogging
Perform drain line cleaning and remove foreign
in the drain line or because the drain line is long
matter.
and thin, and this has damaged the oil seals and
Recheck lines and minimize resistance in line
oil leaking is occurring.
paths.
The amount of hydraulic oil in the hydraulic tank Check the amount of hydraulic oil in the hy-
has decreased and aeration is occurring due to draulic tank and fill with hydraulic oil according
tank taking in air. to the instructions on the machine main unit.
Hydraulic oil within the motor lines and motor Check the motor installation direction and cor-
Cavitation is circuit is flowing out while hydraulic devices are rect it.
causing abnor- turned off because the motor installation direc- Check that the oil surface within the hydraulic
mal noise, rotation is inappropriate or the hydraulic tank posi- tank is above the motor, and either modify it so
tion variation and tion is inappropriate, and this is causing aeration that it is above the motor or set up a self-supply
pressure varia- to occur within the motor just after the motor is circuit so that the insides of the motor circuit and
tion. started. lines are fully supplied with oil before driving.
When the motor is pumping, pressure on the
Perform disassembly and perform repair or re-
motor inlet side becomes negative due to dou-
placement of the double counter balance valve
ble counter balance valve operation problem,
according to the maintenance standards.
and cavitation occurs.
The load is too large and this caused the engine Check the load conditions and change the load
to stall. to an appropriate amount.
Motor rotation Investigate specifications values (especially
stopped during flow amount and motor speed).
operation Seizing occurred in the sliding sections of the If the motor speed has exceeded the upper limit,
piston motor and the motor stopped rotating. lower the flow amount.
It is not possible to reuse the inside of the motor,
so the motor should be replaced.
84551720B NA - August 2012

6002-41
2. Parking brake troubleshooting
Trouble phe-
nomenon
Perform disassembly and replace the parking
Parking brake torque has decreased due to disk
brake disk.
wear.
The motor rotates The disk surface has been altered due to con- Perform disassembly and replace the disk.
if it is stopped with tact errors, etc., and the parking brake torque Also, repair the surface of the disk companion
external load act- has decreased. parts and perform reassembly.
ing on the motor. The springs are worn or damaged and the park- Perform disassembly and replace the spring.
ing brake torque is reduced. Perform reassembly after cleaning parts.
The external load is too large and the parking Check the external load and change the load to
brake capabilities are insufficient. an appropriate amount.
O-rings are damaged and pressure oil is escap- Perform disassembly and replace the O-rings.
ing, so the parking brake cannot be released. Perform reassembly after cleaning parts.
Foreign matter is clogging the orifice inside the
Motor drive force Perform disassembly and remove foreign mat-
parking brake release oil path and pressure oil
is not being pro- ter from the orifice.
is not reaching the parking brake cylinder cham-
duced. Perform reassembly after cleaning parts.
ber, which prevents the parking brake from be-
Motor is heating Also, flush the inside of the line.
ing released.
up to an abnormal
degree. Drain pressure has increased due to clogging
Clean the drain line.
in the drain line or because the drain line is long
Also, recheck the line system and minimize re-
and thin, and the parking brake cannot be re-
sistance in the line path.
leased.
84551720B NA - August 2012

6002-42
3. Relief valve troubleshooting
Trouble phe-
nomenon
There is foreign matter caught between the pop-
Perform disassembly and remove foreign mat-
pet seat and poppet on the relief valve, which
ter.
is causing seating problems, and high-pressure
oil is leaking to the low-pressure side.
Replace the relief valve.
The relief valve spring is damaged and high-
Disassemble the motor and reassemble it after
pressure oil is leaking to the low-pressure side.
cleaning each part.
The motor does
The relief valve spring is worn and the set pres-
not rotate or motor
sure is decreased, which causes the relief to op- Replace the relief valve.
rotation is slow.
erate at low pressure.
There is foreign matter caught in the seat sec-
Remove the relief valve and remove foreign
tion of the free piston and base plate of the relief
matter.
valve and the set pressure has decreased.
There is foreign matter clogging the orifice set
in the poppet of the relief valve, and the set
matter.
pressure has decreased.
There is foreign matter caught between the pop-
pet seat and poppet on the relief valve, which is
ter.
causing seating problems, and the relief valve
does not close.
The relief valve spring is damaged and the relief
Disassemble the motor and reassemble it after
does not close.
cleaning each part.
The motor does The relief valve spring is worn and the set
not stop or stop- pressure has decreased, which has caused the Replace the relief valve.
ping is slow. brake force to decrease.
There is foreign matter caught in the seat sec-
tion of the free piston and base plate of the re- Remove the relief valve and remove foreign
lief valve, and the set pressure and brake force matter.
have decreased.
There is foreign matter clogging the orifice set
in the poppet of the relief valve, and the set
matter.
pressure and brake force have decreased.
There is foreign matter caught in the sliding sec-
tion of the poppet and the poppet is not moving.
Shock at stopping
There is foreign matter caught in the free piston Remove the relief valve and reassemble after
is high
and the piston is not moving. removing foreign matter.
The relief set pressure is too high. Replace the relief valve.
84551720B NA - August 2012

6002-43
4. Counter balance valve troubleshooting
Trouble phe-
nomenon
After investigating whether pressure oil is
reaching the motor inlet side, investigate the
Pressure oil is not reaching the motor inlet and
causes of problems and countermeasures for
the plunger is not switching.
each piece of equipment and perform inspec-
tion and repair.
Measure the pressure of the return side inside
the motor circuit, and check that the pressure
Pressure is reaching the motor inlet, but foreign
has increased.
The motor does matter is clogging the orifice in the pilot oil path
After this, perform disassembly and remove for-
not rotate or motor and the plunger is not switching.
eign matter.
rotation is slow.
Next, perform reassembly.
ter.
Investigate the degree of damage according to
There is foreign matter caught in the plunger
the maintenance standards and reassemble the
and it is not switching.
plunger if reusing is possible.
If scratching makes the plunger unusable, re-
place it using the base plate kit.
ter.
There is foreign matter caught in the plunger, so Investigate the degree of damage according to
the plunger does not return and brake force has the maintenance standards and reassemble the
decreased. plunger if reusing is possible.
If it is unusable, replace it using the base plate
kit.
There is damage to the plunger spring, so the
The motor does plunger does not return and brake force has Perform disassembly and replace the spring af-
not stop or stop- decreased. ter removing foreign matter.
ping is slow. Foreign matter is clogging the orifice in the pilot Perform disassembly and remove foreign mat-
oil path, and the plunger does not return or re- ter.
turn is slow. Next, perform reassembly.
The plunger spring is not fit in place. Fit the spring correctly in place.
The check valve is not fit in place. Fit the check valve correctly in place.
Perform disassembly and replace the spring af-
The check valve spring is damaged.
ter removing foreign matter.
The check valve spring is not fit in place. Fit the spring correctly in place.
When an exter- Perform disassembly and remove foreign mat-
There is foreign matter caught in the plunger
nal load acts on ter. After this, clean the plunger and perform
and plunger movement is not smooth.
the motor and reassembly.
pumping opera- The diameter of the pilot oil path orifice is wrong. Attach the correct orifice.
tion is done, rota-
tion variation oc- The pilot oil path orifice is not fit in place. Attach the orifice in the correct position.
curs.
84551720B NA - August 2012

6002-44
Trouble phe-
nomenon
Investigate the degree of damage according to

There is foreign matter caught in the plunger,
the maintenance standards and reassemble the
plunger movement is poor, and counter balance
plunger if reusing is possible.
functions are not fulfilled.
If reusing is impossible, perform replacement
When an external with the base plate kit.
load acts on the Perform disassembly and replace the spring
There is damage to the plunger spring and
motor and pump- and perform reassembly after removing foreign
counter balance functions are not fulfilled.
ing operation is matter.
done, cavitation The plunger spring is not fit correctly in place
Fit the spring correctly in place.
occurs and abnor- and counter balance functions are not fulfilled.
mal noise is cre- There is damage to the check valve spring and Perform disassembly and replace the spring af-
ated. counter balance functions are not fulfilled. ter removing foreign matter.
The check valve spring is not fit in place and
Fit the spring correctly in place.
counter balance functions are not fulfilled.
Foreign matter is clogging the orifice in the pilot
Perform disassembly and reassemble after re-
oil path, and counter balance functions are not
moving foreign matter.
fulfilled.
84551720B NA - August 2012

6002-45
5. 2-speed control function section troubleshooting
Trouble phe-
nomenon
After investigating whether pilot pressure oil is
reaching the Ps port, investigate the causes of
Pilot pressure oil is not reaching the Ps port.
After performing disassembly and removing for-
eign matter, investigate the degree of damage
There is foreign matter caught between the
according to the maintenance standards and
spool and base plate, and the spool does not
Will not switch to switch. perform reassembly if reusing is possible.
high-speed rota- If reusing is impossible, perform replacement
tion with the base plate kit.
There is abnormal wear in the 2-speed control
Perform disassembly and replace using the
piston section, and pressure oil is leaking into
flange holder kit.
the case.
The 2-speed control piston is not fit in place. Attach the 2-speed piston in the correct position.
Foreign matter is clogging the orifice in the
2-speed oil path, and pressure oil is not reach-
ing the 2-speed control piston.
Switching to high-
speed rotation oc-
curs, but switch-
There is abnormal wear in the 2-speed control
ing to low-speed Perform disassembly and replace using the
piston section, and pressure oil is leaking into
rotation occurs if flange holder kit.
the case.
the hydraulic oil
temperature in-
creases.
Investigate whether the Ps port pressure is 0.5
Even if the speed control switch is set to low
MPa ( 72.5 psi ) or lower and recheck the line
speed, the Ps port pressure does not decrease.
system.
Perform disassembly and replace the spring af-
The 2-speed control valve spring is damaged.
ter removing foreign matter.
The 2-speed control valve spring is not fit in
Attach the spring in the correct position.
place.
Not switching to After performing disassembly and removing for-
low-speed rota- There is foreign matter caught between the eign matter, investigate the degree of damage
tion according to the maintenance standards.
spool and base plate, and the spool does not
Perform reassembly if reusing is possible.
return.
If reusing is impossible, perform replacement
with the base plate kit.
Foreign matter is clogging the orifice in the
2-speed oil path, and pressure cannot escape
from inside the 2-speed control piston chamber.
The 2-speed control valve spring is worn and
Perform disassembly and replace the spring.
the switching pressure is reduced.
Switching to low-
speed rotation oc- Foreign matter is clogging the pilot line, and the
Clean the inside of the line and remove foreign
curs, but switch- pilot pressure increases up to switchover pres-
matter.
ing to high-speed sure due to leaking from the 2-speed control
Also, recheck the line system.
rotation occurs valve.
during operation.
84551720B NA - August 2012

6002-46
6. Reduction gear troubleshooting
Trouble phe-
nomenon
After investigating whether pressure is reaching
There is an operation problem in a piece of
the motor inlet side, investigate the causes of
equipment other than the piston motor or reduc-
tion gear.
There is an operation problem in the motor
See [1] - [5] in troubleshooting.
aside from the reduction gear.
A load exceeding the motor output torque is op- After investigating the load, remove the load
erating. acting on the motor.
Replace the reduction gear.
No rotation Investigate whether an excessive external load
The reduction gear angular bearing is damaged
is acting on the motor.
and will not rotate.
If the external load is excessive, remove this
load.
The gear inside the reduction gear is damaged
and it does not rotate.
The bearing inside the reduction gear is dam-
Replace the reduction gear.
aged and it does not rotate.
The spline inside the reduction gear is damaged
and it does not rotate.
The gear inside the reduction gear is damaged.
The bearing inside the reduction gear is dam- Replace the reduction gear.
aged.
Abnormal noise Perform disassembly and check the status of
is coming from damage.
the reduction gear There is wear on the sliding section of the re- If damage is discovered, replace the reduction
during driving. duction gear and interference between parts is gear.
occurring. In there are no parts that are especially dam-
aged, replace worn parts and reassemble after
cleaning.
Check that there are no locations from which oil
is leaking.
Perform disassembly and check the status of
Reduction gear lubricating oil is insufficient. damage within the reduction gear.
If damage is discovered, replace the reduction
gear. Fill with lubricating oil to the specified
volume.
The reduction Adjust the lubricating oil amount to the specified
There is too much reduction gear lubricating oil.
gear section is volume.
heating up to an The bearing inside the reduction gear is dam-
abnormal degree. Replace the reduction gear.
aged.
Perform disassembly and check the status of
internal damage.
An abnormal thrust load is occurring in the re- If damage is discovered, replace the reduction
duction gear due to inappropriate thrust plate gear.
selection. If no especially notable amount of damage is
discovered, replace the thrust plate with another
one of the correct thickness.
84551720B NA - August 2012

6002-47
Trouble phe-
nomenon
Remove the cover, reapply liquid packing, and
There is looseness in fastening bolts on the re-
tighten the cover to the specified torque.
duction gear cover, and oil leaking is occurring.
Fill with lubricating oil to the specified volume.
Plugs for the oil fill, oil drain and oil check ports Retighten the plugs to the specified torque.
on the reduction gear cover are loose, and oil After tightening, fill with lubricating oil to the stip-
leaking is occurring. ulated volume.
Replace the O-rings for the plugs.
O-rings for oil fill, oil drain and oil check ports on
After replacement, tighten the plugs to the spec-
the reduction gear cover are deteriorating, and
ified torque and fill with lubricating oil to the stip-
oil leaking is occurring.
ulated volume.
Oil leaking is oc- There is cracking in the housing and oil leaking
curring Replace the reduction gear.
is occurring.
There is foreign matter caught on the sliding Disassemble the reduction gear, remove for-
surface of the floating seal and oil leaking is eign matter from the floating seal and perform
occurring. reassembly.
Oil leaking is occurring due to corrosion on the
sliding surface of the floating seal.
The O-ring of the floating seal is deteriorated or Disassemble the reduction gear and replace the
damaged and oil leaking is occurring. floating seal.
The seal collar of the floating seal is split and oil
leaking is occurring.
84551720B NA - August 2012

6002-48
Structural Diagram
84551720B NA - August 2012

6002-49
84551720B NA - August 2012

6002-50
84551720B NA - August 2012

6002-51
Internal Structure Diagram
84551720B NA - August 2012

6002-52
84551720B NA - August 2012

6002-53
Part Table
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
1 Piston motor 1 1-2-19 Orifice 2 1-28 Plug 1
1-1 Flange 1 1-2-20 Plug 5 2 Floating seal 2
1-2 Base plate assembly 1 1-2-21 O-ring 5 3 Angular bearing 2
1-2-1 Base plate 1 1-2-22 Orifice 3 4 Housing 1
1-2-2 Spool assembly 1 1-2-23 Orifice 1 5* Shim t = 0.05 1
Hexagon socket
1-2-2-1 Spool 1 1-2-24 8 5* Shim t = 0.1 1
head bolt
1-2-2-2 Check valve 2 1-3 Shaft 1 5* Shim t = 0.3 1
Cylinder block as-
1-2-2-3 Spring 2 1-4 1 5* Shim t = 0.5 1
sembly
1-2-2-4 Plug 2 1-4-1 Cylinder block 1 5* Shim t = 1.0 1
1-2-2-5 O-ring 2 1-4-2 Piston Assembly 9 6 Holder C 1
1-2-3 Spring seat 2 1-4-3 Retainer plate 1 7 Washer 8
1-2-4 Spring 2 1-4-4 Retainer holder 1 8 Bolt 8
1-2-5 Cap 2 1-4-5 Snap ring 1 9 Thrust plate 4
1-2-6 O-ring 2 1-4-6 Spring seat 1 10 Inner race 4
Relief valve assem-
1-2-7 2 1-4-7 Spring 1 11 Needle bearing 4
bly
1-2-7-1 Relief housing 1 1-4-8 Collar 1 12 Planetary gear C 4
1-2-7-2 Poppet 1 1-4-9 Pin 3 13 Thrust plate 4
1-2-7-3 Poppet seat 1 1-5 Swash plate 1 14 Bolt 4
1-2-7-4 Spring seat 1 1-6 Steel ball 2 15 Sun gear C 1
1-2-7-5 Spring 1 1-7 Piston Assembly 2 16 Snap ring 1
1-2-7-6 Plug 1 1-8 Ball bearing 1 17 Holder B 1
1-2-7-7 O-ring 1 1-9 Ball bearing 1 18 Thrust plate 3
1-2-7-9 Free piston 1 1-10 Pin 1 19 Inner race 3
1-2- Hexagon socket
O-ring 1 1-11 10 20 Needle bearing 3
7-10 head bolt
1-2-7-11 Backup ring 2 1-12 Oil seal 1 21 Planetary gear B 3
1-2-
Spring guide 1 1-13 Disk plate 3 22 Thrust plate 3
7-13
1-2-
O-ring 1 1-14 Friction plate 2 23 Thrust plate 1
7-14
1-2-
Locking screw 1 1-15 Brake piston 1 24 Screw 3
7-15
1-2-
Nut 1 1-16 D-ring 1 25 Drive gear 1
7-16
1-2-
O-ring 1 1-17 D-ring 1 26 * Thrust plate t = 3.6 1
7-17
1-2-
Backup ring 2 1-18 Spring 8 26 * Thrust plate t = 2.3 1
7-18
1-2-8 Plug 8 1-19 Pin 4 26 * Thrust plate t = 2.8 1
1-2-9 Spool assembly 1 1-20 Spring 2 26 * Thrust plate t = 3.0 1
1-2-9-1 Spool A 1 1-21 Valve plate 1 26 * Thrust plate t = 3.2 1
1-2-9-2 Spool C 1 1-22 O-ring 4 27 Cover 1
Hexagon socket
1-2-10 Spring 1 1-23 O-ring 1 28 16
head bolt
1-2-11 Plug 1 1-24 Nameplate 1 29 Plug 3
1-2-12 O-ring 2 1-25 Rivet 2 30 O-ring 3
1-2-13 Spring guide 1 1-26 Plug 2 31 Pin 4
1-2-14 Plug 1 1-27 Plug 1
* 1 is selected and used.
84551720B NA - August 2012

6002-54
Section
6003
Removal and Installation of Swing Unit
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WARNING Removal of Swing Unit

• Be sure to release hydraulic pressure before 1. Use a hexagon wrench [ 5 mm ( 0.197 in. ) ] to
beginning work. remove the 4 bolts (1), and then remove the air
breather (2) on the hydraulic oil tank.
CAUTION • Tightening torque for bolt installation: 2.94 - 4.90
N·m ( 2.1689 - 3.6146 lbf·ft. )
work.
load.
• When removing this product from the equip-
ment it is mounted on, stop that equipment
system and wait for the surface temperature
of this product to fall to about 40 °C ( 104.0 °F )
or below before removing it. Working on this
product while it is still hot can cause burns.
Additionally, always bleed out the pressure
before removing any line from this product.
Removing a pressurized line can result in oil
spraying out and causing injury or oil leak. 2. Attach the specialty adapter (1) to the area where
the air breather was removed, and set the vacuum
Items to prepare pump.
Create negative pressure in the hydraulic oil tank
• Wrenches [ 13 mm ( 0.512 in. ), 14 mm ( 0.551 in. ), using the vacuum pump (2).
19 mm ( 0.748 in. ), 22 mm ( 0.866 in. ), 27 mm (
1.063 in. ), 36 mm ( 1.417 in. ), 41 mm ( 1.614 in. ) ]
• Box wrench [ 36 mm ( 1.417 in. ) ]
• Pliers
• Hammer
• Grease
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Cap
• Plug
• Liftcrane (with the required lifting capacity) 3. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
• Rag 5 bolts (1), and then remove the center cover (2).
• Cleaning fluid
4. Use the wrenches [ 22 mm ( 0.886 in. ), 27 mm (

1.063 in. ), 36 mm ( 1.417 in. ), 41 mm ( 1.614 in. )
] to remove the hoses (1) (2) (3) (4) (5) (6) from the
swing motor.
• Mark the swing motor and hoses so that the con-
nectors can be matched during assembly.
84551720B NA - August 2012

6003-3
• Attach caps or plugs to the swing motor and hoses 7. Use a wrench [ 13 mm ( 0.512 in. ) ] to remove the
to prevent any entry of water, dust or dirt. bolt (2) on the clamp (1) for the hose.
• Clean the swing motor and hoses by spraying
them with a parts cleaner to prevent scratching • Tightening torque for bolt installation: 23.5 - 35.3
N·m ( 17.336 - 26.040 lbf·ft. )
and prevent dirt from accumulating on the con-
nectors.
8. After removing all of the hoses, use pliers to cut the

5. Use a wrench [ 19 mm (0.748 in.) ] to remove wire band (1) that binds the hoses.
the grease hose (1) that feeds grease to the swing
motor reduction gear bearing.

the 11 bolts (1) from the swing unit.
6. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the • Tightening torque for bolt installation: 539.4 -
3 bolts (1), and then remove the under cover (2). 629.6 N·m ( 397.910 - 464.448 lbf·ft. )
• Tightening torque for bolt installation: 63.7 - 73.5
N·m ( 46.991 - 54.220 lbf·ft. )
84551720B NA - August 2012

6003-4
10. Wrap the wire rope (1) around the swing motor and 11. Thoroughly check that the location is safe before
lift it with a liftcrane. lowering the swing unit on wood planks (1).
• A knock pin (2) is driven into the installation sec- • Thoroughly secure the swing unit so that it does
tion of the swing unit. Apply lubricating oil to the not fall over.
knock pin and pull it out together with the main unit
of the swing motor while hitting with a hammer.
84551720B NA - August 2012

6003-5
Installation of Swing Unit

1. To install, perform the reverse of the removal procedure.
• When installing the swing unit, be careful with the position of the knock pin.
• The tightening torque for the bolts for installing the swing unit on the swing frame is 539.4 - 629.6 N・m (397.910
- 464.448 lbf・ft.).
2. Before driving, be sure to fill the inside of the motor casing with hydraulic oil from the oil fill port (1).
Thoroughly perform air bleeding from the air bleed port (2).
Use the level gauge (3) to check that gear oil for the reduction gear is filled to the stipulated volume.
84551720B NA - August 2012

6003-6
Section
6004
Assembly and Disassembly of Swing Unit
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 35352AF10 Disassembly

1. Making a reference mark on the unit matching sur-
CAUTION face
It is useful for reassembly to place a reference mark
1. Read and understand the contents of this (*1) on the matching surface of the housing (1) and
maintenance manual before performing ring gear (2) with paint, etc.
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C ( 104.0 °F ) or below before removing
it.
Working on this product while it is still hot
can cause burns.
before removing any line from this prod-
uct.
2. Removal of level gauge assembly
Removing a pressurized line can result in
Remove the level gauge assembly (1) and cap (2)
oil spraying out and causing injury or oil
[27 mm (1.063 in.) hexagon diameter] and cap (3)
leak.
[10 mm (0.394 in.) hexagon socket diameter].
4. Use the specialty tools and measurement
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury.
7. Check performance after reassembly.
Do not resume use unless performance is 3. Gear oil draining
fully recovered. Loosen the drain hose (*1) end plug, and then drain
Using this product at a sub-par perfor- the gear oil.
mance level may result in product damage. • Gear oil cannot be reused.
8. The cautions (mark !) listed in this main-
tenance manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.
84551720B NA - August 2012

6004-3
4. Removal of hose Assembly

Remove the drain hose (*1) and grease hose (*2).
1. Application of liquid packing
After cleaning and degreasing the reduction gear
ring gear (2) and the motor housing (1) matching
surfaces, apply (*1) liquid packing (ThreeBond
Co.,Ltd. "1215" gray or the equivalent) as shown in
the diagram on the right.
5. Removal of motor
Loosen the hexagon bolts (3) [10 mm (0.394 in.)
hexagon diameter] and remove them along with the
washers (4).
• Use the make-up port (G1) to raise the motor and
remove it. 2. Motor installation
• Liquid packing has been applied to the matching Lift the motor and softly install it in the reduction
surface of the housing (1) and ring gear (2), so gear, tighten the hexagon bolts (4) [19 mm (0.748
use the notch sections (*1) in the diagram on the in.) hexagon diameter] holding the washers (3) in
right to remove the motor. place to the tightening torque of [ 103 N·m (75.98
lb·ft.) ].
• Align the housing (1) and ring gear (2) according
to the reference mark (*1) made before disassem-
bly.
This completes the disassembly.
84551720B NA - August 2012

6004-4
3. Installation of level gauge 5. Grease-up

Install the cap (1) [27 mm (1.063 in.) hexagon Remove the plug (2) [5 mm (0.197 in.) hexagon
socket diameter] on the housing by tightening it to socket diameter] from the gear case (1) and inject
a torque of [49 N·m (36.15 lbf·ft.)], and insert the grease [1 L (0.26 gal.)] from the grease fill port.
level gauge assembly (2).
• When injecting grease, there is the possibility of
the reduction gear oil seal being damaged by in-
ternal pressure, so remove the air bleed port plug
before injecting grease.
Tighten the plug to the gear case to a tightening
torque of [20 N·m (14.75 lbf·ft.)].
After injecting grease, install the grease hose in
the grease fill port.
4. Gear oil filling

Install a plug in the female side of the hose, and
install a hose (*1) in the drain port on the side of the
gear case.
Fill with gear oil [5 L (1.32 gal.)] from the housing
(1) gear oil fill port.
Gear oil fill port cap (2) [10 mm (0.394 in.) hexagon
socket diameter] to the housing at a tightening
torque of [49 N·m (36.15 lbf·ft.)]. This completes the assembly.
84551720B NA - August 2012

6004-5
84551720B NA - August 2012

6004-6
Section
8001A
Overall view
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Overall view
This page is intentionally left blank
84551720B NA - August 2012

8001A-3
Overall view
Overall view
84551720B NA - August 2012

8001A-4
Overall view
1 Housing left side 3 Pomp chamber 5 Fuel tank

2 Swing body center section 4 Hydrauric oil tank
84551720B NA - August 2012

8001A-5
Overall view
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT
84551720B NA - August 2012

8001A-6
Overall view
Horsepower control electro-

1 Hydraulic pump 5 P2 pressure sensor 9
magnetic proportional
Hydraulic oil temperature sen-
2 Accumulator 6 P1 pressure sensor 10
sor
3 Pilot filter 7 Pilot pump
4 5 stack solenid valve 8 N2 pressure sensor
84551720B NA - August 2012

8001A-7
Overall view
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT
84551720B NA - August 2012

8001A-8
Overall view
1 Swing motor
2 Center joint
3 Control valve
84551720B NA - August 2012

8001A-9
Overall view
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT
Cushion valve (with heat cir-

1
cuit)
2 Swing pilot pressure sensor
3 Oil cooler
84551720B NA - August 2012

8001A-10
Overall view
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB
1 Travel remote control valve

Upper operation remote control
2
valve
84551720B NA - August 2012

8001A-11
Overall view
84551720B NA - August 2012

8001A-12
Section
8001B
Port Diagram
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Hydraulic Pump (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valves (upper, travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Control Valves (left-right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Control Valve (travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-way Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Direction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Manifold Under Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifold (accumulator section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifold (hydraulic oil tank section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Port Diagram
Hydraulic Pump (standard model)
Port Port name Port size

A1, A2 Discharge port SAE6000psi 3/4
B1 Suction port SAE2500psi 2-1/2
Dr Drain port G3/4-20
P1 Proportional valve primary pressure port G1/4-13
P2 P2 port G1/4-13
Psv Servo assist port G1/4-15
Pi1, Pi2 Negative control port G1/4-15
a1, a2, a4 Gauge port G1/4-15
a5, a6 Gauge port G3/8-17
a7, a8 Gauge port G1/4-15
A3 Gear pump discharge port G1/2-19
B3 Gear pump suction port G3/4-20
84551720B NA - August 2012

8001B-3
Port Diagram
Control Valve
Relief Valve
Detailed diagram of main relief valve adjustment
1 Boom up 5 Arm out 9 Standard lock nut

2 Arm in 6 Bucket open 10 Pressure boost lock nut
3 Boom down 7 Main a (normal use) 11 Pressure boost adjusting screw
Standard pressure adjusting
4 Bucket close 8 Main b (pressure boost) 12
screw
84551720B NA - August 2012

8001B-4
Port Diagram
Port Port size Port name Port Port size Port name
P1 SAE6000psi 1 Pressure line pb3 G1/4 Left swing pilot line
SAE5000psi
A1 Left travel (forward) line pb4 G1/4 Boom 2-down drain line
3/4
SAE5000psi
B1 Left travel (backward) line pb5 G1/4 Arm 1-in pilot line
3/4
A2 SAE5000psi 1 Option line pb7 G1/4 Bucket-close pilot line
B2 SAE5000psi 1 Option line pb8 G1/4 Boom 1-down pilot line
SAE5000psi
A3 Swing right line pb9 G1/4 Arm 2-in pilot line
3/4
SAE5000psi Negative control power save
B3 Swing left line Pn1 G1/4
3/4 signal
Negative control power save
A5 SAE5000psi 1 Arm-out line Pn2 G1/4
signal
B5 SAE5000psi 1 Arm-in line PH G1/4 Pressure boost signal port
T1 Return line Ps1 G1/4 Negative control line
pb1 G1/4 Left travel backward pilot line T8 G1/4 Heat circuit line
pb6 G1/4 Right travel backward pilot line Pb2 G1/4 Option line
P4 G3/4 Backup confluence line pcc G1/4 Neutral cut line
DR1 G3/8 Drain line T3 G1 Swing motor make up line
84551720B NA - August 2012

8001B-5
Port Diagram
Port Port size Port name Port Port size Port name
P2 SAE6000psi 1 Pressure line pa7 G1/4 Bucket-open pilot line
SAE5000psi
A6 Right travel (forward) line pa3 G1/4 Right swing pilot line
3/4
SAE5000psi
B6 Right travel (backward) line pa8 G1/4 Boom 1-up pilot line
3/4
A7 SAE5000psi 1 Bucket-open line pa4 G1/4 Boom 2-up pilot line
B7 SAE5000psi 1 Bucket-close line pa9 G1/4 Arm 2-out pilot line
A8 SAE5000psi 1 Boom-up line pa5 G1/4 Arm 1-out pilot line
SAE5000psi
B8 Boom-down line PA G1/4 Upper signal
3/4
T2 Return line PT G1/4 Travel signal
pa1 G1/4 Left travel forward pilot line Ps2 G1/4 Negative control line
Swing priority variable orifice
pa6 G1/4 Right travel forward pilot line Pbu G1/4
switch signal
DR3 G1/4 Straight travel drain line Pa2 G1/4 Option line
P3 G3/4 Backup confluence line DR4 G1/4 Drain line
DR2 G1/4 Drain line pc3 G1/4 Swing priority line
84551720B NA - August 2012

8001B-6
Port Diagram
5 Stack Solenoid Valve
Port Port size

C2 G1/4
C3 G1/4
C1 G1/4
View from bottom
Port Port size

B G3/8
T G3/8
Port Port size

C5 G1/4
C4 G1/4
P G3/8
84551720B NA - August 2012
8001B-7
Port Diagram
1 Power save 3 Swing lock 5 Travel high speed

2 Lever lock 4 Pressure boost
84551720B NA - August 2012

8001B-8
Port Diagram
2 Stack Solenoid Valve
B port side A port side
Port Port size

A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4
84551720B NA - August 2012

8001B-9
Port Diagram
Remote Control Valves (upper, travel)

Remote Control Valves (left-right)
Right side Left side
Right
Port name Left side Port name Port size
side
1 Bucket close 1 Swing right G3/8
2 Boom down 2 Arm in G3/8
3 Bucket open 3 Swing left G3/8
4 Boom up 4 Arm out G3/8
P Pressure P Pressure G1/4
T Return T Return G3/8
84551720B NA - August 2012

8001B-10
Port Diagram
Remote Control Valve (travel)

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4
84551720B NA - August 2012

8001B-11
Port Diagram
Cushion Valve
Port Port name Port size Port Port name Port size
E, F Boom up G3/8 I, J Swing right G3/8
G, H Boom down G3/8 Q Swing pressure sensor signal G1/4
O, P Bucket open G3/8 U - G1/4
M, N Bucket close G3/8 S Swing priority orifice switch G1/4
C, D Arm out G3/8 V - G1/4
A, B Arm in G3/8 T Return (drain line) G1/4
K, L Swing left G3/8 R Heat circuit G1/4
84551720B NA - August 2012

8001B-12
Port Diagram
2-way Selector Valve
Remote control valve side Cushion valve side
Port Port name *ISO type Port size Port Port name *ISO type Port size
Remote control valve side/swing-
A G3/8 1 Cushion valve side port G3/8
left port
Remote control valve side/arm-in
B G3/8 2 Cushion valve side port G3/8
port
Remote control valve side/swing-
C G3/8 3 Cushion valve side port G3/8
right port
Remote control valve side/arm-out
D G3/8 4 Cushion valve side port G3/8
port
Direction Valve
Port Port size Port Port size Port Port size

A G1 T1 G1 PP G1/4
B G1 T2 G3/4 DR G1/4
84551720B NA - August 2012

8001B-13
Port Diagram
Shut-off Valve
Port Port size

A G1
B G1
T G3/4
PP G1/4
DR G1/4
84551720B NA - August 2012

8001B-14
Port Diagram
Relief Valve (electromagnetic proportional)
Port Port size Port Port size

A G1 C G3/4
B G1 T G3/4
84551720B NA - August 2012

8001B-15
Port Diagram
HBCV
B port opening side
Port Port size Remarks

SAE6000psi 1 Arm HBCV
A Boom
SAE J6000psi 1
HBCV
SAE6000psi 1 Arm HBCV
B Boom
SAE J6000psi 1
HBCV
C G1/4
DR G3/8
PL G1/4
84551720B NA - August 2012

8001B-16
Port Diagram
Manifold Under Cab

P1 G3/8 P5 G1/4 T4 G1/4
P2 G3/8 T1 G3/8 T5 G1/4
P3 G3/8 T2 G3/8
P4 G1/4 T3 G3/8
Manifold (accumulator section)
Port Port size

P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8
84551720B NA - August 2012

8001B-17
Port Diagram
Manifold (hydraulic oil tank section)

D G1/2 D5 G1/4 T1 G3/8
D1 G3/8 D6 G1/4 N2 G1/4
D2 G1/4 T G1/2
84551720B NA - August 2012

8001B-18
Port Diagram
Swing Motor
Port Port Port

Port Port name Port Port name Port Port name
size size size
Dr Reduction gear oil
Mu Make up G1 B Right swing G3/4 G1/2
(RG) drain port
GA, Pressure measure- Reduction gear
Dr Drain G3/8 G1/4 SGr G1/4
GB ment grease-up port
P Brake release G1/4 Au Air bleed port G1/4
Air bleed port for
A Left swing G3/4 AGr Rc1/8
grease-up
84551720B NA - August 2012

8001B-19
Port Diagram
Travel Motor

P1, P2 Main port G1
T Drain port G1/2
Ps Pilot port G1/4
Pm1,
Pressure detection port G1/4
Pm2
84551720B NA - August 2012

8001B-20
Port Diagram
Center Joint

A, A' Main port (forward right) G3/4
B, B' Main port (forward left) G3/4
C, C' Main port (backward right) G3/4
D, D' Main port (backward left) G3/4
Drain port *E (2 locations), E' (1
E, E' G1/2
location)
Pilot port *F (2 locations), F' (1
F, F' G1/4
location)
84551720B NA - August 2012

8001B-21
Port Diagram
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8001B-22
Section
8001C
Pump P-Q Diagram
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84551720B NA - August 2012
CONTENTS
Pump P-Q Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pump P-Q Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pump P-Q Diagram
Pump P-Q Diagram

Pump P-Q Diagram
Discharge
flow Q [L/m-
in(gpm)]
Discharge pressure Pd [MPa(psi)]
Discharge pressure Pd [Kgf/cm2]
84551720B NA - August 2012

8001C-3
Pump P-Q Diagram
84551720B NA - August 2012

8001C-4
Section
8001D
Pressure Measurement and Adjustment Procedures
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Procedures for Pressure Measurement from the Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Monitor and switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY . . . . . . 4
Hydraulic Oil Temperature Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Procedures for Pressure Measurement by Installing Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Measuring Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Location of Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Attachment pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Boom-down pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Travel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Swing pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Option line pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pilot Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Negative Control Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure measurement and adjustment preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main relief pressure adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overload relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Swing relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pilot Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Procedures for Pressure

Measurement from the Monitor
Display
Monitor and switch panel
1 Liquid crystal monitor 3 Design panel

2 Switch panel 4 Diffuser
Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display. (The pilot pressure cannot be mea-
sured.)
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.
3. MACHINE STATUS the select service support screen.
4. The respective pressures are displayed "P1" (P1 pump main pressure), "P2" (P2 pump main pressure), "N1" (N1
negative control pressure), and "N2" (N2 negative control pressure) columns.
* MENU switch is held down the display returns to the normal screen.
a Normal screen
b Service support screen
84551720B NA - August 2012

8001D-3
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE

FROM THE MONITOR DISPLAY
Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.。
3. MACHINE STATUS the select service support screen.
4. The hydraulic oil temperature is displayed in the "Hyd.OIL TEMP" column.
84551720B NA - August 2012

8001D-4
Procedures for Pressure Measurement by Installing Pressure Gauge

Preparations
Role (worker 1: work supervisor, pressure
Workers 2
adjustment)
Role (worker 2: operator)
Items to Prepare
Wrenches [17 (0.669) 、 19

(0.748) 、 24 (0.945) 、 27
1 ply 5 9 Recording sheet
(1.063) x 2 、 32 (1.259) 、 36
(for vacuum pump)
(1.417) x 2]
Pressure gauge [10 MPa-1
2 6 Rag 10 Pen
(1450.54 psi-1)]
Pressure gauge [60 MPa-2
3 7 Extension cable 11 Cleaning fluid
(8703.22 psi-2)]
Hexagon wrench [8 mm (0.315 Hydraulic oil tank lid
4 8
in.)、6 mm (0.236 in.)] (for vacuum pump)
84551720B NA - August 2012

8001D-5
Pressure Measuring Ports

There are the following 3 ports for pressure measurement.
• Main pressure: pressure ports (P1, P2)
(Remove the Main pressure sensor, then Install the pressure gauge.)
• Negative control pressure: pressure ports (N1, N2)
(Remove the negative control pressure sensor, then Install the pressure gauge.)
• Pilot pressure: pressure port (P3)
84551720B NA - August 2012

8001D-6
84551720B NA - August 2012

8001D-7
1 Pump 3 Pressure port: P1 5 Pressure port: N2

2 Pressure port: P2 4 Pressure port: N1 6 Pressure port: P3
84551720B NA - August 2012

8001D-8
Structure and Operation Explanation of Control Valve

Location of Relief Valves
Tool Pressure per

Set pressure rotation of ad- Measuring
Position Adjusting
Lock nut [ MPa ( psi ) ] justing screw port
screw [ MPa ( psi ) ]
Hexagon diam- Hexagon diam-
a Main 34.3 21.3
eter 27 mm eter 27 mm Monitor P1
(normal use) ( 4975.341 ) ( 3089.643 )
( 1.063 in. ) ( 1.063 in. )
1
Main Hexagon diam- Hexagon diam-
36.8 28.4
b (boosted pres- eter 32 mm eter 27 mm Monitor P1
( 5337.975 ) ( 4119.524 )
sure) ( 1.259 in. ) ( 1.063 in. )
38.7 21.2
2 Boom up Monitor P2
( 5613.577 ) ( 3075.138 )
29.4 21.2
3 Boom down Monitor P2
( 4264.578 ) ( 3075.138 )
21.2 21.2
4 Arm in Hexagon diam- Monitor P1
( 3075.138 ) ( 3075.138 )
eter 17 mm
( 0.669 in. ) Hexagon diam- 38.7 21.2
5 Arm out Monitor P1
eter 6 mm ( 5613.577 ) ( 3075.138 )
( 0.236 in. ) 38.7 21.2
6 Bucket close Monitor P2
( 5613.577 ) ( 3075.138 )
38.7 21.2
7 Bucket open Monitor P2
( 5613.577 ) ( 3075.138 )
Hexagon diam-
3.92 2.0
8 Pilot eter 24.25 mm
( 568.6104 ) ( 290.107 )
( 0.95472 in. )
Detailed diagram of main relief valve adjust-

ment
84551720B NA - August 2012
8001D-9
*1 Pressure boost lock nut

*2 Pressure boost adjusting screw
Standard pressure adjusting
*3
screw
*4 Standard lock nut
84551720B NA - August 2012

8001D-10
Pressure Measurement 3. Main unit installation

Put the main unit on solid, level ground, put the
Preparations bucket cylinder at its open stroke end, the arm cylin-
der at its out stroke end, lower the boom, and touch
1. Items to prepare
the arm top to the ground.
For 10 MPa (1450.54 psi) (for pilot
and negative control pressure mea-
1 ） Pres-
surement)
sure gauge
For 60 MPa (8703.22 psi) (for main
pressure measurement)
Wrench (closed wrench)
2）Tool 17 mm (0.669 in.)
Hexagon wrench 6 mm (0.236 in.)
Rag
3）Others
Cleaning fluid
4. Ignition key
Switch OFF the ignition key (1), check that the en-
gine has stopped, then switch the ignition key ON
again. (Do not start the engine.)
2. Monitor check
Use the service check to check the no-load engine
maximum speed and the SP mode pump input milli-
amp.
Engine max. SP mode milli-amp

2000 min-1 5. Oil temperature check
600 mA (during operation)
(2000 rpm) Use the service check to check the hydraulic oil tem-
perature.
45 - 55 °C
Oil temperature
(113.0 - 131.0 °F)
If the oil temperature is low, raise the oil temperature

according to the warm-up operation procedure in
the operator's manual.
6. Bleeding pressure from inside circuits

84551720B NA - August 2012
8001D-11
Flip the gate lock lever (1) forward, then turn the 7. Bleeding pressure from inside the hydraulic oil tank
upper operation lever (2) about 10 times to bleed Press the air breather button (1) on top of the hy-
out the pressure. draulic oil tank to release the pressure inside the
tank.
3 Gate lever 8. Side door opening and closing

Open the side door (1).
Move the travel lever (1) back and forth about 5 At this time, be sure to use the lock (2).
times to bleed out the pressure.
This completes the preparations.
84551720B NA - August 2012

8001D-12
Pressure Measurement
Main Pressure Measurement
1. Pressure gauge installation
Remove the pressure sensor (a1) (a2) installed
on the hydraulic pump (1) and install the pressure
gauge.
a1: Can be measured a2: Can be measured

Travel left Travel right
Option Bucket
Swing
Arm 1 pump flow Arm 2 pumps flow
Install the pressure gauge (2) on the adapter (1) and
Boom 2 pumps flow Boom 1 pump flow
fasten it.
Pressure gauge
for 60 MPa G1/4
Port size
Install the adapter (2) on the gauge port (1).
84551720B NA - August 2012

8001D-13
Attachment pressure measurement Lever operation Arm-out relief

Oil temperature 45-55 °C (113.1 - 131.0 °F
Example: Arm-out pressure measurement
1 pump: P1 port
Measure with the following operations. Measuring port
2 pumps: P2 port
Boosted pressure: 36.8 MPa
Engine speed 1800 min-1 (1800 rpm)
(5337.975 psi)
Set pressure
Standard: 34.3 MPa (4975.341
Work mode SP mode psi)
a Arm-out relief
When the attachment operates, since the pressure boost operates automatically, the pressure resulting from the pres-
sure boost setting can be checked for about 8 sec.
After 8 sec.or more, the standard set pressure can be checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.
Bucket Bucket Boom

Lever operation Arm out Arm in Boom up
open close down
Work mode SP mode
Oil temperature 45 - 55 °C (113.1 - 131.0 °F)
1 pump flow measuring port P1 P1 P2 P2 P2 P2
2 pumps flow measuring port P2 P2 No No P1 P1
29.4 MPa
Pressure boost 36.8 MPa (5337.975 psi) (4264.578
psi)
29.4 MPa
Standard pressure 34.3 MPa (4975.341 psi) (4264.578
psi)
84551720B NA - August 2012

8001D-14
Boom-down pressure measurement the bucket tip on the ground, carry out the boom-down
operation, and measure.
For pressure measurement with the boom down, put the
arm cylinder at its out stroke end, open the bucket, put
a Boom-down relief
84551720B NA - August 2012

8001D-15
Travel pressure measurement Swing pressure measurement

1. Install the stopper (1) on the crawler sprocket sec- 1. Do not let the bucket move even if swing pressure
tion (2) and lock the travel motor. is relieved with a swing operation such as digging a
2. Measure with the following operations. hole.
2. Measure with the following operations.
Work mode SP mode (1st speed) Engine speed 1800 min-1 (1800 rpm)
Lever operation Travel relief Work mode SP mode
45 - 55°C (113.1 - 131.0 Lever operation Swing relief
Oil temperature
°F) 45 - 55 °C (113.1 - 131.0
Oil temperature
Left travel: P1 port °F)
Measuring port
Right travel: P2 port Measuring port P1 port
Set pressure 34.3 MPa (4975.341 psi) Set pressure 29.4 MPa (4264.578 psi)
84551720B NA - August 2012

8001D-16
Option line pressure measurement 3. Measure with the following operations.

1. Close the option line stop valve (1).
Work mode SP mode
Pedal operation Option relief
45 - 55°C (113.1 - 131.0
Oil temperature
°F)
1 pump: P1 port
Measuring port
2 pumps: P2 port
2. Switch the attachment select switch of the monitor

to the option line to be measured (breaker, crusher).
* Adjust the set pressure to match the specifications of

the attachment used.
84551720B NA - August 2012

8001D-17
Pilot Pressure Measurement

Pressure gauge installation
Remove the plug with the wrench (1) to install a pressure
gauge at the pump pressure measuring port (P3).
Install the adapter (1).
Install the pressure gauge (1) and measure the pres-

sure.
84551720B NA - August 2012

8001D-18
Engine speed 1800 min-1 (1800 rpm) Pressure gauge for 10 MPa (1450.54 psi)
Work mode SP mode Port size G1/4
45 - 55 °C (113.1 - 131.0
Oil temperature
°F)
Measuring port P3 port
Set pressure 3.92 MPa (568.6104 psi)
84551720B NA - August 2012

8001D-19
Negative Control Pressure

Measurement
Pressure gauge installation
Remove the pump N1 pressure sensor (1) or N2 pres-
sure sensor (2) connector (3), and then remove the pres-
sure sensor.(N1, N2: pressure port) (The pressure sen-
sor location becomes the measuring port.)
Install the adapter (1) of the pressure gauge at the port Measure the negative control pressure for each opera-
where the N1 or N2 pressure sensor was removed and tion.
install the pressure gauge (2).
84551720B NA - August 2012

8001D-20
Pressure gauge for 10 MPa (1450.54 psi) Engine speed 1800 min-1 (1800 rpm)
Port size G1/4 Work mode SP mode
45 - 55 °C (113.1 - 131.0
Oil temperature
°F)
P1 pump side: N1 port
Measuring port
P2 pump side: N2 port
3.92 MPa (568.6104 psi)
Set pressure
max.
84551720B NA - August 2012

8001D-21
Pressure Adjustment 1. Loosen the standard lock nut [ 27 mm ( 1.063 in.

) ] (1) and tighten the adjusting screw [ 27 mm (
Main Pressure Adjustment 1.063 in. ) ] (2).
Fasten with a wrench [ 27 mm ( 1.063 in. ) ] so
Pressure measurement and adjustment that the pressure boost adjusting screw does not
preparation work turn.
Pressure is adjusted with control valves.

The following preparations are required for adjusting
with control valves.
1. Engine hood opening and closing
Unfasten the 2 latches (2) on the engine hood (1)
and open the engine hood (1).Pull the latches (2) to
release the locks.
2. After tightening until the adjusting screw stops

turning, tighten the pressure boost lock nut (1).
2. Cover removal
Remove the 5 bolts (1), then remove the cover (2).
3. Start the engine and run it at maximum rotation.

4. Move the arm lever to the in side, set the relief
state, and hold.
5. Loosen the pressure boost lock nut [ 32 mm (
1.260 in. ) ] (1) and adjust the set pressure with
the adjusting screw [ 27 mm ( 1.063 in. ) ] (2).
• When lower than the set pressure, tighten.
For boosted pressure
• When higher than the set pressure, first lower

below the set pressure, then adjust on the tight-
ening side.
6. After adjustment, fasten the adjusting screw with
a wrench [ 27 mm ( 1.063 in. ) ], then tighten the
lock nut.
84551720B NA - August 2012

8001D-22
7. After locking, check the pressure on the boosted 3. After adjustment, tighten the lock nut while fasten-
pressure side. ing the adjusting screw (1) with a wrench (2).
Repeat [1] - [7] until the set pressure is correctly ad-
justed.
For standard pressure
1. Loosen the standard lock nut [ 27 mm ( 1.063 in.
) ] (1).
4. After locking, check the pressure.

Repeat [1], [2], and [3] until the set pressure is cor-
rectly adjusted.
Stop the engine.
2. Loosen the adjusting screw (1), lower below the

set pressure, then adjust on the tightening side.
84551720B NA - August 2012

8001D-23
Main relief pressure adjustment Boosted pressure:

28.4 MPa/rotation
Engine speed 1800 min-1 ( 1800 rpm ) Pressure per rotation of ( 4119.52 psi/rotation )
Work mode SP mode adjusting screw Standard:
Lever operation Arm-in relief 21.3 MPa/rotation
45 - 55℃ ( 3089.64 psi/rotation )
Oil temperature
( 113.0 - 131.0 °F )
Measuring port P1 port Before adjusting, remove the pilot hose for the pressure
Boosted pressure: boost signal (2) connected to the main relief valve (1),
36.8 MPa ( 5337.98 psi ) then insert the plug (3) into the hose side.
Measurement pressure
Standard: The procedures for boosted pressure and standard
34.3 MPa( 4975.34 psi ) pressure are different.
4 Control valve
5 Wrench [ 19 mm ( 0.748 in. ) ]
84551720B NA - August 2012

8001D-24
Overload relief pressure adjustment Boom down: 29.4 MPa

(4264.58 psi)
Measurement pressure
Engine speed 1800 min-1 (1800 rpm) Others: 38.7 MPa
Work mode SP mode (5613.58 psi)
45 - 55 °C (113.0 - 131.0 Pressure per rotation of 21.2 MPa/rotation
Oil temperature adjusting screw (3075.14 psi/rotation)
°F)
Measuring port P1/P2 port
Since the overload relief pressure is set higher than the

main relief pressure, it is necessary to provisionally set
the main relief pressure higher than the overload relief
pressure. (Except for boom down)
1 Control valve 4 Boom up

2 Boom down 5 Arm-out
3 Bucket close 6 Bucket open
84551720B NA - August 2012
8001D-25
Main relief pressure provisional setting

• Using the main pressure adjustment procedure for
reference, temporarily set the boosted pressure and
standard pressure to at least 39.2 MPa.
* For boom down (1), since the overload set pres-
sure is lower than the main relief set pressure,
there is no need to temporarily set the main relief
pressure.
Pressure adjustment
Example: Arm-out (1) overload relief adjustment
2. After adjustment, lock the lock nut (1).
1. Loosen the lock nut (1) with the wrench (2) and
adjust by turning the adjusting screw (3) with the
hexagon wrench (4).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first loosen 3. After adjusting the overload relief pressure, adjust
to a pressure lower than the set pressure, then the boosted pressure and standard pressure to
adjust on the tightening side. their normal values referencing the main pressure
adjustment procedure.
* For the position of each overload relief, see the
"Control Valve Relief Locations".
84551720B NA - August 2012

8001D-26
Swing relief pressure adjustment Pilot Pressure Adjustment

1. Install the pressure gauge (1).
Engine speed 1800 min-1 (1800 rpm) While holding the plug with a wrench [ 24 mm (
Work mode SP mode 0.945 in. ) ] (2), adjust with a hexagon wrench [
45 - 55 °C 6 mm ( 0.236 in. ) ] (3).
Oil temperature
(113.0 - 131.0 °F)
Measuring port P1 port Engine speed 1800 min-1 ( 1800 rpm )
Measurement pressure 29.4 MPa (4264.57 psi) Lever operation Neutral
Measuring port P3
1. Using the swing pressure measurement procedure
for reference, lock the swing, and check the swing Set pressure 3.92 MPa ( 568.61 psi )
pressure.
Check the currently set pressure.
The number of shims for adjustment is determined
by the difference between the current pressure and
the set pressure.
2. Use a hexagon wrench [ 12 mm (0.472 in.) ] to
remove the swing motor port relief assembly from
the motor main unit.
• When removing both sides at the same time, mark
the assemblies so that they can be re-assembled
on the correct sides.
Fasten the port relief assembly with a vise table,
take off the cap, then remove the piston, liner,
spacer, poppet, shim, and spring.
3. Remove the poppet and spring and add (or remove)

one or more shims between the spring and spacer.
Find the number of shims in step 1. After adjusting
the shims, install the poppet, spring, spacer, shims,
piston, and liner in the sleeve.
Fasten the sleeve on the vise table and install the
cap.
Cap tightening torque: 156.9 N·m (115.743 lbf·ft.)
84551720B NA - August 2012

8001D-27
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8001D-28
Section
8001E
Hydraulic Pump Flow Measurement Procedures
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


Preparations
Role (worker 1: work supervisor, pressure ad-
Workers 3
justment)
Role (worker 2: operator)
Role (worker 3: flow, pressure measurement,
recording)
Items to Prepare

1 6 Extension cable 11 Pen
ply
Hydraulic oil tank lid (for vac-
2 Flow meter 7 12 Cleaning fluid
uum pump)
Pressure gauge (60 MPa [
3 8 Adapter (flange type) 13 Rag
8703.22 psi ) x 2]
84551720B NA - August 2012
8001E-3
Hexagon wrench [ 6 mm (
Hydraulic hose (for flow mea-
4 0.236 in. ), 10 mm ( 0.394 in. ) 9
surement)
]
Wrenches [ 17( 0.669 ), 19(
0.748 ), 24( 0.945 ), 27( 1.063
5 10 Recording sheet
) x 2, 32( 1.260 ), 36( 1.417 ) x
2]
Work Preparations 4. Use the bolts removed in 3. to install the hydraulic

oil tank lid (for vacuum pump) (1).
1. Check that the main unit is in its work posture (arm-
vertical).
2. Bleed out the pressure. (See the details on Bleed-
ing Pressure in the Pressure Measurement and Ad-
justment Procedures.)
* Perform a swing prevention check.
5. Install the vacuum pump (1) on the hydraulic oil tank

lid.

feed port cover (1).
6. After setting the vacuum pump (1) as in the diagram

on the right, switch on the power.(If the cable is too
short, use an extension cable.)
84551720B NA - August 2012

8001E-4
7. Use a hexagon wrench (1) [ 10 mm ( 0.394 in. ) ] to 10. Install the hydraulic hose (3) on the flow meter (1)
remove the split flanges (2) and hydraulic hose (3). IN side(2), then fasten with the spanner.
(This section explains flow measurement at the P2 Install the (prepared) hydraulic hose (5) on the flow
pump.) meter (1) OUT side (4), then fasten with the span-
ner.
Installs the adapter (6) to have instralled in opposite
in 8..
* When connecting, always check the connection
positions.
* Always have the metering valve (7) fully open.
Remove the vavuum pump and re-install the hy-
draulic oil tank the same way it was.
Install pressure gauges on P1 and P2.(See "Main
Pressure Measurement".)
Open the engine hood.(See "Main Pressure Adjust-
ment".)
4 Bolt
8. Use the split flange (2) to install the adaptor (flange

type (3)) on the tip of the hydraulic hose (1) removed
in 7..
4 Hydraulic hose
9. Install the adaptor (1) at the position from which the

hydraulic hose was removed. 11. Remove the cover.
If necessary, install an "elbow adaptor" (3) on the 12. Remove the pilot hose for the boosted pressure sig-
(prepared) hydraulic hose (2) connected to the flow nal, then plug the hose side. (See "Main Relief
meter IN side. Pressure Adjustment".)
This completes the preparation for flow measurement.
84551720B NA - August 2012

8001E-5
Flow Measurement 5. Worker 2 lowers the arm-out port relief. (Min: 24

MPa ( 3481.29 psi ) P1+P2)
1. Measure the flow. 6. Start of flow measurement
When measuring the flow, position the workers as 7. The arm-out relief operation is carried out.
in the diagram on the right. 8. Data measured in units of 2.0 MPa ( 290.107 psi )
(Worker 1 (1): Work supervisor, pressure adjust- (P1+P2)
ment)
(Worker 2 (2): Operator) * The measurement is carried out from 24.0 - 76.0
(Worker 3 (3): Flow, pressure measurement, MPa ( 3481.288 - 11024.079 psi ) and ends when
recording) the maximum pressure is reached.
9. Remove the flow meter.
* Because the maximum limit of the flow meter
pressure gauge is exceeded starting from 40
MPa ( 5802.15 psi ).
10. Reset the arm-in port relief valve to normal pres-
sure.(For details on this adjustment, see "Pressure
Adjustment".)
11. Remove the pressure gauges etc. and put every-
thing back to normal.
This completes the work.
2. At the signal from the work supervisor, the operator

starts the engine.
3. Check the hydraulic oil temperature on the monitor.
[ 50 °C ( 122.0 °F ) ]
Check that the engine rotation and pump milli-amp
is normal.
4. The operator signals the arm-out relief operation to
worker 1.
1 Lock nut 17 mm ( 0.669 in. )

Hexagon wrench 6 mm ( 0.236
2
in. )
1 Ignition key
84551720B NA - August 2012

8001E-6
Section
8001F
Drain Volume Measurement Procedures
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preparations 3. Always lay a rag (2) underneath before removing

the drain hose (1).
Measuring conditions Use a wrench [ 27 mm ( 1.063 in. ) ] to remove the
drain hose (1).(Always install a cap on the removed
drain hose (1).)
Engine speed 1800 min-1 ( 1800 rpm )
Mode SP mode
Oil temperature About 50°C ( 122.0 °F )
* Be careful.
The drain volume varies greatly with the oil tempera-
ture.
Travel Motor Drain Volume

Measurement
1. Allow the bucket (2) to touch the ground so as to
elevate one shoe crawler (1) as in the diagram on 4. Install the extension hose for measurement (1) on
the right. the side of the motor from which the drain hose was
removed.

bolts (1), then remove the cover (2). 5. Prepare a waste oil can (1) and measuring con-
Tightening torque for bolt installation：63.7 - 73.5 tainer (2) and set them as in the diagram on the
N・m ( 46.991 - 54.220 lbf・ft. ) right.
84551720B NA - August 2012

8001F-3
6. Catch the stopper (1) between the sprocket section Forward Backward
and the frame and lock the travel motor. 1st 2nd 1st 2nd
speed speed speed speed
Right
Left
* Measure at least 3 times each for left, right, for-

ward, and backward.
7. In SP mode at medium speed, relieve the travel op-

eration, and move the extension hose to the mea-
suring container (1) at the same time the motor
starts. (At starting, start measurement with a stop
watch (2).)
After 30 sec., move the extension hose to the waste
oil can (1).
Measure the volume of oil in the measuring con-
tainer (1) as the drain volume for 30 sec. a 30 seconds
84551720B NA - August 2012

8001F-4
Swing Motor Drain Volume at the same time the motor starts.(At starting, start
measurement with a stop watch (2).)
Measurement After 60 sec., move the extension hose (3) to the
waste oil can (4).
1. Remove the 2 drain hoses (1) and put plugs in the
Measure the volume of oil in the measuring con-
hose side of each. (wrench size: 27 mm ( 1.063 in.
tainer (1) as the drain volume for 60 sec.
), clamp 22 mm ( 0.866 in. ) (hose side))
Measure at least 3 times each for left and right.
Right Left
2. Install the extension hose (1) for measuring the

drain volume on one side of the T nipple.
Install the hose facing in a direction that makes
measurement easy and install a plug (2) on the
other side.
3. Prepare a waste oil receiver and measuring con-

tainer (1) and set them as in the diagram on the
right.
For details on the method for locking the swing mo-
tor, see "Swing relief pressure adjustment".
In SP mode, relieve the swing operation and move
the extension hose to the measuring container (1) a 60 seconds
84551720B NA - August 2012

8001F-5
84551720B NA - August 2012

8001F-6
Section
8001G
Air Bleed Procedure
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Arm Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air Bleed Procedure
CAUTION
Always bleed off any air in the hydraulic cir-
cuits after replacing the hydraulic oil, repairing
or replacing hydraulic equipment, or removing
hydraulic pipes.
Air bleed procedure mode (when bleeding, follow the procedure be-
low.)
Hydraulic
Cylinder air Swing motor Travel motor
pump air Check
bleeding air bleeding air bleeding
bleeding
Hydraulic oil or hydraulic pump re-
placement
Cylinder replacement
Swing motor replacement
Travel motor replacement
* Failure to completely bleed off all the air can reduce

the service life of hydraulic equipment and lead to
damage.
84551720B NA - August 2012

8001G-3
Air Bleed Procedure
Hydraulic Pump Travel Motor

1. Loosen the air bleed plug (1) and check that oil 1. Remove the bolts (2) , then remove the cover (1).
oozes from the air bleed port (2)s. Tightening torque for bolt installation：63.7 - 73.5
If oil does not ooze out, remove the air bleed plug N・m ( 46.991 - 54.220 lbf・ft. )
(1), and fill hydraulic oil(3) from the air bleed port (2)
into the pump (4) case.
Temporarily tighten the air bleed plug (1).
Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air bleed
port (2) section.
Completely tighten the air bleed plug (1).
2. Use a hexagon wrench [ 6 mm ( 0.236 in. ) ] (1) to

remove the air bleed plug (2) as in the figure on the
left.
3. Pour in about 500 cc of hydraulic oil (1) from the air

bleed port.
When inside the motor is filled with hydraulic oil (1)
, tighten the air bleed plug.
4. Start the engine and execute a slow travel opera-

tion.
5. Repeatedly travelling forward and backward bleeds
off the air.
84551720B NA - August 2012

8001G-4
Air Bleed Procedure
Swing Motor HBCV

1. Run the engine at low idle, use a hexagon wrench [ CAUTION
8 mm ( 0.315 in. ) ] (3) to remove the air bleed plug
(2) as in the figure on the right. The HBCV air bleeding work requires 2 work-
Check that oil oozes from the air bleed port section. ers: an operator and an air bleed worker.
Decide the signals beforehand and work safely.
* Do not execute a swing operation.
Set the main unit so that the arm HBCV is at the
highest position.
Boom Cylinder HBCV

1. Start the engine and lower the boom without jacking
up the main unit.
2. In the above state, loosen the hose mouthpiece (1)
at the position in the figure.
Foaming hydraulic oil comes out from the hose
mouthpiece section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece (1).
1 Drain hose
2. If oil does not ooze out, stop the engine for now, and
fill hydraulic oil (2) from the air bleed port (1) into the
motor case.
Temporarily tighten the air bleed plug.
Run the engine at low idle, slightly loosen the air
bleed port (1) , and run until oil oozes from the air
bleed port (1) section.
3. Completely tighten the air bleed plug.

4. With the engine at low idle, slowly swing evenly left
and right at least 2 rotations.
Check
After the air bleeding is complete, stop the engine for at 2 HBCV
least 5 minutes to allow any air bubbles in the hydraulic
oil tank to dissipate. 3. Execute steps 2. for the opposite side boom cylin-
der too.
4. Check boom operations.
If there is a delay in the operation response, bleed
the air again with the same procedure.
84551720B NA - August 2012

8001G-5
Air Bleed Procedure
Arm Cylinder HBCV

1. For arm-in operations, bleed the air from the arm
cylinder HBCV (1) using the same procedure as for
boom cylinder HBCV air bleeding.
2 Hose mouthpiece
84551720B NA - August 2012

8001G-6
Section
8002
Removal and Installation of Hydraulic Oil Tank
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

WARNING Removal of Hydraulic Oil Tank

• Keep away from fire. 1. Drain the oil from the hydraulic oil tank. (For details,
• Bleed off the pressure in the hydraulic oil see "Draining Oil from Hydraulic Oil Tank".)
tank before beginning work. 2. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
• The temperature of the hydraulic oil is high 6 bolts (1), and then remove the under cover (2).
immediately after stopping the engine. Wait Tightening torque for bolt installation: 63.7 - 73.5
until the hydraulic oil temperature has de- N・m ( 46.991 - 54.220 lbf・ft. )
creased (to 40°C ( 104.0 °F ) or less) before
beginning work.
CAUTION
work.
load.
Items to prepare
• Wrenches [ 7 mm ( 0.276 in. ), 19 mm ( 0.748 in. ), 22 3. Prepare a waste oil can (1) under the hydraulic oil
mm ( 0.866 in. ), 24 mm ( 0.945 in. ), 27 mm ( 1.063 tank.
in. ), 36 mm ( 1.417 in. ) ]
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank
4. Use a wrench [ 7 mm ( 0.276 in. ) ] to loosen the

hose bands (1), and then remove the hose (2).
• Use caps to cover the hose to prevent any entry
of water, dust or dirt.
84551720B NA - August 2012

8002-3

5 bolts (1), and then remove the center cover (2).

hose bands (1), and then remove the drain hoses
(2) and (3).
• Use caps to cover the lines to prevent any entry
of water, dust or dirt.
Drain hose [use 27 mm (1.063

1
in.) wrench]
2
in.) wrench]
3
in.) wrench]
7. Use wrenches [ 19 mm ( 0.748 in. ), 22 mm ( 0.866 4
in.) wrench]
in. ), 27 mm ( 1.063 in. ), 36 mm ( 1.417 in. ) ] to Drain hose [use 19 mm (0.748
remove the drain hoses. 5
in.) wrench]
• Mark the hydraulic oil tank and hoses so that the Drain hose [use 19 mm (0.748
6
connectors match at the time of assembly. in.) wrench]
• Attach caps or plugs to the hydraulic oil tank and Drain hose [use 19 mm (0.748
7
hoses to prevent any entry of water, dust or dirt. in.) wrench]
• Clean the hydraulic oil tank and hoses by spray- Drain hose [use 19 mm (0.748
ing them with a parts cleaner to prevent scratches 8
in.) wrench]
and prevent dirt from accumulating on the con- Drain hose [use 22 mm (0.866
nectors. 9
in.) wrench]
Pump drain hose [use 36 mm
10
(1.417 in.) wrench]
84551720B NA - August 2012

8002-4
8. Cut the hose bands on the tank side, and tie the 10. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove
hoses together. the 3 bolts (1) for the L-shaped frame (2) between
the control valve and the hydraulic oil tank, and then
remove the L-shaped frame.

7 bolts (1), and then remove the top cover (2) from
the hydraulic oil tank.
84551720B NA - August 2012

8002-5
11. Use a wrench [ 24 mm ( 0.945 in. ) ] to remove the 13. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove
4 bolts (1) and 4 collars (2) from the bottom of the the 5 bolts (1) from the fuel tank side cover (2), and
hydraulic oil tank. then remove the side cover.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame.
Do not lose them.
Also, mark or write down the location where they
are and how many.
N・m ( 171.439 - 203.601 lbf・ft. )

4 bolts (1), and then remove the side covers (tank)
(2).

2 bolts (2) from the fuel tank front cover (tank) (1),
and then remove the cover (tank).
15. Connect the 2 eyebolts (M12) (1) to the top of the

hydraulic oil tank, and then use the shackles (2),
wire rope (3) and liftcrane to lift the hydraulic oil tank
(4).
• When lifting, be careful that the level gauge (5)
does not interfere with the frame at the side of the
hydraulic oil tank.
by a half turn.
84551720B NA - August 2012

8002-6

lowering the hydraulic oil tank on wood plank (1).
• Thoroughly secure the hydraulic oil tank so that it
does not fall down.
84551720B NA - August 2012

8002-7
Installation of Hydraulic Oil Tank For bolts for which the torque is not specified, check
of the "About This Shop Manual Section • Tightening
To install, perform the reverse of the removal procedure. Torque • Retightening Torque Table" in the explanation
Tighten bolts being installed to the specified torque. in the materials.
84551720B NA - August 2012

8002-8
Section
8003
Removal and Installation of Hydraulic Pump
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Job code JPPU03 Removal of Hydraulic Pump

WARNING 6 bolts (1), and then remove the under cover (2).
• Be sure to release hydraulic pressure before
beginning work.
CAUTION
work.
load.
Items to prepare
19 mm ( 0.748 in. ), 22 mm ( 0.866 in. ), 27 mm ( • Remove the engine hood.
1.063 in. ), 36 mm ( 1.417 in. ) ] For details, see "Removal and Installation of En-
gine Hood".
• Hexagon wrenches [ 8 mm ( 0.315 in. ), 10 mm ( 0.394
in. ) ] • Remove the side door (right). (For details, see
"Removal and Installation of Side Door".)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity) 2. Close the drain cock (1).
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
3. Use pliers to loosen the hose bands (1), and then

remove the 2 hoses (2).
Use a wrench [ 13 mm ( 0.512 in. ) ] to remove
the 2 bolts (3) and 2 washers, and then remove the
pre-filter (4).
84551720B NA - August 2012

8003-3
4. Use a wrench [ 27 mm ( 1.063 in. ) ] to remove the 7. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
hose (1), use a wrench [ 19 mm ( 0.748 in. ) ] to 6 bolts (1), and then remove the cover (2) (3).
remove the hose (2), use a wrench [ 22 mm ( 0.866
in. ) ] to remove the hose (3), use a wrench [ 17
mm ( 0.669 in. ) ] to remove the 2 bolts (4) and 2
washers, and then remove the pilot filter (5).
• Remove the 5 stack solenoid. (For details, see
"Removal and Installation of 5 Stack Solenoid".)

6 bolts (1), and then remove the front duct cover (2).

2 bolts (1), and then remove the rear duct cover (2).
5. Remove the muffler. (For details, see "Removal and

Installation of Muffler".)
8 bolts (1), and then remove the duct cover (2).
84551720B NA - August 2012

8003-4

4 bolts (1), and then remove the center duct cover
(2).
12. Secure the pump with a liftcrane and nylon sling (1)
so that it does not fall during removal and installation
operations.
11. Remove the hoses and connectors that are con-
nected to the pump.
• Use a hexagon wrench [ 8 mm ( 0.315 in. ) ]
to remove the 8 hose bolts (1), and remove the
pressure hose (2).
• Use a wrench [ 36 mm ( 1.417 in. ) ] to remove
the drain hose (3).
the pilot hose (4).
the suction hose (5).
• Remove the connector (6).

12 bolts (1) from the pump.

the hydraulic pilot hoses (7).
• Use a hexagon wrench [ 10 mm ( 0.394 in. ) ] 14. Use a liftcrane and the nylon sling (1) to pull the
to remove the 4 suction line bolts (8) and remove pump out from the shaft and lift the pump.
the suction line (9).
• Mark the pump and hoses so that the connectors
• Attach caps or plugs to the pump and hoses to
• Clean the pump and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
84551720B NA - August 2012

8003-5
15. Thoroughly check that the location is safe before Installation of Hydraulic Pump
placing the pump on the wood plank (1).
• When installing the bolts, tighten them to the specified
• Thoroughly secure the pump so that it does not torque.
fall over. If the torque is not specified for a bolt, see the "Bolt
Size and Torque Table".
• Fill the pump case with hydraulic oil from the drain port
so that no air remains in the pump case.
Additionally, when there is a 2nd option gear pump,
bleed off air from the air bleed port on the top surface
of the power take-off case.
1. Use a liftcrane and nylon sling (1) to secure the
pump.
2. Use a liftcrane and nylon sling (1) to lift the pump

and lower it inside the housing.
3. Use a wrench [19 mm (0.748 in.)] to install the 12

pump bolts (1).
Bolt (1) tightening torque: 63.7 - 72.6 N·m (46.991
- 53.556 lbf·ft.)
• Apply Loctite to the threaded sections of the bolts.
4. Connect the hoses and connectors to the pump.
84551720B NA - August 2012

8003-6
• Use a hexagon wrench [10 mm (0.394 in.)] to in- 6. Use a wrench [19 mm (0.748 in.)] to install the rear
stall the suction line bolts (1), and install the suc- duct cover (2) with the 2 bolts (1).
tion line (2).
• Use a wrench (19 mm) to install the hydraulic pilot
hoses (3).
7. Use a wrench [19 mm (0.748 in.)] to install the front

duct cover (2) with the 6 bolts (1).
• Install the connectors (4).

• Use a wrench [36 mm (1.417 in.)] to install the
suction hose (5).
pilot hose (6).
drain hose (7).
pressure hose (9) with the 8 hose bolts (8).
8. Use a wrench [19 mm (0.748 in.)] to install the cover

(2) (3) with the 6 bolts (1).
5. Use a wrench [19 mm (0.748 in.)] to install the cen-

ter duct cover (2) with the 4 bolts (1).
9. Use a wrench [19 mm (0.748 in.)] to install the duct

cover (2) with the 8 bolts (1).
84551720B NA - August 2012

8003-7
10. Use a wrench [27 mm (1.063 in.)] to install the hose

(1), use a wrench [19 mm (0.748 in.)] to install the
hose (2), use a wrench [22 mm (0.866 in.)] to install
the hose (3), use a wrench [17 mm (0.669 in.)] to
install the 2 bolts (4) and 2 washers, and install the
pilot filter (5).
• Install the 5 stack solenoid. (For details, see "Re-
moval and Installation of 5 Stack Solenoid".)
• Install the side door (right).(For details, see "Re-

moval and Installation of Side Door".)
• Install the engine hood.(For details, see "Removal
and Installation of Engine Hood".)
13. Use a wrench [19 mm (0.748 in.)] to install the under
Bolt (1) tightening torque: 63.7 - 73.5 N·m (46.991
- 54.220 lbf·ft.)
11. Use pliers to tighten the hose bands (1) and install
the 2 hoses (2).
Use a wrench [13 mm (0.512 in.)] to install the 2
bolts (3) and 2 washers, and then install the pre-filter
(4).
12. Open the drain cock (1).
84551720B NA - August 2012

8003-8
Section
8004
Removal and Installation of Control Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Job code 35359AB10 Removal of Control Valve

1. Extend the attachment and bring in contact with the
WARNING ground.
• Keep away from fire. • Drain the oil from the hydraulic oil tank. (For de-
• Be sure to release hydraulic pressure before tails, see "Draining Oil from Hydraulic Oil Tank")
beginning work.
CAUTION
work.
load.
Items to prepare
mm ( 0.748 in. ), 22 mm ( 0.866 in. ), 24 mm ( 0.945
in. ), 41 mm ( 1.614 in. ) ] 2. After opening the engine hood, use a wrench [ 19
• Hexagon wrenches [ 8 mm ( 0.315 in. ), 10 mm ( 0.394 mm ( 0.748 in. ) ] to remove the 5 bolts (1), then
in. ) ] remove the top cover (2).
• Wire cutters
• Wire rope (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid

3 bolts (2), and then remove the under cover (1).
84551720B NA - August 2012

8004-3
4. Remove the connectors (1) (2) (3) from the pressure 7. Use a wrench [ 8 mm ( 0.315 in. ) ] to remove the
sensor. hose band (2), then remove the low-pressure hose
(1).
5. Remove the connectors (1) from the pressure sen-

sor. 8. Use a wrench [ 17 mm ( 0.669 in. ) ] to remove the
2 bolts (1), then remove the bracket (2).

hose band (2), and then remove the low-pressure 9. Use wrenches [ 19 mm ( 0.748 in. ), 22 mm ( 0.866
hose (1). in. ) 41 mm ( 1.614 in. ) ] and hexagon wrenches [
8 mm ( 0.315 in. ), 10 mm ( 0.394 in. ) ] to remove
the control valve lines and hoses.
• Mark the lines and hoses so that the connectors
• Use caps or plugs to cover the lines and hoses to
• Clean the lines by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumu-
lating on the connectors.
84551720B NA - August 2012

8004-4
11. Install the 2 eyebolts (1) (M10) on the control valve.
12. Install the shackles (2) on the eyebolts, then use the
liftcrane and wire ropes (3) to lift the control valve
(1).
13. Place the control valve (1) on wood planks (2).

4 bolts (1) from the control valve.
84551720B NA - August 2012

8004-5
Installation of Control Valve 4. Use wrenches [ 19 mm ( 0.748 in. ), 22 mm ( 0.866

in. ), 41 mm ( 1.614 in. ) ] and hexagon wrenches
1. Install the 2 eyebolts (1) (M10) on the control valve. [ 8 mm ( 0.315 in. ), 10 mm ( 0.394 in. ) ] to install
the control valve lines and hoses.
2. Install the shackles (2) on the eyebolts, then use the

liftcrane and wire ropes (3) to lift the control valve
(1) in such a way that it does not interfere with the
housing, engine parts and pipes.
3. Use a wrench [ 24 mm ( 0.945 in. ) ] to install the 4

bolts (1) for the control valve.
Bolt (1) tightening torque: 267 - 312 N・m ( 196.96
- 230.15 lbf・ft. )
84551720B NA - August 2012

8004-6
5. Use a wrench [ 17 mm ( 0.669 in. ) ] to install the 9. Install the connectors (1) (2) (3) on the pressure
bracket (2) with the 2 bolt (1). sensor.
6. Use a wrench [ 7 mm ( 0.276 in. ) ] to install the 10. Use a wrench [ 19 mm ( 0.748 in. ) ] to install the
low-pressure hose (1) with the hose band (2). under cover (1) with the 3 bolts (2).
- 54.220 lbf・ft. )

low-pressure hose (1) with the hose band (2).
top cover (2) with the bolt (1).
8. Install the connectors (1) on the pressure sensor.
84551720B NA - August 2012

8004-7
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8004-8
Section
8005A
Removal and Installation of Bucket Cylinder
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CAUTION Removal of Bucket Cylinder

• Stop the machine on a level location with • Remove the bucket. (For details, see "Removal and
good footing. Installation of Bucket".)
• Be sure to stop the engine before beginning • Remove the bucket link. (For details, see "Removal
work. and Installation of Bucket Link".)
• When working together with others, always 1. Bring the arm (1) top in contact with the ground.
be sure to exchange signals and pay ade- Retract the bucket cylinder rod.
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.
• Be sure to inspect the nylon sling and other
load.
Items to prepare
• Hammer
• Striking rod
• Nylon sling (with the required lifting capacity) 2. Tie the cylinder rod with wire (1) so that it cannot
• Grease come out.
• Rag
• Cleaning fluid
• Crosstie
• Wire
3. Turn the key switch (1) OFF and stop the engine.
84551720B NA - August 2012

8005A-3
4. Switch the key switch ON again, and then turn the • Use caps or plugs to cover the hoses and lines to
control lever (1) about 10 times to bleed out any prevent any entry of water, dust or dirt.
pressure. • Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
Note:
Do not operate the bucket at this time.
8. Use a liftcrane and nylon sling (2) to secure the

5. Move the travel lever (1) back and forth about 5
bucket cylinder (1).
times to bleed off the pressure.
Return the key switch to OFF. • Wrap the nylon sling to the inside of the line so
that it is not crushed.
6. Press the air breather button (1) on top of the hy-

draulic oil tank to release the pressure inside the 9. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
tank. bolt (1) and washer (2).
7. Use 2 wrenches [ 36 mm ( 1.417 in. ) ] to remove

the hoses (1) (2).
84551720B NA - August 2012

8005A-4
10. Use a hammer (2) and striking rod (3) to push the Installation of Bucket Cylinder
pin (1) out.
• Tighten lines and bolts being installed to the specified
• When removing the pin, be careful not to damage torque.
the installed O-rings or dust seals. • When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.
11. Lift the bucket cylinder (1) and then place it on the
crosstie.
2. Tie the cylinder rod with wire (1) so that it cannot
come out.
3. Use a liftcrane and nylon sling (2) to lift the bucket

cylinder (1).
• Wrap the nylon sling to the inside of the line so
4. Align the bucket cylinder (1) with the arm and use a
hammer (3) to push in the pin (2).
• If a pin is hard to insert, the cylinder is tilted.
• When inserting the pin, be careful not to damage
the installed O-rings or dust seals.
84551720B NA - August 2012

8005A-5
6. Use 2 wrenches [ 36 mm ( 1.417 in. ) ] to install the

hoses (1) (2).
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)

bolt (1) and washer (2).
84551720B NA - August 2012

8005A-6
Section
8005B
Removal and Installation of Arm Cylinder
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Arm Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CAUTION Removal of Arm Cylinder

• Stop the machine on a level location with 1. Use a liftcrane and nylon sling (1) to secure the arm
good footing. cylinder (2).
work.
• When working together with others, always
be sure to exchange signals and pay ade-
ing with a hammer.
load.
Items to prepare
2. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the
• Wrenches [ 19 mm ( 0.748 in ), 36 mm ( 1.417 in ), 41 bolt (1) and washer (2).
mm ( 1.614 in ) ]
• Nylon sling (with the required lifting capacity)
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire
3. Use a hammer (2) and striking rod (3) to remove the

pin (1).
Be careful. The arm and arm cylinder rod may come
out of place at this time.
84551720B NA - August 2012

8005B-3
4. Start the engine, move the arm out at idle, and re- 7. Switch the key switch ON again, and then turn the
tract the arm cylinder (1) rod. control lever (1) about 10 times to bleed out any
pressure.
Do not operate the arm at this time.

come out.
times to bleed off the pressure.
Switch the key switch OFF.

draulic oil tank to release the pressure inside the
tank.

hose (1) and use a wrench [ 36 mm ( 1.417 in ) ] to
remove the hose (2).
• Use caps or plugs to cover the hoses and lines to
• Clean the hoses and lines by spraying them with
84551720B NA - August 2012

8005B-4
• If a pin is hard to remove, there is a load on the

pin.
• When removing the pin, be careful not to damage
the installed dust seals.
11. Use a wrench [ 19 mm ( 0.748 in ) ]) to remove the

grease hose (1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.
14. Place the arm cylinder (1) on the crosstie.

pin (1) out.
84551720B NA - August 2012

8005B-5
Installation of Arm Cylinder

• Tighten lines and bolts being installed to the specified
torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
5. Use a wrench [ 19 mm ( 0.748 in ) ] to tighten the


come out.
6. Use a wrench [ 19 mm ( 0.748 in ) ] to attach the

grease hose (1).
3. Use a liftcrane and nylon sling (2) to lift the arm

cylinder (1).
• Wrap the nylon sling to the inside of the line so

hose (1) and use a wrench [ 36 mm ( 1.417 in ) ] to
attach the hose (2).
4. Align the arm cylinder with the boom and use a ham-
mer (2) to push in the pin (1).
• If a pin is hard to insert, there is a load on the pin.
84551720B NA - August 2012

8005B-6
8. Start the engine, move the arm in at idle, and extend 10. Use a wrench [ 19 mm ( 0.748 in ) ] to tighten the
the arm cylinder (1) rod. bolt (1) and washer (2).
• Grease up.
9. Align the arm cylinder (1) with the arm pin hole and
use a hammer (3) to insert the pin (2).
Be careful. The arm and arm cylinder rod may come
out of place at this time.
84551720B NA - August 2012

8005B-7
84551720B NA - August 2012

8005B-8
Section
8005C
Removal and Installation of Boom Cylinder
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CAUTION Removal of Boom Cylinder

• Stop the machine on a level location with • When removing only the boom cylinder, put the attach-
good footing. ments in the temporary decommissioning posture.
• Be sure to stop the engine before beginning • When removing as far as the boom, first remove the
work. bucket, bucket link, bucket cylinder, arm, arm cylinder
• When working together with others, always according to their respective removal and installation
be sure to exchange signals and pay ade- procedures.
quate attention to safety. Bring the boom top in contact with the ground.
• Always wear protective devices (protective 1. Use a liftcrane and nylon sling (1) to secure the
eyewear and safety shoes, etc.) when work- boom cylinders (right) (left) (2) (3).
ing with a hammer.
load.
Items to prepare
• Wrenches [19 mm (0.748 in.), 30 mm (1.181 in.), 36
mm (1.417 in.)]
• Crowbar
• Wire rope (with the required lifting capacity)
• Nylon sling
• Marking pen
• Cap 2. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the
• Plug grease hoses on the left and right sides (1).
• Hammer
• Striking rod dust or dirt.
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire
3. Use 2 wrenches [ 30 mm ( 1.181 in ) ] to remove the

2 double nuts (1) and bolt (2), and then remove the
fastening ring (3).
Also, remove the cab side in the same way.
84551720B NA - August 2012

8005C-3
4. Use a hammer (2) and striking rod (3) to push the 7. Switch the key switch ON again, and then turn the
pin (1) out. control lever (1) about 10 times to bleed out any
Start the engine, lower the boom at idle, and retract pressure.
the boom cylinder (right) (left) rods.

5. Tie the cylinder rods on the left and right sides with times to bleed off the pressure.
wire (1) so that they cannot come out.
• Switch the key switch OFF.
draulic oil tank to release the pressure inside the
tank.

hose (1).
• Mark the lines and hoses so that the connectors
• Use caps or plugs to cover the hoses and lines to
• Clean the hoses and lines by spraying them with
84551720B NA - August 2012

8005C-4
12. Use a crowbar to remove the pin (1).


Also, remove the cab side in the same way. 13. Use a liftcrane and nylon slings (1) to lift the boom
cylinders (right) (left) (2) (3) and remove.
• Place the boom cylinders (right) (left) (2) (3) on
crossties.
84551720B NA - August 2012

8005C-5
Installation of Boom Cylinder 4. Align the boom cylinders (right) (left) with the swing
frame pin holes and use a hammer (2) to push in
• Tighten bolts being installed to the specified torque. the pin (1).
and Torque Table". • When inserting the pin, be careful not to damage

2. Tie the cylinder rods on the left and right sides with bolt (1) and washer (2).
wire (1) so that they cannot come out. Also, attach the cab side in the same way.
3. Use a liftcrane and nylon slings (1) to lift the boom 6. Use wrench [ 36 mm ( 1.417 in ) ] to install the hose
cylinders (right) (left) (2) (3). (1).
Also, install the cab side hose in the same way.
84551720B NA - August 2012

8005C-6
7. Start the engine, raise the boom at idle, and extend 9. Use a wrench [ 19 mm ( 0.748 in ) ] to attach the
the boom cylinder (right) (left) (1) (2) rods. grease hoses on the right and left sides (1).
Align the boom cylinder (right) (left) (1) (2) with the
boom pin holes and use a hammer (4) to push in • Grease up.
the pin (3). • When installing as far as the boom, first install
the bucket, bucket link, bucket cylinder, arm, arm
• If the insertion of a shim is possible according to cylinder according to their respective removal and
the tolerance adjust the shim. installation procedures.
8. Use 2 wrenches [ 30 mm ( 1.181 in ) ] to attach the 2

double nuts (1) and bolt (2), and install the fastening
ring (3).
Also, install the cab side in the same way.
84551720B NA - August 2012

8005C-7
84551720B NA - August 2012

8005C-8
Section
8006
Removal and Installation of Center Joint
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 35354AA10 Removal of Center Joint

1. Use a hexagon wrench [ 5 mm ( 0.197 in. ) ] to
CAUTION remove the 4 bolts (1), and then remove the air
breather (2) on the hydraulic oil tank.
work.
load.
Items to prepare
27 mm ( 1.063 in. ), 36 mm ( 1.417 in. ) ]
• Hexagon wrenches [ 5 mm ( 0.197 in. ), 6 mm ( 0.236
in. ) ]
• Box wrench [ 19 mm ( 0.748 in. ) ]
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply) 2. Attach the specialty adapter (1) to the area where
• Extension cable the air breather is removed, and set the vacuum
• Marking pen pump (2).
• Cap Create negative pressure in the hydraulic oil tank
• Plug using the vacuum pump.
• Rag
• Cleaning fluid
• Waste oil can

the 8 bolts (2), and then remove the lower under
covers (1).
84551720B NA - August 2012

8006-3
4. Prepare a waste oil can (1) to receive the oil that 7. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
spills out under the center joint. 2 bolts (2), and then remove the center joint lock bar
(1).

travel hoses (1) and a wrench [ 27 mm ( 1.063 in. ) 8. Use a wrench [ 36 mm ( 1.417 in. ) ] to remove the
] to remove the drain hoses (2). 4 travel hoses (1).
• Mark the center joint and hoses so that the con- • Mark the hoses so that the connectors can be
nectors match at the time of assembly. matched during assembly.
• Attach caps or plugs to the center joint and hoses • Attach caps or plugs to the hoses to prevent any
to prevent any entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the center joint and hoses by spraying them • Clean the hoses by spraying them with a parts
with a parts cleaner to prevent scratches and pre- cleaner to prevent scratches and prevent dirt from
vent dirt from accumulating on the connectors. accumulating on the connectors.
6. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the 9. Wrap wire ropes (1) around the center joint and sus-
pilot hoses (1) and a wrench [ 27 mm ( 1.063 in. ) ] pend it with a liftcrane so that the center joint does
to remove the drain hose (2). not fall during removal and installation operations.
• Attach caps or plugs to the center joint and hoses
• Clean the center joint and hoses by spraying them
84551720B NA - August 2012

8006-4
10. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the Installation of Center Joint
4 bolts (1) from the center joint.
For bolts for which the torque is not specified, check the
"Bolt Size and Torque Table".
1. Wrap the wire rope (2) around the center joint (1)
and lift it with a liftcrane.
11. Use the wire ropes (2) and liftcrane to lift the center
joint (1).
Thoroughly check that the location is safe before
lowering the center joint on wood planks.
2. Use a wrench [ 19 mm ( 0.748 in. ) ] to tighten the

4 bolts (1) for the center joint.

travel hoses (1).
84551720B NA - August 2012

8006-5
4. Use a wrench [ 19 mm ( 0.748 in. ) ] to install the 2 7. Use a box wrench [ 19 mm ( 0.748 in. ) ] to install
bolts (2), then install the center joint lock bar (1). the 8 bolts (2) and install the lower under cover (1).
Bolt (2) tightening torque: 88.3 - 107 N・m ( 65.14
- 78.93 lbf・ft. ) • Bolt (2) tightening torque: 63.9 - 73.5 N ・ m (
47.14 - 54.22 lbf・ft. )
• Apply Loctite #262 to the bolts.

5. Use a wrench [ 19 mm ( 0.748 in. ) ] to install the install the 4 bolts (1), then install the air breather (2)
pilot hose (1) and a wrench [ 27 mm ( 1.063 in. ) ] on the hydraulic oil tank to the location from which
to install the drain hose (2). the specialty adapter for the vacuum pump was re-
moved.

travel hoses (1) and a wrench [ 27 mm ( 1.063 in. )
] to install the drain hoses (2).
84551720B NA - August 2012

8006-6
Section
8007A
Removal and Installation of Travel Remote Control Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 35356AK19 Removal of Travel Remote Control

Valve
WARNING
1. Remove the floor mat (1).
beginning work.
CAUTION
work.
Items to prepare
• Wrench [ 19 mm ( 0.748 in. ) ]
• Phillips screwdriver
• Marking pen
• Cap
Plug 2. Use a hexagon wrench [ 8 mm ( 0.315 in. ) ] to re-
•
Rag move the 2 bolts (2) on both the left and right sides,
•
Cleaning fluid and then remove the left and right travel pedals (1).
•

remove the 2 bolts (2) on both the left and right sides
of the lever, and then remove the levers (1).
84551720B NA - August 2012

8007A-3
4. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the 6. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
6 bolts (2), and then remove the under cover (1). 2 hose adapters (1).
5. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the 7. Use a hexagon wrench [ 8 mm ( 0.315 in. ) ] to
6 hoses (1). remove the 2 bolts (1) on both the left and right sides
of the travel lever.
• Mark the valve and hoses so that the connectors
• Install caps or plugs to the valve and hoses to
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
8. Pull up the travel remote control valve (1) into the

cab, and then remove the travel remote control
valve.
84551720B NA - August 2012

8007A-4
Installation of Travel Remote 4. Use a wrench [ 19 mm ( 0.748 in. ) ] to install the 6

hoses (1).
Control Valve Tightening torque: 25.4 - 31.4 N ・ m ( 18.737 -
23.163 lbf・ft. ) /44.0 - 54.0 N・m ( 32.458 - 39.835
Be careful not to connect the hydraulic hoses in incorrect
lbf・ft. )
locations.
Before installing the hoses, check that the hose adapters
are not loose and retighten them to the specified torque.
When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Pull down the travel remote control valve (1) into the
cab, then install the travel remote control valve.

bolts (2) and install the under cover (1).

install the 2 bolts (1) on both the left and right sides
of the travel lever.

install the 2 bolts (2) on both the left and right sides
of the lever, then install the levers (1).

hose adapters (1).
84551720B NA - August 2012

8007A-5
7. Use a hexagon wrench [ 8 mm ( 0.315 in. ) ] to 8. Install the floor mat (1).
install the 2 bolts (2) on both the left and right sides,
then install the left and right travel pedals (1).
84551720B NA - August 2012

8007A-6
Section
8007B
Removal and Installation of Operation Remote Control Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Operation Remote Control Valve (left side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operation Remote Control Valve (left side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Job code 35355AH21 Removal of Operation Remote

Control Valve (left side)
WARNING
1. Roll up the boot (1) of the control lever and use the
• Be sure to release hydraulic pressure before Phillips screwdriver or box wrench [ 10 mm ( 0.394
beginning work. in. ) ] to remove the 2 bolts (2) of the console top
cover.
CAUTION
work.
Items to prepare
• Wrenches [ 19 mm ( 0.748 in. ), 22 mm ( 0.866 in. )]
• Box wrench [ 10 mm ( 0.394 in. ) ]
• Marking pen
• Cap
• Plug
• Rag 2. Use the Phillips screwdriver to remove the 2 screws
• Cleaning fluid (2), and then remove the handle of the tilt lever (1).

remove the 2 bolts (2), and remove the grip (1) of
the gate lock lever.
84551720B NA - August 2012

8007B-3
4. Use the Phillips screwdriver to remove the 2 screws 7. Roll up the boot (1) of the control lever, remove the
(1) of the console top cover. connector (2) of the horn switch, and cut the wire
band (3).
5. Remove the 3 connectors (2) and remove the con-

sole top cover (1). 8. While securing the nut (2) with a wrench [ 22 mm (
0.866 in. ) ], use a wrench [ 19 mm ( 0.748 in. ) ]
to remove the lock nut (3) and remove the control
lever (1).
6. Use the Phillips screwdriver or box wrench [ 10 mm

( 0.394 in. ) ] to remove the 5 bolts (2), then remove
the cover (1).
9. Roll back the hose cover (1).

6 hoses (1).
• Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
84551720B NA - August 2012

8007B-4
Installation of Operation Remote

Control Valve (left side)
1. Clean all the parts with a rag.
11. Use the hexagon wrench [ 5 mm ( 0.197 in. ) ] to

remove the 3 bolts (1) and 3 washers (2).
2. Install the joystick remote control valve (1).
12. Remove the joystick remote control valve (1).

install the 3 bolts (1) and 3 washers (2).

hoses (1).
• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
( 18.738 - 23.163 lbf・ft. )
Hydraulic hose tightening torque: 44 - 54 N·m (
32.459 - 39.835 lbf・ft. )
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque:
44 - 54 N·m ( 32.459 - 39.835 lbf・ft. )
84551720B NA - August 2012

8007B-5

( 0.394 in. ) ] to install the 5 bolts (2), then install
the cover (1).
5. Put the hose cover (1) in place.
9. Install the 3 connectors (2) and install the console

top cover (1).
6. While securing the nut (2) with a wrench [ 22 mm (

to install the lock nut (3) and install the control lever
(1).
10. Use the Phillips screwdriver to install the 2 screws
(1) of the console top cover.
7. Install the horn switch connector (2), bundle with the

wire band (3), then cover the control lever boot (1).
84551720B NA - August 2012

8007B-6
11. Use a hexagon wrench [ 5 mm ( 0.197 in. ) ] to Removal of Operation Remote

install the 2 bolts (2), and install the grip (1) of the
gate lock lever. Control Valve (right side)
1. Roll up the boot (1) of the control lever and use the
Phillips screwdriver or box wrench [ 10 mm ( 0.394
in. ) ] to remove the 2 bolts (2) of the console top
cover.

(2), then install the handle of the tilt lever (1).
2. Use the Phillips screwdriver to remove the 2 screws

(2), and then remove the handle of the tilt lever (1).

( 0.394 in. ) ] to install the 2 bolts (2) for the console
top cover and cover the control lever boot (1).
3. Use the Phillips screwdriver to remove the 2 screws

84551720B NA - August 2012

8007B-7
4. Remove the 3 connectors (2) and remove the con- 7. While securing the nut (2) with a wrench [ 22 mm (
sole top cover (1). 0.866 in. ) ], use a wrench [ 19 mm ( 0.748 in. ) ]
to remove the lock nut (3) and remove the control
lever (1).

( 0.394 in. ) ] to remove the 5 bolts (2), then remove
the cover (1). 8. Roll back the hose cover (1).
6. Roll up the boot (1) of the control lever, remove the 9. Use a wrench [ 22 mm ( 0.866 in. ) ] to remove the
connector (2) of the horn switch, and cut the wire 6 hoses (1).
band (3).
• Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
the connectors.
84551720B NA - August 2012

8007B-8
10. Use the hexagon wrench [ 5 mm ( 0.197 in. ) ] to Installation of Operation Remote
remove the 3 bolts (1) and 3 washers (2).
Control Valve (right side)
1. Clean all the parts with a rag.
11. Remove the joystick remote control valve (1).
2. Install the joystick remote control valve (1).

install the 3 bolts (1) and 3 washers (2).

hoses (1).
• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
( 18.738 - 23.163 lbf・ft. )
Hydraulic hose tightening torque: 44 - 54 N·m (
32.459 - 39.835 lbf・ft. )
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque:
41 - 54 N·m ( 32.459 - 39.835 lbf・ft. )
84551720B NA - August 2012

8007B-9

( 0.394 in. ) ] to install the 5 bolts (2), then install
the cover (1).
5. Put the hose cover (1) in place.
9. Install the 3 connectors (2) and install the console

top cover (1).
6. While securing the nut (2) with a wrench [ 22 mm (

to install the lock nut (3) and install the control lever
(1).
7. Install the horn switch connector (2), bundle with the

wire band (3), then cover the control lever boot (1).
84551720B NA - August 2012

8007B-10
11. Use the Phillips screwdriver to install the 2 screws 12. Use the Phillips screwdriver or box wrench [ 10 mm
(2), then install the handle of the tilt lever (1). ( 0.394 in. ) ] to install the 2 bolts (2) for the console
top cover and cover the control lever boot (1).
84551720B NA - August 2012

8007B-11
84551720B NA - August 2012

8007B-12
Section
8007C
Removal and Installation of 5 Stack Solenoid
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of 5 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of 5 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 35357AG06 Removal of 5 Stack Solenoid Valve

1. Attach the specialty adapter (1) to the area where
WARNING the air breather is removed, and set the vacuum
pump (2).
• Be sure to release hydraulic pressure before Create negative pressure in the hydraulic oil tank
beginning work.
using the vacuum pump.
CAUTION
work.
Items to prepare
19 mm ( 0.748 in. ), 22 mm ( 0.866 in. )]
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
2 cover bolts (1) and then remove the cover (2).
84551720B NA - August 2012

8007C-3
3. Remove the 5 connectors (1). • Clean the solenoid valve and hose by spraying
them with a parts cleaner to prevent scratches
nector.
4. Use wrenches [ 19 mm ( 0.748 in. ), 22 mm ( 0.866

in. )] to remove the hoses (1) (2) (3).
• Mark the solenoid valve and hose so that the con-
nector matches at the time of assembly.
• Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or
dirt.
• Clean the solenoid valve and hose by spraying
nector.

in. )] to remove the hoses (1) (2) (3).
• Mark the solenoid valve and hose so that the con-
nector matches at the time of assembly.
dirt.
• Clean the solenoid valve and hose by spraying
hoses (1) (2).
• Mark the solenoid valve and hose so that the con- and prevent dirt from accumulating on the con-
nector matches at the time of assembly. nector.
dirt.
84551720B NA - August 2012

8007C-4
Installation of 5 Stack Solenoid

Valve
bolts (2), then install the 5 stack solenoid valve (1).

in. )] to install the hoses (1) (2) (3).
Pilot hose [use 19 mm ( 0.748 in. )

1
wrench]
2
wrench]
3
wrench]

2 bolts (2), and then remove the 5 stack solenoid
valve (1).
Pilot hose
1 [use 19 mm ( 0.748 in. )
wrench]
Pilot hose
2 [use 19 mm ( 0.748 in. )
wrench]
Pilot hose
3 [use 22 mm ( 0.866 in. )
wrench]
• The hose connections are as follows.

84551720B NA - August 2012
8007C-5

hoses (1) (2).

in. )] to install the hoses (1) (2) (3).
1 Solenoid valve
5. Install the 5 connectors (1).
*1 Hose assembly
*2 Code
Solenoid valve (left side) de-
*3
tails
Solenoid valve (right side) de-
*4
tails
84551720B NA - August 2012

8007C-6
• The electrical connector connection colors are in- 7. Use a hexagon wrench [ 5 mm ( 0.197 in. ) ] to
dicated below. tighten the 4 bolts (1), then remove the air breather
(2) on the hydraulic oil tank.
• Bolt (1) tightening torque: 2.94 - 4.9 N·m ( 2.1689
- 3.614 lbf・ft. )

cover bolts (1), then install the cover (2).
84551720B NA - August 2012

8007C-7
84551720B NA - August 2012

8007C-8
Section
8007D
Removal and Installation of Cushion Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 35350AF10 Removal of Cushion Valve

1. Attach the specialty adapter (1) to the area where
WARNING the air breather is removed, and set the vacuum
pump (2).
• Be sure to release hydraulic pressure before Create negative pressure in the hydraulic oil tank
beginning work.
using the vacuum pump.
CAUTION
work.
Items to prepare
22 mm ( 0.866 in. ) ]
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag 2. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
• Cleaning fluid 5 bolts (2), and then remove the under cover (1).
3. Prepare the waste oil can (1).
4. Remove the sensor (1).

Use wrenches [ 19 mm ( 0.748 in. ), 22 mm ( 0.866
in. ) ] to remove the hoses connected to the ports.
• Mark the cushion valve, hoses and lines so that
the connectors match at the time of assembly.
• Use caps or plugs to cover the cushion valve,
hoses and lines to prevent any entry of water, dust
or dirt.
• Clean the cushion valve, hoses and lines by
spraying them with a parts cleaner to prevent
the connectors.
84551720B NA - August 2012
8007D-3

4 bolts (1) on the cushion valve bottom, and then
remove the cushion valve.
*2 Use 22 mm ( 0.866 in. ) wrench

*3 Use 19 mm ( 0.748 in. ) wrench
84551720B NA - August 2012

8007D-4
Installation of Cushion Valve

1. Use a wrench [17 mm (0.669 in.)] to install the cush-
ion valve, with the 4 bolt (1) on the cushion valve
bottom.
2. Install the sensor (1).

Use wrenches [19 mm (0.748 in.), 22 mm (0.866
in.)] to connect the hoses to the nipples and elbows
on the ports.
2 Use 22 mm (0.866 in.) wrench

3 Use 19 mm (0.748 in.) wrench
• The hose connections are as follows.
84551720B NA - August 2012

8007D-5
3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
Swing priority switching pilot
11
line
12 Drain line
3. Use a wrench [19 mm (0.748 in.)] to install the under

4. Use a hexagon wrench [5 mm (0.197 in.)] to install

the air breather (2) on the hydraulic oil tank with the
4 bolts (1).
• Bolt (1) tightening torque: 2.94 - 4.9 N・m (2.1689
- 3.6146 lbf・ft.)
1 Arm in
2 Boom up
84551720B NA - August 2012

8007D-6
Section
8008
Procedures for Assembly and Disassembly of Hydraulic

Pump Main Unit
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
Tools Tool name Tool dimensions
Monkey wrench Medium-sized
The table below shows the tools required for assembly Flathead screwdriver
and disassembly of the K3V/K5V pump.The bolts and Screwdriver
(medium size) x 2
plugs may vary by pump type. Plastic hammer
With adjustable specified
Tool name Tool dimensions Torque wrench
torque tightening
4 mm ( 0.157 in. ), 5 mm ( Snap ring pliers For stop ring, TSR-160
0.197 in. ), 6 mm ( 0.236 in. Key material steel rod, 10 x
Hexagon wrench ), 8 mm ( 0.315 in. ), 14 mm Steel rod 8 x 200 ( 0.394 x 0.315 x
( 0.551 in. ), 17 mm ( 0.669 7.874 )
in. ) (B dimension)
Tweezers
Socket wrench, dou-
19 mm ( 0.748 in. ), 27 mm Bolt M8, L = about 50 ( 1.969 )
ble-head (single-
( 1.063 in. )
head) wrench
84551720B NA - August 2012

8008-3
Main Unit
Disassembly procedures 5. After removing the cover (C) (629) subassembly,
remove the outer spring (625), inner spring (626),
1. Select a location for disassembly. and spring seat (C) (624) from the compensation
section, and pull out the adjusting ring (Q) (645),
• Select a clean location.
pilot spring (646), and spring seat (644) from the
so as not to damage the parts. pilot section.
2. Use cleaning oil to remove any dirt or rust from the • The adjusting ring (Q) (645) can be easily re-
surface of the regulator. moved by pulling it out with an M4 bolt.
3. Remove the hexagon socket head bolts (412, 413),
and remove the regulator from the pump main unit.
• Be careful not to lose the O-rings.

and remove the pilot cover (641).
When the pilot cover is removed, remove the set
spring (655) from the pilot section.
4. Remove the hexagon socket head bolts (438), and
remove the cover (C) (629).
• The cover (C) is assembled with an adjusting
screw (C) (628), adjusting ring (C) (627), lock nut
(630), hexagon nuts (801, 802), and hexagon
socket head locking screw (924).
Do not loosen these screws and nuts.
Loosening causes the adjusted pressure and flow
setting to change.
7. Remove the stop ring (814), and remove the spring

seating (653), return spring (654), and sleeve (651).
• The sleeve (651) is assembled with a retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) will fly out, so be careful not to lose it.
84551720B NA - August 2012

8008-4
Main Unit
8. Remove the locking rings (858), and remove the 10. Pull out the pin (874), and remove the feedback
fulcrum plug (614) and adjusting plug (615). lever (611).
• The fulcrum plug (614) and adjusting plug (615) • Use a fine steel rod to push out the pin (874) (pin
can be easily removed by pulling them out with diameter D4) from above without touching lever 1
an M6 bolt. (612).
9. Remove lever 2 (613). 11. Remove lever 1 (612).

Do not pull out the pin (875). Do not pull out the pin (875).
• It can be easily removed by using a pair of tweez- 12. Pull out the pilot piston (643) and spool (652).
ers. 13. Pull out the piston case (622), compensation piston
(621), and compensation rod (623) to complete dis-
assembly of the regulator.
• The piston case (622) can be removed by pushing
out the compensation rod (623) from the opposite
side of the piston case.
* The component parts are small, so be very careful not
to lose them.
84551720B NA - August 2012

8008-5
Main Unit
Assembly procedures
The assembly procedure is the reverse of the disas-
sembly procedure. However, follow the precautions
below.
1. Be sure to repair any parts damaged during dis-
assembly, and prepare replacement parts in ad-
vance.
2. Any foreign matter entering the equipment can
create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow
the equipment, and perform assembly in a clean
location.
3. Make sure to tighten bolts and plugs of each sec-
tion to the specified torque.
4. Be sure to apply clean hydraulic oil to sliding sec- a Lever (1) side
tions before assembly.
Lever (2) side (Fulcrum plug,
5. As a rule, replace all seals such as O-rings with b
adjusting plug side)
new parts.
1. Install the compensation rod (623) into the compen-
5. Install the pilot piston (643) into the flow control hole
sation hole on the casing (601).
on the casing.
2. Insert the pin press fit in lever 1 (612) into the groove
on the compensation rod, and install lever 1 on the • Check that the pilot piston slides smoothly without
pin press fit in the casing. catching.
3. Install the spool (652) and sleeve (651) in the casing
spool hole. 6. Insert the pin press fit in lever 2 (613) into the groove
on the pilot piston, and assemble lever 2.
• Check that the spool and sleeve slide smoothly in
the casing without catching.
• Be careful to assemble the spool in the correct
direction.
7. Assemble the fulcrum plug (614) and install the

locking ring (858) so that the pins press fit in the
fulcrum plug are inserted into the pin holes on lever
2.
*1 Spool
*2 Feedback lever
4. Install the feedback lever (611), and insert the pin

(874) in alignment with the pin hole on the feedback
lever.
• This is easier to assemble by inserting the pin into
the feedback lever to a small degree in advance.
• Be careful to assemble the feedback levers in the
correct direction.
8. Insert the adjusting plug (615), and install the lock-

ing ring.
• Be careful to insert the fulcrum plug and adjusting
plug into the correct openings.
84551720B NA - August 2012
8008-6
Main Unit
• At this time, check that the backlash from the 11. Install the spring seating (644), pilot spring (646),
movement of the feedback lever is not too great and adjusting ring (645) into the pilot hole, and in-
and that the feedback lever does not catch on stall the spring seating (624), inner spring (626), and
anything. outer spring (625) into the compensation hole.
9. Install the return spring (654) and spring seating • Be careful to install the spring seating in the cor-
(653) into the spool hole, and install the stop ring rect direction.
(814).
12. Assemble the cover (C) (629) set with the adjusting
10. Assemble the set spring (655) into the spool hole, screw (628), adjusting ring (C) (627), lock nut (630),
assemble the compensation piston (621) and piston hexagon nuts (801, 802), and the hexagon socket
case (622) into the compensation hole, install the head locking screw (924), and tighten the hexagon
pilot cover (641), and tighten the hexagon socket socket head bolts (438).
head bolts (436, 438).
84551720B NA - August 2012

8008-7
Main Unit
84551720B NA - August 2012

8008-8
Section
8010
Pump Main Unit Maintenance Standards
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Replacement standards for worn parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standards for repairing cylinders, valve plates, and swash plates (shoe plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Attached diagram 1. pump assembly cross-section diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Shaft Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive Shaft Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Regulator adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tables and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Procedures for Assembly and Disassembly of Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Diagram 1. Front-side regulator assembly cross-section diagram (KR3K-9Y04-HV). . . . . . . . . . . . . . . . . . . . . 24
Diagram 2. Rear-side regulator assembly cross-section diagram (KR3K-9Y04-HV) . . . . . . . . . . . . . . . . . . . . . 28

Replacement standards for worn parts

If wear on any part exceeds the standard values below, replace or readjust that part.
If, however, the appearance of the part shows significant damage, replace that part.
Recommended
Reference dimen-
Part name and inspection item replacement Solution
sions
value
Piston and cylinder bore clearance (D0.038 mm 0.065 mm
Replace piston or cylinder.
- d) ( 0.0014961 in. ) ( 0.0025591 in. )
Piston and shoe caulking section 0 - 0.1 mm 0.3 mm Replace piston and shoe assem-
backlash (δ) ( 0 - 0.00393 in. ) ( 0.0118 in. ) bly.
5.4 mm 5.0 mm Replace piston and shoe assem-
Shoe thickness (t)
( 0.2126 in. ) ( 0.1969 in. ) bly.
40.9 mm 40.1 mm
Free height of cylinder spring (L) Replace cylinder spring.
( 1.6102 in. ) ( 1.5787 in. )
Assembled height of holder plate and 23.8 mm 22.8 mm Replace holder plate or spherical
spherical bushing (H - h) ( 0.9370 in. ) ( 0.8976 in. ) bushing.
Cylinder opening diameter
35.17 mm 35.57 mm Replace cylinder and spherical
(spline in cylinder)
( 1.38465 in. ) ( 1.40039 in. ) bushing.
Spherical bushing spline
Clearance between the piston and cylinder bore : D-d Free height of cylinder spring : L
Loseness of piston, shoe, and caulking : δ Combined height of pressure plate and spherical bush :
Thickness of shoe : t H-h
84551720B NA - August 2012

8010-3
Standards for repairing cylinders, valve plates, and swash plates (shoe
plates)
Valve plate (sliding section)
Surface roughness re-
Swash plate (shoe plate 3-Z
quiring repair
section)
Cylinder Standard surface rough-
0.4 Z or lower (lapping)
Surface roughness ness (repair value)
Tightening torque
Tightening torque
Part name Size Tool name [ mm ( in. ) ]
・m ( lbf・
[ N・・ft. ) ]
M5 6.9 ( 5.090 ) B=4 ( 0.157 )
M6 11.8 ( 8.705 ) 5 ( 0.197 )
M8 29.4 ( 21.688 ) 6 ( 0.236 )
M10 56.9 ( 41.974 ) 8 ( 0.315 )
Hexagon socket head bolt M12 98.1 ( 72.367 ) 10 ( 0.394 )
M14 156.9 ( 115.743 ) 12 ( 0.472 )
M16 235.4 ( 173.652 ) 14 ( 0.551 )
M18 333.4 ( 245.945 ) 14 ( 0.551 )
M20 431.5 ( 318.313 ) 17 ( 0.669 )
Rc plug R 1/16 6.9 ( 5.090 ) 4 ( 0.157 )
R 1/8 10.3 ( 7.598 ) 5 ( 0.197 )
NOTE: R 1/4 17.2 ( 12.688 ) 6 ( 0.236 )
Wrap seal tape around the plug 1.5 - 2 R 3/8 34.3 ( 25.303 ) 8 ( 0.315 )
times Hexagon wrench
R 1/2 49.0 ( 36.147 ) 10 ( 0.394 )
G1/4 29.4 ( 21.688 ) 6 ( 0.236 )
G1/2 98.1 ( 72.367 ) 10 ( 0.394 )
G3/4 147.1 ( 108.514 ) 14 ( 0.551 )
PO plug
G1 186.3 ( 137.431 ) 17 ( 0.669 )
G1 1/4 264.8 ( 195.340 ) 17 ( 0.669 )
G1 1/2 274.6 ( 202.569 ) 17 ( 0.669 )
84551720B NA - August 2012

8010-4
Overall View
Attached diagram 1. pump assembly cross-section diagram
Drive shaft front side Drive shaft rear side
84551720B NA - August 2012

8010-5
Drive Shaft Front Side
84551720B NA - August 2012

8010-6
Drive Shaft Rear Side
84551720B NA - August 2012

8010-7
Part Table
Code Part name Q'ty Component part No. (Q'ty) or type
04 Gear pump 1 set ZX10LBRZ1-07A-V
011 Piston subassembly 2 sets 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC)
041 Check valve 1 subassembly 2 sets 541 (1PC), 543 (1PC), 545 (1PC)
Electromagnetic proportional pressure
079 1 set KDRDE5KR-V3-V
reducing valve, casing subassembly
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC)
1 Right rotation valve plate

2 Left rotation valve plate

111 Drive shaft (F) 1 532 Servo piston 2
113 Drive shaft (R) 1 534 Stopper (L) 2
116 1st gear 1 535 Stopper (S) 2
123 Cylinder roller bearing 2 541 Seat 4
124 Needle roller bearing 2 543 Stopper 1 2
127 Bearing spacer 4 544 Stopper 2 2
141 Cylinder block 2 545 Steel ball 4
151 Piston 18 548 Feedback pin 2
152 Shoe 18 702 O-ring 2
153 Holder plate 2 710 O-ring 2
156 Spherical bushing 2 717 O-ring 4
157 Cylinder spring 18 724 O-ring 16
211 Shoe plate 2 725 O-ring 6
212 Swash plate 2 726 O-ring 2
214 Tilting bushing 2 728 O-ring 4
251 Swash plate support board 2 732 O-ring 2
261 Seal cover (F) 1 774 Oil seal 1
271 Pump casing 2 789 Backup ring 2
312 Valve block 1 792 Backup ring 2
313 Valve plate (R) 1 806 Hexagon nut 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eyebolt 2
466 VP plug 2 953 Hexagon socket head stop screw 2
467 VP plug 2 954 Stop screw 2
468 VP plug 4 981 Nameplate 1
490 Insert plug 27 983 Strike rivet 2
531 Tilting pin 2
84551720B NA - August 2012

8010-8
1. Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi.（See the Pilot pressure Pi）
Discharge
volume Q
Pilot pressure Pi
1) When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the location
where the pilot spring (646) force and hydraulic pressure force balance each other.
The pin (875) fixed to lever 2 (613) fits into the crimped groove section [A section] of the pilot piston, so
lever 2 rotates through the movement of the pilot piston with point B [fastened by the fulcrum plug (614)
and pins (876)] as the fulcrum.
The pin (897) fixed to the feedback lever (611) projects into the large opening [C section] of lever 2, so as
lever 2 rotates, the pin (897) moves to the right.
The pin (548) fixed to the tilting pin (531) that shakes the swash plate is bonded to the 2-side width section
[D section] of the feedback lever.
Therefore, as the pin (897) moves, the feedback lever rotates with section D as the fulcrum.
Since the spool (652) is linked to the feedback lever via the pin (874), the spool moves to the right.
When the spool moves, the discharge pressure P1 is led to the servo piston large-bore chamber via the
spool and Cl port.
The discharge pressure P1 is always led to the servo piston small-bore chamber, but the servo piston is
moved to the right due to the surface area difference and the tilting angle is reduced.
When the servo piston moves to the right, point D also moves to the right.
The return spring (654) is mounted on the spool.
Since force pulling the spool to the left is always acting, the pin (897) is pressed into the large opening (C
section) of lever 2.
Because of this, accompanying the point D movement, the feedback lever rotates around the point C as
the fulcrum and the spool moves to the left.
This movement causes the open section between the sleeve (651) and the spool (652) to begin to close,
and the servo piston stops at the point the open section fully closes.
Flow reduction operation
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot spring (646)
force and lever 2 (613) rotates with point B as the fulcrum.
The pin (897) is pressed in the large opening [C section] of lever 2 by the return spring (654) via the spool
(652), pin (874), and feedback lever (611), so accompanying rotation of lever 2, the feedback lever rotates
with point D as the fulcrum and the spool moves to the left.When the spool moves, the Cl port opens to the
tank port, so the pressure in the large-diameter section of the servo piston drains out, the servo piston is
moved to the left by the discharge pressure P1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston, point D moves to the left, the feedback lever rotates with
point C as the fulcrum, and the spool moves to the right.
This operation continues until the open section between the spool and sleeve closes, and then the servo
piston stops at the point the open section fully closes.
84551720B NA - August 2012

8010-9
2. Horsepower control
Discharge
volume Q
Discharge pressure
（1.33P1 + 0.67P2）
The pump tilting angle decreases when the load pressure increases and overload of the power source is pre-
vented and overload of the self pump is prevented.
The regulator utilizes a method to control horsepower in which a hydraulic force that is the sum of the self pump
pressure multiplied by 1.33 and the counterpart pump pressure multiplied by 0.67 is transmitted as a signal.
Compensation piston surface area

Self pump pressurized area: counterpart pump pressurized area = 2 : 1
1) Overload prevention operation

When the self pump discharge pressure P1 or the counterpart pump discharge pressure P2 rises, since
P1 and P2 act on the stepped section of the compensation piston (621), the compensation rod (623) is
pressed to the right and moves to the location where the force of the outer spring (625) and inner spring
(626) balance out the hydraulic pressure force.
The movement of the compensation rod is transmitted to lever 1 through the pin (875) and lever 1 rotates
around the pin (876) (point E) fastened to the casing (601).
The pin (897) fixed to the feedback lever (611) projects into the large opening [F section] of lever 1, so as
lever 1 rotates, the feedback lever rotates with point D as the fulcrum and the spool (652) moves to the right.
When the spool moves, the discharge pressure P1 is led to the large-bore chamber of the servo piston via
the Cl port, the servo piston is moved to the right, and the pump discharge flow is decreased to prevent
overload of the power source.
The servo piston movement is transmitted to the feedback lever via point D.
The feedback lever rotates with point F as the fulcrum and the spool moves to the left.
The spool moves until the open section with the sleeve (651) closes, and then the servo piston stops at the
point the open section closes.
2) Flow return operation
If the self pump discharge pressure P1 or the counterpart pump discharge pressure P2 decreases, the
compensation rod (623) is pressed back by the springs (625, 626) and lever 1 rotates about point E.
Accompanying the lever 1 rotation, the feedback lever rotates around point D as the fulcrum and the spool
moves to the left.
Because of this, the Cl port opens to the tank port, the servo piston large-diameter section pressure drains
off, the servo piston moves to the left and the pump discharge flow increases.
The movement of the servo piston is transmitted to the spool by the feedback mechanism, and this operation
continues until the open section between the spool and the sleeve closes.
84551720B NA - August 2012

8010-10
3. Low tilting (low flow) command priority mechanism
Discharge
volume Q
Discharge pressure
（1.33P1 + 0.67P2）
The flow control and the horsepower control tilting command is transmitted to the feedback lever and spool via
the large openings [C and F sections] of lever 1 and lever 2, but since the C and F sections have a structure in
which a pin (D4) projects into a large hole (D8), the pin (897) only contacts the lever that makes the tilting smaller
and the D8 hole for the lever on the side that has the larger tilting command state is free rather than being in
contact with the pin (897).
This type of mechanical selection method gives priority to flow control and horsepower control commands with
low tilting.
4. Power shift control (decreased horsepower control)
Discharge
volume Q
Discharge pressure
（P1 + P2）
Use the power shift pressure Pf to arbitrarily control the pump set horsepower.(See the Discharge pressure (P1
+ P2)）
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right via the pin (898)
and the compensation piston (621), so the pump tilting angle and the horsepower setting are reduced in the same
way as was explained with the overload prevention operation of horsepower control.
By contrast, as the power shift pressure Pf decreases, the horsepower setting increases.
84551720B NA - August 2012

8010-11
Regulator adjustment
The adjusting screws on this regulator can be used to adjust the maximum flow, minimum flow, horsepower control
properties, and flow control properties. (Each of the adjustment amounts is shown in "6. (1) Regulator adjustment
amount list".)
1. Maximum flow adjustment
Discharge
volume Q
Pilot pressure Pi
Loosen the hexagon nut (808) and tighten (or loosen) the locking screw (954) to adjust the maximum flow.
This only changes the maximum flow.
It does not change the other control properties.
2. Minimum flow adjustment
Discharge
volume Q
Pilot pressure Pi
Loosen the hexagon nut (808) and tighten (or loosen) the hexagon socket head locking screw (953) to adjust (or
tighten) the minimum flow.
Similar to the maximum flow adjustment, this does not change other control properties.
However, if the hexagon socket head locking screw is tightened too much, the required power may increase at
the time of maximum discharge pressure (during relief), so adjust this carefully.
84551720B NA - August 2012

8010-12
3. Input horsepower adjustment

This regulator uses the simultaneous full-horsepower method.
Therefore, when changing the horsepower setting, adjust the adjusting screw of both the front and rear pumps
to the same amount.
The pressure change value resulting from adjustment is the value when pressure boost is simultaneously per-
formed with both pumps.
1) Outer spring adjustment
Discharge
volume Q
Discharge pressure
（P1 + P2）
Loosen the hexagon nut (630) and tighten (or loosen) the adjusting screw (C) (628) to adjust the outer
spring.
As the adjusting screw is tightened, the control diagram shifts to the right as in the diagram on the right and
the input horsepower increases.
When the adjusting screw (C) is rotated N times, the inner spring setting also changes.
Therefore, return the adjusting ring (C) (627) by rotating it N x A times in the opposite direction.
2) Inner spring adjustment
Discharge
volume Q
Discharge pressure
（P1 + P2）
Loosen the hexagon nut (802) and tighten (or loosen) the adjusting ring (C) (627).
As the adjusting screw is tightened, the flow increases as in the diagram on the right and the input horse-
power increases.
84551720B NA - August 2012

8010-13
4. Flow control properties adjustment
Discharge
volume Q
Pilot pressure Pi
Loosen the hexagon nut (801) and tighten (or loosen) the hexagon socket head locking screw (924) to adjust the
flow control properties.
As the hexagon socket head locking screw is tightened, the control diagram shifts to the right as in the diagram
on the right.
84551720B NA - August 2012

8010-14
Tables and diagrams

Speed [ min-1 ( rpm ) ] 2,030 ( 2030 )
Adjusting screw (954) tightening amount (rotation) +1/4
Maximum flow adjustment
Flow change volume [ L/min ( gpm ) ] 6.3 ( 1.664 )
Minimum flow adjustment
Flow change volume [ L/min ( gpm ) ] 5.1 ( 1.347 )
Compensation control start pressure change vol-
1.75 ( 253.84 )
Outer spring adjustment ume [ MPa ( psi ) ]
Input horse- Input torque change volume [ N•m ( lbf・ft. ) ] 71.6 ( 52.82 )
power adjust-
A 1.9
ment
Inner spring adjustment Flow change volume [ L/min ( gpm ) ] 12.1 ( 3.197 )
Input torque change volume [ N•m ( lbf・ft. ) ] 63.7 ( 46.99 )
Adjusting ring (627) tightening amount (rotation) +1/4
Flow control start pressure change volume
Flow control properties adjustment 0.15 ( 21.76 )
[ MPa ( psi ) ]
Flow change [ L/min ( gpm ) ] 16.4 ( 4.335 )
84551720B NA - August 2012

8010-15
(KR3K-9Y04-HV) (KR3K-9X04-HV)
Front side regulator Rear side regulator
Diagram 1. Regulator operation explanation diagram
84551720B NA - August 2012

8010-16
Diagram 2-1. Regulator breakdown diagram (front side)

ANNOTATION:
(N), (M), (L), and (K) in the diagram indicate pump casing installation positions
84551720B NA - August 2012

8010-17
Diagram 2-2. Regulator breakdown diagram (Rear side)

ANNOTATION:
(Z), (Y), (X), and (W) in the diagram indicate pump casing installation positions
84551720B NA - August 2012

8010-18
Procedures for Assembly and Disassembly of Regulator

Tools
Tool name Tools dimensions
4 mm ( 0.157 in. ), 5 mm ( 0.197 in. ), 6 mm ( 0.236 in. ) (B
Hexagon wrench
dimension)
Socket wrench, double-head (single-head) wrench
Monkey wrench Small-sized [ maximum 36 mm ( 1.417 in. ) ]
Screwdriver
Plastic hammer
Torque wrench
Pliers For stop ring, x 2
Steel rod Diameter D4 ( 0.157 ) or less, L = 100 ( 3.937 )
Tweezers
Bolt M4, L = about 50 ( 1.968 )
Disassembly preparations
1. These regulators comprise small precision parts, so assembly and disassembly operations are somewhat com-
plex.
2. The pressure-flow settings of the front side regulator and the rear side regulator differ, so mark the regulators
when disassembling to differentiate between the drive side and the driven side.
3. When disassembling the regulators, read this disassembly procedure thoroughly before following the sequence
below.
The numbers in parentheses after the part names are the codes indicated in "Diagram 1.
Front-side regulator assembly cross-section diagram" "Diagram 2.
Rear-side regulator assembly cross-section diagram".
84551720B NA - August 2012

8010-19
Disassembly procedures 5. After removing the cover (C) (629) subassembly,

remove the outer spring (625), inner spring (626),
1. Select a location for disassembly. and spring seat (C) (624) from the compensation
• Select a clean location. section, and pull out the adjusting ring (Q) (645),
• Place a rubber plate or cloth on the work platform pilot spring (646), and spring seat (644) from the
so as not to damage the parts. pilot section.
2. Use cleaning oil to remove any dirt or rust from the • The adjusting ring (Q) (645) can be easily re-
surface of the regulator. moved by pulling it out with an M4 bolt.
and remove the regulator from the pump main unit.
• Be careful not to lose the O-rings.

and remove the pilot cover (641).
When the pilot cover is removed, remove the set
spring (655) from the pilot section.
4. Remove the hexagon socket head bolts (438), and
remove the cover (C) (629).
• The cover (C) is assembled with an adjusting
screw (C) (628), adjusting ring (C) (627), lock nut
(630), hexagon nuts (801, 802), and hexagon
socket head locking screw (924).
Do not loosen these screws and nuts.
Loosening causes the adjusted pressure and flow
setting to change.
7. Remove the stop ring (814), and remove the spring

seating (653), return spring (654), and sleeve (651).
• The sleeve (651) is assembled with a retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) will fly out, so be careful not to lose it.
84551720B NA - August 2012

8010-20
8. Remove the locking rings (858), and remove the 10. Pull out the pin (874), and remove the feedback
fulcrum plug (614) and adjusting plug (615). lever (611).
• The fulcrum plug (614) and adjusting plug (615) • Use a fine steel rod to push out the pin (874) (pin
can be easily removed by pulling them out with diameter D4) from above without touching lever 1
an M6 bolt. (612).
9. Remove lever 2 (613). 11. Remove lever 1 (612).

Do not pull out the pin (875). Do not pull out the pin (875).
• It can be easily removed by using a pair of tweez- 12. Pull out the pilot piston (643) and spool (652).
ers. 13. Pull out the piston case (622), compensation piston
(621), and compensation rod (623) to complete dis-
assembly of the regulator.
• The piston case (622) can be removed by pushing
out the compensation rod (623) from the opposite
side of the piston case.
* The component parts are small, so be very careful not
to lose them.
84551720B NA - August 2012

8010-21
Assembly procedures
The assembly procedure is the reverse of the disas-
sembly procedure. However, follow the precautions
below.
1. Be sure to repair any parts damaged during dis-
assembly, and prepare replacement parts in ad-
vance.
2. Any foreign matter entering the equipment can
create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow
the equipment, and perform assembly in a clean
location.
3. Make sure to tighten bolts and plugs of each sec-
tion to the specified torque.
4. Be sure to apply clean hydraulic oil to sliding sec-
a Lever (1) side
tions before assembly.
5. As a rule, replace all seals such as O-rings with Lever (2) side (Fulcrum plug,
b
new parts. adjusting plug side)
1. Install the compensation rod (623) into the compen-

sation hole on the casing (601). 5. Install the pilot piston (643) into the flow control hole
2. Insert the pin press fit in lever 1 (612) into the groove on the casing.
on the compensation rod, and install lever 1 on the • Check that the pilot piston slides smoothly without
pin press fit in the casing. catching.
3. Install the spool (652) and sleeve (651) in the casing
spool hole. 6. Insert the pin press fit in lever 2 (613) into the groove
on the pilot piston, and assemble lever 2.
• Check that the spool and sleeve slide smoothly in
the casing without catching.
• Be careful to assemble the spool in the correct
direction.
7. Assemble the fulcrum plug (614) and install the

locking ring (858) so that the pins press fit in the
fulcrum plug are inserted into the pin holes on lever
2.
*1 Spool
*2 Feedback lever
4. Install the feedback lever (611), and insert the pin

(874) in alignment with the pin hole on the feedback
lever.
• This is easier to assemble by inserting the pin into
the feedback lever to a small degree in advance.
• Be careful to assemble the feedback levers in the
correct direction.
8. Insert the adjusting plug (615), and install the lock-

ing ring.
• Be careful to insert the fulcrum plug and adjusting
plug into the correct openings.
84551720B NA - August 2012
8010-22
• At this time, check that the backlash from the 11. Install the spring seating (644), pilot spring (646),
movement of the feedback lever is not too great and adjusting ring (645) into the pilot hole, and in-
and that the feedback lever does not catch on stall the spring seating (624), inner spring (626), and
anything. outer spring (625) into the compensation hole.
9. Install the return spring (654) and spring seating • Be careful to install the spring seating in the cor-
(653) into the spool hole, and install the stop ring rect direction.
(814).
12. Assemble the cover (C) (629) set with the adjusting
10. Assemble the set spring (655) into the spool hole, screw (628), adjusting ring (C) (627), lock nut (630),
assemble the compensation piston (621) and piston hexagon nuts (801, 802), and the hexagon socket
case (622) into the compensation hole, install the head locking screw (924), and tighten the hexagon
pilot cover (641), and tighten the hexagon socket socket head bolts (438).
head bolts (436, 438).
84551720B NA - August 2012

8010-23
Diagram 1. Front-side regulator assembly cross-section diagram (KR3K-9Y04-HV)

Hydraulic circuit diagram
84551720B NA - August 2012

8010-24
84551720B NA - August 2012

8010-25
a DETAIL OF STAMP FOR TYPE

AND SERIAL NUMBER
b TYPE
c SERIAL NUMBER
Component part No. (q'ty) or

Code Part name Q'ty
type
545 (1PC), 546 (1PC), 547
050 Shuttle valve subassembly 1 set
(1PC)
Electromagnetic proportional
079 1 set KDRDE5K-31/30C50-102
pressure reducing valve
Part num- Part num-

ber ber
- Regulator subassembly 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
418 Hexagon socket head bolt 2 654 Return spring 1
436 Hexagon socket head bolt 4 655 Set spring 1
438 Hexagon socket head bolt 8 656 Blind cover 1
466 VP plug 1 708 O-ring 1
496 Insert plug 12 724 O-ring 9
545 Steel ball 1 725 O-ring 1
546 Seat 1 1 727 O-ring 1
547 Seat 2 1 728 O-ring 1
601 Casing 1 730 O-ring 1
611 Feedback lever 1 732 O-ring 1
612 Lever (1) 1 733 O-ring 1
613 Lever (2) 1 734 O-ring 1
614 Fulcrum plug 1 735 O-ring 1
615 Adjusting plug 1 753 O-ring 1
621 Compensation piston 1 755 O-ring 3
622 Piston case 1 756 O-ring 1
623 Compensation rod 1 763 O-ring 1
624 Spring seating (C) 1 801 Hexagon nut 1
625 Outer spring 1 802 Hexagon nut 1
626 Inner spring 1 814 Stop ring 1
627 Adjusting ring (C) 1 836 Retaining ring 1
628 Adjusting screw (C) 1 858 Locking ring 2
629 Cover (C) 1 874 Pin 1
630 Lock nut 1 875 Pin 2
631 Pf sleeve 1 876 Pin 2
641 Pilot cover 1 887 Pin 1
643 Pilot piston 1 897 Pin 1
644 Spring seating (Q) 1 898 Pin 1
Hexagon socket head locking
645 Adjusting ring (Q) 1 924 1
screw
646 Pilot spring 1
Tightening torque
Tightening
Part
Screw size torque
No.
・ft. )
N•m ( lbf・
412,
M8 29 ( 21.39 )
413
418 M5 6.9 ( 5.090 )
436,
M6 12 ( 8.85 )
438
84551720B NA - August 2012
8010-26
Tightening torque
Tightening
Part
Screw size torque
No.
N•m ( lbf・・ft. )
466 G1/4 36 ( 26.56 )
467 G3/8 74 ( 54.59 )
496 NPTF 1/16 8.8 ( 6.492 )
630 M30 x 1.5 160 ( 118.03 )
801 M8 16 ( 11.80 )
802 M10 19 ( 14.02 )
84551720B NA - August 2012

8010-27
Diagram 2. Rear-side regulator assembly cross-section diagram (KR3K-9Y04-HV)

84551720B NA - August 2012

8010-28
84551720B NA - August 2012

8010-29
a DETAIL OF STAMP FOR TYPE

AND SERIAL NUMBER
b TYPE
c SERIAL NUMBER
Component part No. (q'ty) or

Code Part name Q'ty
type
545 (1PC), 546 (1PC), 547
050 Shuttle valve subassembly 1 set
(1PC)
Part num- Part num-

ber ber
466 VP plug 1 656 Blind cover 1
546 Seat 1 1 725 O-ring 1
547 Seat 2 1 727 O-ring 1
612 Lever (1) 1 732 O-ring 1
613 Lever (2) 1 733 O-ring 1
624 Spring seating (C) 1 763 O-ring 1
626 Inner spring 1 802 Hexagon nut 1
627 Adjusting ring (C) 1 814 Stop ring 1
628 Adjusting screw (C) 1 836 Retaining ring 1
629 Cover (C) 1 858 Locking ring 2
645 Adjusting ring (Q) 1 898 Pin 1
646 Pilot spring 1 924 1
screw
Tightening torque
Tightening
Part
Screw size torque N•m (
No.
・ft. )
lbf・
412,
M8 29 ( 21.39 )
413
436,
M6 12 ( 8.85 )
438
466 G1/4 36 ( 26.56 )
467 G3/8 74 ( 54.59 )
496 NPTF 1/16 8.8 ( 6.492 )
630 M30×1.5 160 ( 118.03 )
84551720B NA - August 2012
8010-30
Tightening torque
Tightening
Part
Screw size torque N•m (
No.
・ft. )
lbf・
801 M8 16 ( 11.80 )
802 M10 19 ( 14.02 )
84551720B NA - August 2012

8010-31
84551720B NA - August 2012

8010-32
Section
8011
Procedures for Assembly and Disassembly of Control Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cautions for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of long cap and pull out of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of arm regeneration release valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of load check valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly of antidrift valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of valve housing union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for O-Ring handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for spool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adhesive application method (for male thread section and female thread section of parts requiring adhe-
sion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Procedure for assembly of sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of spool assembly (main spool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of arm 1 parallel-tandem spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of neutral cut spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of antidrift valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Procedure for assembly of control valve main unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of load check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of antidrift valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of arm regeneration release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of arm 1 parallel-tandem spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of neutral cut spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Procedures for assembly and disassembly of main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Procedures for assembly and disassembly of overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Procedures for assembly and disassembly of low-pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Procedures for assembly and disassembly of add-on main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Relief valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Disassembly
Cautions for disassembly
1. On level ground, bring all the operating machines into contact with the ground.
When doing this, have the main machine in a horizontal position.
Check that the machine is in such a state that it will not travel or swing on its own.
Then stop the engine and bleed out the pressure from each actuator.
CAUTION
Do not replace a valve assembly or disassemble a valve with pressure remaining in the system.
This would be dangerous.
High-pressure oil might spray out or parts might suddenly come out.
For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the cir-
cuits.
2. Bleed the air pressure from the tank.

3. Clean well around the location to be disassembled and keep foreign matter from getting into the valve during
disassembly.
4. Identify disassembled parts with shipping tags to show their position for re-assembly.
5. Do not reuse any disassembled seals (O-rings, backup rings).
Replace them with new ones.
6. The spool was selected to fit with the valve housing and sleeve, so do not replace the spool.
84551720B NA - August 2012

8011-3
Disassembly procedure
Removal of long cap and pull out of main spool
1. Loosen the hexagon socket head bolts (74) [ 8 mm ( 0.315 in. ) hexagon socket diameter ] for the 9 caps (8) and
the 1 cap (9), and remove them.
When pulling out the spool only, do not loosen the M6 screws on the plate except for the 4 hexagon socket head
bolts (75) and the 1 hexagon socket head bolt (94) fastening the plate assemblies.
2. Loosen and remove the plugs (91) [ 19 mm ( 0.748 in. ) hexagon diameter ] attached to the ports as necessary.
3. Remove the O-rings (7) (1 in each section) from the plate assemblies (10) and (11).
4. Pull out each spool from the valve housing still in the sub-assembly state.
CAUTION
1) When pulling out the spool, be careful not to cause any dents or scratches.
2) 2Identify each spool with a shipping tag so that there will be no mistake about their positions
when they are re-assembled.
5. Loosen and remove the hexagon socket head bolts (75) [ 8 mm ( 0.315 in. ) hexagon socket diameter ] and
hexagon socket head bolts (94) [ 5 mm ( 0.197 in. ) hexagon socket diameter ] those fastens the plate assemblies
(10), (11), (28) and (29) to the housing.
Remove the plate assemblies still in the assembly state.
Do not disassemble them.
6. Loosen and remove the plugs (91) [ 19 mm ( 0.748 in. ) hexagon socket diameter ] as necessary.
7. Remove the O-rings (7) and (41) from the valve housings (1) and (13).
8. Disassembly of spool assembly
CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
(as in the diagram on the right) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250 °C ( 392.0 - 482.0 °F ).
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one. (Wooden blocks for spool assembly/
disassembly)
(Wooden blocks for spool assembly/disassembly)
L1 30 - 40 ( 1.181 - 1.574 )
L2 3 - 6 ( 0.118 - 0.236 )
L3 70 - 100 ( 2.756 - 3.937 )
1) Loosen the spool assembly (2) - (6) and (14) - (17) spool ends [ 8 mm ( 0.315 in. ) hexagon socket diameter
] and disassemble the spring seat and spring.
2) The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and filters in the spools,
but do not disassemble them unless necessary.
When disassembly is required, heat up the outer edge of the spool to break down the adhesive on the
thread section, then remove the plug.
When assembling, always replace O-rings and backup rings with new ones.
84551720B NA - August 2012

8011-4
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section

1. Loosen and remove the hexagon socket head bolts (78) [ 5 mm ( 0.197 in. ) hexagon socket diameter ] for the
caps (18) and (86).
2. Remove the O-ring (23) from the cap (18).
Remove the O-rings (65) from the housing (1).
3. Pull out the spools (19) and (84) from the valve housing still in the sub-assembly state.
4. Disassembly of spool assembly
CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
for assemble (as in the diagram) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250 °C ( 392.0 - 482.0 °F ).
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one.
1) Loosen the spool (19) spool end (22) [ 5 mm ( 0.197 in. ) hexagon socket diameter ] and disassemble the
spring seat (20) and spring (21).
Disassembly of arm regeneration release valve section

Sub-parts in the assembly are expressed as [main number - sub-number].
CAUTION
1. When removing the plug, pressure left within can make parts fly out dangerously.
2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassem-
ble.
1. Loosen and remove the plug (24) [ 32 mm ( 1.259 in. ) hexagon diameter ] and remove the O-ring (25).
2. Remove the spring (26) and spool (27-1) from the sleeve (27-2).
3. Pull out the sleeve (27-2) from the valve housing.
4. Remove the piston (27-3), O-ring (30), and backup ring (31) from the sleeve (27-2).
84551720B NA - August 2012

8011-5
Disassembly of load check valve section

CAUTION
1. When removing the plug, pressure left within can make parts fly out dangerously.
2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassem-
ble.
1. Loosen and remove the hexagon socket head bolts (75) (4 in each section, 8 mm ( 0.315 in. ) hexagon socket
diameter) for the flanges (37) (6 locations) and (61) (1 location).
Only (61) has a different shape from the others, so keep it separate from (37).
2. Remove the spring (35), poppets (34) and (51) and O-ring (36) from the valve housing.
Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58).
3. Loosen and remove the hexagon socket head bolts (75) [ 8 mm ( 0.315 in. ) hexagon socket diameter ] for the
flanges (52) (2 locations) .
4. Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup ring (55) from the spacer
(53).
5. Remove the spring (35) and poppet (34) from the valve housing.
6. Loosen and remove the plug (72) [ 8 mm ( 0.315 in. ) hexagon socket diameter ]. (D-D cross section)
8. Loosen and remove the plug (72) [ 8 mm ( 0.315 in. ) hexagon socket diameter ]. (D-D cross section)
9. Remove the spacer (57), spring (33), and poppet (32) from the valve housing.
10. Loosen and remove the plug assembly (92) [ 36 mm ( 1.417 in. ) hexagon diameter ]. (P4 section, cross section
H-H )
11. Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm ( 0.315 in. ) hexagon socket diameter)
for the flange (43) .
12. Remove the spring (45), poppet (44), and O-ring (36) from the valve housing.
13. Loosen and remove the plug (46) [ 27 mm ( 1.063 in. ) hexagon socket diameter ] and remove the O-ring (47).
(H-H cross section)
84551720B NA - August 2012

8011-6
Disassembly of antidrift valve section

Sub-parts in the assembly are expressed as [main number - sub-number].
CAUTION
1. When removing the antidrift valve assembly, pressure left within can make seals and other parts fly
out dangerously.
2. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to residual
pressure, then disassemble.
1. Loosen and remove the hexagon socket head bolts (74) (4 in each section, 8 mm ( 0.315 in. ) hexagon socket
diameter) for the 2 antidrift valve assemblies (67).
2. Remove the O-rings (36) and (41) from the valve housing.
4. Disassembly of antidrift valve assembly
CAUTION
1) If parts inside the antidrift valve are disassembled with the antidrift valve installed in the valve
housing, pressure left within can make parts fly out dangerously.
2) Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual
pressure, then disassemble.
1) Loosen and remove the plug assembly (67-14) [ 38 mm ( 1.496 in. ) hexagon diameter ] and remove the
O-ring.
2) Remove the piston (67-3), spool (67-4), and spring (67-6).
3) Loosen and remove the plug (67-14) [ 12 mm ( 0.472 in. ) hexagon diameter ].
4) Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings (67-8) and (67-9),
backup rings (67-10) and (67-11) from the outer edge of the sleeve.
5) Remove the spring seat (67-13) and spring (67-7) from deep in the hole.
Disassembly of relief valve

CAUTION
1. When removing the relief valve, loosen and remove the main unit installation section plug.
2. Do not loosen the set pressure adjustment plug or lock nut.
3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug
turns.
1. Loosen and remove the overload relief valve (69) [ 32 mm ( 1.259 in. ) hexagon diameter ].
2. Loosen and remove the main relief valve (68) [ 32 mm ( 1.259 in. ) hexagon diameter ].
3. Loosen and remove the 2 relief valve assemblies (70) [ 32 mm ( 1.259 in. ) hexagon diameter ].
Remove the O-rings (70-5) and (70-8).
Disassembly of option section

1. Loosen and remove the hexagon socket head bolts (75) [ 8 mm ( 0.315 in. ) hexagon socket diameter ] for the 2
caps (88), and remove the O-rings (89).
2. Loosen and remove the 2 plug assemblies (93) [ 24 mm ( 0.945 in. ) hexagon diameter ], and remove the O-rings
and backup rings.
84551720B NA - August 2012

8011-7
Disassembly of straight travel signal control valve

1. Remove the hexagon socket head bolts (83) [ 5 mm ( 0.197 in. ) hexagon socket diameter ] and remove the
body assembly (42).
2. Loosen and remove the plug assembly (42-5) [ 5 mm ( 0.197 in. ) hexagon socket diameter ] and remove the
O-ring.
3. Pull out the spools (42-2) and (42-3) and spring (42-4).
4. Loosen the orifice plug (42-7) [ 36 mm ( 1.417 in. ) hexagon diameter ] and remove it from the body (42-1).
Disassembly of other plugs

1. Loosen and remove the plug assembly (71) [ 10 mm ( 0.394 in. ) hexagon socket diameter ] and remove the
O-ring.
O-ring.
3. Loosen and remove the orifice plug (40) [ 5 mm ( 0.197 in. ) hexagon socket diameter ]. (D-D cross section)
4. Loosen and remove the plug assembly (92) [ 36 mm ( 1.417 in. ) hexagon diameter ] and remove the O-ring.
O-ring.
Disassembly of add-on section

1. Loosen and remove the 4 hexagon nuts (97) [ 22 mm ( 0.866 in. ) hexagon diameter ].
2. Remove the outlet housing (95).
Execute Steps [3] - [5] below as necessary.
3. Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11).
4. Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4).
5. Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11).
6. Remove the main unit body matching surface O-rings (56) and (64).
7. Loosen the tie rod (96) and remove it from the main unit valve housing (1).
(Use a pipe wrench.)
CAUTION
When removing the add-on section, be careful not to cause any dents, scratches, or the like on
matching surfaces.
Any dents, scratches, or the like on matching surfaces have a danger of allowing oil to leak from
those surfaces and causing malfunction.
Also, be careful not to let any foreign matter enter the oil path.
Such foreign matter has a danger of the spool sticking due to biting of the spool sliding section or
a load check seat defect making the actuator run wild or stop disabled.
Disassembly of valve housing union bolt

CAUTION
1. Do not disassemble the union bolt (77) unless necessary.
2. If such disassembly is necessary, place the main unit on a flat table to do the work.
3. Prepare the replacement O-rings (65) and (66).
1. Loosen and remove the 8 hexagon socket head bolts (77) [ 14 mm ( 0.551 in. ) hexagon socket diameter ].
Tightening torque: 166 - 177 N•m ( 122.46 - 130.57 lbf・ft. )
2. Remove the valve housing matching surface O-rings (65) and (66).
84551720B NA - August 2012

8011-8
Cleaning
Completely clean all the disassembled parts with clean mineral oil.
Dry with compressed air and place each part on clean paper or vinyl for inspection.
Inspection
Inspect all surfaces of each part for burrs, scratches, gouges, and other defects.
1. Inspect the valve housing load check seat surface for scratches, gouges, and also for debris, dents, rust.
Repair any minor scratches with an oilstone.
2. Check that there are no scratches, dents, etc. on the outer edge of the spool.
Repair any small scratches with an oilstone.
3. Sliding parts must all move easily.
Also, all grooves and paths must be free of foreign matter.
4. If a spring is broken or extremely deformed or worn, replace it.
5. If relief valve operation is poor, inspect according to "Troubles and countermeasures Relief valve".
6. Replace all O-rings and backup rings from disassembled parts.
7. After removing caps or plugs, check for any paint fragments around the body opening or plug seating surface. (If
paint fragments were to get inside the valve, they could jam up or clog up the valve, resulting in operation defects
and oil leaks.)
Cautions for assembly

Cautions for O-Ring handling
1. Do not use any O-ring with a molding defect or damage caused by handling.
2. Apply enough grease or hydraulic oil to the O-ring and the section where it is mounted so that it can be mounted
smoothly.
3. Do not stretch an O-ring so far that this causes permanent deformation.
4. When assembling an O-ring, be careful not to roll the O-ring into place.(If an O-ring is mounted twisted, it is
difficult for it to naturally recover to its normal state and that twist causes oil leaks.)
Cautions for spool handling
1. Excessive torque on thread sections causes spool operation defects, so always tighten to just the specified torque.
2. Be careful to assemble all spools, springs, and spool ends in the same combinations as before disassembly.
84551720B NA - August 2012

8011-9
Adhesive application method (for male thread section and female thread section of parts
requiring adhesion)
1. Cleaning (degreasing)
Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent.
2. Drying
Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally.
Inadequate drying reduces the effectiveness of the adhesive.
3. Applying the adhesive
Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at the entrance of the spool
female threads.
At this time, install being careful that the application section does not touch the spring seat.
CAUTION
Do not use "Loctite Primer T" hardening accelerator.
It causes insufficient adhesion strength.
4. Adhesive hardening time

In order to ensure the hardening of the adhesive, after fastening the spool end, leave the part out in the air for
the following period of time.
- Ambient temperature around 22 °C ( 71.6 °F ): 8 hr. or longer
CAUTION
If the parts are not left out in the air for the above period, adequate adhesive strength may not be
achieved.
Procedure for assembly of sub-assembly

CAUTION
Before starting the assembling, check the quantity of each part, the installation location, the required
tools, etc.
Assembly of spool assembly (main spool)

1. Apply adhesive to the thread sections of the spools (2) - (6), (14) - (17) and assemble the spring seat, spring,
and spool end.
2. Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise,
then tighten the spool ends to the specified torque.
Tightening torque: 20 - 22 N・m ( 14.75 - 16.22 lbf・ft. )
3. For spools (3), (4), and (14), insert the poppets and springs from the end opposite from the spool end, then apply
adhesive to the thread sections of the plugs with the O-rings and backup rings mounted, and tighten.
Also, for spool (5), the plug with filter is mounted at this location.
CAUTION
1) Be careful not to apply so much adhesive that it drips into the spool.
2) Be careful not to tighten any spool end with excessive torque.
Excessive torque there would deteriorate spool operation.
3) There are 2 types of spring.
Be careful to assemble each in its correct location. (only boom 2 different)
84551720B NA - August 2012

8011-10
Assembly of arm 1 parallel-tandem spool assembly

1. Apply adhesive to the thread sections of the spool (19) and assemble the spring seat (20), spring (21), and spool
end (22).
CAUTION
Excessive torque there would deteriorate spool operation.
Assembly of neutral cut spool assembly

1. Apply adhesive to the thread sections of the spool (84-1) and assemble the spring seat (84-2), spring (84-3), and
spring end (84-4).
CAUTION
Assembly of antidrift valve assembly

1. Assemble the O-rings (67-8) and (67-9) and backup rings (67-10) and (67-11) into the grooves on the outer edge
of the sleeve (67-5).
CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and the drop
of the actuator from its own weight increasing.
2. Insert the poppet (67-2) and spool (67-4) in the sleeve hole.
Be careful to assemble the spool in the correct direction.
3. Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount on the spring (67-7),
and insert into the body (67-1) together with the sleeve.
CAUTION
Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on the
poppet seat.
4. Screw the plug (67-14) into the body (67-1) and tighten it.
5. Assemble the spring (67-6) and piston (67-3) on the plug (67-14).
6. Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1).
84551720B NA - August 2012

8011-11
Procedure for assembly of control valve main unit

Assembly of relief valve
CAUTION
1. When installing the relief valve, be sure to tighten the main unit installation section plug.
2. Do not tighten the set pressure adjustment plug or lock nut.
3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug
turns.
1. Screw in and tighten the main relief valve (68).

2. Screw in and tighten the 6 overload relief valves (69) at each section.
3. Screw in and tighten the 2 relief valve assemblies with O-rings mounted (70).
Assembly of load check valve

1. Mount the O-rings (36) in the arm 1 section (E-E cross section), Boom 1 and 2 sections (F-F cross sections),
swing section, and bucket section (G-G cross sections) and assemble the poppets (34) and springs (35).
Mount the flanges (37) and tighten with the hexagon socket head bolts (75).
For the arm 2 section (E-E cross section), assemble the sleeve (58), poppet (59) and spring (60), mount the
flange (61), and tighten with the hexagon socket head bolts (75).
2. Mount the O-ring (36) in the travel section (I-I cross section) and assemble the poppet (51) and spring (35).
Tighten the flange (37) with the hexagon socket head bolt (75).
3. Assemble the poppet (34) and spring (35) on the common check section (J-J cross section), then insert the
spacers (53) with the O-ring (54) and backup ring (55) mounted.
Tighten the flange (52) with the hexagon socket head bolt (75).
CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and causing
external leaks.
4. Mount the O-ring (36) in the option section (H-H cross section) and assemble the poppet (44) and spring (45).
Mount the flange (43) and tighten with the hexagon socket head bolts (74).
5. Assemble the poppet (49) and spring (48) in the travel section (H-H cross section).
Screw in and tighten the plug (46) with O-ring (47) mounted.
6. Assemble the poppet (32) and spring (33) in the arm 1 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
7. Assemble the poppet (32), spring (33), and spacer (57) in the arm 2 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
84551720B NA - August 2012

8011-12
Assembly of antidrift valve

1. Mount the O-rings (36) and (41) on the antidrift valve installation surfaces in the arm 1 section (E-E cross section)
and boom 1 section (F-F cross section).
2. Assemble the poppet (38) and spring (39).
3. Install the 2 antidrift valve assemblies (67) and tighten with the hexagon socket head bolts (74).
Assembly of option section

1. Install the 2 caps (88) with O-rings (89) mounted and tighten with the hexagon socket head bolts (75).
2. Screw in and tighten the 2 plug assemblies (93) with O-rings and backup rings mounted.
Assembly of arm regeneration release valve

1. Mount the O-ring (30) and 2 backup rings (31) in the sleeve (27-2).
2. Assemble the piston (27-3) and spool (27-1) in the sleeve and insert into the valve housing.
3. Put the spring (26) into the plug (24) with O-ring (25) mounted, then screw into the valve housing and tighten.
Assembly of arm 1 parallel-tandem spool

1. Assemble the spool (19) in the sub-assembly state into the valve housing.
CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.
2. Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m ( 6.49 - 7.96 lbf・ft. )
Assembly of neutral cut spool

1. Assemble the spool assembly (84) into the valve housing.
CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.
2. Mount the O-ring (65) into the housing and tighten the cap (86) with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m ( 6.49 - 7.96 lbf・ft. )
84551720B NA - August 2012

8011-13
Assembly of main spool

1. Mount the O-rings (7) and (41) on the valve housing cap matching surface.
2. Assemble the spool assemblies (2) - (6), (14) - (17) in the sub-assembly state into the same location as before
disassembly.
CAUTION
1) Line up the spool straight with the opening and insert it slowly.
2) After inserting the spool, slide it to check for any sticky or rough feeling.
3) If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation defect.
3. Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in the order (75), (94).
Be careful not to apply excessive tightening torque to (94).
Tightening torque:
(75) 39 - 44 N•m ( 28.77 - 32.45 lbf・ft. )
(94) 8.8 - 10.8 N•m ( 6.49 - 7.96 lbf・ft. )
4. Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75).
5. Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74).
6. Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross section) short cap and
tighten it.
7. Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross section) and straight travel
section (I-I cross section) long caps and tighten them.
CAUTION
1) Be careful not to apply excessive torque when tightening a plug to a cap.
2) Applying excessive torque could crush the cap threads.
Assembly of straight travel signal control valve

1. Screw the orifice plug (42-7) [ 36 mm ( 1.417 in. ) hexagon diameter ] into the body (42-1) and tighten it.
Tightening torque: 3.0 - 3.8 N・m ( 2.21 - 2.80 lbf・ft. )
2. Being careful about the insertion orientation, assemble the spools (42-2) and (42-3) and spring (42-4).
3. Tighten the plug assembly (42-5) [ 5 mm ( 0.197 in. ) hexagon socket diameter ] with O-ring mounted to the body.
4. Install the body assembly (42) with the hexagon socket head bolts (83) [ 5 mm ( 0.197 in. ) hexagon socket
diameter ].
84551720B NA - August 2012

8011-14
Assembly of add-on section

1. Screw the tie rod (96) into the main unit valve housing (1).
2. Install the main unit body matching surface O-rings (56) and (64).
Execute Steps [1] - [3] below as necessary.
1) Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11).
2) Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4).
3) Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11).
4) Install the outlet housing (95).
5) Tighten the 4 hexagon nuts (97) [ 22 mm ( 0.866 in. ) hexagon diameter ].
Assembly of other plugs

1. Screw in and tighten the plug assembly (71) with O-ring mounted.
3. Screw in and tighten the orifice plug (40).
ightening torque: 14 - 18 N・m ( 10.33 - 13.27 lbf・ft. )
84551720B NA - August 2012

8011-15
Internal structure diagram
84551720B NA - August 2012

8011-16
[FOR HOOK BOLT] 2-M10

a 4 x M16 x 2 THREAD DEPTH c M10 x 1.5,THREAD DEPTH 12
x 1.5 THREAD DEPTH 17 ( b
27 ( 1.063 ) ( 0.472 )
0.669 )
*1 ARM 1 *3 SWING *5 TRAVEL

*2 BOOM 2 *4 OPTION
a WITH MATCHING SURFACE:

6 LOCATIONS
M10 x 1.5 THREAD DEPTH 17
b
( 0.669 )
*1 ARM 2 *3 BUCKET *5 STRAIGHT TRAVEL

*2 BOOM 1 *4 TRAVEL
84551720B NA - August 2012

8011-17
84551720B NA - August 2012

8011-18
*1 PARALLEL LINE *5 CYLINDER PORT *9 TRAVEL

*2 TANK *6 ARM 2 IN ⇔ OUT *10 STRAIGHT TRAVEL
*3 DRAIN *7 BOOM 1 DOWN ⇔ UP
*4 PILOT *8 BUCKET CLOSE ⇔ OPEN
84551720B NA - August 2012

8011-19
84551720B NA - August 2012

8011-20
*1 ARM 1 OUT ⇔ IN *7 CYLINDER LINE *13 CYLINDER

*2 BOOM 2 UP ⇔ DOWN *8 PILOT *14 STRAIGHT TRAVEL LINE
*3 SWING *9 (SUB VALVE) *15 COMMON CHECK LINE
*4 OPTION *10 (CAP) *16 PARALLEL
*5 TRAVEL *11 TANK
*6 DRAIN *12 BRIDGE LINE
84551720B NA - August 2012

8011-21
84551720B NA - August 2012

8011-22
*1 TANK *4 BOOM 1 *7 OPTION

*2 BOOM 2 *5 TRAVEL
*3 UP ⇔ DOWN *6 STRAIGHT TRAVEL
84551720B NA - August 2012

8011-23
84551720B NA - August 2012

8011-24
ADHESIVE APPLIED TO
*1 SWING *4 ARM 1 *7
THREADED SECTIONS
*2 OPEN ⇔ CLOSE *5 OUT ⇔ IN
*3 BUCKET *6 ARM 2
84551720B NA - August 2012

8011-25
Part list
Q't- Q't-
Code Part name Code Part name
y y
1 Valve housing 1 49 Poppet 1
2 Spool assembly 1 51 Poppet 1
3 Spool assembly 1 52 Flange 2
4 Spool assembly 1 53 Spacer 2
5 Spool assembly 2 54 O-ring 2
6 Spool assembly 1 55 Backup ring 2
7 O-ring 20 56 O-ring 1
10 Cap assembly 1 57 Spacer 1
11 Cap assembly 1 58 Sleeve 1
13 Valve housing 1 59 Poppet 1
14 Spool assembly 1 60 Spring 1
15 Spool assembly 1 61 Flange 1
18 Cap 1 65 O-ring 10
19 Spool 1 66 O-ring 13
20 Spring seat 2 67 Antidrift valve assembly 2
21 Spring 1 68 Relief valve kit 1
22 Spool end 1 69-1 Relief valve kit 5
23 O-ring 1 69-2 Relief valve kit 1
24 Plug 1 70 Relief valve assembly 2
25 O-ring 1 71 Plug assembly 3
26 Spring 1 72 Plug assembly 9
27 Spool assembly 1 73 Plug assembly 3
28 Cap assembly 1 74 Socket head bolt 12
29 Cap assembly 1 75 Socket head bolt 46
30 O-ring 1 76 Socket head bolt 20
31 Backup ring 2 77 Socket head bolt 8
32 Poppet 2 78 Socket head bolt 4
33 Spring 2 79 Name plate 1
34 Poppet 7 80 Drive screw 2
35 Spring 8 82 Plug 4
36 O-ring 10 83 Socket head bolt 4
37 Flange 6 84 Spool assembly 1
38 Poppet 2 86 Cap 1
39 Spring 2 88 Cap 2
40 Orifice plug 1 89 O-ring 2
42 Body assembly 1 91 Plug 1
43 Flange 1 92 Plug assembly 2
44 Poppet 1 93 Plug assembly 2
45 Spring 1 95 Outlet housing 1
46 Plug 1 96 Tie rod 4
47 O-ring 1 97 Nut 4
48 Spring 1 110 Plug assembly 1
84551720B NA - August 2012

8011-26
Relief valve
Procedures for assembly and disassembly of main relief valve
Plug [ 32 mm ( 1.259 in. )

1 5 O-ring 9 1-1/16-12UN-2A
hexagon diameter ]
Plug [ 27 mm ( 1.063 in. )
2 O-ring 6 10 Piston
hexagon diameter ]
Hexagon nut [ 30 mm ( 1.181
3 O-ring 7 11 PF1/4 JIS O-ring type
in. ) hexagon diameter ]
Hexagon nut [ 36 mm ( 1.417 Plug [ 27 mm ( 1.063 in. )
4 8
in. ) hexagon diameter ] hexagon diameter ]
1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) [ 32 mm ( 1.259 in. ) diameter ] with a wrench and remove the O-ring (2).
If oil leaks from the nut (4) [ 36 mm ( 1.417 in. ) hexagon diameter ], loosen the nut (4) [ 36 mm ( 1.417 in. )
hexagon diameter ] and the plug (1) [ 32 mm ( 1.259 in. ) hexagon diameter ], and replace the O-ring (3).
If oil leaks from the nut (7) [ 30 mm ( 1.181 in. ) hexagon diameter ], loosen the nut (7) [ 30 mm ( 1.181 in. )
hexagon diameter ] and the plug (8) [ 27 mm ( 1.063 in. ) hexagon diameter ], and replace the O-ring (5).
2. Assembly
Carefully check to make sure there is no debris, paint fragments around the thread sections of the plugs (1) [ 32
mm ( 1.259 in. ) hexagon diameter ], (6) [ 27 mm ( 1.063 in. ) hexagon diameter ], (8) [ 27 mm ( 1.063 in. )
hexagon diameter ] and nuts (4) [ 36 mm ( 1.417 in. ) hexagon diameter ], (7) [ 30 mm ( 1.181 in. ) hexagon
diameter ] and assemble the new O-rings.
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the plug (1) [
32 mm ( 1.259 in. ) hexagon diameter ].
When the plug has been disassembled, adjust the pressure according to the Main relief valve item in 5).
84551720B NA - August 2012

8011-27
Procedures for assembly and disassembly of overload relief valve
Lock nut [ 17 mm ( 0.669 in. )

1 Cap 5 Poppet 9
hexagon socket diameter ]
Adjuster [ 6 mm ( 0.236 in. )
2 O-ring 6 Spring 10
3 Adjuster kit section 7 1-1/16-12UN-2A
Cap [ 31.75 mm ( 1.250 in. )
4 O-ring 8
1. Disassembly
When replacing, loosen the cap (1) [ 31.75 mm ( 1.250 in. ) hexagon socket diameter ] with a wrench and remove
the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).
CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the cap and assemble a new
O-ring (2).
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the cap (1) [
31.75 mm ( 1.250 in. ) hexagon socket diameter ].
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Overload relief valve item in 5).
84551720B NA - August 2012

8011-28
Procedures for assembly and disassembly of low-pressure relief valve
1 Plug 5 O-ring 9 PF1/4

2 Poppet 6 Piston 10 PF3/4
3 Plug 7 Plug 11 1 3/16-12UN-2A
4 Spring 8 O-ring
1. Disassembly
Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and poppet (2).
Then loosen the plug and take out the O-rings (5) and (8) from each part.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring.
Install new O-rings (5) and (8) on the plug and install the plug.
Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug.
Tightening torque: 103 - 113 N・m (75.99 - 83.35 lbf・ft.)
Also clean the valve housing relief valve installation section well and tighten the relief assembly plug (1) [ 36 mm
( 1.417 in. ) hexagon diameter ].
Tightening torque: 103 - 113 N・m (75.99 - 83.35 lbf・ft.)
84551720B NA - August 2012

8011-29
Procedures for assembly and disassembly of add-on main relief valve
Plug [ 32 mm ( 1.259 in. ) Lock nut [ 17 mm ( 0.669 in. )

1 5 Poppet 9
hexagon diameter ] hexagon diameter ]
Adjuster [ 6 mm ( 0.236 in. )
2 O-ring 6 Spring 10
hexagon diameter ]
3 Adjuster kit section 7 1-5/16-12UN-2A
Plug [ 24 mm ( 0.945 in. )
4 O-ring 8
hexagon diameter ]
1. Disassembly
When replacing, loosen the plug (1) [ 32 mm ( 1.259 in. ) hexagon diameter ] with a wrench and remove the
O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).
CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring (2).
Also clean the valve housing relief installation section well, install the relief valve, and tighten the plug.
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Add-on main relief valve item in 5).
84551720B NA - August 2012

8011-30
Relief valve adjustment

CAUTION
This part is neither disassembled nor adjusted. (It is replaced as an assembly.)
Therefore, be aware that proper operation is not guaranteed if pressure is adjusted.
Installation
1. Be careful that the line does not apply excessive force to the valve.
2. Tighten all the bolts the same.
3. Be careful.
Welding close to a valve can damage its seal due to excess heat and sputter.
4. In order to keep out debris, do not remove the cap for a port until it is time to work on the line.
Operation
1. Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pressure (inch the operating
machine in low idle) and check that no oil leaks to the outside.
2. For the oil, use hydraulic oil with an aniline point of 82 - 113 °C ( 179.6 - 235.4 °F ).
3. Do not raise the relief valve above the specified set pressure.
4. Set a difference of at least 2.0 MPa ( 290.11 psi ) between the set pressure for the main relief valve and for the
overload relief valve.
5. Warm up the machine adequately before starting the actual work.
Pay attention to the following points in order to avoid sticking due to spool heat shock particularly when starting
up with the hydraulic oil temperature or valve temperature low.
• Do not operate the main relief valve and overload relief valve right too suddenly after each other.
Raise the temperature of each section uniformly and operate in such a way that the hydraulic oil circulates
within each actuator.
• Fine operations and compound operations generate heat locally due to throttling of individual sections, so do
not suddenly perform these operations with the machine still at low temperature.
84551720B NA - August 2012

8011-31
Troubles and countermeasures

Control valves overall
Trouble content Conceivable cause Countermeasure

Eliminate the section that is providing re-
1.The oil temperature is abnormally high.
sistance to the oil flow in the line.
Replace the hydraulic oil and at the same
2.Dirty hydraulic oil
time, clean the circuits.
3.Line port joint tightened too much Check the torque.
4.The valve housing was warped during
Loosen the installation bolts and check.
installation.
Attach a pressure gauge to the pump and
The spool does not move 5.The pressure is too high. the cylinder port and check the pressure.
through its stroke.
6.The spool is bent. Replace the spool as an assembly.
7.Return spring damage Replace the damaged part.
8.The spring or cap is out of place. Loosen the cap, center it, then tighten it.
9.The temperature distribution within the
Warm up the circuits as a whole.
valve is not uniform.
10.Debris is clogging inside the valve. Remove (flush out) the debris.
Inspect for the pilot valve and pilot relief
11.Pilot pressure insufficient
pressure.
1.Oil leak from cylinder Check the cylinder seal section.
2.Oil from the spool is bypassing. Check for spool damage.
Clean the valve housing seat section and
3.Oil leak from overload relief valve
relief valve seat section.
Disassemble the antidrift valve and clean
the seat section for each part.
The load cannot be held. If a seat section is damaged, replace the
poppet or lap the poppet and seat sec-
4.Oil leak from antidrift valve tion.
If the antidrift valve spool is abnormal,
since the spool and the sleeve are mat-
ing parts, replace them both at the same
time.
1.There is debris jammed in the load
When the spool is switched check valve. Disassemble and clean the check valve.
from the neutral to the raise
2.The check valve poppet or seat section Replace the poppet or lap the poppet and
position, the load falls.
is damaged. seat section.
Relief valve

1.Either the main poppet, sleeve, or
pilot poppet is stuck open or there is
Pressure does not rise at all.
debris jammed in the valve seat sec-
tion.
1.The pilot poppet seat section is Replace the relief valve.
The relief pressure is unstable. damaged.
2.The piston or main poppet is stuck.
1.Seat section worn by debris
The relief pressure is wrong. Set the pressure again, then tighten
2.The lock nut and adjuster are loose.
the lock nut to the specified torque.
1.Relief valve seat section damage
2.Each part is stuck due to debris.
Oil leak
Replace the adjuster or installation
3.An O-ring is worn.
section O-ring.
Hydraulic system overall

84551720B NA - August 2012
8011-32

Check the pressure or replace the
1.Pump trouble
pump.
2.Relief valve trouble Replace the relief valve.
3.Cylinder trouble Repair or replace.
4.Pump load pressure is high. Check the circuit pressure.
The hydraulic system is not working
5.There is a crack in the valve. Replace the valve as an assembly.
properly or is not working at all.
6.The spool does not move through its
Check the spool movement.
full stroke.
7.The tank oil level is too low. Fill the hydraulic oil.
8.The filter in the circuit is clogged. Clean or replace the filter.
9.The circuit line is throttled. Check the line.
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8011-33
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8011-34
Section
8012
Procedures for Operation/Assembly and Disassembly of

Hydraulic Cylinder (made by KYB)
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Specifications and Structure Diagram (including the assembly diagram and parts table) . . . . . . . . . . . . . . . . . . . . . . 3
Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function of Each Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Precautions for Installing the Cylinder on the Machine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Usage Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance and Inspection Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trouble Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Storing Parts Individually (In principle, store indoors.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
When Mounted on Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recommended Anti-rust Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly and Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection after Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Required Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drain the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Secure the Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pull out the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fasten the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove the Piston Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal of Piston etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of the Retraction Side Cushion Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove the Piston Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly of the Buffer Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly of U-ring and Wiper Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal of O-ring and Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly of Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal of Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation of Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Replacement of Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Assembly of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly of Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly of Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Insertion of Piston Rod into the Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cylinder Head Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation of Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Usage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Specifications and Structure Diagram (including the assembly diagram
and parts table)
In this manual, explanation is done using a product with a representative structure for a construction machine hydraulic
cylinder (KCH-6 model).
For details on the specifications and structure of the product being used, see the attached structural diagram.
Basic functions
Hydraulic cylinders are a type of hydraulic actuator.
A hydraulic cylinder converts the energy of pressure supplied from the hydraulic pump into a large force of linear
motion. By operating the hydraulic pressure direction switchover valve, one can switch the direction of operation
between extension and retraction.
This linear motion with large force and the switchover of the operation direction are the basic functions.
Function of Each Location
This manual explains the functions of each section of the cylinder using one of our products with a typical structure.
There may be some slight differences with the product being used, but the functions are the same.
Cylinder Head Assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4) press fit into the inner
diameter of the cylinder head (3). The seal system of the inner diameter of the cylinder head prevents oil from leaking
to the outside and prevents foreign matter from getting into the cylinder. The cylinder head assembly also has the
function of supplying and discharging high-pressure oil from inside the cylinder tube to the retraction side port.
1 Cylinder tube 5 O-ring 9 Wiper ring

2 Piston rod 6 Buffer ring 10 O-ring
3 Cylinder head 7 U-ring 11 Backup ring
4 Bushing 8 Backup ring 12 Installation bolt
• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston rod (2). Together with
the slide rings (18) (19) on the outer circumference of the piston, the bushing divides the lateral load applied to the
cylinder and moves linearly relative to the piston rod. Furthermore, it supports one end of the piston rod and has
the function of minimizing eccentricity which has a negative impact on the sealing.
• Buffer ring
The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7) by the hydraulic oil
to improve durability.
• U-ring and backup ring
The U-ring (7) seals the pressure oil within the cylinder. The U-ring also has the function of forming an appropriate
oil film on the surface of the piston rod in order to prevent rust of the piston rod (2). The backup ring (8) has the
function of suppressing extrusion of the U-ring into the gap between the piston rod and the cylinder head (3) when
the pressure operates and of improving durability.
• Wiper ring
The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder.
This wiper ring (9) prevents dust and water from getting into the cylinder from the outside. It also has the function
of wiping off any mud sticking to the surface of the piston rod as the piston rod moves.
84551720B NA - August 2012

8012-3
Piston Assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is mounted on the
center of the piston (15) to prevent the flow of pressure oil from either the left or right chamber to the other chamber.
There are slide rings (18) (19) mounted at each end of the seal ring. They have the function of a bearing to receive
the cylinder lateral load.
1 Cylinder tube 16 Seal ring 21 Steel ball

2 Piston rod 17 Backup ring 22 Cushion ring
13 Cushion ring 18 Slide ring 23 Cushion seal
14 Cushion seal 19 Slide ring 24 Stopper
15 Piston 20 Locking screw 25 Snap ring
Use caution with the direction

a of the cut surfaces during in-
stallation
b Face the "slit" to the piston side.
For some cylinder sizes, the piston (15) and nut (21) are separate.
84551720B NA - August 2012

8012-4
1 Cylinder tube 17 Backup ring 23 Steel ball

2 Piston rod 18 Slide ring 24 Cushion ring
13 Cushion ring 19 Slide ring 25 Cushion seal
14 Cushion seal 20 Shim 26 Stopper
15 Piston 21 Nut 27 Snap ring
16 Seal ring 22 Locking screw

a of the cut surfaces during in-
stallation
b Face the "slit" to the piston side.
Example of parts numbers for separated piston and nut

• Seal ring and backup ring
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to seal the
ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pressure side and a
low-pressure side with the piston as the boundary. The backup ring (17) has the function of suppressing extrusion
of the seal ring into the gap between the piston and the cylinder tube when the pressure operates and of improving
durability.
• Slide ring
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder tube (1).
Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide ring divides the
lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a
negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the
slide rings (18) (19).
• Cushion ring (for separated piston and nut)
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is fully
retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped gap and
squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.
84551720B NA - August 2012
8012-5
Pipe Assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder tube assembly. It has the
function of supplying and discharging high-pressure oil by connecting with the hydraulic circuits of the machine body.
28 Pipe assembly
29 Pipe assembly
84551720B NA - August 2012

8012-6
Handling Precautions
Precautions for Installing the Cylinder on the Machine Body
• When installing the cylinder on the machine body or removing it from the machine body, secure the piston rod at
the fully retracted position, check safety, and suspend.
CAUTION
Never suspend the cylinder from the line section. This would not only pose the danger of falling but
could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state.
If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the
need for repair or make the piston rod unusable.
Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly.
• Do not weld after the cylinder has been mounted on the machine body.
CAUTION
Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark
within the cylinder and damage parts.
This could cause extensive damage, making it necessary to replace parts or replace the cylinder.
• When painting the machine body, mask the piston rod and wiper ring.
CAUTION
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper
ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and
paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak.
• Clean the cylinder before installing it.
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8012-7
Usage Cautions
• Use under the determined conditions.
CAUTION
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to seal parts.
If the relief valve is set to a value higher than that on the assembly diagram, there is a danger of this
leading to cylinder damage.
General sealing materials cannot handle high ambient temperature [ about 100°C ( 212.0 °F ) or higher
] or low ambient temperature [ -20°C ( -4.0 °F ) or lower ], so the cylinder would be damaged if used at
such temperatures.
Such temperatures require special seal materials, so check if the cylinder being used complies with
this requirement.
The number one cause of cylinder trouble is oil leaks due to piston rod scratches.
Operate very carefully to avoid scratching.
If the piston rod is scratched, handle this according to "Trouble Diagnostics".
• Warm up the equipment adequately before work.

CAUTION
After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck to the
metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
A new cylinder or one that has been left unused for a long time has much air built up inside, so it does
not operate smoothly.
Also, if the cylinder is suddenly operated or pressurized without bleeding out the air, the adiabatic
compression of the air generates high temperatures, which may burn and carbonize seal parts, leading
to a drastically reduced functionality.
Before starting work, always warm up the cylinder by moving slowly through a few full strokes under
no load to bleed off any air in the cylinder.
• For stopping the machine temporarily or storing it, always have the machine in a safely secure posture.
CAUTION
When extended, the cylinder cannot hold a load for a long time in a fixed position.
This is because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil temperature
variation.
This results in the danger of machine moving unexpectedly, which can lead to serious accidents.
For stopping the machine temporarily or storing it, always have the machine in a safely secure posi-
tion.
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8012-8
Maintenance and Inspection Cautions
• Always carry out daily maintenance inspections.
CAUTION
The most important point for realizing the cylinder functions for a longer time is "daily maintenance
inspections".
In order to ensure adequate functioning, execute "Maintenance Inspection and Service".
Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston
rod in a clean state.
However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag.
When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston
rod in order to prevent rusting.
• Use genuine KYB parts for replacement parts.

CAUTION
If replacement parts are used that are not genuine KYB parts, adequate functioning cannot be attained.
Always use genuine KYB parts.
Specialty jigs have been produced so that assembly work and disassembly work can be done safely
and quickly, so order them.
• Be careful about assembly and disassembly too.

CAUTION
Disassembling a cylinder still installed on the machine body is extremely dangerous because it can
cause unexpected movement of the machine body.
Always remove the cylinder from the machine body before disassembling it.
Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder service
life but also damage other hydraulic equipment.
Assemble under clean conditions.
Use the thread part tightening torque indicated in the diagram.
If the torque is either too low or too high, this can cause thread damage.
• Strictly observe the cylinder storage standards.

CAUTION
Execute according to "Assembly and Disassembly Procedures".
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8012-9
Maintenance Inspection and Service
In order to ensure that hydraulic cylinders function properly for a long time, periodically carry out maintenance in-
spection and service based on the "Autonomous inspection table". Repair any trouble locations quickly based on the
Trouble Diagnostics.
CAUTION
For periodic inspection and service, first work to prevent any hazard to operators. Strive to prevent
hazards by working with an attitude based on good sense.
Inspection and ser- Mont-

Inspection and service detail Daily Yearly Remarks
vice location hly
Is the cylinder clean (especially rod sliding ○
sections)?
Appearance Is any oil leaking from line installation sec- ○
tions or other fixed sections?
Is there missing or peeling paint or rust? ○
Is operation smooth and free of abnormal ○
noise and any other abnormality?
Is the responsiveness good? ○
Is any oil leaking from sliding sections? ○
Operation
Are there internal leaks? ○
Is the operating pressure normal? ○
Is the overload relief valve set pressure nor- ○
mal?
Is hydraulic oil dirty or deteriorated? ○
Hydraulic oil Is hydraulic oil replaced periodically? ○
Are filters inspected periodically? ○
Is the supply of grease to pins adequate? ○
Do pin sections have any abnormal noises ○
or seizing?
Section for installa- Do pin sections have any backlash or wear? ○
tion with main unit Are pin seals normal? ○
Are any installation screws loose or fallen ○
out?
Retighten installation screws. ○
Are sliding sections worn? ○ When leaving pis-
Are sliding sections scratched or dented? ○ ton rod sliding
Is sliding section plating peeling off? ○ sections exposed
Piston rod section
Are sliding sections bent? ○ for long periods,
Are there any welding section cracks or apply anti-rust oil
○ to the piston rod.
damage?
Are there any loose bolts or nuts (screws)? ○
Retighten installation screws (bolts and nuts ○
Cylinder tube section (screws)).
(including line sec-
tions) Are there any welding section cracks or ○
damage?
Are there large dents on the tube? ○
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8012-10
Trouble Diagnostics
Hydraulic cylinder trouble, countermeasure and solution
It is not easy to discover trouble locations.
The table below shows general symptoms, suggested causes and also solutions.
For repairs, see the suggested causes and solutions in the table.
The cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship
of one part with another.
In some cases, solutions are required other than those given in the table.
In such a case, contact with our company to investigate the problem and its cause further and take appropriate mea-
sures.
Item Symptom
Piston rod sliding section oil leak
1
(For the judgment values, see "Inspection after Assembly".)
2 Cylinder head matching section oil leak
3 Pipe and cylinder tube welding section oil leak
4 Operation defect
84551720B NA - August 2012

8012-11
Item Symptom Related part Cause Countermeasure and solution
1. Remove the scratches with a
whetstone to make the sliding
surface smooth (1.5 s max.).
If the oil leak continues, the rod
scratches may have damaged
A sliding surface has rust and the U-ring or other seal, so dis-
scratches that catch on a fin- assemble and inspect.
gernail. 2. If the scratches or rust cover too
large an area to be repaired with
Piston rod a whetstone, replace the piston
rod and the U-ring, wiper ring,
or other seal and the piston rod
bearing part.
1. Replate or replace the piston rod.
2. At this time, inspect the seals and
Plating is peeling off. piston rod bearing part as well
and replace any that are dam-
aged.
There is foreign matter caught 1. Remove the foreign matter.
in the inner or outer diameter 2. If the packing is damaged, re-
section. place it.
There are scratches on the in-
Replace.
ner or outer diameter section.
1. This may be scorching due to adi-
abatic compression of air remain-
ing in the cylinder.
Piston rod sliding The lips and groove section are 2. When operating the cylinder for
1 locally carbonized (scorched). the first time after replacing a
section oil leak
packing, run at low pressure and
low speed to adequately bleed off
the air.
The packing has lost its rubber 1. Replace.
elasticity and is in tatters. 2. This may be the end of the pack-
ing service life, deterioration of
the hydraulic oil, or high temper-
Rod packing ature of the hydraulic oil.
(Buffer ring and
U-ring) 1) Replace with a new hy-
draulic oil.
The lip section is defective all 2) Check the temperature of
the way around. the hydraulic oil.(The oil
temperature should be no
higher than 80 °C（ 176.0
°F ）.)
3) Check for local high tem-
perature.
1. Replace.
2. Abnormally high pressure may
be operating on the packing.
There is major extrusion of the 1) Check the pressure during
packing heel section. operation.
2) There may be trouble with
the buffer ring section.
Inspect the buffer ring sec-
tion.
84551720B NA - August 2012

8012-12
1. As a rule, replace the rod packing
too at the same time.
2. Abnormally high pressure is often
Backup ring The part is greatly deformed. the cause.
The check items for this are the
same as those given above for
packing heel section extrusion.
There is foreign matter caught
Remove the foreign matter.
in the lip.
Wiper ring The lip is damaged.
There is other abnormal dam- Replace.
age.
Piston rod sliding
1 There is major wear of the
section oil leak
bushing and the gap with the
piston rod exceeds the limit on Replace.
Bearing part inner diameter wear in "Usage
(bushing) Limits".
1. Replace.
There are large scratches on a
2. Inspect the piston rod sliding sur-
sliding surface.
faces for scratches and rust.
1. Remove the scratches or rust
with a whetstone.
A seal mounting section has
Cylinder head 2. If the repair does not solve the
scratches and rust.
problem, replace the cylinder
head.
1. Remove the foreign matter.
2. If the O-ring is damaged, replace
it.
3. Tube interior surface inspection:
If there are any scratches or rust,
use a whetstone to make the sur-
There is foreign matter caught face smooth.
O-ring in the inner or outer diameter. 4. Cylinder head O-ring groove in-
There is damage to the O-ring. spection: Same as above
5. Backup ring inspection: If the
backup ring is deformed or ex-
truded, replace it.
Check the above and replace the
O-ring.
The part is deformed or ex-
Backup ring Replace together with the O-ring.
truded.
1. Disassemble the cylinder head
Cylinder head and inspect the O-ring and
2 matching section backup ring.
oil leak If there is damage, replace.
2. Check the tube and cylinder head
Cylinder
A part is loose. threads for damage and if there is
head
any damage, replace.
3. When the inspection is complete,
tighten to the specified torque.
See "Assembly Procedures".
4. Stop rotation.
There is looseness, stretching Replace all the bolts and tighten to the
Bolt
or breakage. specified torque.
1. Replace with a new one.
2. Oil leaks at matching sections
may be caused by abnormally
high pressure (including cush-
Cylinder tube There is abnormal swelling.
ion pressure), so if the tube is
swollen or deformed, replace it
with a new one.
Also inspect the circuit pressure.
84551720B NA - August 2012

8012-13
CAUTION
Replace with a new one.
Pipe and cylinder
Pipe and cylinder There are cracks on the weld- The crack progresses and ultimately
tube welding sec-
tube ing section. the part fractures.
tion oil leak
A fracture is extremely dangerous, so
if a crack is seen, quickly stop work
3 and replace that part.
Welding over a crack is ineffective.
Tighten to the specified torque ac-
Line fastening bolt is loose.
cording to the work procedure.
Oil leak from cylin- The line is bent. Replace with a new one.
der line connec- Pipe assembly 1. Use a whetstone to make the sur-
tion section There are scratches on a con- face smooth.
tact surface. 2. If the oil leak does not stop, re-
place.
The bending is large and ex-
2. There may also be damage to
ceeds the stipulated bend
Piston rod seals and sliding parts, so inspect
warp.
Cylinder tube them.
(Bend warp: See "Mainte-
If there is any abnormality, re-
nance Standards".)
place.
Operation defect Replace with a new one.
Movement is not Cylinder tube There are dents. Inspect the seal and sliding parts the
smooth. same as above.
Abnormal wear of sliding parts
Inspect the seal and sliding parts
Piston rod and damage
the same as above.
Cylinder tube Foreign matter caught at the
2. Remove the foreign matter.
Sliding part piston section or the cylinder
Inspect the seal and sliding parts
head sliding section
the same as above.
Replace with a new one.
There are scratches, wear, or
Piston seal Also inspect the cylinder tube interior
other damage.
4 surfaces.
1. Use honing or a whetstone to
eliminate the scratches and rust
and make the surface smooth.
Internal oil leak There are scratches and rust
Cylinder tube If the scratches cover too large an
The piston rod ex- on interior surface.
area to be repaired, replace the
tends and retracts cylinder tube with a new one.
on its own and 2. Replace with a new piston seal.
drops abnormally
1. Tighten to the specified torque.
during operation.
See "Assembly Procedures".
Also, the stipu-
2. The piston rod thread section
lated speed is not
could be stretched.
output. Piston nut Tightening is insufficient.
Measure the diameter where the
rod and piston fit together and if
this area is tapered, replace the
piston rod assembly.
Inspect the amount of valve leakage
Valves Leak from valve.
and perform maintenance.
84551720B NA - August 2012

8012-14
Bleed out the air.
1. Cylinder with no air bleeding
Bleed out the air by moving the
cylinder back and forth at few
times at low pressure and low
speed.
2. Cylinder with air bleeding (air
breather)
After securing the machine so
Operation is un- There is air remaining in the that the cylinder does not move,
Air
steady. cylinder. bleed the air from the air breather.
HINT
The cylinder may extend or retract
somewhat when the cylinder stops
suddenly.
This phenomenon occurs due to the
4 compressibility of the hydraulic oil.
This occurs particularly easily for
cylinders with long strokes.
The impact is high
when switching The gap between the installa- Measure the pin and pin bushing di-
Pin bushing
over between ex- tion section and the pin bushing mensions and replace any part that
Pin
tension and re- is enlarged. exceeds its specified dimension.
traction.
The oil or grease feed is inade-
Cylinder sliding Apply oil or grease.
Pin bushing quate.
operations make
Pin There is seizing at matching Replace with a new part and apply oil
sounds.
section. or grease.
CAUTION
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.
84551720B NA - August 2012

8012-15
Storage Standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during
storage and to extend the product service life, pay attention to the following items.
Storing Parts Individually (In principle, store indoors.)
• Store parts off the floor and do not store in any location with high temperature and humidity, corrosive gas or liquids.
• Before shipment, we operate the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent
has been added (in order to prevent rust within the cylinder), carry out the pre-shipping inspection, retract the pis-
ton rod with ultra-dry air (condensation point -35 °C ( -31.0 °F) or lower) (in order to prevent condensation due to
temperature difference), and then put caps on the ports and line joints before shipping the cylinder.
• Any product that has been in storage in our product warehouse longer than the standard storage period is disas-
sembled and inspected before being shipped.
Therefore, do not store or leave a cylinder unused with a cap removed or with the remaining oil in the cylinder
drained.
Storage for 6 month or longer

Storage for 1 month or longer Storage for 1 year or longer
(3 months for cylinder alone)
Clean any dust from the cylinder, Operate the cylinder back and forth
Since there is a danger of packings
and then apply anti-rust oil to the with clear hydraulic oil, and then pour
deterioration, disassemble, inspect,
1 pin bushings, flange sections, pis- anti-rust oil into the cylinder and store
and replace packings.
ton rod, and other sections that in compliance with the items on the
Also, check for rust inside the cylinder.
rust easily. left for storage of 1 month.
If a cylinder that has been stored for
If the cylinder cannot be operated, a long time is used as is, oil may leak
2 -
seal in anti-rust oil. due to temporary running-in defects of
seals.
3 When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything strike them.
When Mounted on Vehicle Body

1. Operate the cylinder at least once per month.
2. Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-rust oil
at least once per month to the exposed part of the piston rod.
3. Handle carefully to absolutely avoid scratching the piston rod.
4. When putting the cylinder into an environment where rust occurs particularly easily, for example due to exposure
to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possible protect with
polyethylene sheets or VCI paper (vaporizing anti-rust paper).
5. Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as much
as possible keep it off dust seals etc.(For details on anti-rust oil to select, see "Recommended Anti-rust Oil".)
Recommended Anti-rust Oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
b. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked sur-
faces other than parts with Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
oil sealed in
84551720B NA - August 2012

8012-16
Assembly and Disassembly Procedures
Preparations
Prepare the Following before Starting Disassembly:
1. Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or move during work.
2. Tool and materials preparation
Prepare the tools and materials shown on the following pages.
General Work Precautions

1. Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disassembly.
2. Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other
or fall when handling them.
3. If parts are struck or pried off with excessive force during work because they are tight, this may cause burrs or
damage which causing reduction in performance or oil leaking.
Perform work carefully and thoroughly.
4. If a cylinder is left disassembled, humidity and dirt can cause rust on parts.
If a pause in the work is unavoidable, be careful to prevent rust and keep off dust.
Replace sliding parts and seal parts as follows.
1. Bushing
When 1/4 of the circumference is worn brown over the entire length.
2. Seals and slide rings
Replace with new parts when the cylinder is disassembled.
3. Pin bushing
When there is severe seizing.
4. Piston rod
When the piston rod is bent 0.5 mm ( 0.0196 in. )/1 m ( 3.280 ft. ) or more.
84551720B NA - August 2012

8012-17
Inspection after Assembly
Dimension in-
Check the maximum retracted length and stroke as instructed on the diagram.
spection
Pressure with-
Check for looseness, permanent deformation, and external leaks when the test pressure in-
stand inspec-
structed on the diagram is applied to each stroke end for at least 3 min.
tion
Check the amount of oil leak at the rod section.
• Judgment value for rod section oil leak amount
Move the piston rod back and forth 20 times with the oil at a temperature from 20 °C - 40 °C
( 68.0 °F - 104.0 °F ), then judge by the state of the oil ring formed on the rod surface. If the
oil ring is in a broken down A state, this is judged to be trouble. See "Trouble Diagnostics" for
information on how to solve this.
External leak
inspection
Oil leak amount unit: ml/10 min.

Inner diameter Oil leak Inner diameter Oil leak Inner diameter Oil leak
mm ( in. ) amount mm ( in. ) amount mm ( in. ) amount
Internal leak 32 ( 1.259 ) 0.4 100 ( 3.937 ) 4.0 160 ( 6.299 ) 10.0
inspection 40 ( 1.574 ) 0.6 125 ( 4.921 ) 5.6 180 ( 7.086 ) 12.6
50 ( 1.968 ) 1.0 140 ( 5.511 ) 6.0 200 ( 7.874 ) 15.6
63 ( 2.480 ) 1.6 220 ( 8.661 ) 20.0
80 ( 3.149 ) 2.3 250 ( 9.842 ) 22.0
1 Oil ring
a Acceptable
b Not acceptable
84551720B NA - August 2012

8012-18
Required Tool
General Tool
No. Tool name Q'ty
Screwdriver (flathead screw-

1 1
driver)
2 Hexagon wrench 1 set
3 Vise 1
4 Wrench (for piston nuts) 1 set
5 Punch 1
6 Torque wrench 1 set
84551720B NA - August 2012

8012-19
No. Tool name Q'ty
7 Hammer (plastic hammer) 1
8 Monkey wrench 1
9 Scoop 1 set
84551720B NA - August 2012

8012-20
Special Jig
Cylinder assembly requires the following special jigs.
Jig name Sketch
For bushing removal and

press fitting
For wiper ring press fit-

ting
Seal ring insertion jig
Seal ring calibration jig
For cylinder head inser-

tion
For piston insertion
(The following page has a list of jig part numbers.)
84551720B NA - August 2012

8012-21
Special Jigs Part Number List
1. Select jigs for the cylinder head according to the rod diameter.
2. Select jigs for the piston according to the cylinder bore.
Applicable rod diameter Set part No.

65 ( 2.559 ) 3006J-56001
70 ( 2.755 ) 3007J-06001
75 ( 2.952 ) 3007J-56001
80 ( 3.149 ) 3008J-06001
85 ( 3.346 ) 3008J-56001
Cylinder head assembly and
90 ( 3.543 ) 3009J-06001
disassembly jig
95 ( 3.740 ) 3009J-56001
100 ( 3.937 ) 3010J-06001
105 ( 4.133 ) 3010J-56001
110 ( 4.330 ) 3011J-06001
115 ( 4.527 ) 3011J-56001
120 ( 4.724 ) 3012J-06001
Applicable cylinder bore Set part No.
95 ( 3.740 ) 3009J-51001
100 ( 3.937 ) 3010J-01001
105 ( 4.133 ) 3010J-51001
110 ( 4.330 ) 3011J-01001
115 ( 4.527 ) 3011J-51001
120 ( 4.724 ) 3012J-01001
Seal ring insertion and calibra-
125 ( 4.921 ) 3012J-51001
tion jig
130 ( 5.118 ) 3013J-01001
135 ( 5.314 ) 3013J-51001
140 ( 5.511 ) 3014J-01001
145 ( 5.708 ) 3014J-51001
150 ( 5.905 ) 3015J-01001
160 ( 6.299 ) 3016J-01001
170 ( 6.692 ) 3017J-01001
84551720B NA - August 2012

8012-22
Disassembly Procedures ier. When securing the cylinder, use the bottom pin hole
to stop rotation and secure the direction of the axis.
Drain the Oil (When securing the cylinder, if a line or the like inter-
feres, remove it.)
Secure the Cylinder
Secure the cylinder in a vertical or horizontal position. A
vertical position makes assembly and disassembly eas-
84551720B NA - August 2012

8012-23
Removal of Cylinder Head Passing a pipe through the hexagon wrench as in the
diagram below makes the work easier.
Use a hexagon wrench to loosen the cylinder head tight-
ening bolts and remove them.
1 About 1.5 m
2 Cylinder secured
Line band (Removal is unnec-
3 essary when replacement is
unnecessary.)
84551720B NA - August 2012

8012-24
Pull out the Piston Rod CAUTION
1. Check that the line caps are removed.
2. Put the oil pan at the retraction side (cylinder head • When assembling and disassembling
with the cylinder secured horizontally,
side) port.
work paying particular attention to the
3. With the piston rod pulled out all the way, slowly pull
following points.
out the cylinder head and remove it.
In the work of removing the piston rod,
4. Pull out the piston rod together with the cylinder
there is a danger of the piston rod falling
head and place them on crossties.
and damaging parts right after it is re-
CAUTION moved.
Work carefully while holding the rod hor-
• When assembling and disassembling izontal and in contact with the crossties.
with the cylinder secured vertically, work
paying particular attention to the follow-
ing points.
In the work of removing the piston rod,
the cylinder head may come out of the
cylinder tube ahead of the piston due to
friction with the packing, creating a con-
dition in which there is space between
the cylinder head and the piston.
If the work is done in that state, the cylin-
der head may suddenly slip out and in-
jure the operator.
Always work with the cylinder head
touching the piston.
a Crosstie
Working in the horizontal
b
state
c Beware of falling
a Beware of falling
84551720B NA - August 2012

8012-25
Fasten the Piston Rod
Use the rod head bolt width or pin hole to set up a rota-
tion stopper.
Remove the Piston Nut • Loosening a piston nut requires about 1.5 times
that torque. Prepare the power wrench (6) that
1. Remove the locking screw (3). uses the hydraulic jack (4) and hydraulic cylinder
Locking screw is caulked in with a punch at 2 loca- (5).
tions on the outer circumference.
Cut away the caulked sections with a hand drill (1), * For a one-piece type piston and nut, apply the
and then loosen the locking screw. wrench to the hexagonal section of the piston and
2. Remove the steel ball (2) at the bottom of the locking loosen the piston directly.
screw (3).
3. Remove the piston nut.

• The piston nut is tightened with the torque speci-
fied in the assembly diagram.
84551720B NA - August 2012

8012-26
Removal of Piston etc.
Remove the piston (9), cushion ring (8), and cylinder
head (7) in that order.
Disassembly of the Retraction Side Cushion

Ring
1. Remove the piston nut. Disassembly cannot be 4. Remove the cushion ring (14).
done with the nut attached. 5. The cushion seal (13) has a split opening, so spread
2. Remove the snap ring (12). Remove by gently tap- the opening wide and remove the cushion seal.
ping with a plastic hammer in such a way as not to
scratch the piston rod (11) or cushion ring (14).
3. When the cushion ring (14) is slid to the piston rod
thread (11) side, the stopper (split in two) (15) can
be removed.
84551720B NA - August 2012

8012-27
Remove the Piston Seal 3. Pull out the O-ring (19) with a scoop.
1. The slide rings (22) and backup ring (20) can be * The removed seal parts cannot be reused.
removed easily by hand.
2. Stand up a flathead screwdriver (23) as in the di-
agram on the right and tap with a hammer to cut
through the seal ring (16), and then remove the seal
ring.
10 Screw 18 Vise
17 Piston 21 Hardwood
84551720B NA - August 2012

8012-28
Disassembly of the Buffer Ring
1. The buffer ring (27) is mounted in the groove on the
inner diameter of the cylinder head. When removing
this seal, stick in a sharp tool and lift it up, and then
insert a scoop and take it out.
* The removed seal parts cannot be reused.
Disassembly of U-ring and Wiper Ring Removal of O-ring and Backup Ring
1. Use a screwdriver to remove the U-ring (26) and 1. Pull out the O-ring (29) and backup ring (30) with a
backup ring (25). scoop.
2. The wiper ring (24) is press fit.
Stick a screwdriver straight down into the rubber
and tap it to remove the wiper ring.
* The removed seal parts cannot be reused.
84551720B NA - August 2012

8012-29
Disassembly of Bushing 2. For the bushing (33), use the bushing removal jig
(32) as in the diagram on the right and press out
1. Raise the snap ring (28) with a screwdriver, and
the bushing with a press.
then remove it from the cylinder head.
31 Bushing a Press with the press.
84551720B NA - August 2012

8012-30
Removal of Pin Bushing 2. Use the metal block (35) to remove the pin bushing
(37).
1. Remove the wiper ring (24) from the tube and piston
rod. Remove it by using a screwdriver in the same
manner as for the cylinder head.
34 Press If they are left disassembled, there is a danger of their

36 Jig collecting rust and dust and not being able to function
adequately after they are assembled again.
Cleaning and Storage
Clean the removed parts with white kerosene, and then
apply hydraulic oil, cover the parts, and store them.
84551720B NA - August 2012

8012-31
Assembly Procedures Installation of Pin Bushing
CAUTION 1. Use the installation jig to press fit onto the piston rod
(4) and into the tube.
If a part with peeling paint is assembled, the (Apply hydraulic oil in advance.)
peeled off paint can get inside the cylinder. 2. Use the metal block (5) to install the wiper ring (6).
This causes oil leaks, so work being very care-
ful to prevent this.
84551720B NA - August 2012

8012-32
Replacement of Seals • Be careful about the location of the backup ring.
• Apply grease or hydraulic oil to the backup ring
1. When disassembling the cylinder, replace all the
and O-ring so that they slide easily, and then
seals.
assemble them. If they are sliding poorly, O-ring
2. O-rings
may become twisted during assembly, which
• Clean the mounting groove well, and then mount causes oil leaks.
the backup ring (7) and O-ring (8).
Foreign matter in the groove section would cause
an oil leak.
1 Press 3 Pin bushing

2 Installation jig 9 Cylinder head
84551720B NA - August 2012

8012-33
Assembly of Cylinder Head Assembly Assembly of Piston Assembly
1. Use the bushing press fit jig (10) to press fit the 1. Attach the seal ring (24).
bushing (11).
Apply hydraulic oil to the inside surface of the cylin- • Attach the back-up ring (23) for one side and the
O-ring (25) on the piston (26) in advance, place on
der head in advance and after press fitting, check
the press platform, and use the seal ring insertion
that there is no level difference at the bushing.
jig (22) as in the diagram to assemble the seal
2. Use the wiper ring press fit jig (15) to press fit the
wiper ring (16). ring.
3. Mount the backup ring (18) and U-ring (19) in the 2. Calibrate the seal ring.
U-ring groove (17) in that order.
• Mount the seal ring (24) and the other backup
• Check the assembly direction of the U-ring and ring (23), and then immediately calibrate with the
mount it carefully so as not to scratch it. Installing seal ring calibration jig (27) so that the seal ring
backwards can cause an oil leak. does not remain expanded. (Strictly observe this
• After mounting, check that there are no wrinkles instruction.)
or other permanent deformation remaining in the Since the seal ring is stretched when it is
U-ring. mounted, if it is not calibrated, "Insertion of Piston
Rod into the Tube" is not possible.
3. Assemble the slide ring.
• Spread the cut section of the slide ring the min-
imum with both hands and install from the axial
direction.
If it is spread too wide, it cannot be mounted.
* Consult with our company about jigs.
4. Mount the buffer ring (20).

Be careful with the attachment directions of the
seals.
If the seal is attached backwards, extraordinarily
high pressure will be generated between the seal
and the U-ring (19), causing deformation and break-
age of the cylinder.
5. Assemble the bushing retainer snap ring (21).
12 Cylinder head
13 Pressing base
14 Press
84551720B NA - August 2012

8012-34
84551720B NA - August 2012

8012-35
Assembly of Piston Rod Assembly 1) Assemble the cushion ring before assembling
the piston nut.
1. Secure the piston rod (31). The cushion ring cannot be assembled with
2. Assemble the cylinder head (32) on the piston rod the piston nut attached.
(31). 2) Mount in the groove with the side of the cush-
Be careful that the wiper ring and U-ring lips do not
ion seal with the slit (*4) facing the screw side.
catch on the stepped section. Use the cylinder head 3) Assemble with the part of the cushion ring pro-
insertion jig (30) as in the diagram on the right to
cessed to be flat facing as in the diagram be-
assemble the cylinder head on the piston rod. low.
• Apply grease or oil and assemble being careful 4) Insert the stopper (40) into the groove. Press
not to scratch the packing. the cushion ring (39) all the way to the stopper
and strike in the snap ring (37). Strike gently
with a plastic hammer in such a way as not to
scratch the piston rod (4) or cushion ring.
28 Metal block
29 Press
*1 Flat surface processing
*3 Face the slit to the screw side.
3. If there is a cushion on the extension side, assemble
the cushion ring (33) and cushion seal (34) with the
following procedure. 35 Piston
36 Screw
1) Insert into the groove with the side of the cush-
ion seal with the slit (*2) facing the piston side.
2) Assemble with the part of the cushion ring pro- CAUTION
cessed to be flat facing as in the diagram. Make sure that the cushion seal and cush-
ion ring face the correct direction.
If they are installed backwards, the cush-
ion will not be effective.
After installing the cushions, check that
the extension and retraction cushion rings
move up and down and left and right.
5. Tighten the piston nut.

• Always tighten the piston nut to the specified
torque given on the assembly diagram.
• If the tightening torque is insufficient, this causes
internal leaks, nut looseness, and screw cutting
• Also, if the tightening torque is excessive, exten-
sion side cushion ring swelling and piston contact
4. When there is a cushion on the retraction side surface deformation occur.
Assemble the cushion ring (39) and cushion seal • In order to tighten correctly, clean and degrease
(38) with the following procedure. the piston and nut and piston rod thread section
84551720B NA - August 2012

8012-36
adequately (with paint thinner) before tightening Insertion of Piston Rod into the Tube
the nut.
1. Secure the tube (47) vertically or horizontally.
6. Stop the piston from turning. 2. Insert the piston rod (4) into the tube (47).
• After tightening the piston nut, put in the steel ball • If the tube is secured vertically, the piston rod en-
(43), tighten the locking screw (42) to the specified ters the tube due to its own weight.
torque given on the assembly diagram, and then • When the piston section is entering the tube, be
caulk (41) with the punch (44) at 2 locations on careful that the slide rings (46) do not fall out.
the outer circumference.
45 Jig; Nylon pipe (split in two) Cylinder Head Tightening

Slide ring (Shift the abutment
Align the cylinder head with the position on the assem-
46 phase 180° from one ring to the
bly diagram, and then tighten the bolts to the speci-
next.)
fied torque given on the assembly diagram in the order
shown in the diagram below.
84551720B NA - August 2012

8012-37
Bolt tightening order Installation of Line

1. Check that the O-ring is in the groove correctly.
2. Tighten the port section bolts to the specified torque
given on the assembly diagram.
3. Tighten the line bands to the torque on the assembly
diagram, the same on both sides, so that no abut-
ment gap occurs.
84551720B NA - August 2012

8012-38
*5 Tighten the bolts. CAUTION

*6 Be careful about the O-rings.
*7 No abutment opening gap When installing the cylinder lines and the ma-
*8 Normal: OK chine body rubber hoses, nipples, etc., assem-
*9 There is a gap: Not OK ble securing the cylinder line port section with
*10 Band for securing the line a wrench.
If one tightens without securing the port sec-
tion, the line may bend, oil may leak, and the
machine body may get in the way.
84551720B NA - August 2012

8012-39
Test Operation 2. If the cylinder has air bleeding, pressurize so that
the air bleed side is the pressure side (return oil
1. In order to fill the inside of the cylinder with oil, after it side) and bleed off the air.
is installed on the machine body, move the cylinder 3. Apply oil and grease to the pins at both ends.
through its full stroke slowly 8 times or more. If
the cylinder is suddenly moved from the start, the
hydraulic oil may be aerated.
84551720B NA - August 2012

8012-40
Usage Limits
Below are the usage limits for the main sliding sections.
Use them for reference for maintenance.
• Piston rod outer diameter wear limit
Nominal diameter Minimum outer diameter

Solution
[ mm ( in. ) ] [ mm ( in. ) ]
65 - 80 ( 2.559 - 3.149 ) -0.023 ( -0.000905 ) Replace or replate.
85 - 120 ( 3.346 - 4.724 ) -0.027 ( -0.001062 ) Replace or replate.
• Rod bushing inner diameter wear limit
Nominal diameter Standard inner diameter Maximum inner diameter

Solution
[ mm ( in. ) ] [ mm ( in. ) ] [ mm ( in. ) ]
55 - 75 +0.060 - +0.190
+0.30 ( +0.01181 ) Replace the bushing.
( 2.165 - 2.952 ) ( +0.002362 - +0.007480 )
80 - 120 +0.060 - +0.195
+0.30 ( +0.01181 ) Replace the bushing.
( 3.149 - 4.724 ) ( +0.002362 - +0.007677 )
• Piston slide ring thickness wear limit
Nominal diameter Standard thickness Minimum thickness

Solution
[ mm ( in. ) ] [ mm ( in. ) ] [ mm ( in. ) ]
95 - 160 t2.42 - 2.48
t2.37 ( 0.093307 ) Replace the slide ring.
( 3.740 - 6.299 ) ( 0.09528 - 0.09763 )
165 - 250 t2.92 - 2.98
t2.87 ( 0.112992 ) Replace the slide ring.
( 6.496 - 9.842 ) ( 0.114961 - 0.117322 )
84551720B NA - August 2012

8012-41
Structural Diagram
Boom Cylinder
After tightening, punch caulk in

*1 2 locations on the circumfer- *8 With plastic cap
ence
Hexagon bolt width 95 mm ( 90 mm ( 3.543 in ) or greater
*2 *9
3.740 in ) (both sides)
Outer circumference surface Internal thread effective depth
*3 *10
knurling processing 18 mm ( 0.709 in )
Hexagon bolt width 36 mm (
*4 Cushion stroke *11
1.417 in )
Manufacturing No. stamping
*5 To bottom pin center *12
position for right
84551720B NA - August 2012

8012-42
*6 of the cut surfaces during in- *13
position for left
stallation
*7 Slit direction is as in diagram
Maximum retracted length

L1
1753 mm ( 69.016 in )
L2 Stroke 1255 mm ( 49.409 in )
Code kg lb
a 161 354.946
Code ・m
N・・ft
lbf・ Code ・m
N・・ft
lbf・
b 267 203.69 e 41.6 - 60.8 30.688 - 44.851
c 5340 3939.26 f 50.9 - 74.3 37.549 - 54.810
d 46.2 - 67.6 34.082 - 49.867 g 25.62 - 37.38 18.8996 - 27.5747
Code mm in Code mm in
r D3.937008 -
h 150 5.906 D100H8
3.939133
s D3.740158 -
i D85 D3.346 D95H8
3.742283
j D120 D4.724 t 90 3.543
k D139 D5.472 u 105 3.937
l 50 1.968 v R70 R2.756
m 101 3.976 w D85 D3.346
n 108 4.252 x D181 D7.126
o 100 3.937 y D80 D3.150
p 7.5 0.295 z R68 R2.677
q 85 3.346

01 Tube subassembly 1 20 Locking screw 1
02 Rod subassembly 1 21 Steel ball 1
03 Cylinder head 1 22 Pin bushing 1
04 Bushing 1 23 Wiper ring 2
05 Snap ring 1 24 Pin bushing 1
06 Buffer ring 1 25 Wiper ring 2
07 U-ring 1 26 Pipe subassembly 1
08 Backup ring 1 27 Pipe subassembly 1
09 Wiper ring 1 28 O-ring 2
10 O-ring 1 29 Hexagon socket head bolt 8
11 Backup ring 1 30 Band subassembly 1
12 Hexagon socket head bolt 12 31 Band 1
13 Cushion ring 1 32 Bolt 2
14 Cushion seal 1 33 Washer 2
15 Piston 1 34 Pipe holder 2
16 Seal ring assembly 1 35 Bolt 1
17 Backup ring 2 36 Spring washer 1
18 Slide ring 2 37 Grease nipple 1
19 Slide ring 2
84551720B NA - August 2012

8012-43
Arm Cylinder
84551720B NA - August 2012

8012-44
Internal thread effective depth
*1 2 locations on the circumfer- *5 To bottom center *9
21 mm ( 0.827 in )
ence
Hexagon bolt width 115 mm ( 105 mm ( 4.133 in ) or greater
*2 *6 of the cut surfaces during in- *10
4.528 in ) (both sides)
stallation
Outer circumference surface Hexagon bolt width 36 mm (
*3 *7 Slit direction is as in diagram *11
knurling 1.417 in )
Manufacturing number stamp-
*4 Cushion stroke *8 *12 With plastic cap
ing position

L1
2020 mm ( 79.528 in )
L2 Stroke 1460 mm ( 57.480 in )
Code kg lb
a 251 553.363
Code N・m lbf・ft Code N・m lbf・ft

b 367 270.73 e 74.9 - 109.9 55.253 - 81.071
c 8900 6565.43 f 25.62 - 37.38 18.8996 - 27.5747
d 46.2-67.6 34.082 - 49.867
Code mm in Code mm in
g 162 6.378 o 120 4.724
h D100 D3.937 p 7.5 0.2953
i D140 D5.512 q 105 4.134
r D3.740158 -
j D165 D6.496 D95H8
3.742283
k 60 2.362 s D80 D3.150
l 114 4.488 t R75 R2.953
m 45 1.772 u D207 D8.150
n 127 5.000

01 Tube subassembly 1 21 Steel ball 1
02 Rod subassembly 1 22 Cushion ring 1
03 Cylinder head 1 23 Cushion seal 1
04 Bushing 1 24 Stopper 2
05 Snap ring 1 25 Snap ring 1
06 Buffer ring 1 26 Pin bushing 2
07 U-ring 1 27 Wiper ring 4
08 Backup ring 1 28 Joint 1
09 Wiper ring 1 29 Pipe subassembly 1
11 Backup ring 1 31 Hexagon socket head bolt 8
12 Hexagon socket head bolt 10 32 Band subassembly 1
13 Cushion ring 1 33 Band 1
14 Cushion seal 1 34 Bolt 2
15 Piston 1 35 Washer 2
16 Seal ring assembly 1 36 Pipe holder 1
17 Backup ring 2 37 Bolt 1
18 Slide ring 2 38 Spring washer 1
20 Locking screw 1
84551720B NA - August 2012

8012-45
Bucket Cylinder
84551720B NA - August 2012

8012-46
*1 2 locations on the circumfer- *4 Cushion stroke *7
position
ence
Hexagon bolt width 95 mm ( 89 mm ( 3.504 in. ) or greater
*2 *5 To bottom pin center *8
3.740 in. ) (both sides)
Outer circumference surface Internal thread effective depth
*3 *6 of the cut surfaces during in- *9
knurling processing 18 mm ( 0.709 in. )
stallation

L1
1565 mm ( 61.614 in. )
L2 Stroke 1010 mm ( 39.764 in. )
Code kg lb
a 145 319.67
Code N・m lbf・ft. Code N・m lbf・ft.

b 267 196.96 e 41.59 - 60.81 30.6805 - 44.8588
c 6740 4972.02 f 25.62 - 37.38 18.8996 - 27.5747
d 46.2 - 67.6 34.082 - 49.867
Code mm in. Code mm in.

g q D3.937008 -
150 5.906 D100H8
3.939133
r D3.543308 -
h D85 D3.346 D90H8
3.545433
i D120 D4.724 s 100 3.937
j D140 D5.512 t 5 0.197
k 50 1.969 u D85 D3.346
l 105 4.134 v R75 R2.953
m 151 5.945 w D181 D7.126
n 95 3.740 x D75 D2.953
o 7.5 0.2953 y R65 R2.559
p 80 3.150 z 90 3.543

01 Tube subassembly 1 19 Locking screw 1
02 Rod subassembly 1 20 Steel ball 1
03 Cylinder head 1 21 Pin bushing 1
04 Bushing 1 22 Wiper ring 2
05 Snap ring 1 23 Pin bushing 1
06 Buffer ring 1 24 Wiper ring 2
07 U-ring 1 25 Joint 1
08 Backup ring 1 26 Pipe subassembly 1
09 Wiper ring 1 27 O-ring 2
10 O-ring 1 28 Hexagon socket head bolt 8
11 Backup ring 1 29 Band subassembly 1
12 Hexagon socket head bolt 12 30 Band 1
13 Cushion ring 1 31 Bolt 2
14 Piston 1 32 Washer 2
15 Seal ring assembly 1 33 Pipe holder 1
16 Backup ring 2 34 Bolt 1
17 Slide ring 2 35 Spring washer 1
84551720B NA - August 2012

8012-47
84551720B NA - August 2012

8012-48
Section
8013
Procedures for Assembly and Disassembly of Operation

Remote Control Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Causes of Trouble and Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Procedures for Assembly and Disassembly of Operation Remote Control
Valve
Job code 35355AA18
CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after
thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean
location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or com-
promise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts,
take precautions to prevent the parts from rusting or collecting dust.
Items to prepare
Maintenance Procedures
Required Tools and Tightening Torque
Dimension [ mm ( in. ) Tightening torque
Tools Part No. Part name Screw size
] ・ft. ) ]
[ N·m ( lbf・
63.7 - 73.5
22 ( 0.866 ) 312 Adjusting nut M14
Wrench ( 46.991 - 54.220 )
32 ( 1.260 ) 302 Disk M14
44.2 - 50.0
Special jig 24 ( 0.945 ) 301 Joint M14
( 32.606 - 36.884 )
Other
• Vapor corrosion inhibitor
• White kerosene
• Heat-resistant grease
• Sandpaper (#1000, #2000)
• Whetstone
• Vise
• Screwdriver
• Torque wrench
84551720B NA - August 2012

8013-3
Control Valve
Maintenance in-
Standard Remarks
spection item
When handle is in neutral 1000 cc/min or more
Conditions
During operation 2000 cc/min or more
Leak amount Primary pressure 2.94 MPa ( 426.4578 psi )
If either condition occurs, replace the remote
Oil viscosity 23 mm2/S
control valve as one unit.
When wear on the sliding sections exceeds
The same approximate conditions as those
wear on the non-sliding sections by 10 μm or
Spool listed above for leak amount are expected when
more, replace the remote control valve as one
the condition on the left occurs.
unit.
If the end section is worn by 1 mm ( 0.039 in. ) or more, perform replacement.
Push rod
Replace the operation section disk (302) and

Operation section Make adjustments if the backlash is due to
joint section (301) if there is backlash of 2 mm (
backlash looseness in the tightening sections.
0.079 in. ) or more due to wear.
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be re-
Operation stability solved with "Causes of Trouble and Counter-
measures", replace the remote control valve as
a unit.
NOTE:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse
these after it is confirmed that they are not damaged.
84551720B NA - August 2012

8013-4
Control Valve
Disassembly Procedures 4. If the return springs are strong, the plate (2), plugs,
and push rods (3) will rise at the same time the joint
1. Use copper plate (or lead plate) to secure the re- (1) is loosened, so be careful of parts flying off when
mote control valve in a vise, then remove the bel- removing the joint.
lows (1).
• Be careful not to tear the bellows.
5. Remove the plate (1).
2. Use a wrench on the bolt width of the adjusting nut

(1) and disk (2) to loosen them, then remove the
adjusting nut and disk.
6. If the return springs are weak, the plugs (1) will re-
main in the casing due to the sliding resistance of
the O-rings, so use a flathead screwdriver to re-
move it.
3. Use a jig (1) to remove the joint. • Use the groove in the outer circumference of the
plugs and remove them while making sure they
are not damaged by an unbalanced load.
• Use caution as plugs may fly off when they are
being removed due to the return springs.
84551720B NA - August 2012

8013-5
Control Valve
7. Remove the push rods (1), plugs (2), pressure re- 10. Remove push rods (2) from the plugs (1).
ducing valve assembly, and the return springs (3)
from the casing.
• Record the relation of parts to the casing hole po-
sitions through marking, etc.
11. Remove the O-rings (2) from the plugs (1).

8. For disassembly of pressure reducing valve, press

in the spring seating (1), move the spring seating
to the side while bending the secondary pressure
spring (2), and remove the spring from the spools
(3) by passing through the larger hole.
• Do not press in the spring seating by 6 mm ( 0.236
in. ) or more.
12. Remove the seal (1).

Use a small flathead screwdriver, etc. to remove
seals.
• The seal cannot be reused.
9. Separate the spool (1), spring seating (2), sec-

ondary pressure spring (3), and washer (4).
• Be careful not to scratch the surface of the spools.
• Handle as an assembly until assembly is per-
formed.
13. Cleaning parts

Clean all parts by placing them in a rough cleaning
container filled with white kerosene. (rough clean-
ing)
Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thoroughly
clean each part, including the interior, while slowly
rotating the part. (finish cleaning)
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
84551720B NA - August 2012

8013-6
Control Valve
• Scratching can easily occur if cleaning of a part bris and moisture being dispersed into the atmos-
is begun just after parts are immersed in white phere.
kerosene, so let each part sit in white kerosene
Preventing rust on parts
until debris and grease sufficiently loosen from the
Apply an anti-rust agent to each part.
surface of the part and float to the surface.
• If the white kerosene is dirty, this will encourage • Rust will form on parts if they are left as is af-
damage to parts and result in reduced perfor- ter cleaning, and this will cause reduced perfor-
mance after reassembly. Thoroughly manage the mance of functions after reassembly.
level of cleanliness of the white kerosene.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to de-
84551720B NA - August 2012

8013-7
Control Valve
Assembly Procedures 4. Install O-rings (2) on the plugs (1).
1. Insert washer (4), secondary pressure spring (3)

and spring seating (2) onto each of the spool (1) in
that order.
5. Install seal (1) on the plug (2).

• Install so that the seal lips are as shown in the
diagram below.
2. Press in the spring seating (1) and move it to the
side while bending the secondary pressure spring
(2) to pass the seating over the larger hole and in-
stall it on each of the spools.
• Do not press in the spring seating by 6 mm ( 0.236
in. ) or more.
3 Push rod
a Hydraulic oil application
3. Install the return springs (1) in the casing (2).

Install the pressure reducing valve assembly (3) in
the casing (2).
• Install them in the positions they were in before
disassembly.
84551720B NA - August 2012

8013-8
Control Valve
6. Install push rods (1) into the plugs (2). 9. Install the plate (1).
• Apply hydraulic oil to surface of the push rod.
10. Use a jig, and tighten the joint (1) to the casing (2)
to the specified torque.
7. Install the plug assembly (1) in the casing (2). Tightening torque: 44.2 - 50.0 N·m ( 32.606 - 36.884
If the return spring is weak, it will be stopped by the lbf・ft. )
sliding resistance of the O-ring.
• Be careful not to scratch the casing hole by forcing
in the spool.
11. Install the disk (1) onto the joint (2).

• Screw the disk in until it is equally touching each
of the 4 push rods (3).
8. If the return spring is strong, use the plate (1) to Secondary pressure will cause faulty operation of
install all 4 plug assemblies at the same time and the machine if the disk is screwed in too much,
temporarily tighten them with the joint (2). so pay attention to adjustment of the tightening
position.
• Be careful of the plug assemblies and plate flying
off.
12. Install the adjusting nut, use a wrench on the bolt

width of the disk (1) to secure it, and tighten the
adjusting nut to the specified torque.
• Tightening torque: 63.7 - 73.5 N·m ( 46.991 -
54.220 lbf・ft. )
• During tightening, do not move the disk position.
84551720B NA - August 2012

8013-9
Control Valve
• Inject vapor corrosion inhibitor into each port, and
then place plugs in the ports.
13. Apply grease to the rotating section of the joint and

to the top of the push rods (1).
14. Install the bellows (1).

• Be careful not to tear the bellows.
84551720B NA - August 2012

8013-10
Control Valve
Causes of Trouble and Countermeasures
A few problems that may sometimes occur are listed in the table below.
Repairs are difficult, so refer to the possible causes and solutions in the table.
The table below shows general symptoms, suggested causes, and also solutions.
However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another.
Also keep in mind that solutions other than those listed in the table may sometimes be necessary.
The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1 Remote control
valve assembly cross-section diagram".
The table below does not include all possible causes and countermeasures.
Further investigation of problems and causes should be done by an experienced and qualified repair person, as nec-
essary.
Symptom Cause Solution

1. Maintain primary pressure.
1. Insufficient primary pressure
2. Replace it with new part.
2. Secondary pressure spring (241) is broken or
3. Replace the remote control valve
Secondary pressure is worn.
as one unit.
not rising. 3. The gap between spool (201) and the casing
4. Assemble and disassemble
(101) is abnormally large.
and/or replace the handle sec-
4. There is backlash in the handle section.
tion.
1. Repair the sticking sections.
1. Sliding parts are sticking.
Secondary pressure is 2. Return directly to the oil tank.
2. Tank line pressure is variable.
unstable. 3. Perform operation several times
3. Air is getting into lines.
and let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
84551720B NA - August 2012

8013-11
Control Valve
Attached diagram 1. Remote control valve assembly cross-section diagram
Grease application to rotating

a Grease application to top c sliding sections. Be careful
with the installation direction.
Secondary pressure adjust-
ment shim
b d Hydraulic symbol
Design central value
t = 0.4 1 shim

101 Casing 1 217 Washer 4
151 Plate 1 221-1 Return spring (port 1) 1
201 Spool 4 221-2 Return spring (port 3) 1
211 Plug 4 221-3 Return spring (ports 2, 4) 2
Secondary pressure spring
212-1 Push rod (ports 1, 3) 2 241-1 2
(ports 1, 3)
84551720B NA - August 2012
8013-12
Control Valve
Secondary pressure spring
212-2 Push rod (ports 2, 4) 2 241-2 2
(ports 2, 4)
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating (ports 1, 3) 2 312 Adjusting nut 1
216-2 Spring seating (ports 2, 4) 2 501 Bellows 1
Tightening torque
Code Screw size Tightening torque
44.2 - 50.0 N·m
301 M14
( 32.61 - 36.88 lbf・ft. )
302 63.7 - 73.5 N·m
M14
312 ( 46.99 - 54.22 lbf・ft. )
Detailed diagram of jig main unit (1) and (2) are inserted by tightening. Attached diagram 2. Jig main unit
84551720B NA - August 2012

8013-13
Control Valve
(1) Material: SCM415 (N) car-
*1 *3 (Bolt width)
burized
Hole H6 + 0.13
*2 (2) Material: S45C *4
Shaft n6 + 0.028
Detailed diagram of bushing

Joint installation state Material: SCM415 (N) carburized
Quantity: 2
Attached diagram 3. Joint disassembly jig
c Bushing
84551720B NA - August 2012

8013-14
Section
8014
Procedures for Assembly and Disassembly of Travel

Remote Control Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Procedures for Assembly and Disassembly of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Causes of Trouble and Countermeasures and Cross-section Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Procedures for Assembly and Disassembly of Travel Remote Control
Valve
Job code 35356AK20
CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• When removing devices or positioning devices at the time of installation, use a removal jig and a ham-
mer or steel rod.
• Follow the precautions below when suspending the load.
• The liftcrane must be operated by a qualified operator.
• Do not stand or pass under the suspended load.
• Check the weight of the load to determine whether it can be carried by hand or whether a liftcrane
must be used.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction.
Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and as-
semble in a clean location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or
compromise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust.
Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting
or collecting dust.
Items to prepare
• Wrench
• Screwdriver
• Specialty jigs
• Vise
• Loctite 262
• White kerosene
84551720B NA - August 2012

8014-3
Control Valve
Maintenance Procedures
Disassembly Procedures 4. Remove the cams (1) as an assembly with the lock-
ing screws and lock nuts left attached.
1. Use a shock plate to secure the remote control valve Record the positions of the cams in relation to the
in a vise, then remove the bellows (1) from the cover covers (2).
(2).
• Be careful when removing, as the push rods (3)
• Be careful not to tear the bellows. may fly off.
2. Use a hexagon wrench (1) on the hexagon socket 5. Use a hexagon wrench (1) on the hexagon socket
head locking screws to loosen them. head bolts to loosen and remove them.
Be careful, as application of Loctite #241 makes the
loosening torque high.
6. Remove the cover (1).
3. Place a round rod [ D8 mm ( D0.315 in. ) or less • Record the positions of the covers in relation to
] against one end of the cam shafts (1) and lightly the casings (4).
strike it with a hammer to remove the shafts. Be careful when removing, as the push rods (2) or
plugs (3) may fly off due to the damping springs.
(The plugs are only kept in the casing by the slid-
ing resistance of the O-rings.)
84551720B NA - August 2012

8014-4
Control Valve
7. Remove push rods (2) from the plugs (1). 10. Remove the damping springs (2) (3) from the casing
Record the positions of the plugs in relation to the (1).
push rods. Record the positions of the damping springs in re-
Be careful not to scratch the surface of the push lation to the casing holes.
rods.
Be careful when removing, as the plugs may fly off.
11. Remove the spring seating (2) from the casings (1).
8. Remove the plugs (1) with the grease caps and • Record the positions of the spring seating in rela-
NHU packings left attached. tion to the casing holes.
Record the positions of the plugs in relation to the
casing holes.
Be careful when removing parts, as the pistons (3)
may fly off due to the damping springs (2).
12. Use a magnet, etc. to remove steel balls (1).

Be careful not to lose the steel balls.
9. Remove the pistons (1).

Record the positions of the pistons in relation to the
casing holes.
84551720B NA - August 2012

8014-5
Control Valve
13. Use the hexagon wrench to remove the hexagon 16. Remove the return spring (1) from the casing (2).
socket head bolts (1).
17. Lay the covers (1) on their sides on a level surface,

14. Remove the damper casing (1) and remove the place special tool 1 against the bushings, and re-
O-rings (4) (3) from the casing. move the bushings by lightly striking them with a
hammer.
• Record the positions of the damper casing in re-
lation to the casing (2).
• Be careful when removing parts, as the pressure
reducing valve assembly may fly off due to the
return springs.
18. Secure each cam assembly (1) in a vise, use a

wrench to loosen the lock nuts (2), and remove the
lock nuts and locking screws (3).
• As neutral adjustment of locking screws is neces-
sary during assembly, handle them as part of the
15. Remove the pressure reducing valve assembly (1)
cam assembly as long as replacement of locking
from the casing (2).
screws is not necessary.
• Record the positions of these parts in relation to
the casing holes.
84551720B NA - August 2012

8014-6
Control Valve
19. For disassembly of the pressure reducing valve as- 22. Remove the NHU packings (2) from the plugs (1).
semblies, place the bottom end of the spools (1) Use a small flathead screwdriver, etc. to remove.
perpendicular on a level work platform, lower the
spring seating (2), and use the end of a small flat- • Be careful not to scratch the inner surface of the
plugs.
head screwdriver to remove the 2 half-circle wash-
ers 1 (3).
Be careful not to scratch the surface of the spool.
Do not press in the spring seating by 4 mm ( 0.157
in. ) or more.
23. Remove the O-rings (2) from the plugs (1).
20. Separate the spools (1), spring seating (2), sec-

ondary pressure springs (3), washers 2 (4), and
washers 3 (5).
Handle as an assembly until assembly is performed.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used, so record the status for each
assembly.
24. Cleaning parts

• Clean all parts by placing them in a rough clean-
ing container filled with white kerosene. (rough
cleaning)
• Scratching can easily occur if cleaning of parts
is begun just after parts are immersed in white
kerosene, so let each part sit in white kerosene
until debris and grease sufficiently loosen off from
the surface of parts and float to the surface.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced perfor-
mance after reassembly. Thoroughly manage the
21. Remove the grease cups (2) from the plugs (1). level of cleanliness of the white kerosene.
• Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thor-
oughly clean each part, including the interior,
while slowly rotating it (finish cleaning).
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to de-
bris and moisture being dispersed into the atmos-
phere.
• Preventing rust on parts
Apply an anti-rust agent to each part.
Rust will form on parts if they are left as is af-
ter cleaning, and this will cause reduced perfor-
mance of functions after reassembly.
84551720B NA - August 2012

8014-7
Control Valve
Assembly Procedures 3. Install the return springs (1) in the casing (2).
1. Install the washers 3 (5), washers 2 (4), secondary • Install them in the positions they were in before
pressure springs (3), and the spring seating (2) onto disassembly.
each of spools (1) in that order.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used.
Check the status recorded during disassembly and
attach parts accordingly.
4. Install the pressure reducing valve subassemblies

(1) assembled in steps 1) and 2) above into the cas-
ing (2).
disassembly.
2. Place the bottom end of the spools (1) perpendicu-

lar on a level work platform, push the spring seating
(2) down, and install the 2 half-circle washers 1 (3)
onto the spring seating in such a way that they are
not on top of each other.
• When installing the pressure reducing valve sub-

assemblies, be careful not to strongly strike the
casing corners (b) with the bottom ends of the
spools.
• Install the washers 1 so that the sharp edge side

(a) faces up and the washer catches the head of
the spool.
Do not press in the spring seating by 4 mm ( 0.157
in. ) or more.
84551720B NA - August 2012

8014-8
Control Valve
5. Install O-rings (1) (2) on the casing (3). 8. Install the spring seating (1) into the bushings.
disassembly.
6. Tighten the damper casing (1) and casing (2) with

the hexagon socket head bolts (3) to the specified
torque.
9. Install the damping springs (2) (3) in the casing (1).
disassembly. • Install them in the positions they were in before
• Tighten the 2 hexagon socket head bolts (3) disassembly.
evenly, and tighten the damper casing (1) in a
parallel orientation.
• Hexagon socket head bolt (3) tightening torque:
7.8 - 9.8 N·m ( 5.754 - 7.229 lbf・ft. )
10. Install the pistons (1).

disassembly.
7. Install the steel balls (1) into the bushings.
84551720B NA - August 2012

8014-9
Control Valve
11. Install O-rings (2) on the plugs (1). 14. Install push rods (2) into the plugs (1).
• Before installing push rods, apply hydraulic oil to
the rod surfaces.
Do not press the rods in strongly, as this may dam-
age the NHU packing lip sections.
12. Install NHU packings into the plugs (1).
15. Install the push rod subassemblies assembled in

steps 11), 12), 13), 14) above into the casing (1).
• When installing the NHU packings (1), be careful

of the installation direction. (See the diagram.)
Before installing NHU packings, apply a thin layer
of grease.
16. Use special tool 1 on the covers (1) to press down

the bushings, and lightly strike the bushings with a
hammer to press fit them.
• Be careful that the ends of the bushings do not
stick out from within the cover.
13. Install grease cups (2) into the plugs (1).
17. Install the covers (1) on the casing (2).

disassembly.
• Be careful of the cover rising up due to the damp-
ing springs.
84551720B NA - August 2012

8014-10
Control Valve
20. Install the cams (1) on the covers (2).
disassembly.
18. Tighten the hexagon socket head bolts to the spec-

ified torque.
• Be careful that the cover is horizontal.
• Hexagon socket head bolt tightening torque: 21. While holding the cams (1), insert the cam shafts
45.2 - 64.8 N·m ( 33.344 - 47.802 lbf・ft. ) (2) from the outside.
19. Temporarily install the locking screws (3) and lock 22. Apply Loctite #241 or the equivalent to the surfaces
nuts (2) on the cams (1). of the hexagon socket head locking screws (1).
84551720B NA - August 2012

8014-11
Control Valve
23. Tighten the hexagon socket head locking screws to 25. Tilt the cams (1) and fill the grease cups of the plugs
the specified torque. with grease while coating the top of the push rods
with grease.
• Hexagon socket head locking screw tightening
torque: 5.9 - 7.9 N·m ( 4.353 - 5.827 lbf・ft. ) • For grease application and filling, use a flat object
made of soft material so as to not scratch the push
rod or plug surfaces.
24. Adjust the height of the locking screws so that the

top surface of the cams (1) and the bottom surface
of the covers (2) are parallel, and tighten the lock 26. After mounting the top end of the bellows (1) on the
nuts to the specified torque after rotating the cams cams, mount the bottom end into the grooves on the
left and right to check if there is any neutral back- covers (2).
lash.
Even if the push rods are pressed in too much by the • Before mounting the bottom end of the bellows
locking screws, backlash during neutral will occur. into the grooves of the covers, spray anti-rust oil
Use caution as this may cause sudden movement on the parts within the bellows.
when starting the engine. • Be careful that the bellows are properly mounted
in the grooves and not twisted, as this may reduce
• Locking screw tightening torque: 29.9 - 36.7 N·m anti-rust and anti-moisture protection.
( 22.057 - 27.073 lbf・ft. )
84551720B NA - August 2012

8014-12
Control Valve
Causes of Trouble and Countermeasures and Cross-section Diagram
A few problems that may occur are listed in the table below.
Repairs are difficult, so refer to the possible causes and solutions in the table.
The table below shows general symptoms, suggested causes, and also solutions.
However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another.
Also keep in mind that solutions other than those listed in the table may sometimes be necessary.
The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1 Remote control
valve assembly cross-section diagram".
Also, the table below does not include all possible causes and countermeasures.
Further investigation of problems and causes should be done by an experienced and qualified repair person, as nec-
essary.

1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring (324) is worn. 2. Replace it with new part.
Secondary pressure is
3. The gap between spool and the casing is 3. Replace spool and casing assembly.
not rising.
abnormally large. 4. Disassemble and assemble or re-
4. There is backlash in the operation section. place operation section parts.
Secondary pressure is 2. Return directly to the oil tank.
2. Tank line pressure is variable.
unstable. 3. Perform operation several times and
3. Air is getting into lines.
let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
1. Perform operation several times and
1. Air is gathering in the piston chamber.
let out air.
3. Damping springs (336) (337) are worn.
3. Replace it with new part.
4. The gap between piston (224) and the cas-
Damping is not working. 4. Replace piston and casing assem-
ing is abnormally large.
bly.
5. There are check valve operation problems.
5. Disassemble and adjust the check
6. The piston metering hole is abnormally
valve section.
large.
6. Replace piston.
1. Sliding parts are sticking. 1. Repair the sticking sections.
Damping torque is high.
2. Piston metering hole is clogged. 2. Repair or replace piston.
84551720B NA - August 2012

8014-13
Control Valve
Hydraulic symbols Cross section B-B
Attached diagram 1. Remote control valve assembly cross-section diagram
84551720B NA - August 2012

8014-14
Control Valve
ANNOTATION:
Since hydraulic equipment is crucial to safety, we cannot guarantee performance and functions if disassembly and
reassembly are performed.

101 Casing 1 271 Hexagon socket head bolt 2
102 Casing (damper) 1 301 Spool 4
201 Cover 2 311 Spring seating 4
202 Plug 4 313 Washer 3 4
203 Grease cup 4 324 Spring 4
210 NHU packing 4 335 Spring 4
211 O-ring 2 336 Spring 4
213 O-ring 4 412 Bushing 4
214 Push rod 4 413 Camshaft 2
245 Washer 1 8 420 Cam 2
217 Washer 2 4 423 2
screw
218 Spring seating 4 471 Locking screw 4
220 Hexagon socket head bolt 2 472 Lock nut 4
224 Piston 2D085 4 501 Bellows 2
225 Steel ball 2
Tightening torque list

Code Screw size Tightening torque Code Screw size Tightening torque
5.9 - 7.9 N･m
7.8 - 9.8 N･m
220 M6 423 M6 （ 4.35 - 5.82 lbf・ft. ）
( 5.75 - 7.22 lbf・ft. )
(Loctite coating)
45.2 - 64.8 N･m 29.9 - 36.7 N･m
271 M12 472 M10
（ 33.34 - 47.80 lbf・ft. ） ( 22.06 - 27.07 lbf・ft. )
a Grease application to top

Filling of grease cup with
b
grease
Attached diagram 2. Jig dimension diagram
c Center hole possible [ D2 (

0.079 ) or less ]
84551720B NA - August 2012

8014-15
Control Valve
84551720B NA - August 2012

8014-16
Section
8016
Assembly and Disassembly of Cushion Valve
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Written Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly Procedures
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit
together, so do not disassemble it as much as possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only disassemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
• Check the internal structure before starting work, and carefully study the disassembly objective and scope.
Reverse Operation Spool Section Check Plunger Section with Throttle

1. Remove the plugs (1) and O-rings (2). 1. Remove the plugs (1) and O-rings (2).
• Remove the springs (3). • Remove the springs (3) and remove the check
• Remove the spools (4) with the cap screws and plungers (4).
O-rings assembled in them.
CAUTION
The check plungers have similar shapes,
so identify them in such a way that no
one will mix them up with each other.
Diagram 1
2. Fasten the spool (3) assemblies taken out in 1. in a
vise.
CAUTION
Diagram 3
Use a piece of wood (jig) (4) to prevent
scratches.
• Remove the cap screws (1) and O-rings (2).
Diagram 2
84551720B NA - August 2012

8016-3
Shuttle Valve Section

1. Remove the plugs (1) and O-rings (2) (3).
• Remove the steel balls (4).
Diagram 4
84551720B NA - August 2012

8016-4
Assembly Procedures
This valve has a structure that forms small gaps.
It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as
possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only assemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Clean the disassembled parts and prepared parts.
• Study the internal structure before starting the work and prepare the parts required by the disassembly objective
and scope.
Reverse Operation Spool Section CAUTION

1. Assemble the cap screw (1) with O-ring (2) on the The spool assemblies are symmetrical left/
spool (3). right, so the insertion direction does not
matter.
• Tightening torque: 9.8 - 14.7 N·m ( 7.23 - 10.84
lbf・ft. )
• Insert the springs (2) and assemble the plugs (3)
CAUTION with the O-rings (4) attached.
Use a piece of wood (jig) (4) to prevent lbf・ft. )
scratches.
Diagram 6
Diagram 5
2. Insert the spool assemblies (1) assembled in 1. into
the body.
84551720B NA - August 2012

8016-5
Check Plunger Section with Throttle Shuttle Valve Section

1. Insert the check plungers (1). 1. Insert the steel balls (1).
CAUTION • Assemble the plugs (2) with the O-rings (3) (4)
attached.
The check plungers have similar shapes, • Tightening torque: 39.2 - 49.0 N ・ m ( 28.92 -
so be careful to insert each one in its cor- 36.14 lbf・ft. )
rect position.
• Insert the springs (2) and assemble the plugs (4)

with the O-rings (3) attached.
lbf・ft. )
Diagram 8
Diagram 7
84551720B NA - August 2012

8016-6
Written Materials
1. Check plunger table
Metering orifice diame-

Part No. Name Remarks
ter (D)
65301-11705 Check plunger 0.5 ( 0.0197 )
65301-11706 Check plunger 0.6 ( 0.0236 )
65301-11707 Check plunger 0.7 ( 0.0276 )
65301-11708 Check plunger 0.8 ( 0.0315 )
65301-11709 Check plunger 0.9 ( 0.0354 )
65301-11710 Check plunger 1.0 ( 0.0394 )
65301-11711 Check plunger 1.1 ( 0.0433 )
65301-11712 Check plunger 1.2 ( 0.0472 )
65301-11713 Check plunger 1.3 ( 0.0512 )
65301-11714 Check plunger 1.4 ( 0.0551 )
65301-11715 Check plunger 1.5 ( 0.0591 )
2. Cushion valve assembly diagram
External shape diagram
84551720B NA - August 2012

8016-7
Cross section X - Cross section Y -
Cross section V -
Cross-section diagram
Code Part name Code Part name Code Part name

1 Body 9 Check plunger 17 Seat
2 Spool 10 Check plunger 18 O-ring
3 Spring 11 Check plunger 19 Plug
4 Plug 12 Check plunger 20 O-ring
5 O-ring 13 Spring 21 Name plate
6 Cap screw 14 Plug 22 Drive screw
7 O-ring 15 O-ring 23 Plug
8 Plug 16 Steel ball 24 Plug
84551720B NA - August 2012

8016-8
Section
8017A
Removal and Installation of Arm HBCV
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of arm HBCV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CAUTION 2. Use a hexagon wrench [ 10 mm ( 0.394 in. ) ] to

remove the 4 hexagon socket head bolts (1), and
• Stop the machine in the temporary decom- then remove the line (2).
missioning posture on a level location with
good footing. • Use caps or plugs to cover the HBCV and line to
work. • Clean the HBCV and line by spraying them with
• When working together with others, always dirt from accumulating on the connectors.
beginning work.
Items to prepare
• Wrench [ 22 mm ( 0.866 in. ) ]
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
Removal of arm HBCV 3. Use a hexagon wrench [ 10 mm ( 0.394 in. ) ] to

then remove the arm HBCV (2).
hoses (1) and (2).
• Mark the HBCV and hoses so that the connectors
• Use caps or plugs to cover the hoses and HBCV
• Clean the hoses and HBCV by spraying them with
Installation of arm HBCV

The tightening torque for line installation and HBCV in-
stallation is 74.9 - 109.9 N•m ( 55.253 - 81.071 lbf・ft. ).
84551720B NA - August 2012

8017A-3
84551720B NA - August 2012

8017A-4
Section
8017B
Removal and Installation of Boom HBCV
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 2. Use a hexagon wrench [ 8 mm ( 0.315 in. ) ] to

• Stop the machine on a level location with then remove the line (2).
good footing.
• Be sure to stop the engine before beginning N・m ( 30.688 - 44.851 lbf・ft. )
work.
• Use caps or plugs to cover the HBCV and lines to
• When working together with others, always prevent any entry of water, dust or dirt.
quate attention to safety. • Clean the HBCV and lines by spraying them with
• Be sure to release hydraulic pressure before dirt from accumulating on the connectors.
beginning work.
Items to prepare
• Wrench [ 19 mm ( 0.748 in. ), 22 mm ( 0.866 in. ), 27
mm ( 1.063 in. ) ]
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Crossties
Removal of Boom HBCV

in. ) ] to remove the hoses from the tool box side
then remove the boom HBCV (2).
boom HBCV (1), (2), (3) and (4).
• Mark the HBCV and hoses so that the connectors N・m ( 30.688 - 44.851 lbf・ft. )
• Use caps or plugs to cover the HBCV and lines to
• Clean the HBCV and lines by spraying them with

in. ) ] to remove the hoses (1), (2), (3) and (4) from
the cab side boom HBCV in Step 1.
boom bottom pressure sensor (5).
• Tightening torque for boom bottom pressure sen-
Pilot hose sor installation: 82 - 98 N・m ( 60.49 - 72.29 lbf・
1 [ use 19 mm ( 0.748 in. ) ft. )
wrench ] • Mark the HBCV and hoses so that the connectors
Drain hose match at the time of assembly.
2 [ use 22 mm ( 0.866 in. ) • Use caps or plugs to cover the HBCV and lines to
wrench ] prevent any entry of water, dust or dirt.
Drain hose • Clean the HBCV and lines by spraying them with
3 [ use 22 mm ( 0.866 in. ) a parts cleaner to prevent scratches and prevent
wrench ] dirt from accumulating on the connectors.
Pilot hose
4 [ use 22 mm ( 0.866 in. )
wrench ]
84551720B NA - August 2012

8017B-3

Pilot hose
then remove the boom HBCV (2).
1 [ use 22 mm ( 0.866 in. )
wrench ] • Tightening torque for bolt installation: 41.6 - 60.8
Drain hose N・m ( 30.688 - 44.851 lbf・ft. )
2 [ use 19 mm ( 0.748 in. )
wrench ]
Pilot hose
3 [ use 22 mm ( 0.866 in. )
wrench ]
Pilot hose
4 [ use 22 mm ( 0.866 in. )
wrench ]

then remove the line (2).
N・m ( 30.688 - 44.851 lbf・ft. )
• Use caps or plugs to cover the HBCV and line to
Installation of boom HBCV
• Clean the HBCV and line by spraying them with To install, perform the reverse of the removal procedure.
a parts cleaner to prevent scratches and prevent The tightening torque for line installation and HBCV in-
dirt from accumulating on the connectors. stallation is 41.6 - 60.8 N•m ( 30.688 - 44.851 lbf・ft. ).
84551720B NA - August 2012

8017B-4
Section
8018
Assembly and Disassembly of Center Joint
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS

CAUTION CAUTION
• The following cautions for hydraulic equip- General cautions
ment should be observed with these parts.
• To ensure safe operations, wear protective • Be careful not to drop precision parts or let
devices for the work and follow all precau- bump them with other parts during work.
tions. • Do not forcefully open or hit parts in an effort
• When removing devices or positioning de- to speed up operations.
vices at the time of installation, use a removal Pay careful attention and proceed slowly so
jig and a hammer or steel rod. as not to damage any parts, create any oil
• Make sure that the jig is used for disassembly leaks, or compromise the efficiency of the
of the axle and rotor. equipment, etc.
• Follow the precautions below when suspend- • Disassembled parts can easily rust or collect
ing the load. dust. Therefore, immediately after disassem-
• The liftcrane must be operated by a quali- parts from rusting or collecting dust.
fied operator. • Make sure that foreign matter such as debris
• Do not stand or pass under the suspended and moisture does not enter.
load. • The work platform used should be solid, sta-
• Check the weight of the load to deter- ble, and sufficiently spacious.
mine whether it can be carried by hand or Also, items should be clean and free of debris
whether a liftcrane must be used. and moisture.
Remove debris and moisture before perform-
disassembly, and prepare replacement parts ing work.
in advance. • Inspect, remove debris and moisture, and
clean tools and jigs before work.
clean them before disassembling. • Jigs and tools that are appropriate to the con-
tents of work should be used.
Therefore, after thoroughly cleaning the Items to prepare
equipment with cleaning oil, air blow the • Hexagon wrenches [ 6 mm ( 0.236 in. ), 14 mm ( 0.551
equipment, and assemble in a clean location. in. ), or 17 mm ( 0.669 in. ) ]
• When assembling V-rings, O-rings, and other • Torque wrench
sliding parts, be sure to coat them with new • Socket wrenches [ 6 mm ( 0.236 in. ), 14 mm ( 0.551
grease. in. ), or 17 mm ( 0.669 in. ) ]
• As a rule, replace all O-rings and other seal • Lights
parts with new parts. • Mirror
• Specialty jigs
84551720B NA - August 2012

8018-3
Code Part name

1 Axle
2 V-ring
3 O-ring
4 Packing ring
5 Hexagon socket head bolt
6 O-ring
7 Cover
8 Thrust plate
9 Rotor
10 Loctite
84551720B NA - August 2012

8018-4
Dimension Diagram
Maximum gap 10.0 ( 0.394 )

1 Axle 7 Cover *1
Minimum gap 8.5 ( 0.3346 )
Maximum gap 0.7 ( 0.0276 )
2 V-ring 8 Thrust plate *2
Minimum gap 0.3 ( 0.0118 )
2 x M12, screw depth 18 mm (
3 O-ring 9 Rotor *3 0.709 in. ), bottom hole depth
23 mm ( 0.906 in. )
4 Packing ring 10 Loctite #262 *4 G1/2-A class
5 Hexagon socket head B 11 Company nameplate *5 G1/4-A class
6 O-ring 12 Parker rivet *6 4 x G3/4-A class
Do not coat any processed surfaces marked with a symbol or port processed surfaces.
84551720B NA - August 2012

8018-5

Axle removal jig
1 Axle removal jig Cover (7) installation dimen-

*1
M16 - M20 full threaded bolt sions
2 L = 370 - 420 mm ( 14.567 -
16.535 in. )
3 M16 - M20 female thread
Hexagon socket head bolt (5)
4
M8 x 25
Backing plate
Axle (1) outer diameter - about
5
5 mm ( 0.197 in. )
t = about 5 mm ( 0.197 in. )
Removal jig (for O-ring and

1
V-ring)
84551720B NA - August 2012
8018-6
Disassembly Procedures 4. Use axle removal jig 1 to push out the axle (2) from
the rotor (1).
remove the 4 hexagon socket head bolts (3) from • Do not strike it with the hammer at this time.
the rotor (1), then remove the cover (2).
5. Use removal jig 1 or the like to remove the V-ring

2. Remove the O-ring (2) from the rotor (1). (2) from the axle (1).
3. Use a hexagon wrench [ 6 mm ( 0.236 in. ) ] to 6. Use removal jig 1 or the like to remove the O-ring
remove the 4 hexagon socket head bolts (2), then (2) and packing ring (3) from the rotor (1).
remove the thrust plate (1).
84551720B NA - August 2012

8018-7
Assembly Procedures 3. Use cleaning fluid or compressed air to clean the

rotor (1).
1. Place parts in a rough cleaning container filled with After cleaning, check inside the rotor and in the
kerosene (1) to clean off any adhered matter that groove sections for burrs, barbs and scratches and
can form sharp points and cause scratches. for scratches caused by striking.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.
4. Check the quantity of packing rings (1) and O-ring

(2).
Coat with grease and install in the sequence below.
2. Place parts in a finish cleaning container filled with • Set one packing ring (1) in each of the 7 grooves
kerosene (1) and clean while gently moving the from the 2nd groove on the axle insertion side to
parts. the thrust plate side.
After cleaning, wipe away the kerosene with a clean • Set the O-ring (2) in the front-most groove on the
rag. axle insertion side.
• Use new packing rings (1) and a new O-ring (2).
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts.
After drying, coat parts with engine oil.
• Polish away burrs, barbs, and scratches with a
whetstone.
84551720B NA - August 2012

8018-8
5. After installing the O-ring and packing rings on the 8. Using a hexagon wrench [ 6 mm ( 0.236 in. ) ],
rotor (1), use the mirror to check for any parts that coat the hexagon socket head bolts (3) with Loctite,
are sticking out or are twisted. install the thrust plate (2) on the axle (1), and tighten
Also, check for installation mistakes. to the specified tightening torque.
After checking, coat with grease. After coating with
grease, check again for any parts sticking out, etc. • Bolt (3) tightening torque: 31.4 - 37.3 N·m (
23.164 - 27.515 lbf・ft. )
6. Install the V-ring (2) on the axle (1) and coat suffi-
ciently with grease. 9. Install the O-ring (2) on the rotor (1).
Be careful that no water or dirt gets into the grease. • Use new O-ring (2).
• Use a new V-ring (2).
10. Using a hexagon wrench [ 6 mm ( 0.236 in. ) ], coat

7. Install the axle (2) on the rotor (1). the hexagon socket head bolts (3) with Loctite #262,
Set in a way that the V-ring will not be cut or dam- install the cover (2) on the rotor (1), and tighten to
aged. the specified tightening torque.
• Bolt (3) tightening torque: 31.4 - 37.3 N·m (
23.164 - 27.515 lbf・ft. )
84551720B NA - August 2012

8018-9
84551720B NA - August 2012

8018-10
Section
8019
Assembly and Disassembly of Swing Motor
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Causes of Trouble and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance Standard Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Swing Motor Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Job code 35352AF10
CAUTION
1. Read and understand the contents of this
maintenance manual before performing
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C ( 104.0 °F ) or below before removing
it.
Working on this product while it is still hot
can cause burns.
before removing any line from this prod-
uct.
Removing a pressurized line can result in
oil spraying out and causing injury or oil
leak.
4. Use the specialty tools and measurement
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury.
7. Check performance after reassembly.
Do not resume use unless performance is
fully recovered.
Using this product at a sub-par perfor-
mance level may result in product damage.
8. The cautions (mark !) listed in this main-
tenance manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.
84551720B NA - August 2012

8019-3
Causes of Trouble and Solutions

This list consists of actions to be taken when an abnormality is sensed or there are problems with functions during
use of the hydraulic motor. Additionally, details concerning disassembly inspection and reassembly are listed after
this, but sufficient caution should be exercised in handling during these actions so as to prevent scratching of sliding
parts of the motor.
1. General cautions
This list consists of actions to be taken when an abnormality is sensed during use of the hydraulic motor.
General cautions are listed below.
1) Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work and think whether this same kind of problem
has occurred before.
Also, reconfirm whether the motor is the source of the problem.
2) Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So be careful that dust and dirt do not get into parts during
disassembly.
3) Parts handling
Parts are manufactured with a high degree of precision, so be careful not to scratch them during handling.
4) Do not damage O-rings or gasket surfaces while performing work. Also, it is recommended that O-rings
are replaced for new ones during disassembly.
2. Investigating abnormalities in the motor main unit
It is very difficult to search for the source of troubles in the hydraulic circuits. Inspect the following items and
thoroughly investigate whether the motor is the source of troubles.
1) Inspecting oil within the casing
Remove the drain plug and inspect the hydraulic oil within the casing. If a large amount of metal particles
come out at the same time as oil, it is very likely that there is damage with parts within the motor.
2) Existence of abnormal noise
Check whether abnormal noise is coming from the motor main unit.
3) Measure pressure for each part.
Do not perform disassembly inspection carelessly. Measure pressure for each part and look for abnormal-
ities in each area.
4) Measure the amount of oil drained from the motor.
1) Operation is normal if about 6 L/min ( 1.585 gpm ) or less of oil drains from the motor when pressure
oil is applied after the swing is locked.
2) 2 L/min ( 0.528 gpm ) or less of drained oil at constant swing is normal.
3. Trouble conditions and countermeasures
1) Hydraulic motor does not rotate.

1) Incorrect setting of the circuit safety 1) Reset safety valve correctly.
valve 2) Disassemble and inspect.
2) Operation problems with relief
valve 1) Repair or replace sticking
Pressure does not
section.
rise.
1) Plunger sticking 2) Disassemble and clean.
2) Clogged plunger orifice
3) Check seating sections and replace
3) Plunger seating problem scratched part.
1) Eliminate load.
1) Overload
2) Inspect and repair piston/shoe,
2) Seizing of driving part
cylinder/valve plate, etc.
3) No release pressure acting on the
3) Inspect and repair circuit.
Pressure rises. brake
4) Disassemble and inspect.
4) Piston sticking to the brake
5) Spool for brake release sticking
6) Disassemble and inspect. Replace
6) Friction plate seizing
seizing part.
84551720B NA - August 2012

8019-4
2) Rotation direction is reversed.

1) Check the rotation direction and as-
Reversed rotation di- 1) Motor rotation direction reversed.
semble correctly.
rection 2) Input and output for line reversed.
2) Correct line configurations.
3) Motor speed is not reaching the set value.

1) Insufficient oil flow amount
1) Check the pump discharge volume
Motor speed is not 2) High temperature and severe leak
and the circuit up to the motor.
reaching the set of oil
2) Lower the temperature of the oil.
value. 3) Wear or damage on each sliding
3) Replace.
section
4) Hydraulic motor does not rotate.

1) Wear on the friction plate
parts worn beyond the limit.
2) Brake piston sticking
Insufficient braking 3) Brake release pressure cannot be
3) Inspect and repair circuit.
torque released.
4) Spool for brake release sticking
5) Damaged friction plate spline
damaged part.
5) Severe hydraulic motor slipping

Investigate the amount of oil drained from the hydraulic motor. Motor operation is normal if the amount is
500 cc/min or less.

1) Operation problems with relief
Slipping is severe valve 1) Repair or replace sticking
when an external section.
1) Plunger sticking
driving torque acts on 2) Disassemble and clean.
2) Clogged plunger orifice
the hydraulic motor.
2) Check seating section and replace
2) Plunger seating problem
scratched part.
6) Oil leak
1) Oil leak from oil seal

1) Debris lodged in lip causing
scratching. 1) Replace oil seal.
2) Shaft scratched or worn 2) Stagger the position of the lip and
Oil leak from oil seal 3) Pressure within the casing becom- shaft or replace.
ing abnormally high caused oil seal 3) Repair any clogged drain line.
lip to turn up. 4) Disassemble and repair.
4) Shaft rusted.
2) Oil leak from matching surface

1) Insert O-ring and assemble cor-
1) O-ring has not been inserted. rectly.
Oil leak from match- 2) Scratched O-ring 2) Replace.
ing surface 3) Scratched seal surface 3) Disassemble and repair.
4) Loosened or damaged bolt 4) Tighten to the specified torque or
replace.
84551720B NA - August 2012
8019-5
Maintenance Standard Table

1. Replacement standards for worn parts
If wear on any part exceeds the standard values below, replace or readjust.
However, parts should be replaced regardless of these standards if they appear to be extremely damaged based
on appearance.
Recom-
Standard mended
dimen- replace-
Item sions ment Solution
[ mm ( in. ) value
] [ mm ( in. )
]
Clearances between piston and cylinder
0.028 ( 0.058 (
bore Replace the piston or cylinder.
0.001102 ) 0.002283 )
(D-d)
Piston and shoe caulking section back- 0.3 ( 0.0118
0 Replace the piston and shoe assembly.
lash (δ) )
5.5 ( 5.3 (
Shoe thickness (t) Replace the piston and shoe assembly.
0.2165 ) 0.2087 )
2.0 ( 1.6 (
Friction plate thickness Replace.
0.0787 ) 0.0630 )
Clearance (D-d) Piston and shoe backlash (δ)
Shoe thickness (t)
2. Sliding surface repair standards

If the roughness of the sliding surface in any section exceeds the standard values below, repair or replace.
Surface roughness
Part name Standard surface roughness
requiring repair
Shoe 0.8 - Z (Ra = 0.2) (lapping) 3 - Z (Ra = 0.8)
Shoe plate 0.4 - Z (Ra = 0.1) (lapping) 3 - Z (Ra = 0.8)
Cylinder 1.6 - Z (Ra = 0.4) (lapping) 12.5 - Z (Ra = 3.2)
Valve plate 0.8 - Z (Ra = 0.2) (lapping) 6.3 - Z (Ra = 1.6)
Note:
1) Using lapping, make the degree of surface roughness of each sliding surface equal to or lower than the
standard value.
84551720B NA - August 2012
8019-6
2) If the plate spring and cylinder spherical surface sliding section are rough, these should be replaced as
a set.
84551720B NA - August 2012

8019-7
Required Tools
1. Bolt tightening torque
Tightening torque values for bolts used in the motor are indicated in Table 3. When assembling, securely tighten
bolts to the values in Table 3.
Tightening torque Applicable

Screw size Name
・ft. )
N·m ( lbf・ part code
Hexagon socket
M20 431 ( 317.94 ) 401
head bolt
M33 x P1.5 Relief valve 177 ( 130.57 ) 051
M36 x P1.5 ROMH plug 539 ( 397.61 ) 469
PF1/4 ROH plug 36 ( 26.56 ) 467
If there is a variance with the part codes listed above, see the assembly cross-section diagram.
2. Tools for assembly and disassembly
The necessary tools for assembly and disassembly are indicated in Tables 4 and 5. The bolts and plugs used
vary for each type, so prepare tools based on examination beforehand.
Applicable
Name Size Bolt width Tools
part code
Hexagon socket
M20 17(0.669) 401 Hexagon wrench
head bolt
Hexagon wrench, socket
Relief valve M33 x P1.5 41(1.614) 051
wrench
ROMH plug M36 x P1.5 17(0.669) 469 Hexagon wrench
ROH plug PF1/4 6(0.236) 467 Hexagon wrench
If there are variances with the plugs and bolts listed above, see the assembly cross-section diagram.
Tools Dimensions
Screwdriver Flathead Medium-sized x 2
Steel rod About size 10 x 8 x 200 ( 0.394 x 0.315 x 7.874 ) 1
Plastic hammer
Hammer 1 each
Hammer
Torque adjustment range
• For 5 - 10 N·m ( 3.69 - 7.37 lbf・ft. )
Torque wrench • For 10 - 45 N·m ( 7.38 - 33.19 lbf・ft. )
• For 40 - 275 N·m ( 29.51 - 202.86 lbf・ft. )
• For 75 - 550 N·m ( 55.32 - 405.72 lbf・ft. )
Slide hammer bearing puller
Brake piston removal jig See the next page
84551720B NA - August 2012

8019-8
Jig
84551720B NA - August 2012

8019-9
1 Brake piston removal jig

2 Brake piston
3 Casing
84551720B NA - August 2012

8019-10
Disassembly 5. Remove the ROH plug (469) from valve casing H0

(303) and take out the springs and plungers.
1. Wrap the wire rope around the outer circumference Be careful not to scratch the plunger seating sec-
of the motor, lift the motor with a liftcrane, and clean tions.
with white kerosene. After cleaning, dry the motor
using compressed air.
• To prevent foreign matter from entering the motor,
mask each port with tape, etc. Also clean off ad-
hered dirt and dust.
2. From the drain plug, drain the oil inside the housing.
3. Point the shaft end of the drive shaft downwards and
place a reference mark (*1) on the matching surface
of valve casing H0 (303) and casing JA1 (301) with
paint, etc.
• Select a clean location. Place a rubber plate or
cloth on the work platform so as not to damage
the parts.
6. Loosen the hexagon socket head bolt (401) and re-
move valve casing H0 (303) from casing JA1 (301).
• The valve casing H0 (303) will rise up from the
casing JA1 (301) when the bolts are removed due
to the force of the brake springs (712).
7. Remove valve plate B (131) from valve casing H0
(303).
• Do this carefully so as not to let valve plate B (131)
fall from valve casing H0 (303). (Valve plate B
(131) may be attached to the cylinder side.)
• When prying open the matching surface with a
screwdriver, be careful not to scratch the surface.
4. Loosen the relief valves (051) and remove them

from valve casing H0 (303).
• Be sure to replace the O-ring (051-1). The O-ring
(051-1) is damaged when the relief valve is loos-
ened.
8. Take out the brake springs (712) from the brake pis-
ton (702).
84551720B NA - August 2012

8019-11
9. Use a jig and remove the brake piston (702) from

casing JA1 (301).
• Apply the tips of the jig to the grooves of the brake
piston, and pull straight up.
10. Reposition the motor on its side, and remove the

cylinder (111) from the drive shaft. Next, remove
the pistons (121), holder plate (123), plate spring
(114), and shoe plate (124).
• Be careful not to scratch the sliding surfaces of
the cylinder (111), shoe (122), etc.
13. Perform the following as necessary. Do not reuse a

removed bearing.
• Use a press to remove the inner race of the roller
bearing (443) from the drive shaft (101). When
using a steel rod to hit the inner race of the roller
bearing, hit the inner race evenly while being care-
ful not to damage the bearing.
• Using a steel rod, tap from the housing section
side of the oil seal, and pull out the outer race of
the roller bearing from the housing.
• Use a slide hammer bearing puller (*3) to remove
the roller bearing (404) from valve casing H0
11. Take out the friction plate (742) and separator plate (303).
(743) from casing JA1 (301).
12. Take out the drive shaft (101) and shoe plate (124).
• The spline will damage the oil seal (491) when the
drive shaft is removed, so wrap the spline section
of the drive shaft with vinyl tape, etc. (*2).
84551720B NA - August 2012

8019-12
Assembly
1) Check each part for scratches from use or from
disassembly. If there are any scratches, remove them
with a whetstone or sandpaper of the necessary grain,
clean with pure cleaning oil, then dry off with an air
blower.
2） Replace seal parts with new ones.
3） Thoroughly clean all parts with cleaning fluid and
dry with compressed air.
4 ） When assembling sliding sections, apply clean
hydraulic oil before assembling.
1. Place the housing on an appropriate platform with
the cover on top.
2. If the roller bearing (443) was removed, shrink fit
This completes the disassembly.
the inner race of the roller bearing to the drive shaft
(101).
• Be careful with the direction of the flange of the
roller bearing.
3. Use a jig to insert the oil seal (491) into casing JA1
(301).
• Be careful with the direction of the oil seal.
• Apply a thin layer of grease to the oil seal lip sec-
tion.
• Be careful to evenly hit it without scratching the
outer circumference.
84551720B NA - August 2012

8019-13
4. Use a steel rod to install the outer race of the roller 7. Set the plate spring (114) on the holder plate (123),
bearing (443) into casing JA1 (301). and then set the pistons (121).
5. Mount the drive shaft (101) in casing JA1 (301). 8. Install the piston subassembly (10) on the cylinder
(111).
• Carefully insert it so as not to scratch the lip sec-
tion of the oil seal (491).
• Wrap vinyl tape, etc. around the shaft spline sec-
tion to protect it.
9. Align the piston subassembly (10) and cylinder

(111) with the drive shaft spline and insert into the
housing.
6. Lay casing JA1 (301) horizontal and insert the shoe
plate (124).
• Install with the larger chamfered side of the shoe
plate (124) on the casing JA1 side.
• Apply a thin layer of grease to the matching sur-
face to prevent it from falling out.
10. Set the housing down with the oil seal side facing
downwards, and alternately install separator plates
(743) and friction plates (744) in that order to the
housing. Install the 4 separator plates and 3 friction
plates.
84551720B NA - August 2012

8019-14
13. Install the brake springs (712) into the brake piston
(702).
14. If the roller bearing (444) was removed, use a ham-

mer and steel rod to insert it into valve casing H0
(303).
11. Mount the O-rings (706) (707) on casing JA1 (301).

• If grease is applied to the O-ring, it will not break
easily when inserting the brake piston.
15. Install valve plate B (131) in valve casing H0 (303).

• Apply a thin layer of grease to the matching sur-
face (*1) of the valve plate.
12. Install the brake piston (702) into the housing.
84551720B NA - August 2012

8019-15
16. Mount the O-ring (472) to the cover. 19. Mount the relief valve (051) in valve casing H0
(303).
• Apply grease to the O-ring. Tightening torque: 177 N·m ( 130.57 lbf・ft. )
17. Install valve casing H0 (303) on casing JA1 (301) 20. Assembly confirmation
and tighten with the bolt (401). Open the input/output ports, apply 3.2 - 4.9 MPa
• Be careful with the installation direction of the ( 464.172 - 710.762 psi ) of pilot pressure to the
valve. brake release port to check if the output shaft ro-
• Make sure that valve plate B (131) does not fall tates smoothly for at least 1 rotation with about 30 -
over. 40 N·m ( 22.13 - 29.51 lbf・ft. ) of torque. There is
• Make sure that the brake springs (712) do not fall an assembly problem if it does not rotate, so disas-
over. semble again and adjust it.
Tightening torque: 430 N·m ( 317.21 lbf・ft. ) • At this time, have the drain port open.
18. Insert plungers H2 (351) and springs (355) into This completes the assembly.
valve casing H0 (303) and tighten the ROMH plugs
(469) with the O-rings (488) mounted on them. • Check that the set pressure of the relief assembly is
at the correct pressure after the hydraulic motor is in-
• Check that plunger H2 (351) moves smoothly. stalled in the actual machine.
Tightening torque: 539 N·m ( 397.61 lbf・ft. )
84551720B NA - August 2012

8019-16
Relief internal structural diagram 6 Liner

7 Piston
1 Seat 8 Cap
2 Poppet 9 Backup ring
3 Spring 10 O-ring
4 Spring seat 11 Holder
5 Shim
84551720B NA - August 2012

8019-17
Swing Motor Internal Structure Diagram
84551720B NA - August 2012

8019-18

1 Inner race 1 23 Snap ring 1
2 Oil seal 1 24 Cylinder 1
3 Tapered roller bearing 1 25 Housing 1
4 Receiving spring 1 26 Collar 1
5 Cam plate 1 27 Snap ring 1
6 Return plate 1 28 Bypass valve assembly 2
7 Piston assembly 9 29 Backup ring 2
8 Friction plate 3 30 O-ring 4
9 Partner plate 3 31 O-ring 2
10 O-ring 1 32 Cover 1
11 Piston 1 33 Cap 1
12 O-ring 2 34 Relief assembly 2
13 Spring 20 35 O-ring 4
14 Piston 2 36 Hexagon socket head bolt 4
15 Parallel pin 3 37 Check valve 2
17 Cap 2 39 Cap 2
18 Scrowave spring 4 40 Backup ring 2
19 Teflon ring 4 41 Level gauge assembly 1
20 Bushing 4 42 O-ring 1
21 Balance plate 1 43 Cap 1
22 Needle bearing 1
84551720B NA - August 2012

8019-19
84551720B NA - August 2012

8019-20
Section
8020A
Explanation of Hydraulic Circuit and Operations (standard

model)
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS Heat circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Auto pressure boost circuit (bucket close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CX210C LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CX210C LC NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Travel low-speed circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Travel low-speed circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Travel high-speed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Travel high-speed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Straight travel circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Straight travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Straight travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Swing speed limit control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Swing relief cut-off control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Swing speed limit control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Swing priority circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Swing relief cut-off control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Swing brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Swing priority circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Swing parking circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Swing brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Swing parking circuit (brake release) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Swing parking circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Swing parking circuit (machine stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Swing parking circuit (brake release) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Boom Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Swing parking circuit (machine stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Boom-up circuit (independent operation) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Boom Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Boom-up circuit (compound boom-up + arm-in) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Boom-up circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Boom-down regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Boom-up circuit (compound boom-up + arm-in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Boom-down tilting prevention circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Boom-down regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Boom-down load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Boom-down tilting prevention circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Arm Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Boom-down load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Arm-out circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Arm Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Arm-in forced regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Arm-out circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Arm-in load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Arm-in forced regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Arm-in load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Bucket-open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Bucket-close regenerative circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Bucket-open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Negative Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Bucket-close regenerative circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Negative control circuit (power save solenoid OFF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Negative Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Negative control power save circuit (power save solenoid ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Negative control circuit (power save solenoid OFF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Negative control circuit (bucket close, power save solenoid OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Negative control power save circuit (power save solenoid ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Horsepower Boost Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Negative control circuit (bucket close, power save solenoid OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Arm-in Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Horsepower Boost Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Travel Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Arm-in Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Other Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Travel Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Cushion circuit (arm-out operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Other Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Cushion circuit (arm-out operation stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cushion circuit (arm-out operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Cushion circuit (arm-out → arm-in operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Cushion circuit (arm-out operation stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Heat circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Cushion circuit (arm-out → arm-in operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Auto pressure boost circuit (bucket close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Explanation of Hydraulic Circuit and Operations (standard model)
CX210C LC NLC
Travel Circuit
Travel low-speed circuit
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8020A-2
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line
1 Travel motor 7 Travel high speed 13 Check valve

2 Travel high-speed select switch 8 Lever lock 14 Oil cooler
3 Computer A 9 5 stack solenoid valve 15 Backward left
4 Control valve 10 Console lever lock switch 16 Forward left
5 Travel (left) 11 Hydraulic pump 17 Forward right
6 Travel (right) 12 Travel remote control valve 18 Backward right
As an example, this section explains the forward travel operation.

The travel motor 2-stage tilting angle is a large angle side.Even if the travel switchover is set to the high-speed side, switching
the key switch OFF and then ON again always returns the system to this state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
The travel high-speed solenoid valve goes OFF, the travel motor Ps port oil connects with the tank line, and the travel motor
tilting angle moves to the large tilting side.
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8020A-3
Travel high-speed circuit
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8020A-4
Pilotpressure line


Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
The travel motor has an automatic switchover function that switches the speed to low speed according to the load pressure
on the travel motor only during high-speed travel conditions.
Electrical signals are sent to the computer A by operation of the travel high-speed select switch and the computer A sends
electrical signals to the travel high-speed solenoid valve.
Due to the switching of the travel high-speed solenoid valve, the pilot pressure [3.9 Mpa (565.709 psi)] from the C1 port enters
the left and right travel motor Ps ports through the center joint and sets the travel motor tilting angle to a small angle to raise
the speed.
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8020A-5
Straight travel circuit
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8020A-6
Pilotpressure line
1 Travel motor 10 Straight travel signal (left) 19 Boom cylinder

2 Boom (up) 11 Straight travel signal (right) 20 Travel remote control valve
3 Boom (down) 12 Travel high-speed select switch 21 Check valve
4 Cushion valve 13 Computer A 22 Oil cooler
Remote control valve
5 14 Travel high speed 23 Backward left
(boom, bucket)
6 Control valve 15 Lever lock 24 Forward left
7 Travel (left) 16 5 stack solenoid valve 25 Forward right
8 Travel (right) 17 Console lever lock switch 26 Backward right
9 Straight travel valve 18 Hydraulic pump
As an example, this section explains simultaneous forward travel and boom-up operations.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight
travel signal (right).
On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left)
via the straight travel signal (right).
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4
port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to
the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to
prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right
travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel
is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize
the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.
When the circuit has an HBCV, switching the spool lets the oil flow through the HBCV check valve and into the boom cylinder
bottom side and the boom-up operation is carried out.
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8020A-7
Straight travel circuit
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8020A-8
Pilotpressure line

(boom, bucket)
is possible.
the drop in speed.
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8020A-9
Swing Circuit
Swing speed limit control circuit
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8020A-10
Pilotpressure line
1 Swing motor 9 Travel pilot pressure sensor 17 P1 flow control proportional valve
2 Swing 10 Upper pilot pressure sensor 18 Hydraulic pump
Horsepower control proportional
3 Cushion valve 11 Computer A 19
valve
4 Right swing 12 Lever lock 20 P2 pressure sensor
5 Left swing 13 Swing brake 21 Check valve
6 Swing pilot pressure sensor 14 5 stack solenoid valve 22 Oil cooler
7 Remote control valve (arm, swing) 15 Console lever lock switch
8 Control valve 16 P1 pressure sensor
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode)
For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal, the
computer A outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 280 L/min (73.970 gpm) by the signal output from the computer A to
the P1 flow control proportional valve.
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8020A-11
Swing relief cut-off control circuit
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8020A-12
Pilotpressure line
1 Swing motor 9 Travel pilot pressure sensor 17 P1 flow control proportional valve
valve
This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil drained from
the swing motor relief valve for the starting pressure boost for a independent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals, com-
puter A outputs a signal to the hydraulic pump P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pressure to reduce the hydraulic
pump A1 side discharge flow.
Also, the input signal from hydraulic pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge
flow.
84551720B NA - August 2012

8020A-13
Swing priority circuit
84551720B NA - August 2012

8020A-14
Pilotpressure line
1 Swing motor 10 Remote control valve (arm, swing) 19 Arm load holding valve check valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 5 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 14 Console lever lock switch 23 Arm (2)
6 Cushion valve 15 Arm cylinder 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 16 Arm (1) 25 Hydraulic pump
8 Shuttle valve 17 Swing 26 Check valve
9 Computer A 18 Arm load holding valve spool 27 Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing
spool.
Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
When the circuit has an HBCV, the arm cylinder rod side pressurized oil goes through the HBCV check valve.
84551720B NA - August 2012

8020A-15
Swing brake circuit
84551720B NA - August 2012

8020A-16
Pilotpressure line
1 Swing motor 7 Hydraulic pump 13 Computer A

2 Cushion valve 8 Check valve 14 Control valve
3 Right swing 9 Lever lock 15 Oil cooler
4 Left swing 10 Swing brake 16 Upper pilot pressure sensor
5 Swing pilot pressure sensor 11 5 stack solenoid valve
As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and the control
valve swing spool returns to neutral.
The pressurized oil fed to the swing motor B port from the control valve A3 port is cut.
At the same time, the destination location is eliminated for the pressurized oil flowing from the swing motor A port to the control
valve B3 port, so the pressure rises to the swing motor relief valve set pressure.
The pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In order to make up the shortfall
in the oil volume, oil is supplied from the make-up line connected to the swing motor Mu port from the control valve T3 port to
open the make-up check valve and oil is suctioned in to prevent cavitation.
84551720B NA - August 2012

8020A-17
Swing parking circuit (lever in neutral)
84551720B NA - August 2012

8020A-18
Pilotpressure line
1 Swing motor 7 Check valve 13 Computer A

2 Cushion valve 8 Oil cooler 14 Control valve
3 Right swing 9 Lever lock 15 Upper pilot pressure sensor
4 Left swing 10 Swing brake 16 Hydraulic pump
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from computer A.
The swing motor P port oil goes from the 5 stack solenoid valve C2 port through the swing brake solenoid, and returns to the
hydraulic oil tank to hold the swing parking brake.
84551720B NA - August 2012

8020A-19
Swing parking circuit (brake release)
84551720B NA - August 2012

8020A-20
Pilotpressure line
1 Swing motor 7 Swing 13 Control valve

2 Cushion valve 8 Lever lock 14 Upper pilot pressure sensor
3 Right swing 9 Swing brake 15 Hydraulic pump
4 Left swing 10 5 stack solenoid valve 16 Check valve
5 Swing pilot pressure sensor 11 Console lever lock switch 17 Oil cooler
6 Remote control valve (arm, swing) 12 Computer A
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input), the
pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 0.5 MPa (72.527 psi) or higher at the pressure sensor in the swing pilot line,
the output from computer A to the swing brake solenoid valve goes OFF, the swing motor P port pressure rises, the swing
parking brake is released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve pa3 port
via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the
electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.The pilot pressure oil is
fed to the swing motor P port from the swing brake solenoid valve C2 port to release the swing parking brake.
spool.
The pressurized oil from the swing motor A port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure sensor
and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake solenoid valve output from
computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when about
1 sec. passes after the end of the upper operation, the swing parking brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the end of
the upper operation, the swing parking brake works again.
Swing pilot pressure Upper pilot pressure Swing brake solenoid Swing motor mechani-
Key switch
sensor sensor valve cal brake
OFF 0 MPa (0 psi) 0 MPa(0 psi) OFF ON
ON 0 MPa (0 psi) 0 MPa(0 psi) ON ON
ON 0.5 MPa (72.527 psi) min. 0 MPa(0 psi) OFF OFF
ON 0 MPa(0 psi) 0.5 MPa (72.527 psi) min. OFF OFF
ON 0.5 MPa (72.527 psi) min. 0.5 MPa (72.527 psi) min. OFF OFF
Pilot pressure sensor judgment standard

Operation is judged when at 0.5 MPa (72.527 psi) or above.
Non-operation is judged when at 0.3 MPa (43.516 psi) or below.
84551720B NA - August 2012

8020A-21
Swing parking circuit (machine stop)
84551720B NA - August 2012

8020A-22
Pilotpressure line

When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the swing brake solenoid C2
port through the lever lock solenoid and returns to the hydraulic oil tank, holding the swing parking brake hold status.
84551720B NA - August 2012

8020A-23
Boom Circuit
Boom-up circuit (independent operation)
84551720B NA - August 2012

8020A-24
Pilotpressure line
1 Cushion valve 9 Control valve 17 Computer A

Boom load holding valve check
2 Boom (up) 10 18 P1 pressure sensor
valve
3 Boom (down) 11 Boom (1) 19 P2 pressure sensor
4 Boom (2) 12 Boom cylinder 20 Hydraulic pump
Remote control valve (boom,
5 13 Travel pilot pressure sensor 21 Check valve
bucket)
6 Lever lock 14 Upper pilot pressure sensor 22 Oil cooler
7 Boost pressure relief 15 Console lever lock switch 23 Boom HBCV check valve
8 5 stack solenoid valve 16 Monitor display
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve Pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the Pa4 port separated in the
internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom (1) spool
via the parallel oil path, merges with the discharge oil from boom (2), pushes open the boom load hold valve check valve,
(flows through the boom cylinder HBCV check valve when the circuit has an HBCV) and into the bottom side, and the boom-up
operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
84551720B NA - August 2012

8020A-25
Boom-up circuit (compound boom-up + arm-in)
84551720B NA - August 2012

8020A-26
Pilotpressure line
1 Arm cylinder 12 Arm (1) 23 Upper pilot pressure sensor

2 Arm (in) 13 Boom (2) 24 Console lever lock switch
3 Arm (out) 14 Arm load holding valve spool 25 Monitor display
4 Boom (up) 15 Load holding valve check valve 26 Computer A
5 Boom (down) 16 Regeneration release valve 27 P1 pressure sensor
6 Cushion valve 17 Control valve 28 P2 pressure sensor
7 18 Swing priority variable orifice 29 Hydraulic pump
bucket)
8 Remote control valve (arm, swing) 19 Arm (2) 30 Check valve
9 Lever lock 20 31 Oil cooler
valve
10 Boost pressure relief 21 Boom cylinder 32 HBCV check valve
11 5 stack solenoid valve 22 Travel pilot pressure sensor
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2)
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-27
84551720B NA - August 2012

8020A-28
Pilotpressure line
1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

2 Check valve 10 18 Boom (1)
bucket)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 5 stack solenoid valve 21 Console lever lock switch
6 Bleed-off 14 Control valve 22 Monitor display
7 Cushion valve 15 P2 pressure sensor 23 Computer A
8 Boom (up) 16 Hydraulic pump 24 Boom HBCV check valve
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom (1) spool to the down side.
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches
the spool.
This opens the HBCV check valve.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.
84551720B NA - August 2012

8020A-29
Boom-down tilting prevention circuit
84551720B NA - August 2012

8020A-30
Pilotpressure line
1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 11 5 stack solenoid valve 19 Console lever lock switch
6 Boom (up) 14 Hydraulic pump 22 P1 pressure sensor
7 Boom (down) 15 Boom cylinder 23 Boom HBCV check valve
8 16 Boom (1)
(boom,bucket)
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
84551720B NA - August 2012

8020A-31
Boom-down load holding valve circuit
84551720B NA - August 2012

8020A-32
Pilotpressure line

1 9 5 stack solenoid valve 17 Console lever lock switch
valve
2 Load holding valve spool 10 Control valve 18 Monitor display
3 Cushion valve 11 Check valve 19 Computer A
4 Boom (up) 12 Oil cooler 20 P1 pressure sensor
5 Boom (down) 13 Boom cylinder 21 P2 pressure sensor
6 14 Boom (1) 22 Hydraulic pump
bucket)
7 Lever lock 15 Travel pilot pressure sensor 23 Boom HBCV check valve
8 Boost pressure relief 16 Upper pilot pressure sensor
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
spool to the left.
the spool. This opens the HBCV check valve.
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and the boom (1) spool and
returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-33
Arm Circuit
Arm-out circuit
84551720B NA - August 2012

8020A-34
Pilotpressure line
1 Arm cylinder 9 Control valve 17 Computer A

2 Arm (in) 10 Load holding valve check valve 18 P1 pressure sensor
3 Arm (out) 11 Arm (1) 19 P2 pressure sensor
4 Cushion valve 12 Arm (2) 20 Hydraulic pump
5 Remote control valve (arm, swing) 13 Travel pilot pressure sensor 21 Check valve
7 Boost pressure relief 15 Console lever lock switch 23 Arm HBCV check valve
8 5 stack solenoid valve 16 Monitor display 24 Arm HBCV
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-35
84551720B NA - August 2012

8020A-36
Pilotpressure line
1 Load holding valve spool 11 Remote control valve (arm, swing) 21 Console lever lock switch
2 Load holding valve check valve 12 Lever lock 22 Monitor display
3 Oil cooler 13 Boost pressure relief 23 Computer A
4 Regeneration check valve 14 5 stack solenoid valve 24 P1 pressure sensor
5 Metering large 15 Control valve 25 P2 pressure sensor
6 Metering small 16 Arm cylinder 26 Hydraulic pump
7 Forced regeneration release valve 17 Arm (1) 27 Check valve
8 Arm (in) 18 Arm (2) 28 Arm HBCV check valve
9 Arm (out) 19 Travel pilot pressure sensor 29 Arm HBCV
10 Cushion valve 20 Upper pilot pressure sensor
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
spool to the right.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.
84551720B NA - August 2012

8020A-37
Arm-in load holding valve circuit
84551720B NA - August 2012

8020A-38
Pilotpressure line
1 Load holding valve spool 10 5 stack solenoid valve 19 Computer A

2 Load holding valve check valve 11 Control valve 20 P1 pressure sensor
3 Oil cooler 12 Arm cylinder 21 P2 pressure sensor
4 Arm (in) 13 Arm (1) 22 Hydraulic pump
5 Arm (out) 14 Arm (2) 23 Check valve
6 Cushion valve 15 Travel pilot pressure sensor 24 Arm HBCV check valve
7 Remote control valve (arm, swing) 16 Upper pilot pressure sensor 25 Arm HBCV
8 Lever lock 17 Console lever lock switch
9 Boost pressure relief 18 Monitor display
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load hold
valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil
path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
The pilot pressure oil from the Pb5 port separated in the internal path flows into the HBCV PL port and switches the spool.
The pilot pressure oil from the Pb5 port separated in the internal path is fed to the load hold valve spool and moves the spool
to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line through the load hold
valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the HBCV check valve, load hold valve check valve and the arm (1)
spool and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-39
Bucket Circuit
Bucket-open circuit
84551720B NA - August 2012

8020A-40
Pilotpressure line

2 Bucket (close) 9 Bucket 16 P1 pressure sensor
3 Bucket (open) 10 Bucket cylinder 17 P2 pressure sensor
4 11 Travel pilot pressure sensor 18 Hydraulic pump
bucket)
5 Lever lock 12 Upper pilot pressure sensor 19 Check valve
6 Boost pressure relief 13 Console lever lock switch 20 Oil cooler
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the control
valve pa7 port and switches the bucket spool to the open side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket
spool.
Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-41
84551720B NA - August 2012

8020A-42
Pressure line Pilot tank line pressure, the greater the volume of regeneration. When the cylinder rod side load pressure becomes high, the check valve is
Tank line Electric line closed and the cylinder bottom side return oil goes through the bucket spool without regeneration and returns to the hydraulic
Pilotpressure line oil tank.
1 Regeneration check valve 9 Boost pressure relief 17 Monitor display

2 Oil cooler 10 5 stack solenoid valve 18 Computer A
3 Orifice 11 Control valve 19 P1 pressure sensor
4 Cushion valve 12 Bucket 20 P2 pressure sensor
5 Bucket (close) 13 Bucket cylinder 21 Hydraulic pump
6 Bucket (open) 14 Travel pilot pressure sensor 22 Check valve
7 15 Upper pilot pressure sensor
bucket)
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve pb7 port and switches the bucket spool to the close side.
spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.Through this, the return oil
pushes open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cylinder rod side load
84551720B NA - August 2012

8020A-43
Negative Control Circuit
Negative control circuit (power save solenoid OFF)
84551720B NA - August 2012

8020A-44
Pilotpressure line Negative control line
1 P1 negative control relief 8 Lever lock 15 P1 flow control proportional valve

2 P2 negative control relief 9 Power save 16 Hydraulic pump
3 Control valve 10 5 stack solenoid valve 17 Check valve
4 Travel pilot pressure sensor 11 P1 pressure sensor 18 Oil cooler
N1 negative control pressure sen-
5 Upper pilot pressure sensor 12 P2 pressure sensor 19
sor
6 Computer A 13
sor
7 Console lever lock switch 14
valve
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve P1 and P2 ports through the center bypass oil path, and through the downstream negative control variable
relief, and returns to the hydraulic oil tank.
The discharged oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve,
is fed to the control valve Pn1 and Pn2 ports, and holds the P1 and P2 negative control relief at the set pressure of 2.55 MPa
(369.8869 psi).
The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and Ps2 ports to the hydraulic
pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is reduced.
84551720B NA - August 2012

8020A-45
Negative control power save circuit (power save solenoid ON)
84551720B NA - August 2012

8020A-46
1 Control valve 7 Power save 13 P1 flow control proportional valve

2 Travel pilot pressure sensor 8 5 stack solenoid valve 14 Hydraulic pump
3 Upper pilot pressure sensor 9 P1 pressure sensor 15 Check valve
4 Computer A 10 P2 pressure sensor 16 Oil cooler
N2 negative control pressure sen- N1 negative control pressure sen-
5 Console lever lock switch 11 17
sor sor
6 Lever lock 12
valve
The purpose of this control is to reduce fuel consumption during standby by reducing the back pressure for the negative control
signal.
When the remote control valve operation lever is set to neutral, the non-operation state signal enters the computer A from the
travel pilot pressure sensor and the upper pilot pressure sensor installed on the control valve PT port and PA port.
After about 1 sec., the power save solenoid valve is excited and switched ON by the signal output from computer A, and the
oil path is switched.
The pressurized oil from the control valve negative control relief Pn1 and Pn2 ports goes through the power save solenoid
valve and returns to the hydraulic oil tank.
Therefore, the negative control relief set pressure is switched to low pressure to further reduce the A1 and A2 pump discharge
pressure.
With the system running this way, the negative control signal is cut off and the P1 and P2 pump discharge volume increases.
The discharge oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve, is
fed to the hydraulic pump P2 port from the C5 port, moves the A2 side pump tilting to the minimum flow side, and this reduces
the discharge flow.
At the same time, the discharge oil from the pilot pump A3 is fed to the hydraulic pump P1 port by the signal from computer
A to the P1 flow restriction proportional valve, moves the A1 side pump tilting to the minimum flow side, and this reduces the
discharge flow.
84551720B NA - August 2012

8020A-47
Negative control circuit (bucket close, power save solenoid OFF)
84551720B NA - August 2012

8020A-48
1 Control valve 8 Computer A 15 P2 pressure sensor

Remote control valve (boom, N2 negative control pressure sen-
2 Travel pilot pressure sensor 9 16
bucket) sor
3 Upper pilot pressure sensor 10 Console lever lock switch 17 P1 flow control proportional valve
4 Cushion valve 11 Lever lock 18 Hydraulic pump
5 Bucket (close) 12 Power save 19 Check valve
6 Bucket (open) 13 5 stack solenoid valve 20 Oil cooler
7 Bucket cylinder 14 P1 pressure sensor 21
sor
As an example, this section explains the bucket-close operations.

The discharge oil from the hydraulic pump A2 enters the control valve P2 port, is fed to the bucket spool, flows into the bucket
cylinder bottom side because of the spool switching and the bucket-close operation is carried out.
At the same time, the upper pilot pressure sensor signal is detected and through the signal output from computer A to switch
OFF the power save solenoid valve, pilot pressure oil enters the negative control relief, and the pressure becomes the set
pressure of 2.55 MPa (369.8869 psi).
Because the bucket spool switches and the pressurized oil on the center bypass downstream side is cut off, the Pi2 pump
negative control pressure oil from the Ps2 port is eliminated, the pump tilting moves to the increase side, and the flow is
increased.
Also, the command milli-amp to the P1 flow control proportional valve is lowered and the pressurized oil from the hydraulic
pump A3 is cut off, but the negative control pressurized oil is fed from the control valve Ps1 port to the Pi1 port, moves the
pump tilting to the minimum flow side, and the hydraulic pump A1 discharge volume is reduced.
84551720B NA - August 2012

8020A-49
Horsepower Boost Circuits
Arm-in Horsepower Boost Circuit
84551720B NA - August 2012

8020A-50
1 Arm (in) 9 Arm pilot pressure sensor 17 Computer A

2 Arm (out) 10 Control valve 18 P1 pressure sensor
3 Cushion valve 11 Arm (1) 19 P2 pressure sensor
4 Remote control valve (arm, swing) 12 Arm (2) 20
sor
5 Lever lock 13 Travel pilot pressure sensor 21 Hydraulic pump
6 Boost pressure relief 14 Upper pilot pressure sensor 22 Check valve
7 5 stack solenoid valve 15 Console lever lock switch 23 Oil cooler
8 Arm cylinder 16 Monitor display
For the arm-in operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the arm pilot pressure sensor input signal and P1 pressure sensor and P2 pressure sensor input signals.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional
valve from computer A.
Condition under which the arm-in horsepower boost control is entered
Arm-in pilot pressure 0.5 MPa (72.527 psi) or higher (arm-in operation)
P1＋P2 45 MPa (6527.42 psi)
Conditions under which the arm-in horsepower boost control is ended
Arm-in pilot pressure 0.3 MPa (43.516 psi) or lower (arm-in operation end)
P1＋P2 45 MPa (6527.42 psi)
When either occurs
84551720B NA - August 2012

8020A-51
Travel Horsepower Boost Circuit
84551720B NA - August 2012

8020A-52
Pilotpressure line
1 Travel motor 7 Travel high-speed select switch 13 P1 pressure sensor

2 Travel remote control valve 8 Computer A 14 P2 pressure sensor
3 Travel high speed 9 Control valve 15
sor
4 Lever lock 10 Travel (left) 16 Hydraulic pump
5 5 stack solenoid valve 11 Travel (right) 17 Check valve
6 Console lever lock switch 12 Travel pilot pressure sensor 18 Oil cooler

For travel single operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the travel pilot pressure sensor input signal.
Conditions under which the travel horsepower boost control is entered
Travel pilot pressure 0.5 MPa (72.527 psi) or higher.
SP mode
Conditions under which the travel horsepower boost control is ended
Travel pilot pressure 0.3 MPa (43.516 psi) or lower.
AUTO mode, H mode
Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is stopped,
and when an arm-out operation is followed by an arm-in operation.
84551720B NA - August 2012

8020A-53
Cushion circuit (arm-out operation)
84551720B NA - August 2012

8020A-54
Pilotpressure line
1 Arm (in) 7 Remote control valve (arm, swing) 13 Console lever lock switch
2 Arm (out) 8 Lever lock 14 Hydraulic pump
3 Cushion spool 9 5 stack solenoid valve 15 Check valve
4 Orifice 10 Control valve 16 Oil cooler
5 Check valve 11 Arm (1)
6 Cushion valve 12 Arm (2)
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control valve 2 port
into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9 ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through the
cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the cushion
valve R port and returns to the hydraulic oil tank, so heat performance is improved.
84551720B NA - August 2012

8020A-55
Cushion circuit (arm-out operation stopped)
84551720B NA - August 2012

8020A-56
Pilotpressure line
1 Arm (in) 6 Remote control valve (arm, swing) 11 Arm (2)

2 Arm (out) 7 Lever lock 12 Console lever lock switch
3 Cushion spool 8 5 stack solenoid valve 13 Hydraulic pump
4 Orifice 9 Control valve 14 Check valve
5 Cushion valve 10 Arm (1) 15 Oil cooler
When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5 and pa9
ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve to the hydraulic
oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is improved.
84551720B NA - August 2012

8020A-57
Cushion circuit (arm-out → arm-in operation)
84551720B NA - August 2012

8020A-58
Pilot pressure line
1 Arm (in) 6 Remote control valve (arm, swing) 11 Arm (2)

When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the pilot
pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check valve, and
reaches the control valve pb5 port and pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes through the
cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is improved.s
84551720B NA - August 2012

8020A-59
Heat circuit (lever in neutral)
84551720B NA - August 2012

8020A-60
Pilotpressure line
1 Arm (in) 5 Lever lock 9 Hydraulic pump

2 Arm (out) 6 5 stack solenoid valve 10 Check valve
3 Cushion valve 7 Control valve 11 Oil cooler
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion spool to
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat perfor-
mance.
84551720B NA - August 2012

8020A-61
Auto pressure boost circuit (bucket close)
84551720B NA - August 2012

8020A-62
Pilotpressure line

3 Bucket (open) 10 Bucket cylinder 17 Hydraulic pump
4 11 Upper pilot pressure sensor 18 Check valve
bucket)
5 Lever lock 12 Console lever lock switch 19 Oil cooler
7 5 stack solenoid valve 14 Computer A
When an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 - 36.8 MPa (4975.341
- 5337.975 psi) according to the engine load ratio and hydraulic load pressure, then ends the pressure boost after 8 sec.
As an example, this section explains bucket-close operations.
At the same time, the output signal from the upper pilot pressure sensor that detected the pressurized oil separated from the
pilot internal path is input to computer A, which judges that there is upper operation.
Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to
the pressure boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH
port to hold the pressure boost relief set pressure for 8 sec.
There is no boost for the option circuit and during travel operation.
84551720B NA - August 2012

8020A-63
CX210C LR
Travel Circuit
Travel low-speed circuit
84551720B NA - August 2012

8020A-64
Pilotpressure line


The travel motor 2-stage tilting angle is a large angle side.Even if the travel switchover is set to the high-speed side, switching
the key switch OFF and then ON again always returns the system to this state.
The travel high-speed solenoid valve goes OFF, the travel motor Ps port oil connects with the tank line, and the travel motor
tilting angle moves to the large tilting side.
84551720B NA - August 2012

8020A-65
Travel high-speed circuit
84551720B NA - August 2012

8020A-66
Pilotpressure line


Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
The travel motor has an automatic switchover function that switches the speed to low speed according to the load pressure
on the travel motor only during high-speed travel conditions.
Electrical signals are sent to the computer A by operation of the travel high-speed select switch and the computer A sends
electrical signals to the travel high-speed solenoid valve.
Due to the switching of the travel high-speed solenoid valve, the pilot pressure [3.9 Mpa (565.709 psi)] from the C1 port enters
the left and right travel motor Ps ports through the center joint and sets the travel motor tilting angle to a small angle to raise
the speed.
84551720B NA - August 2012

8020A-67
Straight travel circuit (with HBCV)
84551720B NA - August 2012

8020A-68
Pilotpressure line

(boom, bucket)
is possible.
the drop in speed.
84551720B NA - August 2012

8020A-69
Swing Circuit
Swing speed limit control circuit
84551720B NA - August 2012

8020A-70
Pilotpressure line

1 Swing motor 9 Travel pilot pressure sensor 17
valve
tional valve
Remote control valve (arm,
7 15 Console lever lock switch
swing)
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode)
For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal, the
computer A outputs a signal to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 280 L/min (73.970 gpm) by the signal output from the computer A to
the P1 flow control proportional valve.
84551720B NA - August 2012

8020A-71
Swing relief cut-off control circuit
84551720B NA - August 2012

8020A-72
Pilotpressure line

1 Swing motor 9 Travel pilot pressure sensor 17
valve
tional valve
swing)
This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil drained from
the swing motor relief valve for the starting pressure boost for a independent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals, com-
puter A outputs a signal to the hydraulic pump P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pressure to reduce the hydraulic
pump A1 side discharge flow.
Also, the input signal from hydraulic pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge
flow.
84551720B NA - August 2012

8020A-73
Swing priority circuit (with HBCV)
84551720B NA - August 2012

8020A-74
Pilotpressure line
Remote control valve (arm, Arm load holding valve check

1 Swing motor 10 19
swing) valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 5 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 14 Console lever lock switch 23 Arm (2)
6 Cushion valve 15 Arm cylinder 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 16 Arm (1) 25 Hydraulic pump
8 Shuttle valve 17 Swing 26 Check valve
9 Computer A 18 Arm load holding valve spool 27 Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
84551720B NA - August 2012

8020A-75
Swing brake circuit
84551720B NA - August 2012

8020A-76
Pilotpressure line
1 Swing motor 7 Hydraulic pump 13 Computer A

2 Cushion valve 8 Check valve 14 Control valve
3 Right swing 9 Lever lock 15 Oil cooler
4 Left swing 10 Swing brake 16 Upper pilot pressure sensor
swing)
As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and the control
valve swing spool returns to neutral.
The pressurized oil fed to the swing motor B port from the control valve A3 port is cut.
At the same time, the destination location is eliminated for the pressurized oil flowing from the swing motor A port to the control
valve B3 port, so the pressure rises to the swing motor relief valve set pressure.
The pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In order to make up the shortfall
in the oil volume, oil is supplied from the make-up line connected to the swing motor Mu port from the control valve T3 port to
open the make-up check valve and oil is suctioned in to prevent cavitation.
84551720B NA - August 2012

8020A-77
Swing parking circuit (lever in neutral)
84551720B NA - August 2012

8020A-78
Pilotpressure line

swing)
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from computer A.
The swing motor P port oil goes from the 5 stack solenoid valve C2 port through the swing brake solenoid, and returns to the
hydraulic oil tank to hold the swing parking brake.
84551720B NA - August 2012

8020A-79
Swing parking circuit (brake release)
84551720B NA - August 2012

8020A-80
Pilotpressure line
1 Swing motor 7 Swing 13 Control valve

2 Cushion valve 8 Lever lock 14 Upper pilot pressure sensor
3 Right swing 9 Swing brake 15 Hydraulic pump
4 Left swing 10 5 stack solenoid valve 16 Check valve
5 Swing pilot pressure sensor 11 Console lever lock switch 17 Oil cooler
6 12 Computer A
swing)
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input), the
pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 0.5 MPa (72.527 psi) or higher at the pressure sensor in the swing pilot line,
the output from computer A to the swing brake solenoid valve goes OFF, the swing motor P port pressure rises, the swing
parking brake is released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve pa3 port
via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the
electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.The pilot pressure oil is
fed to the swing motor P port from the swing brake solenoid valve C2 port to release the swing parking brake.
spool.
The pressurized oil from the swing motor A port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure sensor
and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake solenoid valve output from
computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when about
1 sec. passes after the end of the upper operation, the swing parking brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the end of
the upper operation, the swing parking brake works again.
Swing pilot pressure Upper pilot pressure Swing brake solenoid Swing motor mechani-
Key switch
sensor sensor valve cal brake
OFF 0 MPa (0 psi) 0 MPa(0 psi) OFF ON
ON 0 MPa (0 psi) 0 MPa(0 psi) ON ON
ON 0.5 MPa (72.527 psi) min. 0 MPa(0 psi) OFF OFF
ON 0 MPa(0 psi) 0.5 MPa (72.527 psi) min. OFF OFF
ON 0.5 MPa (72.527 psi) min. 0.5 MPa (72.527 psi) min. OFF OFF
Pilot pressure sensor judgment standard

Operation is judged when at 0.5 MPa (72.527 psi) or above.
Non-operation is judged when at 0.3 MPa (43.516 psi) or below.
84551720B NA - August 2012

8020A-81
Swing parking circuit (machine stop)
84551720B NA - August 2012

8020A-82
Pilotpressure line

swing)
When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the swing brake solenoid C2
port through the lever lock solenoid and returns to the hydraulic oil tank, holding the swing parking brake hold status.
84551720B NA - August 2012

8020A-83
Boom Circuit
Boom-up circuit (independent operation) (with HBCV)
84551720B NA - August 2012

8020A-84
Pilotpressure line

2 Boom (up) 10 18 P1 pressure sensor
valve
3 Boom (down) 11 Boom (1) 19 P2 pressure sensor
4 Boom (2) 12 Boom cylinder 20 Hydraulic pump
bucket)
7 Boost pressure relief 15 Console lever lock switch 23 Boom HBCV check valve
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve Pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the Pa4 port separated in the
internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom (1) spool
via the parallel oil path, merges with the discharge oil from boom (2), pushes open the boom load hold valve check valve,
(flows through the boom cylinder HBCV check valve when the circuit has an HBCV) and into the bottom side, and the boom-up
operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
84551720B NA - August 2012

8020A-85
Boom-up circuit (compound boom-up + arm-in) (with HBCV)
84551720B NA - August 2012

8020A-86
Pilotpressure line
1 Arm cylinder 12 Arm (1) 23 Upper pilot pressure sensor

2 Arm (in) 13 Boom (2) 24 Console lever lock switch
3 Arm (out) 14 Arm load holding valve spool 25 Monitor display
4 Boom (up) 15 Load holding valve check valve 26 Computer A
5 Boom (down) 16 Regeneration release valve 27 P1 pressure sensor
7 18 Swing priority variable orifice 29 Hydraulic pump
bucket)
8 19 Arm (2) 30 Check valve
swing)
9 Lever lock 20 31 Oil cooler
valve
10 Boost pressure relief 21 Boom cylinder 32 HBCV check valve
11 5 stack solenoid valve 22 Travel pilot pressure sensor
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-87
Boom-down regenerative circuit (with HBCV)
84551720B NA - August 2012

8020A-88
Pilotpressure line
1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

2 Check valve 10 18 Boom (1)
bucket)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 5 stack solenoid valve 21 Console lever lock switch
8 Boom (up) 16 Hydraulic pump 24 Boom HBCV check valve
valve pb8 port and switches the boom (1) spool to the down side.
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
spool to the left.
the spool.
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.
84551720B NA - August 2012

8020A-89
Boom-down tilting prevention circuit (with HBCV)
84551720B NA - August 2012

8020A-90
Pilotpressure line
1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 11 5 stack solenoid valve 19 Console lever lock switch
6 Boom (up) 14 Hydraulic pump 22 P1 pressure sensor
7 Boom (down) 15 Boom cylinder 23 Boom HBCV check valve
8 16 Boom (1)
(boom,bucket)
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
84551720B NA - August 2012

8020A-91
Boom-down load holding valve circuit (with HBCV)
84551720B NA - August 2012

8020A-92
Pilotpressure line

1 9 5 stack solenoid valve 17 Console lever lock switch
valve
2 Load holding valve spool 10 Control valve 18 Monitor display
3 Cushion valve 11 Check valve 19 Computer A
4 Boom (up) 12 Oil cooler 20 P1 pressure sensor
5 Boom (down) 13 Boom cylinder 21 P2 pressure sensor
6 14 Boom (1) 22 Hydraulic pump
bucket)
7 Lever lock 15 Travel pilot pressure sensor 23 Boom HBCV check valve
8 Boost pressure relief 16 Upper pilot pressure sensor
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
spool to the left.
the spool. This opens the HBCV check valve.
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and the boom (1) spool and
returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-93
Arm Circuit
Arm-out circuit (with HBCV)
84551720B NA - August 2012

8020A-94
Pilotpressure line
1 Arm cylinder 9 Control valve 17 Computer A

2 Arm (in) 10 Load holding valve check valve 18 P1 pressure sensor
3 Arm (out) 11 Arm (1) 19 P2 pressure sensor
4 Cushion valve 12 Arm (2) 20 Hydraulic pump
swing)
7 Boost pressure relief 15 Console lever lock switch 23 Arm HBCV check valve
8 5 stack solenoid valve 16 Monitor display 24 Arm HBCV
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-95
Arm-in forced regenerative circuit (with HBCV)
84551720B NA - August 2012

8020A-96
Pilotpressure line

1 Load holding valve spool 11 21 Console lever lock switch
swing)
2 Load holding valve check valve 12 Lever lock 22 Monitor display
3 Oil cooler 13 Boost pressure relief 23 Computer A
4 Regeneration check valve 14 5 stack solenoid valve 24 P1 pressure sensor
5 Metering large 15 Control valve 25 P2 pressure sensor
6 Metering small 16 Arm cylinder 26 Hydraulic pump
Forced regeneration release
7 17 Arm (1) 27 Check valve
valve
8 Arm (in) 18 Arm (2) 28 Arm HBCV check valve
9 Arm (out) 19 Travel pilot pressure sensor 29 Arm HBCV
10 Cushion valve 20 Upper pilot pressure sensor
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
spool to the right.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.
84551720B NA - August 2012

8020A-97
Arm-in load holding valve circuit (with HBCV)
84551720B NA - August 2012

8020A-98
Pilotpressure line
1 Load holding valve spool 10 5 stack solenoid valve 19 Computer A

2 Load holding valve check valve 11 Control valve 20 P1 pressure sensor
3 Oil cooler 12 Arm cylinder 21 P2 pressure sensor
4 Arm (in) 13 Arm (1) 22 Hydraulic pump
5 Arm (out) 14 Arm (2) 23 Check valve
6 Cushion valve 15 Travel pilot pressure sensor 24 Arm HBCV check valve
7 16 Upper pilot pressure sensor 25 Arm HBCV
swing)
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load hold
valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil
path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
The pilot pressure oil from the Pb5 port separated in the internal path flows into the HBCV PL port and switches the spool.
The pilot pressure oil from the Pb5 port separated in the internal path is fed to the load hold valve spool and moves the spool
to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line through the load hold
valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the HBCV check valve, load hold valve check valve and the arm (1)
spool and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-99
Bucket Circuit
Bucket-open circuit
84551720B NA - August 2012

8020A-100
Pilotpressure line

3 Bucket (open) 10 Bucket cylinder 17 P2 pressure sensor
4 11 Travel pilot pressure sensor 18 Hydraulic pump
bucket)
5 Lever lock 12 Upper pilot pressure sensor 19 Check valve
6 Boost pressure relief 13 Console lever lock switch 20 Oil cooler
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the control
valve pa7 port and switches the bucket spool to the open side.
spool.
Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020A-101
84551720B NA - August 2012

8020A-102
Pressure line Pilot tank line pressure, the greater the volume of regeneration. When the cylinder rod side load pressure becomes high, the check valve is
Tank line Electric line closed and the cylinder bottom side return oil goes through the bucket spool without regeneration and returns to the hydraulic
Pilotpressure line oil tank.
1 Regeneration check valve 9 Boost pressure relief 17 Monitor display

2 Oil cooler 10 5 stack solenoid valve 18 Computer A
3 Orifice 11 Control valve 19 P1 pressure sensor
4 Cushion valve 12 Bucket 20 P2 pressure sensor
5 Bucket (close) 13 Bucket cylinder 21 Hydraulic pump
6 Bucket (open) 14 Travel pilot pressure sensor 22 Check valve
7 15 Upper pilot pressure sensor
bucket)
spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.Through this, the return oil
pushes open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cylinder rod side load
84551720B NA - August 2012

8020A-103
Negative Control Circuit
Negative control circuit (power save solenoid OFF)
84551720B NA - August 2012

8020A-104
N2 negative control pressure

1 P1 negative control relief 7 Console lever lock switch 13
sensor
2 P2 negative control relief 8 Lever lock 14
tional valve
3 Control valve 9 Power save 15
valve
the control valve P1 and P2 ports through the center bypass oil path, and through the downstream negative control variable
relief, and returns to the hydraulic oil tank.
The discharged oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve,
is fed to the control valve Pn1 and Pn2 ports, and holds the P1 and P2 negative control relief at the set pressure of 2.55 MPa
(369.8869 psi).
The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and Ps2 ports to the hydraulic
pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is reduced.
84551720B NA - August 2012

8020A-105
Negative control power save circuit (power save solenoid ON)
84551720B NA - August 2012

8020A-106

1 Control valve 7 Power save 13
valve
5 Console lever lock switch 11
sensor
6 Lever lock 12
tional valve
The purpose of this control is to reduce fuel consumption during standby by reducing the back pressure for the negative control
signal.
When the remote control valve operation lever is set to neutral, the non-operation state signal enters the computer A from the
travel pilot pressure sensor and the upper pilot pressure sensor installed on the control valve PT port and PA port.
After about 1 sec., the power save solenoid valve is excited and switched ON by the signal output from computer A, and the
oil path is switched.
The pressurized oil from the control valve negative control relief Pn1 and Pn2 ports goes through the power save solenoid
valve and returns to the hydraulic oil tank.
Therefore, the negative control relief set pressure is switched to low pressure to further reduce the A1 and A2 pump discharge
pressure.
With the system running this way, the negative control signal is cut off and the P1 and P2 pump discharge volume increases.
The discharge oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve, is
fed to the hydraulic pump P2 port from the C5 port, moves the A2 side pump tilting to the minimum flow side, and this reduces
the discharge flow.
At the same time, the discharge oil from the pilot pump A3 is fed to the hydraulic pump P1 port by the signal from computer
A to the P1 flow restriction proportional valve, moves the A1 side pump tilting to the minimum flow side, and this reduces the
discharge flow.
84551720B NA - August 2012

8020A-107
Negative control circuit (bucket close, power save solenoid OFF)
84551720B NA - August 2012

8020A-108

Remote control valve (boom, N2 negative control pressure
2 Travel pilot pressure sensor 9 16
bucket) sensor
3 Upper pilot pressure sensor 10 Console lever lock switch 17
valve
4 Cushion valve 11 Lever lock 18 Hydraulic pump
5 Bucket (close) 12 Power save 19 Check valve
6 Bucket (open) 13 5 stack solenoid valve 20 Oil cooler
7 Bucket cylinder 14 P1 pressure sensor
As an example, this section explains the bucket-close operations.

The discharge oil from the hydraulic pump A2 enters the control valve P2 port, is fed to the bucket spool, flows into the bucket
cylinder bottom side because of the spool switching and the bucket-close operation is carried out.
At the same time, the upper pilot pressure sensor signal is detected and through the signal output from computer A to switch
OFF the power save solenoid valve, pilot pressure oil enters the negative control relief, and the pressure becomes the set
pressure of 2.55 MPa (369.8869 psi).
Because the bucket spool switches and the pressurized oil on the center bypass downstream side is cut off, the Pi2 pump
negative control pressure oil from the Ps2 port is eliminated, the pump tilting moves to the increase side, and the flow is
increased.
Also, the command milli-amp to the P1 flow control proportional valve is lowered and the pressurized oil from the hydraulic
pump A3 is cut off, but the negative control pressurized oil is fed from the control valve Ps1 port to the Pi1 port, moves the
pump tilting to the minimum flow side, and the hydraulic pump A1 discharge volume is reduced.
84551720B NA - August 2012

8020A-109
Horsepower Boost Circuits
Arm-in Horsepower Boost Circuit
84551720B NA - August 2012

8020A-110
1 Arm (in) 9 Arm pilot pressure sensor 17 Computer A

2 Arm (out) 10 Control valve 18 P1 pressure sensor
3 Cushion valve 11 Arm (1) 19 P2 pressure sensor
Remote control valve (arm, N2 negative control pressure
4 12 Arm (2) 20
swing) sensor
5 Lever lock 13 Travel pilot pressure sensor 21 Hydraulic pump
6 Boost pressure relief 14 Upper pilot pressure sensor 22 Check valve
7 5 stack solenoid valve 15 Console lever lock switch 23 Oil cooler
8 Arm cylinder 16 Monitor display
For the arm-in operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the arm pilot pressure sensor input signal and P1 pressure sensor and P2 pressure sensor input signals.
Condition under which the arm-in horsepower boost control is entered
Arm-in pilot pressure 0.5 MPa (72.527 psi) or higher (arm-in operation)
P1＋P2 45 MPa (6527.42 psi)
Conditions under which the arm-in horsepower boost control is ended
Arm-in pilot pressure 0.3 MPa (43.516 psi) or lower (arm-in operation end)
P1＋P2 45 MPa (6527.42 psi)
When either occurs
84551720B NA - August 2012

8020A-111
84551720B NA - August 2012

8020A-112
Pilotpressure line
1 Travel motor 7 Travel high-speed select switch 13 P1 pressure sensor

2 Travel remote control valve 8 Computer A 14 P2 pressure sensor
3 Travel high speed 9 Control valve 15
sensor
4 Lever lock 10 Travel (left) 16 Hydraulic pump
5 5 stack solenoid valve 11 Travel (right) 17 Check valve
6 Console lever lock switch 12 Travel pilot pressure sensor 18 Oil cooler

For travel single operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the travel pilot pressure sensor input signal.
Conditions under which the travel horsepower boost control is entered
Travel pilot pressure 0.5 MPa (72.527 psi) or higher.
SP mode
Conditions under which the travel horsepower boost control is ended
Travel pilot pressure 0.3 MPa (43.516 psi) or lower.
AUTO mode, H mode
Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is stopped,
and when an arm-out operation is followed by an arm-in operation.
84551720B NA - August 2012

8020A-113
Cushion circuit (arm-out operation)
84551720B NA - August 2012

8020A-114
Pilotpressure line

1 Arm (in) 7 13 Console lever lock switch
swing)
2 Arm (out) 8 Lever lock 14 Hydraulic pump
3 Cushion spool 9 5 stack solenoid valve 15 Check valve
4 Orifice 10 Control valve 16 Oil cooler
5 Check valve 11 Arm (1)
6 Cushion valve 12 Arm (2)
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control valve 2 port
into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9 ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through the
cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the cushion
valve R port and returns to the hydraulic oil tank, so heat performance is improved.
84551720B NA - August 2012

8020A-115
Cushion circuit (arm-out operation stopped)
84551720B NA - August 2012

8020A-116
Pilotpressure line

1 Arm (in) 6 11 Arm (2)
swing)
When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5 and pa9
ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve to the hydraulic
oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is improved.
84551720B NA - August 2012

8020A-117
Cushion circuit (arm-out → arm-in operation)
84551720B NA - August 2012

8020A-118
Pilot pressure line

1 Arm (in) 6 11 Arm (2)
swing)
When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the pilot
pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check valve, and
reaches the control valve pb5 port and pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes through the
cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is improved.s
84551720B NA - August 2012

8020A-119
Heat circuit (lever in neutral)
84551720B NA - August 2012

8020A-120
Pilotpressure line
1 Arm (in) 5 Lever lock 9 Hydraulic pump

2 Arm (out) 6 5 stack solenoid valve 10 Check valve
3 Cushion valve 7 Control valve 11 Oil cooler
swing)
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion spool to
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat perfor-
mance.
84551720B NA - August 2012

8020A-121
Auto pressure boost circuit (bucket close)
84551720B NA - August 2012

8020A-122
Pilotpressure line

3 Bucket (open) 10 Bucket cylinder 17 Hydraulic pump
4 11 Upper pilot pressure sensor 18 Check valve
bucket)
5 Lever lock 12 Console lever lock switch 19 Oil cooler
7 5 stack solenoid valve 14 Computer A
When an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 - 36.8 MPa (4975.341
- 5337.975 psi) according to the engine load ratio and hydraulic load pressure, then ends the pressure boost after 8 sec.
As an example, this section explains bucket-close operations.
At the same time, the output signal from the upper pilot pressure sensor that detected the pressurized oil separated from the
pilot internal path is input to computer A, which judges that there is upper operation.
Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to
the pressure boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH
port to hold the pressure boost relief set pressure for 8 sec.
There is no boost for the option circuit and during travel operation.
84551720B NA - August 2012

8020A-123
84551720B NA - August 2012

8020A-124
Section
8020B
Explanation of Hydraulic Circuit and Operations (option)
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS Multi-purpose circuit (breaker Q control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Multi-purpose circuit (2 pumps flow crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2nd option circuit (hydraulic rotation fork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CX210C LC NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CX210C LR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Option Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Option Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Breaker circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2nd option circuit (hydraulic rotation fork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Double-acting circuit (hydraulic fork). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CX210C LC NLC
Option Circuits
Breaker circuit (independent operation)
84551720B NA - August 2012

8020B-2
Pilotpressure line
1 Control valve 8 Monitor display 15 P1 pressure sensor

2 Manifold 9 Breaker switch 16 P2 pressure sensor
3 Relief valve 10 Option remote control valve 17
sor
4 Breaker 11 Option pilot pressure switch 18 P1 flow control proportional valve
5 Travel pilot pressure sensor 12 Console lever lock switch 19 Hydraulic pump
6 Upper pilot pressure sensor 13 Lever lock 20 Check valve
7 Computer A 14 5 stack solenoid valve 21 Oil cooler
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the relief valve A port through the B port and into the breaker.
The breaker set pressure is set by this relief valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display with the ON
signal from the breaker switch in the cab, the optimum operating flow can be selected.
84551720B NA - August 2012

8020B-3
Double-acting circuit (hydraulic fork)
84551720B NA - August 2012

8020B-4
Pilotpressure line
1 Control valve 6 Computer A 11 Option remote control valve

2 Hydraulic fork 7 Lever Lock 12 Option pilot pressure switch
3 Travel pilot pressure sensor 8 5 stack solenoid valve 13 Check valve
4 Upper pilot pressure sensor 9 Console lever lock switch 14 Oil cooler
5 Monitor display 10 Hydraulic pump
As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool to the close side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the option spool,
flows into the hydraulic fork because of the option spool switching and operates to the close side.
At this time, the option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil tank.
84551720B NA - August 2012

8020B-5
Multi-purpose circuit (breaker Q control)
84551720B NA - August 2012

8020B-6
Pilotpressure line

2 3-direction valve 9 Monitor display 16 P2 pressure sensor
3 Shut-off valve 10 Option switchover solenoid valve 17
sor
4 Breaker 11 Console lever lock switch 18 P1 flow control proportional valve
5 Option remote control valve 12 Lever lock 19 Hydraulic pump
6 Option pilot pressure switch 13 5 stack solenoid valve 20 Check valve
7 Multi-purpose circuit switch 14 21 Oil cooler
valve
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the computer A to the option
switchover solenoid valve to switch the valve.
The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is fed to the 3-direction valve
PP port and shut-off valve PP port and each valve is switched.
Always switch the 2 pumps flow select switch to the 1 pump side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve.
The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.
84551720B NA - August 2012

8020B-7
Multi-purpose circuit (2 pumps flow crusher)
84551720B NA - August 2012

8020B-8
Pilotpressure line
1 3-direction valve 10 Monitor display 19 5 stack solenoid valve

2 Shut-off valve 11 Computer A 20 Console lever lock switch
3 Crusher 12 Multi-purpose circuit switch 21
valve
4 Option switchover solenoid valve 13 2 pumps flow select switch 22 P1 pressure sensor
5 2 pumps flow solenoid valve 14 Control valve 23 P2 pressure sensor
6 Option remote control valve 15 Neutral cut valve 24
sor
7 Check valve 16 Travel pilot pressure sensor 25 P1 flow control proportional valve
8 Oil cooler 17 Upper pilot pressure sensor 26 Hydraulic pump
9 Option pilot pressure switch 18 Lever lock
When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal (24 V) is output from the
computer A to the 2 pumps flow solenoid valve to switch the valve.
When the multi-purpose circuit switch is flipped to the crusher side, the crusher circuit is formed without outputting a signal
from the computer A to the option switchover solenoid valve and without switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms the A
⇔ B circuit.
By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool.
At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the A2 port and is fed to the
control valve pcc port and the control valve neutral cut valve is switched.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and goes through the center bypass oil path and
since the neutral cut valve has closed the port to the tank, the oil goes from the P3 port via the P4 port and merges on the
upstream side of the option spool.
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the crusher.
The return oil from the crusher returns from the 3-direction valve A port through the B port and the option spool and returns
to the hydraulic oil tank.
Because the crusher operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.
84551720B NA - August 2012

8020B-9
2nd option circuit (hydraulic rotation fork)
84551720B NA - August 2012

8020B-10
Pilotpressure line
1 Control valve 6 Console lever lock switch 11 2nd option pilot pressure switch
2 Travel pilot pressure sensor 7 2nd option remote control valve 12 Monitor display
3 Upper pilot pressure sensor 8 Check valve 13 Computer A
4 Lever lock 9 Oil cooler 14 4th pump
5 5 stack solenoid valve 10 Hydraulic rotation fork 15 Hydraulic pump
As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve par2
port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and flows to
the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
84551720B NA - August 2012

8020B-11
CX210C LR
Option Circuits
2nd option circuit (hydraulic rotation fork)
84551720B NA - August 2012

8020B-12
Pilotpressure line
1 Control valve 6 Console lever lock switch 11 2nd option pilot pressure switch
2 Travel pilot pressure sensor 7 2nd option remote control valve 12 Monitor display
3 Upper pilot pressure sensor 8 Check valve 13 Computer A
4 Lever lock 9 Oil cooler 14 4th pump
5 5 stack solenoid valve 10 Hydraulic rotation fork 15 Hydraulic pump
As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve par2
port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and flows to
the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
84551720B NA - August 2012

8020B-13
This page is intentionally left blank
84551720B NA - August 2012

8020B-14
Section
8030A
Structure and Operation Explanation of Hydraulic Pump
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Structure and Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Pump Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive Shaft Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Shaft Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Regulator Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Regulator Operation Explanation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front Side Regulator Internal Structure Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear Side Regulator Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gear Pump Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Structure and Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Structure and Operation Explanation

This pump has a structure with 2 pumps positioned on the same shaft coupled with the 1st gear (116) and rotational
force is distributed to different shafts by the gear structure. The 2 pumps are driven by transmitting the rotation of the
power source to the front side drive shaft (111). Auxiliary pumps installed on different shafts can also be driven at the
same time.
The pump can be roughly divided into the rotary group, which is the main part of the pump rotating, the swash plate
group, which changes the discharge flow, the valve block group, which switches between oil suction and discharge,
and the PTO group that transmits the gear pump drive shaft.
The rotary group is made up of drive shaft F (111), cylinder block (141), piston shoes (151, 152), holder plate (153),
spherical bushing (156), and cylinder spring (157).
The drive shaft is supported at both ends with bearings (123, 124).
The shoe is caulked to the piston and forms the spherical joint, reduces the thrust force generated by the load pres-
sure, and has a pocket section for balancing the hydraulic pressure for sliding lightly on the shoe plate (211).
The piston shoe sub-group is pressed against the shoe plate by the cylinder spring via the holder plate and spherical
bushing so that it can slide smoothly on the shoe plate.
Also, in the same way the cylinder block is pressed against the valve plate (313) by the cylinder spring.
The swash plate group comprises the swash plate (212), shoe plate (211), swash plate support board (251), tilting
bushing (214), tilting pin (531), and servo piston (532).
The swash plate is supported by the swash plate support board at the cylindrically shaped section formed by the
opposite side of the shoe sliding surface.
By leading the hydraulic pressure controlled by the regulator into the hydraulic pressure chambers on both sides of
the servo piston, the servo piston moves left and right. This moves the swash plate back and forth on the swash plate
support board via the tilting pin spherical section and changes the tilting angle (α).
The valve block group comprises the valve block (312), valve plate (313), and valve plate pin (885).
The valve plate, which has 2 oval-shaped ports, is installed on the valve block. Its function is to feed oil to the cylinder
block and recover it from the cylinder block.
The oil switched by the valve plate is connected through the valve block to the outside lines.
Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block is also rotated at the
same time via the spline coupling.
When the swash plate tilts, the piston located at the center of the cylinder block moves reciprocally relative to the
cylinder while turning with the cylinder block.
Therefore, looking at 1 piston, while the cylinder block turns one rotation, the piston moves away from the valve plate
(oil intake stroke) for 180° of the cylinder block rotation, then moves toward the valve plate (oil discharge stroke) for
the remaining 180°.
When the swash plate tilting angle is 0, the piston does not move through a stroke and oil is not discharged.
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8030A-3
Hydraulic Pump Internal Structure

Diagram
Overall View
Drive shaft front side Drive shaft rear side
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8030A-4
Drive Shaft Front Side
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8030A-5
Drive Shaft Rear Side
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8030A-6
Part Table
Code Part name Q'ty Component part No. (Q'ty) or type

04 Gear pump 1 set ZX10LBRZ1-07A-V
011 Piston subassembly 2 sets 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC)
Electromagnetic proportional pressure
079 1 set KDRDE5KR-V3-V
reducing valve, casing subassembly
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC)
1 Right rotation valve plate

2 Left rotation valve plate

111 Drive shaft (F) 1 532 Servo piston 2
113 Drive shaft (R) 1 534 Stopper (L) 2
116 1st gear 1 535 Stopper (S) 2
123 Cylinder roller bearing 2 541 Seat 4
124 Needle roller bearing 2 543 Stopper 1 2
127 Bearing spacer 4 544 Stopper 2 2
141 Cylinder block 2 545 Steel ball 4
151 Piston 18 548 Feedback pin 2
152 Shoe 18 702 O-ring 2
153 Holder plate 2 710 O-ring 2
156 Spherical bushing 2 717 O-ring 4
157 Cylinder spring 18 724 O-ring 16
211 Shoe plate 2 725 O-ring 6
212 Swash plate 2 726 O-ring 2
214 Tilting bushing 2 728 O-ring 4
251 Swash plate support board 2 732 O-ring 2
261 Seal cover (F) 1 774 Oil seal 1
271 Pump casing 2 789 Backup ring 2
312 Valve block 1 792 Backup ring 2
313 Valve plate (R) 1 806 Hexagon nut 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eyebolt 2
466 VP plug 2 953 Hexagon socket head stop screw 2
467 VP plug 2 954 Stop screw 2
468 VP plug 4 981 Nameplate 1
490 Insert plug 27 983 Strike rivet 2
531 Tilting pin 2
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8030A-7
Regulator
Regulator Operation Explanation
1. Flow control
• Operation explanation (See the Regulator Operation Explanation Diagram.)
1) Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the diagram below.
Discharge flow amount Q
Pilot pressure Pi
1) Flow reduction operation

When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the location
where the pilot spring (646) force and hydraulic pressure balance each other. The pin (875) fixed to
lever 2 (613) fits into the grooved section of the pilot piston (643), so, through the movement of the pilot
piston (643), lever 2 rotates with the B section (fastened by the fulcrum plug (614) and pin (876)) as
the fulcrum. The pin (897) fixed to the feedback lever (611) projects into the large opening (C section)
of lever 2 (613), so as lever 2 (613) rotates, the pin (897) moves to the right. The pin (548) fixed to
the tilting pin (531) that shakes the swash plate (212) is bonded to the bolt width section (D section)
of the feedback lever (611). Therefore, as the pin (897) moves, the feedback lever (611) rotates with
D section as the fulcrum. Since the spool (652) is linked to the feedback lever (611) via the pin (874),
the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the servo piston large-diameter
chamber via the spool and CI port. The discharge pressure Pd1 is always led to the servo piston
small-diameter chamber. As a result, the servo piston is moved to the right due to the surface area
difference and reduces the flow.
When the servo piston (532) moves to the right, the D section also moves to the right. The return
spring (654) is mounted on the spool (652). Since force pulling the spool to the left is always operating,
the pin (897) is pressed into the large opening (C section) of lever 2 (613). Therefore, accompanying
the D section movement, the feedback lever (611) rotates around the C section as the fulcrum and
the spool (652) moves to the left. This movement causes the open section between the sleeve (651)
and the spool (652) to begin to close, and the servo piston (532) stops at the point the open section
fully closes.
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot spring
(646) force and lever 2 (613) rotates with the B section as the fulcrum. The pin (897) is pressed in
the large opening (C section) of lever 2 (613) by the return spring (654) via the spool (652), pin (874),
and feedback lever (611), so accompanying rotation of lever 2 (613), the feedback lever (611) rotates
with the D section as the fulcrum and the spool (652) moves to the left.
When the spool (652) moves, the CI port opens to the tank port, so the pressure in the large-diameter
chamber of the servo piston drains out, the servo piston (532) is moved to the left by the discharge
pressure Pd1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston (532), the D section moves to the left, the feedback
lever (611) rotates with the C section as the fulcrum and the spool (652) moves to the right. This
operation continues until the open section between the spool (652) and sleeve (651) closes, and then
the servo piston stops at the point the open section fully closes.
3) High-pressure selection function
The pilot pressure Pi, which serves as the flow control signal, is the pressure for which high pressure
is selected from among multiple command pressures via the shuttle valve subassembly (050).
KR3K-9Y04-HV selects the higher pressure from Pi1 or the proportional valve 2nd pressure and
KR3K-9X04-HV selects the higher pressure from Pi2 or the external command pressure P2.
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8030A-8
2. Horsepower control
1) Horsepower control
As the load pressure increases, the pump tilting angle decreases and the overload of the engine is pre-
vented as in the diagram below. Since this regulator uses the simultaneous full-horsepower control method,
the tilting angles (displacement volumes) of the 2 pumps are controlled to be the same value as in the fol-
lowing equation.
Tin = Pd1 x q/2π + Pd2 x q/2π = (Pd1 + Pd2) x q/2π
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(See the pages on Flow control for the detailed movement of each part.)
Discharge pressure (Pd1 + Pd2)
1) Overload prevention operation

When the self pump discharge pressure Pd1 or the counterpart pump discharge pressure Pd2 rises,
since Pd1 and Pd2 operate on the stepped section of the compensation piston (621), the compen-
sation rod (623) is pressed to the right and moves to the location where the force of the outer spring
(625) and inner spring (626) balance out the hydraulic pressure force. The movement of the compen-
sation rod (623) is transmitted to lever 1 (612) through the pin (875) and lever 1 (612) rotates around
the pin (876) (E section) fastened to the casing (601). The pin (897) fixed to the feedback lever (611)
projects into the large opening (F section) of lever 1 (612), so as lever 1 (612) rotates, the feedback
lever (611) rotates with the D section as the fulcrum and the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the large-diameter section of the
servo piston via the CI port, the servo piston (532) is moved to the right, and the pump discharge flow
is decreased to prevent overload of the power source.
The servo piston (532) movement is transmitted to the feedback lever (611) via the D section. The
feedback lever (611) rotates with the F section as the fulcrum and the spool (652) moves to the left.
The spool (652) moves until the open section between the spool (652) and sleeve (651) closes, and
then the servo piston stops at the point the open section fully closes.
2) Flow return operation
If the self pump discharge pressure Pd1 or the counterpart pressure pump discharge pressure Pd2
decreases, the compensation rod (623) is pressed back by the outer spring (625) and the inner spring
(626) and lever 1 (612) rotates about the E section. Accompanying the lever 1 (612) rotation, the
feedback lever (611) rotates around the D section as the fulcrum and the spool (652) moves to the left.
Because of this, the CI port opens to the tank port, the servo piston large-diameter section pressure
drains off, the servo piston (532) moves to the left and the pump discharge flow increases.
The movement of the servo piston (532) is transmitted to the spool (652) by the feedback mechanism,
and this operation continues until the open section between the spool (652) and the sleeve (651)
closes.
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8030A-9
3. Low tilting (low flow) command priority mechanism

As above, the flow control and the horsepower control tilting command is transmitted to the feedback lever (611)
and spool (652) via the large opening (C and F sections) of lever 1 (612) and lever 2 (613), but since the C and F
sections have a structure in which a pin (D5) projects into a large hole (D9), the pin (897) only contacts the lever
that makes the tilting smaller and the D9 hole for the lever on the side that has the larger tilting command state
does not contact the pin (897), but is free. This type of mechanical selection method gives priority to flow control
and horsepower control commands with low tilting.
4. Power shift control (decreased horsepower control)
Use the power shift pressure Pf to arbitrarily control the pump set horsepower as in the diagram below.
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right via the pin (898)
and the compensation piston (621), so the pump tilting angle is reduced and the horsepower setting is reduced
in the same way as was explained for the operation to prevent overload of the horsepower control. By contrast,
as the power shift pressure Pf decreases, the horsepower setting increases.
Discharge pressure (Pd1 + Pd2)
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8030A-10
Regulator Operation Explanation Diagram
Connected to CI port servo pis-

*1
ton large bore chamber
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8030A-11
KR3K-9Y04-HV KR3K-9X04-HV
Front side Rear side
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8030A-12
Front Side Regulator Internal Structure Diagrams
Hydraulic circuit
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8030A-13
1 Front side regulator

2 Rear side regulator
Component part No. (Q'ty) or

Code Part name Q'ty
type
Shuttle valve 545 (1PC), 546 (1PC), 547
050 1 set
subassembly (1PC)
Electromag-
netic propor-
079 1 set KDRDE5K-31/30C50-102
tional pressure
reducing valve
- Regulator sub-
1 626 Inner spring 1 730 O-ring 1
assembly
Hexagon socket
412 2 627 Adjusting ring (C) 1 732 O-ring 1
head bolt
Hexagon socket Adjusting screw
413 2 628 1 733 O-ring 1
head bolt (C)
Hexagon socket
418 2 629 Cover (C) 1 734 O-ring 1
head bolt
Hexagon socket
436 4 630 Lock nut 1 735 O-ring 1
head bolt
Hexagon socket
438 8 631 Pf sleeve 1 753 O-ring 1
head bolt
466 VP plug 1 641 Pilot cover 1 755 O-ring 3
467 VP plug 1 643 Pilot piston 1 756 O-ring 1
496 Insert plug 12 644 Spring seating (Q) 1 763 O-ring 1
545 Steel ball 1 645 Adjusting ring (Q) 1 801 Hexagon nut 1
546 Seat 1 1 646 Pilot spring 1 802 Hexagon nut 1
547 Seat 2 1 651 Sleeve 1 814 Stop ring 1
601 Casing 1 652 Spool 1 836 Stop ring 1
611 Feedback lever 1 653 Spring seating 1 858 Locking ring 2
612 Lever 1 1 654 Return spring 1 874 Pin 1
613 Lever 2 1 655 Set spring 1 875 Pin 2
614 Fulcrum plug 1 656 Blind cover 1 876 Pin 2
615 Adjusting plug 1 708 O-ring 1 887 Pin 1
Compensation
621 1 722 O-ring 3 897 Pin 1
piston
622 Piston case 1 724 O-ring 9 898 Pin 1
Compensation Hexagon socket
623 1 725 O-ring 1 924 1
rod head stop screw
625 Outer spring 1 728 O-ring 1
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8030A-14
Rear Side Regulator Internal Structure Diagram
Hydraulic circuit
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8030A-15

Code Part name Q'ty
type
Shuttle valve sub- 545 (1PC), 546 (1PC), 547
050 1 set
assembly (1PC)

466 VP plug 1 656 Blind cover 1
546 Seat 1 1 725 O-ring 1
547 Seat 2 1 727 O-ring 1
612 Lever 1 1 732 O-ring 1
613 Lever 2 1 733 O-ring 1
626 Inner spring 1 802 Hexagon nut 1
627 Adjusting ring (C) 1 814 Stop ring 1
628 Adjusting screw (C) 1 836 Stop ring 1
629 Cover (C) 1 858 Locking ring 2
645 Adjusting ring (Q) 1 898 Pin 1
Hexagon socket head stop
646 Pilot spring 1 924 1
screw
KSJ12240-D00S3
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8030A-16
Gear Pump
Gear Pump Internal Structure Diagram
Hydraulic circuit
*1 To main pump

Code Part name Q'ty
type
307 (1PC), 308 (1PC), 351
Gear case (1PC)
350 1 set
subassembly 353 (1PC), 354 (1PC), 361
(1PC)
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8030A-17
307 Poppet 1 353 Drive gear 1 466 VP plug 1
308 Seat 1 354 Driven gear 1 700 Angle ring 1
309 Ring 1 355 Filter 1 710 O-ring 1
310 Spring 1 361 Front case 1 725 O-ring 1
311 Adjusting screw 1 433 Flange socket 2 732 O-ring 1
312 Lock nut 1 434 Flange socket 2 850 Locking ring 1
351 Gear case 1 435 Flange socket 4
Structure and Operation Explanation

Structure
The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear (353), driven gear
(354) pair and the relief valve for setting the discharge pressure are installed.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309), adjusting screw (311),
and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted on the front case (361).
Operation
Oil suctioned in from suction port B3 is discharged from discharge port A3 by the drive and driven gears.
The discharge oil is held at the set pressure of 3.9 MPa ( 565.709 psi ) by the relief valve.
Unnecessary discharge oil is drained from the drain port via the relief valve.
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8030A-18
Section
8030B
Structure and Operation Explanation of Travel Motor
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84551720B NA - August 2012
CONTENTS
Travel motor operation explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Explanation of Component Device Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Double Counter Balance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crossover Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Automatic 2-speed Switchover Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parking Brake Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Travel motor operation explanation

Explanation of Component Device Operation
Double Counter Balance Valve
The purpose of the "double counter balance valve" is to control the speed of the motor according to the feed flow.
Therefore, motor rotation getting away due to external load is prevented.
As the roles of the double counter balance valve, there are
1. The overrun prevention function that controls the piston motor speed to match feed quantity in the state of rota-
tion at or higher than the speed determined by the flow feed from the piston motor for the external load (below,
pumping action).
2. The brake function used together with the crossover relief valve to make up the brake circuit that gradually stops
the rotation of the piston motor by applying braking force to the piston motor rotation.
3. The high-pressure selection shuttle valve function for releasing the parking brake through its own pressure.
Diagram 3 shows a structural diagram of the standard double counter balance valve.
This section explains the operations of each function using this standard double counter balance valve.
Diagram 3 Double counter balance valve structural diagram (stopped state)
a Oil path C1 f Oil path B k Spring chamber 2

c Damper chamber A1 g Oil path C2
e Spring chamber 1 i Damper chamber A2
1) Stopped state (Diagram 3)

When the control valve is in neutral (the motor stopped), since pressure is generated at neither the P1 port
nor the P2 port, the M1 and M2 ports are locked (hydraulically) with the spool (1) and the check valves (2-1)
(2-2) and the piston motor does not rotate.
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8030B-3
2) Motor starting (Diagram 4)

When the pressure oil discharged from the hydraulic pump is led to the double counter balance valve P1
port, the check valve (2-1) moves to the left against the spring (3), the oil path C1 (a) is opened, pressure
oil flows from the M1 port into the piston motor and attempts to rotate the piston motor.
On the other hand, the return oil from the piston motor flows from the M2 port into the double counter balance
valve, and then flows to the check valve (2-2). The P1 port side goes to high pressure and operates the
spring chamber 1 (e) and the damper chamber A1 (c), and that oil pressure moves the plunger (1) to the
right against the opposite side spring (7-2) with force proportional to the pressure.
At this time, the M2 port return oil flows through the oil path B (f) in the circumferential notch section of the
plunger (1) and into the P2 port while generating back pressure at the M2 port and this return oil returns to
the tank through the control valve and the piston motor starts rotating.
3) Counter balance function (Diagram 4)
During piston motor rotation, if the piston motor is forced to rotate by the external load, pumping action
occurs in the piston motor, and it runs wild.
In this case, since the P1 port section becomes the suction side of the pump action, that pressure drops.
At the same time, the pressure also drops in the spring chamber 1 (e) and the damper chamber A1 (c).
Therefore, the plunger (1) is moved to the left by the spring (7-2), oil path B (f) is closed, and when the
return oil flow stops, the suction side flow stops at the same time.
When the flow of oil through oil path B (f) is stopped, in an instant, the P1 port side pressure rises again
due to the hydraulic pump discharge oil and this moves the plunger (1) to the right.
In this way, the plunger (1) moves in small steps when there is pumping action due to the external load to
hold the opening surface area of oil path B (f) in an appropriate state.
Therefore, rotation of the piston motor at a speed appropriate to the feed flow from the hydraulic pump is
maintained and vacuum in the hydraulic circuit is prevented. This prevents the piston motor from running
wild.
Diagram 4 Double counter balance valve when motor rotating
g Oil path C2
i Damper chamber A2
k Spring chamber 2
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8030B-4
4) Piston motor braking (Diagram 5)

The double counter balance valve makes up the brake circuit together with the crossover relief valve.
When the control valve is returned to neutral, the pressure oil from the hydraulic pump is cut off and the P1
and P2 ports go to the same pressure.
Therefore, the plunger (1) moves to the neutral position, and the oil path B (f) opening surface area becomes
small.
On the other hand, because the piston motor still attempts to rotate due to the inertial energy of the external
load (piston motor pumping action), the M2 port pressure rises and acts as a braking force on the rotation
of the piston motor.
At this time, when the M2 port side pressure reaches the set pressure for the relief valve (8), the M1 port
side poppet (8-1) moves to the left against the spring (8-2) and the pressure oil escapes to the M1 port side.
In this way, the shock pressure due to the M2 port side inertial energy is controlled and at the same time
the occurrence of a vacuum on the M1 port side is prevented.
Diagram 5 Double counter balance valve and relief valve during piston motor braking
a Oil path C1 e Spring chamber 1 i Damper chamber A2

c Damper chamber A1 g Oil path C2 k Spring chamber 2
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8030B-5
5) High-pressure selection shuttle valve function (Diagram 6 and Diagram 7)

The double counter balance valve has a high-pressure selection shuttle valve function added for releasing
the parking brake through its own pressure.
When pressure oil is fed from the P1 port, the plunger (1) moves to the right side creating the state in
Diagram 6.
Therefore, the motor case drain oil path F (m) is closed, the oil path D (l) to the parking brake cylinder
chamber E (p) is opened, the pressure oil is led into oil path G (o) via the orifice (n) and flows into the
parking brake cylinder chamber E (p), releasing the parking brake.
Also, when the piston motor stops, the plunger (1) returns to the neutral state of diagram 7, the oil path D
(l) closes, and the motor case drain oil path F (m) opens, so the oil in the parking brake cylinder chamber
E (p) is led to the motor case drain and the parking brake operates.
Diagram 6 High-pressure selection function High-pressure selection
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8030B-6
Diagram 7 High-pressure selection function Release to motor case drain
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8030B-7
Crossover Relief Valve

The purpose of the "crossover relief valve" is to determine the motor drive force and braking force.
Therefore, this valve has a shockless function to soften the shock of motor starting and stopping in order to provide
good operability.
Diagram 8 shows the structure of the relief valve.
This relief valve has a shockless function for reducing the shock that occurs at the start of startup and braking of the
differential surface area type direct action relief valve.
Diagram 8 Structure of relief valve

1. Relief valve operation and functions
When the control valve moves and the piston motor is started up or braked, when the poppet (2-9-2) front surface
pressure rises above the set pressure, this pressure wins out over the spring (2-9-5), the poppet (2-9-2) moves to
the right and separates from the poppet seat (2-9-3), and the high-pressure oil at the poppet (2-9-2) front surface
bypasses to the low-pressure oil path.
In this way, by allowing the high-pressure oil to bypass to the low-pressure oil path, the shock pressure due to
the inertial energy of the high-pressure oil path is controlled and at the same time the occurrence of a vacuum in
the low-pressure oil path is prevented.
Diagram 9 Shockless function operation
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8030B-8
2. Shockless function (Diagram 10)

When the relief valve starts to operate, the shockless piston (2-9-9) moves to the left.
Therefore, inside the spring chamber D, the pressure is held low.
Therefore, the surface of the poppet (2-9-2) pressurized area becomes S1, a quite large pressurized area com-
pared to the pressurized area S1 - S2 for the normal relief valve setting.
Therefore, while the shockless piston (2-9-9) movement is completing, the relief valve operating pressure is held
to about 1/3 of the normal set pressure, absorbing the shock pressure due to the inertial energy of the high-
pressure oil path.
When the shockless piston movement is complete, the pressure inside the spring chamber D rises, the pressure
in front and behind the poppet (2-9-2) become equal, and the relief valve operates with its normal set pressure.
Pressure Pressure
Time Time
Conventional type Shockless type
Diagram 10 Shockless function and pressure wave comparison
q Area S2
r Area S1
s Spring chamber D
Operating the relief valve in 2 stages in this way reduces the shock that occurs when the piston motor is started or
braked and provides good operability.
Diagram 10 compares the pressure waveforms of the conventional type and the shockless type.
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8030B-9
Automatic 2-speed Switchover Mechanism

This motor has the automatic "2-speed switchover mechanism" that can switch the motor between 2 speeds, low
speed and high speed.
1. Motor low-speed (high-capacity) position
Diagram 11 shows the state with the motor capacity fixed to the low-speed (high-capacity) position. When the
speed control switch is set to low speed and the pilot pressure acting on the Ps port is released to the tank, the
motor capacity control valve built into the motor is fixed to the low-speed (high-capacity) position.
2. Automatic 2-speed position that selects the motor capacity according to the load pressure
Diagram 12 shows the state of the automatic 2-speed position that selects the motor capacity according to the
load pressure.
When the speed control switch is set to high speed and the regulation pressure is allowed to operate on the Ps
port, the pressure oil operating on the Ps port operates on the front surface of the motor capacity control valve
built into the motor and the position becomes the automatic 2-speed position that switches the motor capacity
according to the load pressure going to the motor.
3. High-speed motor state for automatic 2-speed position
Diagram 13 shows the high-speed motor state for the automatic 2-speed position.
When the regulation pilot pressure is allowed to operate on the Ps port, the pilot pressure oil operates on the
pilot hydraulic chamber on the motor capacity control valve front surface via oil path A and this pushes the motor
capacity control valve to the right. Also, the load pressure Pin on the motor operates on the motor load pressure
chamber via oil path B and pushes the motor capacity control valve to the left. When Pin is lower than the motor
capacity control pressure P determined by the ratio of the pilot pressure pressurized area and the motor load
pressure pressurized area, the motor capacity control valve is held in the state in Diagram 13 and the motor
operates in high-speed (low-capacity) mode.
4. Low-speed motor state for automatic 2-speed position
Diagram 14 shows the low-speed motor state for the automatic 2-speed position.
When the load pressure pin on the motor rises and becomes higher than the motor capacity control pressure
P discussed above, the motor capacity control valve moves to the left, switching the motor to low-speed (high-
capacity) mode, so the motor operates at low speed.
84551720B NA - August 2012

8030B-10
Diagram 11 Motor high-speed (high-capacity) fixed mode
t Pilot pressure
u Pressure in motor
v Motor load pressure
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8030B-11
Diagram 12 Automatic 2-speed control mode using load pressure
t Pilot pressure
u Pressure in motor
v Motor load pressure
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8030B-12
Diagram 13 Motor high-speed (low-capacity) position for automatic 2-speed mode
t Pilot pressure w Pilot oil pressure chamber

u Pressure in motor x Oil path A
v Motor load pressure y Motor load pressure chamber
84551720B NA - August 2012

8030B-13
Diagram 14 Motor low-speed (high-capacity) position for automatic 2-speed mode
t Pilot pressure w Pilot oil pressure chamber

u Pressure in motor x Oil path A
v Motor load pressure y Motor load pressure chamber
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8030B-14
Parking Brake Function

The "parking brake function" is built into the piston motor. When the motor is stopped, the mechanical brake operates
to prevent the motor from being rotated due to external load by locking the motor shaft.
Diagram 15 shows a structural diagram of the parking brake section.
The parking brake is made up of the disks (1) coupled with the cylinder block (z), the friction plate (2) mounted between
the disks, the brake piston (3), and the spring (4) that applies force to the brake piston.
A. Releasing the parking brake (Diagram 15)
When pressure oil is fed from the P1 port and attempts to start driving the piston motor, when the "High-pressure
selection shuttle valve function" explained in Item E of "[1] Double Counter Balance Valve" leads pressure oil to the
parking brake cylinder chamber E (ac) via oil path D, the hydraulic pressure force (aa) operates on the brake piston
(3) and moves it to the left against the spring (4).As a result, the force pressing the disks (1) disappears, the disks
(1) enter the free state, and the parking brake is released.
B. Operating the parking brake (Diagram 16)
When the control valve is returned to the neutral position, the feed of pressure oil to the P1 port is cut off, and an
attempt is made to stop the piston motor, because the "High-pressure selection shuttle valve function" explained in
Item E of "[1] Double Counter Balance Valve" connects oil path D to motor case drain oil path F, the pressure oil
in the parking brake cylinder chamber E (ac) is led to the motor case drain and the pressure drops.Therefore, the
brake piston (3) is moved to the right side by the spring (4), the disks (1) are tightened with the force (ad) of the
spring (4) by the brake piston (3) and motor case (ab), so the piston motor shaft is locked and the parking brake
operates.
Diagram 15 Parking brake released state Diagram 16 Parking brake engaged state
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8030B-15
Piston Motor
The "piston motor" is a swash plate-type piston motor that converts the fluid energy of the pressure oil sent from the
hydraulic pump into mechanical energy and outputs high-speed, low-torque power.
A swash plate-type piston motor is used as the piston motor.
Diagram 17 shows a structural diagram of the piston motor.
9 pistons (4-2) are incorporated in the cylinder block (4-1) and the end of the cylinder block (4-1) touches a valve plate
(22) that has 2 sausage-shaped ports, B and C. The pressure oil discharged from the hydraulic pump flow in from the
P1 port or the P2 port and while the piston motor rotates, flows out from the P2 port or P1 port.
Also, the drain oil in the case that has leaked from the sliding sections and the gap returns to the hydraulic tank from
the base plate (2-1) T1 or T2 port.
1. The high-pressure oil from the P1 port enters the valve plate (22) sausage-shaped B port, the piston (4-2) is
pressurized, and the top of the swash plate (5) rotates and moves from top dead center to bottom dead center.
2. The P2 port becomes the low-pressure side and while the piston (4-2) rotates and moves from bottom dead
center to top dead center, the oil is discharged to the P2 port via the valve plate (22) sausage-shaped C port.
3. Accompanying the reciprocal movement of the piston (4-2), the cylinder block (4-1) and the shaft (3) spline cou-
pled to it rotate in the counter-clockwise direction of the arrow in the diagram.
4. When the piston motor rotates clockwise, the P1 port side becomes the low-pressure side and the P2 port side
becomes the high-pressure side.
In this way, the piston motor converts the fluid energy of the pressure oil sent from the hydraulic pump into mechanical
energy and outputs high-speed, low-torque rotation power. Also, the piston motor torque and speed are determined
by the pressure and flow. Therefore, the larger the pressure and flow, the higher the piston motor torque and speed.
Diagram 17 Piston motor structural diagram
a C port
b B port
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8030B-16
Reduction Gear
Diagram 18 shows a structural diagram of the reduction gear.
The reduction gear structure combines in two stages the simple planetary reduction gear system made up of the drive
gear, sun gear, holder, planetary gear, and ring gear (with teeth cut in the inner diameter of the housing).
When pressure oil flows into the piston motor, the piston motor shaft rotates at high speed and power is input to the
reduction gear section.In the reduction gear section, this high-speed rotation has its speed reduced in 2 stages by
the simple planetary 2-stage reduction system. Low-speed, high-torque output is obtained from the rotation of the
housing with ring gears (1-3) (2-3).
1. 1st stage reduction section operation
The 1st stage reduction section comprises the drive gear (1-1), planetary gear A (1-2), ring gear (1-3), holder
(1-4), needle bearing (1-5), and inner race (1-6).
The planetary gear A (1-2) meshes with the drive gear (1-1). When the drive gear (1-1) rotates clockwise, the
planetary gear A (1-2) rotates counter-clockwise. On the other hand, since it meshes with the ring gear, it kicks
the tooth of the ring gear and tries to revolve clockwise around the circumference of the drive gear (1-1).
Because the planetary gear (1-2) is fixed in a state in which it rotates freely on the holder (1-4) via the needle
bearing (1-5), this clockwise revolution movement is transmitted to the holder (1-4) and the holder (1-4) starts to
rotate in the clockwise direction.
Also, since the holder (1-4) is spline coupled with the 2nd stage sun gear (2-1), this holder (1-4) rotation is trans-
mitted to the 2nd stage sun gear (2-1).
2. 2nd stage reduction section operation
The 2nd stage reduction section comprises the sun gear (2-1), planetary gear B (2-2), ring gear (2-3), holder
(2-4), needle bearing (2-5), and inner race (2-5).
The planetary gear B (2-2) meshes with the sun gear (2-1). When the sun gear (2-1) rotates clockwise, the
planetary gear B (2-2) rotates counter-clockwise.
The planetary gear B (2-2) is fixed in a state in which it rotates freely on the holder (2-4) via the needle bearing
(2-5). Furthermore, the holder (2-4) is coupled to the flange (5) by the bolts (3) (4) and the flange (5) is fastened
to the frame of the machine main unit, so it cannot rotate.
Therefore, the planetary gear B (2-2) cannot revolve as in the 1st stage reduction section and rotates counter-
clockwise at the position at which it was incorporated. Also, because the planetary gear B (2-2) is meshed with
the ring gear, the counter-clockwise revolution of the planetary gear B (2-2) is transmitted to the ring gear and
the ring gear is rotated counter-clockwise.
Through the above action, the housings (1-3) (2-3) with the ring gear cut into their inner diameters receive the
force of the planetary gears (2-2) (1-2) and rotate. This transmits power to the driven section of the machine main
unit which is coupled with the housings (1-3) (2-3).
84551720B NA - August 2012

8030B-17
Diagram 18 Reduction gear structural diagram
a Piston motor shaft

Secured to machine main unit
b
frame
c Connected to driven section of
machine
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8030B-18
Section
8030C
Structure and Operation Explanation of Swing Motor
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84551720B NA - August 2012
CONTENTS
Swing Motor Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Motor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve Casing Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relief Valve Operation Explanation (relief valve model: KRD22EK10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Motor Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Swing Motor Operation

Explanation
Hydraulic Motor Section
As the diagram below shows, when the high-pressure oil passes through the valve plate (1) inlet-side port (a) and flows
into the cylinder, the hydraulic pressure operates on the piston (5) and a force F is generated in the axial direction.
This force F is divided into 2 vectors, a force F1 perpendicular to the swash plate (3) via the shoe (2) and a force F2
perpendicular to the shaft.
This force F2 is transmitted to the cylinder block (4) via the piston (5), generating a rotational couple around the output
shaft.
9 pistons (5) are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the output shaft (6) by
multiple pistons (5) linked with the high-pressure oil inlet-side port.
When the oil in and out directions are reversed, the rotation of the output shaft (6) also reverses.
The theoretical output torque T [N·m] is given by the following equation.
Diagram 1 Motor section operation explanation diagram
q Compartments per rotation

[cm3]
p Effective pressure difference
[MPa]
*1 Low-pressure oil *3 Outlet

*2 High-pressure oil *4 Inlet
84551720B NA - August 2012

8030C-3
Valve Casing Section

1. Anti-cavitation check section
Because the system using this type of motor does not have a valve with a counter-balance function, the motor
sometimes rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil shortfall.
Diagram 2 Hydraulic circuit diagram
1 M port
2 Control valve
84551720B NA - August 2012

8030C-4
Brake Section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate (743) is constrained for
circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is pressed to the casing
(301) by the brake spring (712) via the separator plate (743) and the brake piston (702), friction force is generated
between the friction plate and casing and between the separator plate and the brake piston. The drive shaft is con-
strained and braked by this friction force.
On the other hand, when brake release pressure is applied to the oil chamber (1) formed between the brake piston
and the casing and the hydraulic pressure (3) wins out over the spring force (2), the brake piston moves, the force
pressing the friction plate against the casing disappears, and the brake is released.
Diagram 3 Brake operation diagram
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8030C-5
Relief Valve Operation Explanation (relief valve model: KRD22EK10)

1. Operation explanation for when the relief valve is pressurized
In the case where the P port is pressurized with the tank pressure,the P and R ports are initially at the tank
pressure and the valve status is as shown in Diagram 4 (1).
At the pressure where there is balance between the hydraulic pressure determined by the product of the pressure
P and the pressurized area A1 of the plunger (301) on the one hand and the hydraulic pressure determined by
the product of the spring (321) load FSP and plunger (301) pressurized area A2 and the g chamber pressure Pg
on the other, the relief valve starts to operate.
After that, the g chamber pressure rises and the piston (302) starts its stroke.
Accompanying this movement, the load on the spring (321) increases.
Through the operation above, the relief pressure P is increased from P1 to Ps in the pressure boost time t1.
This process is explained below in terms of the relationship between the movement state of the parts in diagrams
4-(2) - (4) and the relief pressure.
1) State shown in Diagram 4-(2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via the orifice m in the
plunger (301).
When the hydraulic pressure operating on the plunger (301) increases and reaches the pressure at which
it balances the spring (321) load FSP, the relief valve carries out the relief operation at pressure P1.
The relationship at this time is expressed by the following equation.
P1 x A1 = FSP1 + Pg1 x A2 FSP1: Initial set load for the spring (321)
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302).
When this hydraulic pressure becomes larger than the load on the spring (321), the piston starts to move
to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug (401) is discharged
into the g chamber via the orifice n set up on the piston (302) while the piston moves to the left, so the h
chamber functions as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting plug end section
and the relief pressure P rises smoothly.
When the piston (302) reaches the adjusting plug (401) end section, it does not move farther to the left, so
the constant relief state is reached and the relief pressure is held at P2.
Through the processes (1) - (4) above, the relief pressure varies as in Diagram 5.
2. Operation explanation for when the relief valve is depressurized
In the case where the P port pressure falls,the P port pressure and the g chamber pressure fall together to the
tank pressure when the pressurization of the P port ends.
Through this process, the plunger (301) which was open moves to the left and is placed in the seat (401).
At the same time, the piston (302) also is moved to the right by the spring (321) and returns to the state in Diagram
4-(1).
84551720B NA - August 2012

8030C-6
Diagram 4 Relief valve operation explanation diagram
a Orifice m c A1 pressurized area e g chamber

b h chamber d Orifice n
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8030C-7
Diagram 5 Pressure boost characteristics
84551720B NA - August 2012

8030C-8
Swing Motor Internal Structure Diagram
84551720B NA - August 2012

8030C-9

1 Inner race 1 23 Snap ring 1
2 Oil seal 1 24 Cylinder 1
3 Tapered roller bearing 1 25 Housing 1
4 Receiving spring 1 26 Collar 1
5 Cam plate 1 27 Snap ring 1
6 Return plate 1 28 Bypass valve assembly 2
7 Piston assembly 9 29 Backup ring 2
8 Friction plate 3 30 O-ring 4
9 Partner plate 3 31 O-ring 2
10 O-ring 1 32 Cover 1
11 Piston 1 33 Cap 1
12 O-ring 2 34 Relief assembly 2
13 Spring 20 35 O-ring 4
14 Piston 2 36 Hexagon socket head bolt 4
15 Parallel pin 3 37 Check valve 2
17 Cap 2 39 Cap 2
18 Scrowave spring 4 40 Backup ring 2
19 Teflon ring 4 41 Level gauge assembly 1
20 Bushing 4 42 O-ring 1
21 Balance plate 1 43 Cap 1
22 Needle bearing 1

1 Seat 5 Shim 9 Backup ring
2 Poppet 6 Liner 10 O-ring
3 Spring 7 Piston 11 Holder
4 Spring seat 8 Cap
84551720B NA - August 2012

8030C-10
Section
8030D
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Basic configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


Basic configuration
This valve is based on the main unit housing which combines the P1 side housing and P2 side housing with the rear
surfaces against each other and has a configuration that makes it possible to mount the inlet, add-on section, and
outlet on the P2 side housing top.
84551720B NA - August 2012

8030D-3
Operation
1. When all spools in neutral
1) Neutral path [Fig. 1, Fig. 2]
1) When Pn1 and Pn2 ports are pressurized
The oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) through the low-
pressure relief orifice (Lc1) and returns to ports T1 - T8.
The oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) through the low-
pressure relief orifice (Rc1) and returns to the T1 - T8 ports.
The pressure in the pressure chambers (L2) and (R2) upstream from the low-pressure relief valve is
led into the pump from the ps1 and ps2 ports and controls the P1 and P2 pump discharge volume.
Also, if excess oil flows into the neutral path (L1), the poppet opens to provide low-pressure relief.
This prevents the ps1 and ps2 port pressures from becoming abnormally high.
2) When Pn1 and Pn2 ports are not pressurized
In this case, the low-pressure relief poppets open at lower pressure than in (a).
Therefore, the oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) primarily
through the low-pressure relief valve discharge port (L3) and returns to the T1 - T8 ports.
Also, the oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) primarily through
the low-pressure relief valve discharge port (R3) and returns to the T1 - T8 ports.
84551720B NA - August 2012

8030D-4
84551720B NA - August 2012

8030D-5
84551720B NA - August 2012

8030D-6
1 Low-pressure relief valve (L) 6 Travel 11 Arm 2

2 Arm 1 7 Outlet 12 Boom 1
3 Boom 2 8 Attachment 2 13 Bucket
4 Swing 9 Inlet 14 Straight travel
5 Option 10 Attachment 1 15 Low-pressure relief valve (R)
a (Section 5) f P1 side k (Section 7)

b (Section 4) g (Section R2 ) l (Section 6)
c (Section 3) h (Section R1) m (Section ST)
d (Section 2) i (Section 9) n P2 side
e (Section 1) j (Section 8)
84551720B NA - August 2012

8030D-7
84551720B NA - August 2012

8030D-8
84551720B NA - August 2012

8030D-9
Variable arm regeneration ori-

1 6 Travel 11 Boom 1
fice
2 Arm 1 7 Attachment 2 12 Bucket
3 Boom 2 8 Attachment 1 13 Travel
4 Swing 9 Neutral cut 14 Straight travel
5 Option 10 Arm 2
a Open j (Section R2 ) s Down

b Close k (Cylinder extension) t Up
c (Section 5) l (Cylinder retraction) u (Section 8)
d Up m Down v Close
e Down n Up w Open
f (Section 4) o (Section R1) x (Section 7)
g (Section 3) p Close y (Section 6)
h (Section 2) q Open z (Section ST)
i (Section 1) r (Section 9)
84551720B NA - August 2012

8030D-10
2) Signal, straight travel signal control valve, plate assembly [Fig. 3]

There are 2 signals, (a) and (b) below. The pilot signal for each spool for which a lever is operated is used
to generate the pressure that is output.
The straight travel signal control valve integrates each signal pressure and controls straight travel spool
switchover. Also, the plate assembly has a function for picking up the pilot pressures with the built-in shuttle.
1) Travel signal (PT)
The highest of the pilot pressures applied to the travel section 1 (pa1, pb1) and travel section 6 (pa6,
pb6) is selected and output to the PT port.
Therefore, when the travel spool is in the neutral position (no-load pilot pressure), no pressure is
generated at the PT port.
2) Front signal (PA)
The highest of the pilot pressures (pa2 - 9 and pb2 - 9) applied to sections 2 - 9 that use the pressurized
oil from the P1 and P2 pumps, except for the travel sections, is selected and output to the PA port.
(Note 1)
Therefore, when all the spools are in the neutral position (no-load pilot pressure), no pressure is gen-
erated at the PA port.
<Note 1>
When an add-on (main pump add-on) is used through the feed from P2, the branches for the add-on pilot
signals par1 and pbr1 are connected to the respective main unit valves, prs1 and prs2 ports, and thus
incorporated in the front signal PA selection area.
Be careful. If the above line connection is not done, the PA pressure will not rise through add-on selection.
Also, when using 2 main pump add-ons, set the circuit so that the maximum of the add-on pilot pressures
(par1 and 2, pbr1 and 2) can be taken out as desired and connect to either prs1 or prs2.
84551720B NA - August 2012

8030D-11
Straight travel signal control

1 5 Boom 9 Option
valve
2 Travel 6 Arm 10 Add-on (main pump)
Main unit housing section (op-
3 7 Bucket
tion)
4 Plate assembly 8 Swing
a RCV Remote control valve c RCV Remote control valve e RCV Remote control valve
b MCV d MCV f MCV
84551720B NA - August 2012

8030D-12
2. Independent operation
1) Travel spool switchover [Fig. 4 and Fig. 5]
When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1 (Pa1), the oil fed
from the P1 port flows from the neutral path (L1) through the spool neck section and into the B1 (A1) port.
The return oil returns to the tank path (Ta) from the A1 (B1) port through the spool neck section.
When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6 (Pa6), the oil fed
from the P2 port flows from the neutral path (R1) through the spool neck section or path (S6-1) and into the
B6 (A6) port.
For independent travel operation, the parallel path (R3) and the path (S6-1) have the same pressure, so
the poppet (S6-2) does not open. The return oil returns to the tank path (Ta) from the A6 (B6) port through
the spool neck section.
1 Switching state 3 Option

2 Neutral state 4 Travel
a (Section 2)
b (Section 6)
84551720B NA - August 2012

8030D-13
1 Switching state 3 Travel

2 Neutral state 4 Straight travel
a (Section 1)
b (Section ST)
84551720B NA - August 2012

8030D-14
2) Option spool switchover [Fig. 4]

When the option spool is switched by pressurizing from the option (section 2) pilot port Pb2 (Pa2), the
neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load
check valve (S2-2), path (S2-1), and the spool neck section, and into the B2 (A2) port.
The return oil returns to the tank path (Ta) from the A2 (B2) through the spool neck section.
Also, when oil is fed from the P4 port, it passes through the inside of the load check valve (S2-2) and merges
with path (S2-1).
1 Switching state 3 Option

2 Neutral state 4 Travel
a (Section 2)
b (Section 6)
84551720B NA - August 2012

8030D-15
1 Switching state 3 Travel

2 Neutral state 4 Straight travel
a (Section 1)
b (Section ST)
84551720B NA - August 2012

8030D-16
3) Swing spool switchover [Fig. 6]

When the swing spool is switched by pressurizing from the swing (section 3) pilot port Pb3 (Pa3), the neutral
path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load check
valve (S3-2), path (S3-1), and the spool neck section, and into the B3 (A3) port.
The return oil returns to the tank path (Ta) from the A3 (B3) through the spool neck section.
1 Switching state 3 Swing

2 Neutral state 4 Bucket
a (Section 3)
b (Section 7)
84551720B NA - August 2012

8030D-17
4) Bucket spool switchover [Fig. 7 and Fig. 8]

1) Close (regeneration) [Fig. 7]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pb7, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load
check valve (S7-2), path (S7-1), and the spool neck section, and into the B7 port.
At the same time, the return oil from the A7 port returns to the tank path (Ta).
After part of the return oil pushes open the poppet (S7-3) inside the bucket spool, it merges into the
B7 port to prevent cylinder head side cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the
port pressure conditions.
Bucket close (regeneration)
1 Neutral state 3 Swing

2 Switching state 4 Bucket
a (Section 3)
b (Section 7)
84551720B NA - August 2012

8030D-18
2) Open [Fig. 8]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pa7, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3),
the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7 port.
The return oil returns to the tank path (Ta) from the B7 port through the spool neck section.
Bucket open
1 Neutral state 3 Swing

2 Switching state 4 Bucket
a (Section 3)
b (Section 7)
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8030D-19
5) Boom spool switchover [Fig. 9, Fig. 10, and Fig. 11]

1) Neutral [Fig. 9]
This valve mounts an anti-drift valve on the boom 1 cylinder head (A8) side.
In neutral, the poppet (AD1) is reliably seated by the pressure of the A8 port itself led through path
(AD2) and the spool (AD3) into the spring chamber (AD4) to cut off the return oil from the A8 port.
Neutral
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
84551720B NA - August 2012

8030D-20
2) Boom up (2 pumps flow) [Fig. 10]

When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port Pa8, the
check valve (S8-2), and the spool neck section and into the A8 port.
When the boom 2 spool is switched by pressurizing from the boom 2 (section 4) pilot port Pa4, the
neutral path (L1) is closed. The oil fed from the P1 port flows through the parallel path (L3), the load
check valve (S4-2), the spool neck section, and path (4) and merges into the A8 port. The return oil
returns to the tank path (Ta) from the B8 port through the spool neck section.
Up (2 pumps flow)
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
84551720B NA - August 2012

8030D-21
3) Boom down (regeneration) [Fig. 11]

When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port pb8, the
check valve (S8-2), and the spool neck section and into the B8 port.
The pilot pressure applied to pb8 at this time moves the anti-drift valve spool (AD3) through the path
built into the housing at the same time that the spool is switched and reduces the pressure of the
spring chamber (AD4) to open the poppet (AD1).
Through this movement, the cutoff of the A8 port is released before the spool is switched.
After that, the return oil from the A8 port returns to the tank path (Ta).
Part of the return oil pushes open the poppet (S8-3) inside the boom 1 spool, passes through path
(S8-1), and merges into the B8 port to prevent cylinder rod side cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the
port pressure conditions.
Down (regeneration)
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
84551720B NA - August 2012

8030D-22
6) Arm spool switchover [Fig. 12 - 15]

1) Neutral [Fig.12]
This valve mounts an anti-drift valve on the arm 1 cylinder rod side.
In neutral, the poppet (AD1) is led through path (AD2) and the spool (AD3) into the spring chamber
(AD4). It is reliably seated by the pressure of the A5 port itself to cut off the return oil from the A5 port.
Neutral
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
84551720B NA - August 2012

8030D-23
2) Arm in (2 pumps flow) [Fig. 13]

When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pb5, the oil fed
from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1),
and the spool neck section and into the B5 port. When the arm 2 spool is switched by pressurizing
from the arm 2 (section 9) pilot port Pb9, the oil fed from the P2 port flows from the neutral path (R1)
through the load check valve (S9-2), path (S9-1), the spool neck section, and path (6) and merges
into the B5 port.
The pilot pressure applied to pb5 at this time moves the anti-drift valve spool (AD3) through the path
built into the housing at the same time that the spool is switched and reduces the pressure of the
spring chamber (AD4) to open the poppet (AD1). Through this movement, the cutoff of the A5 port is
released before the spool is switched.
After that, the return oil from the A5 port splits into the flow through the regeneration check in the spool
that is regenerated at the B5 port and the flow returning to the tank path (Ta) through the regeneration
control valve.
(For details on the regeneration function, see the regeneration valve operation explanation in next
section 3).)
Arm in (2 pumps flow)
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
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8030D-24
3) Arm in (variable regeneration) [Fig. 14]

For an arm-in operation, after the return oil from the A5 port passes through the notch (a), it divides
into 2 paths:
1. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the regeneration control
valve, path (e), and the variable orifice (f).
2. The return oil passes through the fixed orifice (b) in the arm 1 spool, the regeneration check (c),
and the fixed orifice (i), then merges into the bridge path (S5-1).
Here, when the bridge path (S5-1) pressure goes higher due to the port B5 load pressure, the regen-
eration control valve spool (h) is pressed through the regeneration control valve piston (g), and the
variable orifice (f) section opening surface area increases, so the quantity of oil returning to the tank
path (Ta) increases.
On the other hand, the quantity of oil regenerated in the B5 port decreases.
Though this variable mechanism, both the regeneration ratio for low loads is secured and reduction
in the return back pressure for high loads is established.
Arm in (variable regeneration)
Regeneration control valve

1
(variable)
2 Arm 1
a (Section 5)
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8030D-25
4) Arm out (2 pumps flow) [Fig. 15]

When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pa5, the oil fed
from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1),
and the spool neck section and into the A5 port.
When the arm 2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pa9, the oil fed
from the P2 port flows from the neutral path (R1) through the load check valve (S9-2) and path (S9-1),
merges into the arm 1 section path (S5-1) and heads toward the A5 port through the arm 1 spool neck
section. The return oil from the B5 port returns to the tank path (Ta) through the spool neck section.
Arm out (2 pumps flow)
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
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8030D-26
7) Arm parallel orifice [Fig. 16]

Metering by the spool is installed in the arm 1 parallel path of this valve to control the quantity of oil fed to
arm 1 for compound operations.
The oil fed from the arm 1 (Section 5) parallel path (L3) pushes open the poppet (S5-3) and passes through
the variable metering spool orifice (Lc8), then is connected to path (L5).
Here, the quantity metered by the orifice (Lc8) is adjusted by pressurizing the pilot port (Pbu).
For boom up (for Pbu pressur-

1 Low-pressure relief valve (L) 3
ization)
2 Pbu signal path 4 For neutral
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8030D-27
8) Relief valve
1) Main relief valve [Fig. 17]
The oil fed from the P1 port passes through the poppet (LP) and the oil fed from the P2 port passes
through the poppet (RP) and path (3) and is led to the main relief valve. The maximum pressure of
the P1 and P2 side pumps is controlled by the operation of the main relief valve.
84551720B NA - August 2012

8030D-28
2) Overload relief valve [Fig. 18]

There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder ports to prevent
any abnormal rise in actuator pressure, for example due to an external force.
This relief valve is also equipped with a function for preventing cavitation (suction function) by taking
in oil from the tank when the cylinder port pressure becomes negative pressure.
a Suction function Operating
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8030D-29
3. Compound operation
1) Travel compound operation [Fig. 19, Fig. 20]
Under the conditions below when the travel left/right and the front system are operated at the same time,
the straight travel spool is switched, and the straight travel characteristic is maintained.
1 When the front is operated during travel left/right simultaneous operation (forward, backward, or pivot
turn)
2 When the left/right are operated simultaneously during front system operation
Front system operation is not affected by the switchover section or quantity of switchovers.
1) Signal circuit [Fig. 19]
(A) When the [Travel 1] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then switches the switchover valve [V1].
(B) When the [Travel 2] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then if the switchover valve [V1] is switched, it
switches the switchover valve [V2] through the path. On the other hand, if the switchover valve [V1]
is in the neutral state, the path is cut off by the switchover valve [V1]. Therefore, if both (A) and (B)
are established at the same time, the straight travel spool internal path (Pst) is connected to PA.
Also, if either (A) or (B) are established, the travel signal (PT) pressure rises.
(C) If at least one of the front systems is switched, the highest pressure of all the pilot pressures
in the front system is selected and is connected to the front signal port (PA). Therefore, if (A), (B),
and (C) are established at the same time, the straight travel spool switchover quantity is determined
proportional to the front signal (PA) pressure through the internal straight travel signal path (Pst).
[Fig. 19] shows the example of a case of travel left/right forward + boom up.
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8030D-30

1 5 Boom 9 Option
valve
2 Travel 1 6 Arm 10 Add-on (main pump)
3 Travel 2 7 Bucket 11
tion)
a Advance d Down g Right

b Reverse e Close h Left
c Up f Open
84551720B NA - August 2012

8030D-31
2) Main unit circuit [Fig. 20]

When the straight travel spool is switched, the oil fed from the P1 port flows from the neutral path (L1)
to travel (section 1) and at the same time passes through path (2), the straight travel spool neck sec-
tion, and the neutral path (R1) and into travel (section 6) and feeding to travel left and right becomes
possible.
On the other hand, when the oil fed from the P2 port flows to the parallel path (R3), at the same time
it passes through the straight travel spool neck section and path (1) and into the parallel path (L3), so
it becomes possible to feed oil to the entire front system.
When the front system is switched during travel and that pressure becomes higher than the load
pressure on travel (section 6), part of the oil fed from the P2 port pushes up the poppet (S6-2) from
the parallel path (R3) and the oil flows through the orifice at the poppet tip and merges into path (S6-1).
This softens the shock on the machine body of the sharp drop in speed caused by the switchover to
1 pump travel.
As described above, because travel (sections 1 and 6) operates with the oil fed from the P1 port and
operations other than travel are operated with oil fed from the P2 port, travel curving is prevented and
straight travel characteristics are maintained during compound operations.
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8030D-32
1 Switching state 3 Straight travel

2 Travel 4 Travel
a (Section 1)
b (Section 6)
c (Section ST)
4. Anti-drift valve
The anti-drift valve is mounted on the arm rod (boom head) side cylinder port to prevent the arm (boom) cylinder
from dropping naturally.
Also, the release signal operates led by the internal path from the pilot signal.
(The arm side (A5) is shown as a typical example.)
1) Neutral (A5 port hold)
1) The A5 port hold pressure passes from path (a) through path (b), through path (c), and is connected
to the poppet (1) spring chamber (d).
2) Therefore, the A5 port pressurized oil is cut off by the seat section (S1) and the seat section (S2).
1 Main spool
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8030D-33
2) Release signal application

1) When the pi port is pressurized, the piston (2) moves and the spool (3) operates.
2) Furthermore, the spool (3) operates the poppet (4).
3) Then, the operation of the poppet (4) cuts off the connection between the A5 port and the spring
chamber (d).
1 Main spool
3) Ending hold state

1) When the piston (2) operates further, the spring chamber (d) passes from path (c) through path (e)
and is connected to the drain chamber [DR] through the (T2) section.
2) The spring chamber (d) pressure becomes the drain pressure and the main poppet (1) operates.
1 Main spool
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8030D-34
5. Relief valve
1) Main relief valve operation
1) This relief valve is incorporated between the neutral path "HP" and the low-pressure path "LP". The
oil passes through the metering hole of the main poppet (C) and charges the interior space (D). Also,
the sleeve (E) and the main poppet (C) seat securely operating on the different surface areas [A] and
[B].
2) When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (F)
opens. The oil flows around the poppet, passes through the notch hole (G), and is led to the low-
pressure path "LP".
84551720B NA - August 2012

8030D-35
3) Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C) opens, so the
oil flows directly into the path "LP".
"Boosted pressure operation"

When pressure is applied to the pilot port "PH", the piston (H) is moved to the set position by the plug (I).
Because of this, the pilot spring force rises and the "HP" pressure rises.
2) Overload relief valve operation

1) This relief valve is incorporated between the cylinder port "HP" and the low-pressure path "LP". The
oil passes through the metering hole of the piston (C) and charges the interior space (G). The sleeve
(K) and the main poppet (D) seat securely operating on the different surface areas [A] and [B].
84551720B NA - August 2012

8030D-36
2) When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (E)
opens. The oil flows around the poppet, passes through the notch hole (H), and is led to the low-
pressure path "LP".
3) Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of the piston (C),
a pressure difference is generated between the path "HP" and the rear side of the piston (C), and the
piston (C) moves and seats with the poppet (E).
4) The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the ring-shaped
gap between the poppet (D) and the piston (C) and through the orifice (F), so the pressure difference
increases.
Because of this, the poppet (D) opens and the oil flows directly into the path "LP".
84551720B NA - August 2012

8030D-37
3) Overload relief valve intake operation

1) This relief valve has a built-in anti-void unit that supplies oil if cavitation occurs at the cylinder port
"HP".
When the cylinder port "HP" pressure is lower than the low-pressure side "LP", the sleeve (K) is
opened by the surface area difference between (A) and (B). Oil enters the cylinder port "HP" from the
low-pressure side "LP" to prevent cavitation.
6. Neutral cut spool [Fig. 21]

This valve is equipped as standard with a neutral cut spool in the P2 side housing neutral path (R1) minimum
flow (low-pressure relief valve upstream).
When the pcc port is pressurized and the neutral cut spool is switched, the path through the orifice [Lc7] to
low-pressure relief is cut off and output to the outside from the P3 port becomes possible.
1 Low-pressure relief valve (R)
84551720B NA - August 2012

8030D-38
7. Plate assembly [Fig. 22]

This valve is equipped with a plate assembly hermetically sealed with a gasket piling a plate on the housing side
surface.
The shuttle is built into the inside and this valve has a function for selecting and controlling the spool pilot pressure.
Also, in order to protect the shuttle section from contamination from the outside, a filter is mounted between the
plates.
When removing, do not loosen the screws shown in the diagrams and be careful that internal parts are not dis-
persed.
[Short cap side] [Long cap side]
1 Subassembly screw
84551720B NA - August 2012

8030D-39
8. Straight travel signal control valve [Fig. 19, Fig. 23]

This valve integrates the pilot pressure for the spool of the front system and travel selected with each plate as-
sembly and is used to switch the straight travel spool.
When the Travel 1 pilot pressure is pressurized, the spool [V1] is switched.
When the Travel 2 pilot pressure is pressurized at the same time, the spool [V2] can be switched.
Here, when the front system pilot pressure [PA] is pressurized, the PA pressure flows into Pst and is led to the
straight travel spool pilot chamber and the spool is switched.
a Travel 2
b Travel 1
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8030D-40

1 5 Boom 9 Option
valve
2 Travel 1 6 Arm 10 Add-on (main pump)
3 Travel 2 7 Bucket 11
tion)
a Advance d Close g Left

b Reverse e Open
c Up f Right
84551720B NA - August 2012

8030D-41
9. Add-on [Fig. 24, Fig. 25]

1) Add-on main relief valve
The oil fed from the Pr port is led to the main relief valve. The Pr pump maximum pressure is regulated by
the operation of the main relief valve.
a Advance d Close g Left

b Reverse e Open
c Up f Right
2) Spool section
When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and switched, the neutral
path [Pg] is closed. The oil fed from the Pg port flows from the parallel path [Rg] through the load check
valve [S10-1], the path [S10-2], and the spool neck section, and into the AR1 (BR1) port.
The return oil returns to the tank path [Ta] from the BR1 (AR1) through the spool neck section.
84551720B NA - August 2012

8030D-42
3) Low-pressure relief valve operation [Fig. 26, Fig. 27]

1) Signal pressure generation (when pin1 (pin2) port pressurized)
The oil fed from the pump port (P1 (P2)) flows through the neutral path (L1 (R1)), then flows from the
low-pressure relief path (L2 (R2)) through the orifice (Lc1 (Rc1)) and out into the tank path (Ta).
At this time, the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)) is led to the low-
pressure relief signal port (Ps1 (Ps2)).
When the (L2 (R2)) upstream main spool operates, the oil flowing through (L2 (R2)) is reduced, so
the (Ps1 (Ps2)) signal pressure becomes lower.
2) Relief operation
When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure generated in path (L2
(R2)) by the orifice (Lc1 (Rc1)).
Through this poppet operation, the oil flows from the path, through the notch hole path, and out to the
tank path [Ta]. This prevents the generation of excess pressure at the low-pressure relief signal port.
4) Add-on main relief valve

1) Add-on main relief valve operation
This relief valve is incorporated between the neutral path "HP" and the tank path "LP". The oil passes
through the metering hole of the main poppet [1] and charges the interior space [C].
Also, the sleeve [2] and the main poppet [1] seat securely operating on the different surface areas "A"
and "B".
84551720B NA - August 2012

8030D-43
2) When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet [3] opens.
The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the ring-shaped
gap [D] and is led to the tank path "LP".
3) Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the main poppet
[1] opens, so the "HP" oil flows directly into the path "LP".
84551720B NA - August 2012

8030D-44
Section
8030E
5 Stack Solenoid Valve Operation Explanation
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
External Shape Diagram and Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

External Shape Diagram and Component Parts

This valve is made up of the body and the electromagnetic switchover valve.
Normal closed type solenoid; SP, S1, S3 Normal open type solenoid; S2 4-port type solenoid; S4
1 Electromagnetic switchover valve

2 Body
84551720B NA - August 2012

8030E-3

The pressure oil fed from the P port feeds pressure oil to the C1 - C5 ports according to the excitation or non-excitation
of electromagnetic switchover valves S1 - S4 resulting from exciting electromagnetic switchover valve SP.
Electromagnetic switchover valves S1, S3 → Oil passing through when valve excited
Electromagnetic switchover valve S2 → Oil passing through when valve not excited
→ Oil passing to C5 when valve excited Oil passing to
Electromagnetic switchover valve S4
C4 when valve not excited
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8030E-4
Section
8030F
Structure and Operation Explanation of Upper Pilot Valve

(remote control valve)
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Structure
The structure of the remote control valve is as shown in the Structural Diagram. There is a longitudinal axial hole in
the casing and the pressure reduction valve is installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring (241), return spring (221),
spring seating (216), and washer 2 (217).
The secondary pressure setting spring (241) is set so that the secondary pressure calculation is 0.5 - 1 MPa ( 72.527
- 145.05 psi ) (depending on the model). The spool (201) is pressed against the push rod (212) by the return spring
(221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring seating goes down at
the same time and the secondary pressure setting spring (241) setting is changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, furthermore, the secondary
pressure is taken out from the ports 1, 2, 3, 4.
Function
1. Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction, etc. This is done by
operating the pilot valve output pressure on the control valve spool end section.
In order to satisfy this function, the remote control valve is made up of the following elements.
1) Inlet port (P) to which the oil is fed from the hydraulic pump
2) Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the control valve spool
end
3) Tank port (T) required for controlling the above output pressure
4) Spool connecting the output port to the inlet port or tank port
5) Mechanical means including a spring operating on the above spool in order to control the output pressure
2. Main part functions
The function of the spool (201) is to switch the oil path either to have the hydraulic pressure fed from the hydraulic
pump received by the P port and lead the P port pressure oil to the output ports (1, 2, 3, 4) or to lead the output
port pressure oil to the T port. The output pressure operating on this spool (201) is determined by the secondary
pressure setting spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the push rod (212) is
inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates to return the push
rod (212) in the displacement zero direction regardless of the output pressure and makes the spool (201) neutral
return reliable. It also has the effect of a counter-force spring for giving an operator an appropriate operation feel.
84551720B NA - August 2012

8030F-3
Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Diagram 1) and operation
explanation diagrams (Diagram 2 - Diagram 4).
Diagram 1 is a typical usage example for the remote control valve.
Diagram 1 Remote control valve usage example
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Control valve 6 Hydraulic cylinder
84551720B NA - August 2012

8030F-4
1. When the handle is in neutral (See Diagram 2.)
The force of the secondary pressure setting spring (241) that determines the remote control valve output pressure
does not operate on the spool (201). Therefore, the spool (201) is pushed up by the return spring (221) (spring
seating (216)) and the output ports (2, 4) are connected with the T port. Therefore, the output pressure is the
same as the tank pressure.
Diagram 2 When the handle is in neutral
84551720B NA - August 2012

8030F-5
2. When the handle is tilted (See Diagram 3.)
When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seating (216)) spool (201)
moves down and the oil fed from the pilot pump flows out to the ports (2, 4) through the P port and the ports (2,
4) and pressure is generated.
Diagram 3 When the handle is tilted
84551720B NA - August 2012

8030F-6
3. When the handle is held (See Diagram 4.)
When the handle is tilted and the pressure of the ports (2, 4) rises to a pressure equivalent to the set spring force
(241), the hydraulic pressure and the spring force are in balance. When the ports (2, 4) pressure becomes higher
than the set pressure, the ports (2, 4) and the P port close and the ports (2, 4) and the T port open. When the
ports (2, 4) pressure becomes lower than the set pressure, the ports (2, 4) and the P port open and the ports (2,
4) and the T port close, so the secondary pressure is held constant.
Diagram 4 When handle held (secondary pressure at or above set pressure)
1 T port
2 P port
4. Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top end section touches
the push rod bore bottom section and the output pressure goes into the state of still being connected with the P
port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside the push rod, when
the handle is flipped down beyond a certain angle, the push rod bore bottom section and the spring touch. That
spring force changes the 2nd pressure gradient and after that the push rod bore bottom section and the spring
seating top end section touch, and the output pressure remains connected to the P port.
84551720B NA - August 2012

8030F-7
Structural Diagram
Code Part name Q'ty

101 Casing 1
151 Plate 1
201 Spool 4
211 Plug 4
212-1 Push rod 2
212-2 Push rod 2
213 Seal 4
214 O-ring 4
216-1 Spring seating 1 2
216-2 Spring seating 1 2
217 Washer 2 4
221-1 Spring (port 1) 1
221-2 Spring (port 3) 1
84551720B NA - August 2012
8030F-8
Code Part name Q'ty
221-3 Spring 2
241-1 Spring 2
241-2 Spring 2
301 Joint 1
302 Disk 1
312 Adjusting nut 1
501 Bellows 1
84551720B NA - August 2012

8030F-9
84551720B NA - August 2012

8030F-10
Section
8030G
Structure and Operation Explanation of Travel Pilot Valve

(remote control valve))
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Reduction Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Section Damping Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation
The remote control valve with built-in damper (hereinafter, remote control valve with damper) is a remote control valve
that incorporates into the remote control valve main unit a damping function for preventing the man-machine system
hunting (lever hunting) phenomenon.
Operation of the remote control valve with damper is divided into the Pressure Reduction Valve Section and the Op-
eration Section Damping Mechanism Section. The explanations in these 2 sections are based on the hydraulic circuit
diagram, assembly cross-section diagram, and damping operation explanation diagram below. The diagram below is
a typical usage example for the remote control valve.
1 Remote control valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
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8030G-3
Pressure Reduction Valve Section
1. For the neutral state
The spool (301) is pushed up by the return spring (335) via the spring seating (311) and washer 1 (215) and is in
the neutral position shown in the assembly cross-section diagram.
Therefore, since the output port is connected only to port T by the spool switching function, the pressure at output
ports 1 and 2 is the same as the pressure at port T.
2. When the remote control valve operation section is tilted from the neutral state
In the assembly cross-section diagram, when the cam (420) is rotated clockwise, the port 1 side push rod (214)
is pushed down, the spool moves down via washer 1, the spring seating, the secondary pressure setting spring
(324), washer 2 (217), and washer 3 (313), the port P and port 1 are connected, and the oil fed from the pilot
pump flows to port 1 and generates pressure.
When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting spring force that
has been set by tilting the operation section, the hydraulic pressure on the spool and the spring force come into
balance and the port 1 output pressure is held constant. The port 2 spool stays in the neutral state and the oil
from the control valve is discharged via port T.
Some specifications are of the type that near the maximum angle of the operation section, a push rod directly
touches the spool top section and forcibly pushes in the spool to connect port P and the output port so that they
have the same pressure.
Operating Section Damping Mechanism Section

1. For the neutral state
The push rod is pushed up by the damping springs (333, 337) via the piston (224) and is in the position shown
in the assembly cross-section diagram.
2. When the operation section is tilted from the neutral state (See Damping operation explanation diagram (1).)
In the assembly cross-section diagram, when the cam is rotated clockwise, the port 1-side push rod is pushed
down and the piston moves down (2-1).
At this time, the oil in the damping piston chamber is discharged from the piston metering hole and the pressure
generated at this time generates damping force.
On the other hand, the port 2-side push rod is moved up by the damping spring via the piston.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings (223)
and steel balls (225) and into the damping piston chamber.
The oil outside the piston chamber drains out from the path that leads from the casing top end section to port T.
3. When the operation section is tilted back from a full tilt (See Damping operation explanation diagram (2).)
In the assembly cross-section diagram, after the cam is fully tilted clockwise then rotated counter-clockwise, the
port 2-side push rod is pushed down and the piston moves down.
At this time, as described above, the oil in the damping piston chamber is discharged from the piston metering
hole and the pressure generated at this time generates damping force (3-1).
On the other hand, the port 1-side push rod is moved up by the return spring (335) and the damping spring (3-2).
At the same time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings
and steel balls and into the damping piston chamber (3-3).
Also, the oil outside the piston chamber drains out from the path that leads from the casing top end section to
the tank port (3-4).
In other words, the structure is such that damping force works for either tilt operation, from the neutral position to
the full tilt position or from the full tilt position to the neutral position.
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8030G-4
Damping operation explanation diagram
1. Operation when lever is moved through its stroke from the neutral position
1 Push rod 3 Piston

2 Orifice 4 Piston chamber
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8030G-5
2. Lever stroke state and operation when lever is moved back
*1 Neutral *3 (⇒ during operation)

*2 Full stroke 12.5° *4 Oil drains to T.
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8030G-6
Structural Diagram

101 Casing 1 271 Hexagon socket head bolt 271
151 Plug 2 301 Spool 301
201 Cover 2 311 Spring seating 311
202 Plug 4 313 Washer 3 313
203 Grease cup 4 324 Spring 324
210 NHU packing 4 335 Spring 335
214 Push rod 4 337 Spring 337
215 Washer 1 8 412 Bushing 412
217 Washer 2 4 413 Camshaft 413
218 Spring seating 4 420 Cam 420
221 Locking ring 4 423 Hexagon socket head locking screw 423
223 Bushing 4 471 Locking screw 471
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8030G-7
224 Piston 2D085 4 472 Lock nut 472
225 Steel ball 12 501 Bellows 501
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8030G-8
Section
8030H
Structure and Operation Explanation of Cushion Valve
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CONTENTS
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Structure
This valve is made up of a shuttle valve section and cushion valve section with heat circuit.
The cushion valve with a heat circuit is connected between the hydraulic shovel car control valve and the pilot oper-
ation valve to reduce body shaking (cushion function) caused by emergency stop operations by the operator.
This valve is also equipped with a circuit with which the operator can deliberately disable the cushion function for
reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems.
This valve has 2 circuits.
*1 Arm
*2 Boom
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8030H-3
1. Normal operation
The pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) pushes up the check plunger
and is sent to the B port (or D, F, or H port).
The pressure oil that has passed through the B port operates on the control valve spool and operates the actuator.
The oil pushed out from the control valve spool passes through the D port (or B, F, or H port) and flows out to the
T port.
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8030H-4
2. Cushion operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is closed by the pilot
operation valve, the pressure oil that has operated on the control valve spool is pushed back to the B port (or the
D, F, or H port) by the return spring on the spool.
The returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E, or G port),
and is drained from the pilot operation valve.
At this time, by passing through the metering orifice, the pressurized oil holds down the control valve spool speed,
which prevents the sudden stopping of the actuator and reduces shaking of the body. (Cushion function)
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8030H-5
3. Reverse operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is switched to the C port
(or A, E, or G port), the pressure oil that has operated on the control valve spool is pushed back to the B port.
Because the pushed back oil flows out to the T port without passing through the check plunger metering orifice,
it does not hold down the control valve spool speed, so the cushion function does not work.
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8030H-6
4. Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through the inside of the
reverse operation spool and flows out to the T port, which heats up the inside of the valve.
When pressure oil is being fed from the pilot operation valve to the A port (or C, E, or G port), the oil fed to the
R port flows out to the C port (or A, E, or G port) and heats up the circuit to the pilot operation valve and inside
the valve.
5. Shuttle valve
The steel ball is pressed from the higher of the pressures between the I and J ports and the K and L ports to the
lower of these pressures. Through this process, high-pressure oil is fed to the S port or the Q port.
In the same way, oil of the higher pressure between the M and N ports and the O and P ports is fed to the U port.
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8030H-7
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8030H-8
Section
9002
Removal and Installation of Counterweight
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84551720B NA - August 2012
CONTENTS
Removal of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CAUTION Removal of Counterweight

• Be sure to stop the engine before beginning 1. Remove the following before beginning work.。
work.
• Engine hood, gas damper and lock stay
• Be sure to inspect the wire rope and other • Rear view camera and electrical parts bracket
• Do not stand or pass under the suspended 2. Remove the 2 rubber plugs (2) from the top of the
load. counterweight (1).
• Thoroughly secure the removed counter-
weight with the wire ropes and liftcrane so
that it does not fall over.
Items to prepare
• Box wrench [ 50 mm ( 1.969 in. ) ]
• Eyebolt (M42)
• Balance lifting device
• Wire rope (with the required breaking load x 4)
• Rag
• Cleaning fluid
3. Install the 2 eyebolts (M42) (1) in place of the re-
moved caps.
• Apply lubricating oil to the eyebolts.
by a half turn.
4. Connect the eyebolts to the shackles (1), and then

use the wire ropes (2) and liftcrane to secure the
counterweight so that it does not fall during removal
and installation operations.
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9002-3
5. Use a box wrench [ 50 mm ( 1.969 in. ) ] to remove 7. Thoroughly check that the location is safe before
the 4 bolts (1) and spacers (2) on the lower section lowering the counterweight on wood planks (1).
of the counterweight.
• Thoroughly secure the counterweight with the
wire ropes and liftcrane so that it does not fall
over.
6. Use the wire ropes and liftcrane to lift and remove

the counterweight.
• Move the counterweight about 50 cm ( 19.685 in. )
to the rear while lifting it so that it does not interfere
with the housing, engine parts and pipes.
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9002-4
Installation of Counterweight 3. Use a box wrench [ 50 mm ( 1.969 in. ) ] to attach

the 4 bolts (1) and spacers (2) on the lower section
1. Connect the shackles (1) to the eyebolts, and thor- of the counterweight.
oughly secure the counterweight with the wire ropes
(2) and liftcrane so that it does not fall over. • Bolt (1) tightening torque: 1862 - 2058 N·m (
1373.58 - 1518.16 lbf・ft. )
2. Use the wire ropes and liftcrane to lift and install the
counterweight. 4. Remove 2 eyebolts (M42) (1).
• Suspend the counterweight so that it does not in-
terfere with the housing, engine parts and pipes.
5. Attach the 2 rubber plugs (1) in place of the removed

eyebolts.
6. Install the following after finishing work.

• Engine hood, gas damper and lock stay
• Rear view camera and electrical parts bracket
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9002-5
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9002-6
Section
9003A
Removal and Installation of Bucket
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84551720B NA - August 2012
CONTENTS
Removal of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION Removal of Bucket

• Stop the machine on a level location with • Place the back of the bucket parallel to the ground.
good footing. 1. Use a screwdriver to remove the pin (2) rings (1),
• Be sure to stop the engine before beginning and then remove the bucket side and arm side pins.
work.
ing with a hammer.
Items to prepare
• Hammer
• Striking rod
• Screwdriver
• Grease
• Rag
• Cleaning fluid
bucket side pin (3) and arm side pin (2) out, and
then remove the bucket (1).
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9003A-3
Installation of Bucket
3. Use a screwdriver to attach the pin (2) rings (1), and

then insert the bucket side and arm side pins.
• Grease up.
2. Place the back of the bucket parallel to the ground.
Use a hammer (4) to press in the bucket side pin (3)
and arm side pin (2), and then install the bucket (1).
Do not force it in. Adjust the bucket installation
position.
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9003A-4
Section
9003B
Removal and Installation of Bucket Link
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84551720B NA - August 2012
CONTENTS
Removal of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION Removal of Bucket Link

• Stop the machine on a level location with • Remove the bucket. (For details, see "Removal and
good footing. Installation of Bucket".)
• Be sure to stop the engine before beginning 1. Place the bucket link (1) parallel to the ground.
work.
ing with a hammer.
Items to prepare
• 2 wrenches [ 30 mm ( 1.181 in. ) ]
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid 2. Use 2 wrenches [ 30 mm ( 1.181 in. ) ] to remove
the double nuts (1), and then pull out the bolts (2)
(3).

pin (2) out and remove the bucket link (1).
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9003B-3
4. Use a hammer (4) and striking rod (5) to push out Installation of Bucket Link
the pin (3) and remove the arm links (1) (2).
2. Use a hammer (4) to push in the pin (1) and install

the arm links (2) (3).
3. Place the bucket link (1) parallel to the ground.

Use a hammer (3) to push in the pin (2) and install
the bucket link (1).
4. Use 2 wrenches [ 30 mm ( 1.181 in. ) ] to attach the

double nuts (1), and then install the bolts (2) (3).
• Grease up.
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9003B-4
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9003B-5
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9003B-6
Section
9003C
Removal and Installation of Arm
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84551720B NA - August 2012
CONTENTS
Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 84912AA10 Removal of Arm

• Remove the bucket. (For details, see "Removal and
CAUTION Installation of Bucket".)
• Remove the bucket link. (For details, see "Removal
• Stop the machine on a level location with and Installation of Bucket Link".)
good footing.
• Remove the bucket cylinder. (For details, see "Re-
• Be sure to stop the engine before beginning moval and Installation of Bucket Cylinder".)
work.
• Remove the arm cylinder. (For details, see "Removal
• When working together with others, always and Installation of Arm Cylinder".)
quate attention to safety. 1. Bring the arm (1) top in contact with the ground and
• Always wear protective devices (protective use a liftcrane and nylon sling (2) to secure it.
eyewear and safety shoes, etc.) when work- At this time, insert the arm cylinder pin (3) and se-
ing with a hammer. cure with the nylon sling.
load.
Items to prepare
• Wrench [19 mm (0.748 in.)]
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
Crosstie 2. Use a wrench [19 mm (0.748 in.)] to remove the
•

pin (2) out and remove the arm (1).
• If a pin is hard to remove, there is a load on the
pin.
• Be very careful. When the pin is removed, the
arm may fall slightly.
• Be very careful. The arm may fall over to the side.
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9003C-3
Installation of Arm
• Tighten bolts being installed to the specified torque.
and Torque Table".
4. Lift the arm and then place it on the crosstie.
2. Bring the arm (1) top in contact with the ground and
use a liftcrane and nylon sling (2) to secure it.
At this time, insert the arm cylinder pin (3) and se-
cure with the nylon sling.
3. Align the arm (1) with the boom and use a hammer
(3) to push in the pin (2) and then install the arm (1).
4. Use a wrench [19 mm (0.748 in.)] to tighten the bolt

(1) and washer (2).
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
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9003C-4

84551720B NA - August 2012

9003C-5
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9003C-6
Section
9003D
Removal and Installation of Boom
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84551720B NA - August 2012
CONTENTS
Removal of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CAUTION 1. Bring the boom (1) top in contact with the ground.
• Stop the machine on a level location with

good footing.
work.
ing with a hammer.
load. 2. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the
grease hoses on the left and right sides (1).
Items to prepare
• Wrenches [ 10 mm ( 0.394 in ), 19 mm ( 0.748 in ), 27 dust or dirt.
mm ( 1.063 in ), 30 mm ( 1.181 in ), 41 mm ( 1.614 in
)]
• Slide hammer [ 24 mm ( 0.945 in ) ]
• Marking pen
• Cap
• Plug
• Rag
• Striking rod
• Cleaning fluid
• Wood piece
• Square wooden pieces
• Wire
Removal of Boom double nuts (1) and bolt (2), and then remove the
fastening ring (3).
• Remove the bucket. (For details, see "Removal and Also, remove the cab side in the same way.
• Remove the bucket link. (For details, see "Removal
• Remove the bucket cylinder. (For details, see "Re-
• Remove the arm cylinder. (For details, see "Removal
and Installation of Arm Cylinder".)
• Remove the arm. (For details, see "Removal and In-
stallation of Arm".)
• This section explains the procedure for when attaching
the boom cylinder to the frame.
When removing the boom cylinder too, see "Removal
and Installation of Boom Cylinder".
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9003D-3
4. Use a hammer (2) and striking rod (3) to push the 7. Use a wrench [ 10 mm ( 0.394 in ) ] to remove the
pin (1) out. grease nipple (1), and then secure the base of the
Use a liftcrane and nylon slings (4) to hold the boom boom cylinders (right) (left) with the batten (2).
cylinders (right) (left) so that they does not fall.
8. Lower the boom cylinders (right) (left) and let them

5. Start the engine, lower the boom at idle, and retract rest on the batten (1).
the boom cylinder (1) (2) rod.
9. Install the pin (1) removed in Step 4.

6. Tie the cylinder rods on the left and right sides with Use a wrench [ 30 mm ( 1.181 in ) ] to tighten the
wire (1) so that they cannot come out. bolt (3) with the 2 double nuts (2), and then install
the fastening ring (4).
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9003D-4
10. Wrap nylon slings (1) around the pins on the left and 12. Use a slide hammer (1) [ 24 mm ( 0.945 in ) ] to
right sides installed in Step 9 and secure with the remove the pin (2).
liftcrane.
13. Back up the machine and remove the boom (1).

84551720B NA - August 2012

9003D-5
Installation of Boom 4. Tie the cylinder rods on the left and right sides with
wire (10) so that they cannot come out.
• This section explains the procedure for when not in-
stalling the boom cylinder.
and Torque Table".
5. Align the boom with the swing frame pin hole and
use a slide hammer (1) [ 24 mm ( 0.945 in ) ] to
tighten the pin (2).
• When inserting pins, be careful not to damage the
dust seals.
• If the insertion of a shim is possible according to
2. Install the pin (1). the tolerance adjust the shim.
Use a wrench [ 30 mm ( 1.181 in ) ] to tighten the
bolt (3) with the 2 double nuts (2), and then install
the fastening ring (4).

• Grease up.
3. Wrap the nylon slings (1) around pins on the left and
right sides installed in Step 2 and secure with the
liftcrane.
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9003D-6
7. Start the engine, raise the boom at idle, and extend 10. Use a wrench [ 19 mm ( 0.748 in ) ] to attach the
the boom cylinder (1) (2) rod. grease hoses on the right and left sides (1).
8. Use a hammer (2) to push in the pin (1). 11. Bring the boom (1) top in contact with the ground.
Use a liftcrane and nylon slings (3) to hold the boom
cylinders (right) (left) so that they does not fall. • When installing the boom cylinder too, see "Re-
moval and Installation of Boom Cylinder".
• Install the arm. (For details, see "Removal and
Installation of Arm".)
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-

double nuts (1) and bolt (2), and install the fastening
ring (3).
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9003D-7
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9003D-8
Section
9004
Removal and Installation of Operator's Seat
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 90120AD17 3. Use a wrench [ 13 mm ( 0.512 in. ) ] to remove the

2 bolts (1) from the rear of the seat.
Tightening torque for bolt (1) installation: 19.6 N・
Items to prepare
m ( 14.459 lbf・ft. )
• Wrench [ 13 mm ( 0.512 in. ) ]
Removal of Operator's Seat

1. Pull the slide lever (1) to slide the seat (2) to the
rear.
2 bolts (3) from the front of the seat.
Tightening torque for bolt (3) installation: 19.6 N・
m ( 14.459 lbf・ft. )
4. Remove the operator's seat (1).
2. Pull the slide lever (1) to slide the seat forward, and
then pull the reclining lever (2) to fold the seatback
forward.
Installation of Operator's Seat

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9004-3
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9004-4
Section
9005A
Removal and Installation of Cab Assembly
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84551720B NA - August 2012
CONTENTS
Removal of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Job code 90150AB08 Removal of Cab Assembly

• Remove the operator's seat. (For details, see "Re-
CAUTION moval and Installation of Operator's Seat".)
• Be sure to stop the engine before beginning 1. Use a box wrench [ 13 mm ( 0.512 in. ) ] to remove
work. the 6 bolts (1), and the
• Be sure to inspect the wire rope and other Tightening torque for bolt (1) installation: 5.9 - 7.8
lifting equipment before beginning work. N・m ( 4.352 - 5.754 lbf・ft. )
load.
Items to prepare
13 mm ( 0.512 in. ), 19 mm ( 0.748 in. ), 41 mm (
1.614 in. ) ]
), 19 mm ( 0.748 in. ) ]
• Longnose pliers
• Eyebolt (M24 x 4)
• Chains (wire ropes) (with the required breaking load)
• Lubricating oil
the 3 bolts (1), and then remove the air conditioner
• Rag
ducts on both sides (2) (3).
• Cleaning fluid
Tightening torque for bolt (1) installation: 2.9 - 3.9
N・m ( 2.139 - 2.877 lbf・ft. )
3. Use a Phillips screwdriver or box wrench [ 10 mm

( 0.394 in. ) ] to remove the 2 bolts (1), and then
remove the side front lower trim (2).
N・m ( 4.352 - 5.754 lbf・ft. )
84551720B NA - August 2012

9005A-3
4. Use a flathead screwdriver or longnose pliers to re- 7. Use a wrench [ 13 mm ( 0.512 in. ) ] to remove the
move the clip pins (1), and then remove the air con- bolts (2) for the ground wire (1) connecting the cab
ditioner ducts (2) by pulling them forward. and frame.
5. Use a wrench [ 13 mm ( 0.512 in. ) ] to remove the 8. Remove the connector (1) and wire band (2), and
2 bolts (2), and then remove the bracket (1) and air then use a wrench [ 13 mm ( 0.512 in. ) ] to remove
conditioner duct (3). the 2 bolts (3).
6. Remove the radio antenna (1). 9. Remove the washer fluid hose (1).
84551720B NA - August 2012

9005A-4
10. Use a wrench [ 13 mm ( 0.512 in. ) ] to remove 13. Use a wrench [ 10 mm ( 0.394 in. ) ] to remove the
the 4 bolts (1), use a wrench [ 12 mm ( 0.472 in. ) 2 bolts (1), and then remove the bracket (2).
] to remove the 3 bolts (4) and 2 nuts (2), and then
remove the rear brackets (3) (5).

3 bolts (1), and then remove the bracket (2).
15. Remove the 4 connectors (1) and the 2 wire bands

(2).
12. Use a flathead screwdriver or longnose pliers to re-

move the 2 clips (1), and then remove the suction
ducts (2) (3).
16. Remove the 4 caps (1) from the top of the cab.
84551720B NA - August 2012

9005A-5
17. Install the 4 eyebolts (M24) (1) in place of the re- 19. Use a wrench [ 19 mm ( 0.748 in. ) ] to remove the
moved caps. 8 cab bolts (1) and 4 nuts (2).
by a half turn.
18. Use chains (1) and liftcrane to secure the cab.

anchor bolt (1).
84551720B NA - August 2012

9005A-6
21. Use chains (1) and liftcrane to remove the cab (2). Installation of Cab Assembly
If the torque is not specified, see the "Tightening Torque"
section.

lowering the cab on wood planks (1).
• Thoroughly secure the cab with the chains and
liftcrane so that it does not fall down.
84551720B NA - August 2012

9005A-7
84551720B NA - August 2012

9005A-8
Section
9005B
Removal and Installation of Wiper
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Items to prepare 2. Use the Phillips screwdriver to remove the 1 screw

(1), and then remove the wiper (2).
• Wrench [ 17 mm ( 0.669 in. ) ]
Removal of Wiper
1 nut (1), and then remove the wiper arm (2).
Tightening torque for nut (1) installation: 12 - 16 N・
m ( 8.85 - 11.80 lbf・ft. )
Installation of Wiper
84551720B NA - August 2012

9005B-3
84551720B NA - August 2012

9005B-4
Section
9005C
Removal and Installation of Wiper Controller
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of wiper controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code RZWP03 2. Remove the connector (2) from the wiper controller
(1).
Items to prepare
• Wrench [ 10 mm ( 0.394 in. ) ]
• Box wrench [ 10 mm ( 0.394 in. ) ]
Removal of Wiper Controller

remove the side rear B trim (2).
3. Use a flathead screwdriver to slightly bend the 4 in-

stallation clips (1), and then remove the wiper con-
troller (2).
Installation of wiper controller

For bolts for which the torque is not specified, see the
"Tightening Torque" section.
84551720B NA - August 2012

9005C-3
84551720B NA - August 2012

9005C-4
Section
9005D
Removal and Installation of Wiper Motor
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 55518AZ46 3. Use a Phillips screwdriver or box wrench [ 10 mm

( 0.394 in. ) ] to remove the 2 bolts (1), use a
hexagon wrench [ 5 mm ( 0.197 in. ) ] to remove
Items to prepare
the 3 bolts (2) and 3 washers (3), and then remove
• Hexagon wrench [ 5 mm ( 0.197 in. ) ] the front upper trim assembly (4).
• Wrenches [ 10 mm ( 0.394 in. ), 17 mm ( 0.669 in. ) ] Tightening torque for bolt (1) installation: 5.9 - 7.8
• Box wrench [ 10 mm ( 0.394 in. ) ] N・m ( 4.352 - 5.754 lbf・ft. )
• Flathead screwdriver (longnose pliers)
Removal of Wiper Motor

N・m ( 4.352 - 5.754 lbf・ft. )

1 nut (1), and then remove the wiper arm (2).
Tightening torque for installation: 12 - 16 N・m (
8.85 - 11.80 lbf・ft. )
2. Use a flathead screwdriver or longnose pliers to re-

move the clip pins (1), and then remove ducts B (2).

1 nut (1).
Tightening torque for installation: 11 - 13 N・m (
8.11 - 9.58 lbf・ft. )
84551720B NA - August 2012

9005D-3
6. Use a box wrench [ 10 mm ( 0.394 in. ) ] to remove Installation of wiper motor

the 4 bolts (1), and then remove the wiper motor
assembly (2). To install, perform the reverse of the removal procedure.
• Be careful about the wiper link and wiper arm installa-
tion location.
• Check the wiper arm wipe location and stop location.
84551720B NA - August 2012

9005D-4
Section
9005E
Removal and Installation of Monitor
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 55512BQ14 3. Remove the connector (1).
Items to prepare
• Wrench [ 10 mm ( 0.394 in. ) ]
Removal of Monitor
• Bolt (1) tightening torque: 5.9 - 7.8 N・m ( 4.35 -
5.75 lbf・ft. )

4 bolts (2), and then remove the monitor (1).

( 0.394 in. ) ] to remove the 2 bolts (1), use a
hexagon wrench [ 5 mm ( 0.197 in. ) ] to remove
the 3 bolts (2) and 3 washers (3), and then remove
the front upper trim assembly (4).
Installation of Monitor
• Bolt (1) tightening torque: 5.9 - 7.8 N・m ( 4.35 -
5.75 lbf・ft. ) To install, perform the reverse of the removal procedure.
84551720B NA - August 2012

9005E-3
84551720B NA - August 2012

9005E-4
Section
9005F
Removal and Installation of Cab Front Glass
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Front Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 90156AL10 3. Use a wrench [ 10 mm ( 0.394 in. ) ] to remove the

3 bolts (1) each, and then remove the brackets (2)
(3).
CAUTION Tightening torque for bolt (1) installation: 880 - 1270
N・cm ( 77.90 - 112.42 lbf・in. )
Reinforced glass is used for the front win-
dow.
Be extremely careful not to damage it when
touching it during removal or installation.
Items to prepare
• Wrench [ 10 mm ( 0.394 in. ) ]
• Rag
• Cleaning fluid
Removal of Cab Front Glass

1. Use a Phillips screwdriver to remove the 8 clips (2),
and then remove the cover (1). 4. Remove the covers (1) (2) for the bracket.
2. Use a Phillips screwdriver to remove the screw 5. Use a wrench [ 10 mm ( 0.394 in. ) ] to remove
(1), and then install the removed screw (1) into the the 3 bolts (1), and then remove the front glass left
screw hole (2). lower bracket (2).
Tightening torque for bolt (1) installation: 880 - 1270
• The assist spring is locked.
N・cm ( 77.90 - 112.42 lbf・in. )
84551720B NA - August 2012

9005F-3
6. Use a wrench [ 10 mm ( 0.394 in. ) ] to remove the Installation of Cab Front Glass
3 bolts (1), and then remove the front glass right
lower bracket (2). To install, perform the reverse of the removal procedure.
Tightening torque for bolt (1) installation: 880 - 1270 Tighten bolts being installed to the specified torque.
N・cm ( 77.90 - 112.42 lbf・in. ) If the torque is not specified, see the "Tightening Torque"
section.
7. Remove the cab front glass (1).
84551720B NA - August 2012

9005F-4
Section
9005G
Window Lock Adjustment Procedures
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Window Lock (front side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Window Lock (rear side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Items to prepare 3. Set the cab front glass (1) in place.

• Wrench [ 10 mm ( 0.394 in. ) ]
• Rag
• Cleaning fluid
Window Lock (front side)

1. Release the lock with the lever (1), and then remove
the lock of the cab front glass.
4. Use a wrench [ 10 mm ( 0.394 in. ) ] to retighten

the 2 bolts (1).

2 bolts (1).
84551720B NA - August 2012

9005G-3
Window Lock (rear side) 3. Set the cab front glass (1) in place.
1. Use a Phillips screwdriver to remove the 8 clips (2),

and then remove the cover (1).
4. Use a wrench [ 10 mm ( 0.394 in. ) ] to retighten

the 4 bolts (1).

4 bolts (1).
84551720B NA - August 2012

9005G-4
Section
9005H
Tightening torque
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Tightening torque
Tightening torque
When installing cab inner and outer parts, for bolts and screws for which the torque is not specified, tighten according
to the following.
Bolt nominal di-

ameter M3 x 0.5 M4 x 0.7 M5 x 0.8 M6 x 1.0 M8 x 1.25 M10 x 1.5
(size)
0.59 - 0.79 1.27 - 1.86 2.45 - 3.53 4.52 - 6.14 9.84 - 14.74 19.58 - 28.4
N•m
( 0.4353 - ( 0.9369 - ( 1.8074 - ( 3.1131 - ( 7.2589 - ( 14.4440 -
( lbf・ft. )
0.5827 ) 1.3721 ) 2.6040 ) 4.5515 ) 10.8735 ) 20.9503 )
kgf•m 0.06 - 0.08 0.13 - 0.19 0.25 - 0.36 0.43 - 0.63 1.00 - 1.50 2.0 - 2.9
84551720B NA - August 2012

9005H-3
Tightening torque
84551720B NA - August 2012

9005H-4
Section
9006
Air Conditioner Overall Diagram
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Equipment Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Conditioner Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Explanation of Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Explanation of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Mix Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Blow Mode Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refresh/Recirculate Switch Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Blower Amp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Compressor Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COOLMAX Control and HOTMAX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Abnormality Detection and Control after Abnormality Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Door Switch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inside Air Filter Clogging Detection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Air Mix Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Refresh/Recirculate Switch Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mode Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Self-diagnosis Function with Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Abnormality Display and Self-check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Abnormality Display Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Explanation of Abnormality Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Motor Actuator Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Explanation of Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Monitor Mode Display Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Monitor Mode Display Operating Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Display Contents in Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Part Function and Good/Poor Judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Air Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Refresh/Recirculate Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Blow Mode Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Dual Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Solar Radiation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inside Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51


Frame
84551720B NA - August 2012

9006-3
Compressor; Air condi- Dryer receiver [ D60.5
1 Cooler hose (Liquid 2) 1 5 1 9 1
tioner ( 2.382 ) ]
Cooler hose (Liquid
2 Cooler hose (Suction) 1 6 Slide shaft 1 10 1
1)
Rubber hose 16 x 5600 Tension pulley (With Bracket receiver [
3 2 7 1 11 1
( 0.629 x 220.472 ) cover) D60.5 ( 2.382 ) ]
Cooler hose (Dis-
4 1 8 Air condenser 1 12 V belt B-45.5 1
charge)
White marking
a Air conditioner unit e Heater (Engine output) i Must be connected with the air
conditioner unit.
b Engine f Heater (Unit outlet) j Clamp
c Heater (Engine return) g Heater (Unit inlet)
Must be connected with the air
d White marking h
conditioner unit.
84551720B NA - August 2012
9006-4
* in the diagram indicates a clamp position. Figures indicate hose lengths.
84551720B NA - August 2012

9006-5
Cab
84551720B NA - August 2012

9006-6
1 Control panel (AC) 1 7 Duct; Face-C 1 13 Air filter (Fresh) 1
2 Drain hose 2 8 Duct; H and C box 1 14 Duct; Intake-A (Fresh) 1
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3 Flange plate 1 9 Bracket; Box 1 15 Duct; Intake-B (Fresh) 1
4 Grille; Air vent 7 10 Box; Hot and cool 1 16 Unit; Air conditioner 1
5 Duct; Face-B 1 11 Duct; Vent (Left) 1 17 Duct; Foot 1
6 Duct; Def-C 1 12 Duct; Vent (Right) 1 18 Duct; Def-B 1
a e Should be connected with the

Monitor display Heater hose (Eng.Out) i
console harness.
b Trim side; Front (Right) f Cooler hose (Suction) j Wire harness (Console)
c Trim side; Front (Left) g Cooler hose (Liquid) k Floor
d Heater hose (Eng.Return) h Cover; Top (Console left)
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Equipment Layout Diagram
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9006-9

Motor actuator (refresh/recir-
1 Motor actuator (mode) 4 7 Blower amp
culate switch)
2 Compressor relay 5 Interior temperature sensor 8 Motor actuator (air mix)
3 Blower OFF relay 6 Blower motor 9 Evaporator sensor
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Circuit Diagram
Air Conditioner Circuit Diagram
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5 V system
5 V are always applied.
Analog Signal:0 - 5 V are applied
GND
P W B R Y G L Br Lg O Sb V
Light Sky
Pink White Black Red Yellow Green Blue Brown Orange Violet
green blue

1 Main key switch 7 Compressor 13 Inside air sensor
2 A/C main power supply 8 Blower OFF relay 14 Motor actuator (air mix)
Power supply for compres-
3 9 Blower motor 15 Motor actuator (mode)
sor clutch
Motor actuator (refresh/re-
4 Power supply for controller 10 Blower amp 16
circulate switch)
5 Sunlight sensor 11 Compressor relay 17 CAN signal
Pressure switch (receiver Control panel (TKS-
6 12 Evaporator sensor 18
dryer) CP208C0)
NOTE:
• Wire diameters that are not indicated are 0.5.
• Broken lines indicate wiring on the vehicle side.
• Codes displayed on the connectors indicate the code colors seen from the connection ports of the connectors.
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Explanation of Functions
Explanation of Control
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the vehicle main key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next time air
conditioner operation starts, it goes into the same state as before it was stopped.
When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 sec. of switch input, that switch input is not stored into
memory.
Also, the data read out from EEPROM when the power is switched ON is judged to see if it is within the valid range.
If data outside the valid range was written into memory, for example due to noise, then operation starts from the default
setting values to avoid abnormal operation.
Fahrenheit temperature display
To switch, hold down both the temperature setting UP and DOWN switches for 5 sec.
The display toggles between Celsius and Fahrenheit display each time the switches are both held down for 5 sec.
The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained.
Internal calculations are all done in Celsius.
Only the operation panel display is in Fahrenheit.
Therefore, the display may differ slightly from the exact Fahrenheit temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal processing.
CAUTION
These specifications are written with Celsius as the standard.
Therefore, if the temperature is displayed in Fahrenheit, convert the temperature to centigrade by using
the table below.
Fahrenheit dis- Interior recognition set temper-

play [°F] ature (Celsius) [°C]
63 18.0
64 18.5
65 19.0
：：
77 25.0
：：
91 32.0
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Air Mix Motor Actuator Control

1. Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the current blow
mode, various restrictions are applied, and the target degree of opening is calculated.
Then drive is output to move the motor actuator position to the target degree of opening.
Below are the details.
2. Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position.
However, if the target degree of opening is less than 0°, the actuator is treated as having reached the target
degree of opening when it reaches 0°, then it moves to the specified position. (A stop in the fully-open direction
is used as the reference.)
3. Motor actuator operation priority order
The operation priority for this motor actuator is No. 1.
This means that if the target degree of opening for this motor actuator changes and operation becomes necessary,
even if some other motor actuator is operating, that other motor operation is paused, and this motor actuator
operates.
4. Motor actuator retry control
Even when there are no changes to the target values after the target is attained, if the difference between the
current value and the target value once every 5 min. is equal to or greater than the operation start angle, the
motor actuator is operated.
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Blow Mode Motor Actuator Control

The blow mode is switched by rotating the diffuser switching damper with the motor actuator.
There are 2 types of control: auto and manual.
2. Auto control
When AUTO blow mode is set, the blow mode changes to auto control.
During auto control, the diffuser is switched according to the target blow temperature
Auto control continues until operation of the blow mode select switch is recognized.
*1 Target blow temperature *3 MODE 2 VENT *5 MODE 4 FOOT

*2 Blow mode *4 MODE 3 B/L
3. Manual control
1) When operation of the blow mode select switch is recognized, the blow mode motor actuator is driven to
attain the output shaft angle below and the display is switched too.
Each time operation of the switch is recognized, the display switches MODE 1 → MODE 2 → MODE 3 →
MODE 4 → MODE 1 →...
However, if this switch is pressed during auto control, auto control is ended and the diffuser is fixed at its
current position.
2) MODE 5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode becomes the one
that was in effect just before operation of the DEF select switch was recognized.
Also, even if the DEF switch is pressed again during this mode, the mode is not canceled.
MODE MODE MODE MODE MODE

Blow mode
1 2 3 4 5
Blow mode motor actuator degree of opening 90° 67° 48° 26° 0°
FACE VENT B/L FOOT DEF
Panel display
4. Blow mode control priority order

The priority order for auto control and manual control is as follows.
Priority order Control

1 Manual control
2 Auto control
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Refresh/Recirculate Switch Motor Actuator Control

1. Recirculate mode
In refresh mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been
closed, the system goes into recirculate mode.At this time, the display switches to recirculate and the motor
actuator operates to the refresh angle (damper angle) of 0°.
2. Refresh mode
In recirculate mode, when it is recognized that the refresh/recirculate select switch on the operation panel has
been closed, the system goes into refresh mode. At this time, the display switches to refresh and the refresh/
recirculate switch motor actuator operates to the refresh angle.
1) Refresh mode I
When blow mode control is manual and is set to B/L or FOOT, the set temperature is set to 32 °C ( 89.6 °F
) (HOTMAX), and air flow control is manual and is set to Hi, the refresh angle (damper angle) operates to
67°.
2) Refresh mode II
When in a mode other than refresh mode I, the refresh angle (damper angle) operates to 30°.
3. Operation stop judgment
1) The operating motor actuator stops when the current position comes within the target position range.
2) The stopped motor actuator operates when the current position goes beyond the target position range.
Refresh/recirculate mode and refresh/recirculate display

Refresh/recirculate mode Recirculate Outside air
Panel display
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Blower Amp Control

The air flow is controlled by outputting to the blower amp connected in series with the blower motor.
The air flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increas-
ing or decreasing the blower motor speed.
There are 2 types of air flow control: auto air flow control and manual air flow control.
Also, in auto air flow control, the air flow is restricted by the cold blast prevention control etc.
2. Manual air flow control
Each time it is recognized that the air flow UP switch has been closed, the air flow is fixed to the next higher level
of air flow from Lo → M1 → M2 → M3 → M4 → Hi.
When Hi is already displayed, the air flow is not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed, the air flow is fixed
to the next lower level of air flow from Hi → M4 → M3 → M2 → M1 → Lo.
When Lo is already displayed, the air flow is not changed.
The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is dis-
played, if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and AUTO is
no longer displayed.
Also, the change speed for air flow output switchover is the same as discussed for auto below.
Relationship between air flow and display during manual operation

Lo Hi
Air flow (minimum air M1 M2 M3 M4 (maximum air
flow) flow)
Blower air
40 % 46 % 54 % 64 % 80 % 100 %
flow %
Display
3. Auto air flow control

When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and AUTO
is displayed.
1) During auto air flow control, the air flow is set according to the target blowing temperature as shown in the
diagram below.
2) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized.
3) The auto air flow amount calculation results are continuous, not divided into levels.
4) When it is recognized that the AUTO switch has been closed, the display becomes as in the table below
according to the results of the auto air flow amount calculation.
5) The normal auto air flow output change is roughly 5 V/sec.
6) Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.
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*1 Target blow temperature *4 M4 *7 M1

*2 Auto air flow *5 M3 *8 Lo
*3 Hi *6 M2
Relationship between air flow and target blow temperature
Display refreshing and air flow output correspondence table

Current display Item Target % (about)
Lo display Output range changed to M1 When 44 % or higher
Output range changed to Lo When 40 % or lower
M1 display
Output range changed to M2 When 52 % or higher
Output range changed to M1 When 48 % or lower
M2 display
M3 display
M4 display
Output range changed to Hi When 88 % or higher
Hi display Output range changed to M4 When 84 % or lower
4. Cold blast prevention control

The air flow is restricted according to the value of the coolant temperature data and other parameters sent from
the vehicle side via CAN communication.
The air flow restriction has 2 levels - air flow 0 and air flow Lo. Whether or not to use the restriction is determined
from the judgment results.
1) Conditions under which cold blast prevention control is used
1) Auto air flow
2) When set temperature - inside air sensor temperature 11.
3) When the coolant temperature signal from vehicle is the less than 30 °C ( 86.0 °F ) signal or the 30
°C ( 86.0 °F ) or higher but less than 45 °C ( 113.0 °F ) signal
Under the condition above, the inside air sensor temperature is the value immediately after the vehicle main
key power supply is switched ON and AUTO and Tset are according to the current switch states.
Therefore, when the AUTO switch is pressed after the air flow has been set manually, if the coolant tem-
perature is within the cold blast prevention range, the air flow is restricted.
In the same way, even if the set temperature is changed, if the conditions are met, the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted air flow.
2) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 30 °C ( 86.0 °F ), the air flow is set to 0.
This continues until a coolant temperature signal of 30°C ( 86.0 °F ) or higher is received.
Once a coolant temperature signal of 30 °C ( 86.0 °F ) or higher is received and these conditions are no
longer met, air flow 0 is ended.
3) Air flow Lo control
When the coolant temperature signal from vehicle is the 30 °C ( 86.0 °F ) or higher but less than 45 °C (
113.0 °F ) signal, the air flow is set to Lo.
This continues until a coolant temperature signal of 45 °C ( 113.0 °F ) or higher is received.
Also, the same as for [2], this shift is irreversible.
Once a coolant temperature signal of 45 °C ( 113.0 °F ) or higher is received, control is normal.
5. Blower air flow control when mode motor actuator angle switched
When the mode motor actuator is operated with the blower air flow at M1 or higher, the mode motor actuator is
operated with the blower air flow first set to Lo.
After the end of operation, the original blower air flow returns.
Changes to the blower output at this time are the same as normal auto air flow control.
However, the blower display is not changed during control.
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6. Air flow control priority order

The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as follows.
Priority or-
Control
der
Blower air flow control when mode motor actuator angle
1
switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
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Compressor Clutch Control

The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an external relay.
This control is executed by thermo operation and the fletching prevention function.
Thermo operation has control mode 1 and control mode 2. These modes are applied according to the blow mode
and other conditions.
However, for blower air flow 0, the compressor clutch is switched OFF.
The operation temperature does not include the thermistor variation.
2. Thermo operation (AC switch ON)
1) Control mode switchover
• When the blow mode is B/L and the target blow temperature is as in the diagram below, control mode 2
is used.
As the diagram shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.
*1 Target blow temperature

*2 Control mode 1
*3 Control mode 2
3. Fletching prevention function

1) Operation conditions
After the end of initial operation, if 4 - 5 min. continue with the air flow M3 or higher and the compressor
clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the vehicle main key power supply being switched OFF and this control starts
again when this power supply is switched ON again.
2) This control takes priority over all other control.
4. AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is displayed.
1) Compressor clutch control is the same control as for the AC switch being switched ON.
2) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out.
Even when it is recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power supply is switched OFF, then ON again, since the AC ON, air flow
AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.
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COOLMAX Control and HOTMAX Control

1. When the set temperature is 18.0 °C ( 64.4 °F ) [COOLMAX] (or 18.E)
1) The air mix motor actuator is set to the 0° limiter position (fully closed).
2) For auto air flow control, the air flow is set to Hi.
3) For AUTO blow mode control, the blow mode is set to VENT.
2. When the set temperature is 32.0 °C ( 89.6 °F ) [HOTMAX] (or 32.E)
1) The air mix motor actuator is set to the 90° limiter position (fully open).
2) For auto air flow control, the air flow is set to M4.
3) For AUTO blow mode control, the blow mode is set to FOOT.
Abnormality Detection and Control after Abnormality Detected
If there is an abnormality in a motor actuator drive line or sensor computer input circuit, the abnormality is detected
and control after detection is performed as described below.
In all cases, abnormality control does not end once abnormality has been detected and the location is returned
to normal.
Trouble control is only ended when the vehicle main key power supply is switched OFF or when air conditioner
operation is stopped with the ON/OFF switch on the operation panel.
However, motor actuator restriction is only ended by switching OFF the main key power supply.
2. Trouble in a motor actuator and its input/output circuits
1) Disconnection detection
After the main key power supply is switched ON, if a motor actuator potentio-meter line is disconnected or
shorted, the display in the table below for that motor actuator is carried out and that motor actuator is not
driven until the main key power supply is switched OFF, then ON again.
Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.
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9006-22
2) Motor lock detection

If the output shaft rotation angle of a motor actuator does not reach the target value within 15 sec., locking
is detected, output to that motor is stopped, and the abnormality is displayed on the computer according to
the abnormality location.
Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.
3. Trouble in a sensor or its input/output circuits (disconnection or short)

1) Disconnection or short in the inside air sensor or its input/output circuits
1) Operator compartment temperature control end
• The operator compartment temperature control (all control related to target blow temperature) is
stopped and the air mix degree of opening is directly adjusted according to the temperature adjust-
ment switch input.
• Accompanying this, the operation panel set temperature display changes as in the diagram below.
* is a value between 0 - 9, and each time the DOWN switch is closed, this value decreases by 1; each
time the UP switch is closed, this value increases by 1.
* value Motor actuator degree of opening (°)

0 0°
1-8 * value x 10°
9 90°
2) Auto air flow control end

• The air flow is temporarily fixed at the setting that was in effect when the inside air sensor abnor-
mality was detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3) AUTO blow mode control end
• The blow mode is temporarily fixed at the setting that was in effect when the inside air sensor ab-
normality was detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4) Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not
displayed in the * section below the decimal point and the air mix damper degree of opening display
is given priority.
• HL. E is only displayed for air mix motor actuator trouble.
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5) Thermo operation control mode fixed

• Switching of the control mode according to the blow mode and target blow temperature is stopped
and the control mode is fixed at control mode 1.
2) Disconnection or short in evaporator sensor or its input/output circuits
1) Compressor control is not executed and the compressor clutch is always OFF.
2) E is displayed in the first fraction position of the set temperature display LCD.
See the diagram below. (The temperature setting is in 1 °C ( 33.8 °F ) steps.)
However, E is not displayed for inside air sensor trouble.
3) The AC mark flashes.
Disconnection or short in evaporator sensor or its input/output circuits
*1 The AC mark flashes

*2 E is not displayed
3) Disconnection or short in solar radiation sensor or its input/output circuits

1) The solar radiation compensation data is set to 0.
2) E is not displayed in the first fraction position of the set temperature display LCD as it is for other
sensors.
4) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.
4. CAN communication abnormality processing
1) Recovery from bus off
1) Initial retry processing: 5 msec.
2) Re-retry processing: every 1 sec.
Bus off retry processing is performed at the above rate.
2) Receiving data abnormality
1) Definition: The data field is outside the prescribed range regardless of whether the receiving data is
operating normally or abnormally.
2) Processing: In the case of the former, all data that time are discarded and the previous data are
retained.
In the case of the latter, data is discarded only for those items determined to be abnormal.
3) Communication interruption abnormality
1) Interruption judgment
Monitor Display: When normal reception is not possible 1 sec. or more since the previous normal
reception
Engine: When normal reception is not possible 10 sec. or more since the previous normal reception
2) Internal use data: Shift to alternate data (processing)
3) Sending process: Continue
4) Recover: As soon as valid data is received
4) Alternate data (processing)
＜Sending mode: ENGINE ECU＞
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9006-24
1) Outside air data abnormality

Perform estimated outside air control.
* However, once there is a shift to estimated outside air, estimated outside air control continues until
the ignition is switched OFF.
2) Coolant temperature data abnormality
Control the internal coolant temperature data to 45 °C ( 113.0 °F ) (the temperature at which to avoid
cold air prevention control).
＜Sending mode: MONITOR DISPLAY ECU＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.
5) Alternate data (processing) up to initial normal reception
＜Send node: ENGINE ECU＞
1) Outside air data abnormality
Within 5 sec. after ignition is turned on: No data
After 5 sec. after ignition is turned on: Perform estimated outside air control.
2) Coolant temperature data abnormality
Within 5 sec. after ignition is turned on: Perform control at 30 °C ( 86.0 °F ) (the temperature at
which to control cold air prevention)
After 5 sec. after ignition is turned on: Perform control at 45 °C ( 113.0 °F ) (the temperature at
which to avoid cold air prevention control)
＜Send node: MONITOR DISPLAY ECU＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.
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Monitor Mode
Monitor mode is a mode for understanding abnormalities in the operation panel itself or in other control.
The system goes into monitor mode when there is the special switch input below on the operation panel.
2. Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON/OFF switch closed path con-
tinues for 1 sec. while the refresh/recirculate select switch closed path is ongoing, monitor mode is started.
3. Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 sec.
An LCD with trouble does not light up.
2) Sensor diagnosis
The detection value (AD value or °C ( °F )) for each sensor is displayed.
3) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4. Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is dis-
played in the 3-digit of the 7-segment display for the temperature setting.
The data displayed is selected with the blower UP/DOWN switches and AUTO switch.
The blower UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through 16
displays, 0 - F, and the corresponding data is displayed.(Table A)
Hexadecimal data display and decimal data display can be selected with the AUTO switch. Only for the coolant
temperature signal recognition value, the value detected immediately before entry into monitor mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3rd-digit of the 7-segment display
for the temperature setting. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 - 9)
are displayed there.
1) Hexadecimal display
AD values 00H - FFH are displayed.
When the AD value corresponds to that in Table B (or Table C for the solar radiation sensor), this indicates
a disconnection or short.
In the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadecimal display
changes with it.
If the display before entering monitor mode was , the error judgment value is displayed. (In other
words, the detected value before the abnormality was detected) In the same way, if the display before
entering monitor mode was , the display becomes **.E and the error judgment value is displayed.
2) Decimal display
Decimal display is used from -99.9 °C - 99.9 °C ( -147.8 °F - 211.8 °F ).
Also, the "-" minus display is displayed on the left side of the 3 digit segment.
5. Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until monitor mode
is ended, operations and settings of basic control through all the switches are not possible.
6. Ending monitor mode
In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 sec. while the refresh/recir-
culate select switch closed path is ongoing, monitor mode is ended and the system returns to the basic control
state.
The same also occurs if the vehicle main key power supply is switched OFF.
Exclusively for monitor

mode Display contents
7 seg
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
3 Outside air data
4 -
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9006-26
Exclusively for monitor

mode Display contents
7 seg
Coolant temperature signal status data
30 °C ( 86.0 °F ) or
Lower than 30°C ( higher 45 °C ( 113.0 °F )
C Abnormal
86.0 °F ) Lower than 45°C ( or higher
113.0 °F )
4 1 2 3
5-F Data (sensor diagnosis etc.)
Sensor Discon-
Short
name nection
Inside air
F6H 0CH
sensor
Evaporator
F6H 0CH
sensor
Sensor
5 V short Ground short
name
Solar radia-
D5H 0CH
tion sensor
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Door Switch Control

This control adds a restriction to air conditioner operation with the door switch or front window switch. Its purpose
is to prevent overheating of the vehicle main unit.
Concretely, it suppresses condenser heating and controls in a way restricted in order to obtain a feeling of comfort.
2. Door switch/front window switch signal
Due to data sent from CAN communication.
Message ID: 0x18FF1028
Sending mode: Monitor Display
Send cycle: 10 ms
Data: Open door signal and open window signal data
Data judgment: Set with continuous 5 times of the same data for 20 ms cycle sampling
3. Control restricted by door switch/front window switch
1) Starting restricted control
When either the door or front window is open continuously for 1 sec. or longer, it is recognized that the
switch is open.
At the count of 60 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control is starting and that control starts.
2) Restricted control
1) For both auto and manual blow mode control
Regardless of being selected in either auto or manual blow mode, unless the blow mode is FACE, the
following air flow restriction is executed. (If the blow mode is FACE, the air flow is not restricted.)
Ⅰ. If the target blow temperature ＜ 20 °C ( 68.0 °F ), the air flow upper limit is set to M1.
Ⅱ. If the target blow temperature 25 °C ( 77.0 °F ), the air flow restriction in I is ended.
2) When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3) When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed
to FACE.
After this, all the blow modes can be selected with manual operation.
3) Ending the restriction
When both the door and front window are closed continuously for 1 sec. or longer, it is recognized that the
switches are closed.
After a count of 1 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change
from VENT to FACE in 3. are ended and control returns to normal.
However, if the blow mode has been manually selected, even if the mode was changed from VENT to FACE
by the above restriction, it does not return to VENT when the restricted control is ended.
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Inside Air Filter Clogging Detection Control

This control recognizes the blower current with the dedicated shunt resistor voltage input, judges from that value
whether or not the A/C unit inside air filter is clogged and if it judges that that filter is clogged, it issues a warning
to encourage the operator to replace the filter.
2. Filter detection control
1) Starting detection control (detection timing)
5 sec. after the end of initial operation, if the air conditioner is operating and the cold blast prevention con-
ditions are not present, this control is started. Also, this control is executed every 50 hours of air conditioner
(blower) operation. However, during a temporary filter clog or filter clog, it is executed every time.
2) Detection method
Cooling / heating is judged from the operation mode and in this way the air mix motor actuator target position
is determined. Also, the mode motor actuator target value is set to FOOT, the blower air flow target value
is set to M1, and output is made to attain the target values. When all the target values are attained, the
blower current from the shunt resistor voltage is recognized, and the filter clog is judged by comparing this
current with the default current value.
(cooling / heating judgment)

When the operation mode is FACE or VENT, : Cooling (COOLMAX)
When FOOT or DEF : Heating (HOTMAX)
When B/L: Final inside air temperature If < 22 ºC, heating
When B/L: Final inside air temperature If ≥ 22 ºC, cooling
(detection current threshold)
Relative to the default current value For cooling : 0.35 - 0.39 A min.
For heating : 0.48 - 0.54 A min.
If the value is below this three times in a row, it is judged that there is a clog.
(default current value)
Current found in the initialization operation described below.
3) Clog warning
(buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 sec.
(display)
"FIL" is displayed on the 7-segment display for the set temperature for 10 sec. Other marks go out.
However, if there is any switch input, the "FIL" display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50 % of the clog detection threshold.
5) ON/OFF switching
This function is switched ON/OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF] switches
at the same time. The factory setting for this function is OFF. This function does not come ON until the
initialization operation discussed below is executed.
(buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state after switching.
Other marks go out.
6) Initialization operation
When the [Refresh / Recirculate] and [DEF] switches are pressed at the same time, the default current
value is detected and all the data for filter detection is initialized. Before executing this operation, make
sure that the air conditioner unit (with a new inside air filter installed), ducts, and grilles (with all grilles fully
open) are all installed in their normal states on the vehicle. If initialization is carried out in any other state,
there is a danger of the clog detection judgment control making an incorrect judgment. Immediately after
replacing the inside air filter with a new one, execute the initialization operation.
(buzzer)
When operation of the switch is recognized, the buzzer buzzes with the normal switch input sound. When
the detection ends, the buzzer buzzes for 3 sec.
7) Detection processing avoidance
84551720B NA - August 2012
9006-29
• When the inside / outside air damper is not at the recirculate position immediately before the current value
is read
• When the power supply voltage is not in the tolerance range for the voltage during the initialization oper-
ation
• Trouble in any of the motor actuators
84551720B NA - August 2012

9006-30
Actuator Inspection
Air Mix Motor Actuator Inspection
• Structural diagram
Air mix damper operation defect

↓
See the chart.
↓
Specifying the trouble location
1 Control panel 3 Connector 1

2 Air mix motor actuator 4 Connector 9
• Chart
Standard
Step Action Yes No
value
Press the temperature setting
switches and set to COOLMAX
1 [ 18.0 °C ( 64.4 °F ) ]. Go to Step 2 Go to Step 3
Does the actuator operate at
all?
2 Is an error displayed? Go to Step 6 Damper lock or link defect
Press the temperature setting
switches and set to HOTMAX [
3 32.0 °C ( 89.6 °F ) ]. Go to Step 2 Go to Step 4
Does the actuator operate at
all?
4 Is an error displayed? Go to Step 5 Control panel defect
Is there continuity in harness
Actuator defect or damper
5 between the actuator and con- Harness defect
lock or link defect
trol panel?
Remove the actuator connec-
tor (9).
About 4.7
6 Is the resistance between L/Y Go to Step 7 Actuator defect
KΩ
and B/L of the actuator about
4.7 KΩ?
Is there continuity between the
7 G/L and L/Y and between G/L Control panel defect Actuator defect
and B/L of the actuator?
Set temperature Air mix motor actuator position

COOLMAX [ 18 °C ( 64.4 °F ) ] 0°
HOTMAX [ 32 °C ( 89.6 °F ) ] 90°
84551720B NA - August 2012

9006-31
Refresh/Recirculate Switch Motor Actuator Inspection

Inside/outside air mix damper op-

eration defect
↓
See the chart.
↓

2 Refresh/recirculate motor actuator 4 Connector 11
• Chart
Standard
Step Action Yes No
value
Press the refresh/recirculate
1 switch. Does the actuator operate Go to Step 2 Go to Step 3
at all?
Is there continuity in harness be-
4 tween the actuator and control Harness defect
lock or link defect
panel?
Remove the actuator connector
(11). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the L/G
6 and L/Y and between L/G and B/L Control panel defect Actuator defect
of the actuator?
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9006-32
Mode Motor Actuator Inspection

Mode damper operation defect

↓
See the chart.
↓

2 Mode motor actuator 4 Connector 10
• Chart
Standard
Step Action Yes No
value
Press the mode select switch.
1 Go to Step 4 Go to Step 2
Does the actuator operate at all?
Is there continuity in harness be-
3 tween the actuator and control Harness defect
lock or link defect
panel?
Remove the actuator connector
(10). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the Y/L
6 and L/Y and between Y/L and B/L Control panel defect Actuator defect
of the actuator?
Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5

Blow mode motor actuator degree of open-
90° 67° 48° 26° 0°
ing
FACE VENT B/L FOOT DEF
Panel display
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9006-33
Self-diagnosis Function with Panel Display

Abnormality Display and Self-check Procedures
Motor actuator and sensor abnormalities can be checked on the panel display.
Abnormality Display Position
a This segment is displayed only in the monitor mode

below.
b Error is displayed on the 3-digit 7-segment display.
Explanation of Abnormality Display

Motor Actuator Abnormality
1. HL. E displayed on 3-digit 7-segment display.
Check the air mix damper motor actuator for a harness disconnection or disconnected
connector.
This is also displayed when locked due to air mix motor actuator abnormality and link
abnormality.
2.
flashes.
Check the blow mode damper motor actuator for a harness disconnection or discon-
nected connector.
84551720B NA - August 2012

9006-34
3.
flashes.
Check the refresh/recirculate damper motor actuator for a harness disconnection or

disconnected connector.
CAUTION
The above display and flashing is displayed on the 3-digit 7-segment display when trouble occurs with
the panel ON/OFF switch ON status.
After trouble occurs, when the panel ON/OFF switch is switched ON, the function is displayed.
After trouble is resolved, the abnormality display and flashing are not ended until the main switch is
switched OFF → ON.
Sensor Abnormality
1. HL. * displayed on 3-digit 7-segment display
Check the inside air sensor and check its harness for disconnection, short, or connector
connection defect.
a (* is any number 0 - 9.)
2.
**.E and the mark flashing are flashing on the 3-digit 7-segment display. (** displays the set temperature
value at that time still remaining.)
Check the evaporator sensor and check its harness for disconnections, shorts, or con-
nector connection defects.
CAUTION
The display in 1 and 2 above is displayed on the 3-digit 7-segment display when trouble occurs with the
panel ON/OFF switch ON status.
After the trouble section is repaired, end the abnormality display by switching the panel ON/OFF switch
OFF → ON.
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9006-35
Explanation of Monitor Mode

When sensor abnormality is displayed, the sensor status (disconnection, short) can be checked in monitor mode.
Monitor Mode Display Position
a 3-digit 7-segment
b 7-segment dedicated to monitor display
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9006-36
Monitor Mode Display Operating Method
Refresh/recirculate select
1
switch
Blower switch UP/DOWN
2
switch
3 ON/OFF switch
1. Hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for 1 sec. or longer.
2. Press the AUTO switch.
(All the 7 segments light up for 1 sec., then the system enters monitor mode.)
3. Numbers 0 - 9 or letters A - F are displayed in the 2nd and 3rd digit of the 3-digit 7-segment display.
"H" is displayed in the 1st-digit.
4. The display of 0 - 2 on the dedicated 7-segment display is carried out with the blower UP/DOWN switches. The
necessary sensor is selected from the table below.
7-segment display table dedicated to

monitor
0 Inside air sensor
1 Evaporator sensor
2 Solar radiation sensor
(Display other than the above (3 - 9, B -

F) is not used during service.)
5. To end the monitor display, either hold down the refresh/recirculate select switch and the ON/OFF switch at the
same time for 1 sec. again or longer or switch the vehicle main switch OFF.
CAUTION
1. During monitor mode, operations and settings of basic control through all the switches are not pos-
sible until the air conditioner control operation is stopped and monitor mode ended.
2. During monitor mode, even if a sensor is repaired, the abnormality display is recorded in memory,
and until the ON/OFF switch is switched OFF, then ON again, the abnormality display is not ended.
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9006-37
Display Contents in Monitor Mode

See the dedicated monitor 7-segment display table and 3-digit 7-segment table.
1. Display example 1
The dedicated monitor 7-segment display is 0 (indicates the inside air sensor
state).
From the 3-digit 7-segment table 3F → The sensor is normal.
→ The inside air sensor is normal.
The dedicated monitor 7-segment display is 1 (indicates the evaporator sensor

state).
From the 3-digit 7-segment table 0C → The sensor is disconnected.
→ The evaporator sensor is disconnected.
The dedicated monitor 7-segment display is 2 (indicates the solar radiation sen-
sor state).
From the 3-digit 7-segment table D5 → The sensor is shorted on the 5 V side.
→ The solar radiation sensor is shorted.
3-digit 7-segment table
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9006-38
a Solar radiation sensor short g Solar radiation sensor 5 V side

2nd-digit of 7-segment display d
OCH2 display short D5H2 display
Inside air sensor disconnection e Inside air sensor short F6H0
b 3rd-digit of 7-segment display h
OCH0 display display
c Evaporator sensor disconnec- Evaporator sensor short F6H1
f Sensors normal i
tion OCH1 display display
Air conditioner troubleshooting

The blow temperature does not go down.
* M/A means motor actuator.
Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected
or has a contact defect.
When the AUTO switch or AC • Air mix motor actuator de-
switch is pressed, HL. E is dis- fect
1 Go to Step 2
played in the panel set temper- • Main harness continuity
ature display section. defect
Inspect and repair or re-
place part.
HL. * is displayed on the panel
set temperature display sec-
tion.
* is No. 0 to 9.
84551720B NA - August 2012

9006-39
Standard
Step Action Yes No
value
• Inside air sensor or har-
ness disconnection or
• Inside air sensor and short
evaporator sensor simul-
The inside air sensor con-
taneous disconnection or •
nector is disconnected or
3 The panel snow mark flashes. short
has a contact defect.
• Computer breakdown
See the Monitor Mode sec-
tion too.
tion too.
place part.
• The evaporator sensor
or there is a contact de-
fect.
• Evaporator sensor simul-
4 The panel snow mark flashes. taneous disconnection or Go to Step 5
short
tion too.
place part.
When the set temperature is
18.0 and the blow mode is set
5 18.0 ﾟC Go to Step 6 Go to Step 7
to vent mode, the blow temper-
ature drops.
Inspect the duct or eliminate Computer breakdown or in-
Cool air is flowing into the in-
6 the cause of the cool air inside air sensor defect
side air sensor section.
filtration. Inspect and replace.
Switch compressor clutch
ON/OFF and inspect and
The air mix damper is at the repair the power supply cir-
7 Go to Step 8
COOLMAX position. cuit.
See the cooling cycle trou-
bleshooting.
If motor actuator operation
• Inspect, repair, or replace
stops midway, remove the
Motor actuator breakdown the motor actuator lever
cause or correct the problem, 1.5 kgf or link section.
8 or computer breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?
The blow temperature does not go up.
84551720B NA - August 2012

9006-40
Standard
Step Action Yes No
value
• The air mix motor actuator
or has a contact defect.
HL. E is displayed on the panel • Air mix motor actuator de-
1 set temperature display sec- fect Go to Step 2
tion. • Main harness continuity
defect
place part.
• Inside air sensor or har-
ness disconnection or
short
HL. * is displayed on the panel • The inside air sensor con-
set temperature display sec- nector is disconnected or
2 has a contact defect. Go to Step 3
tion.
* is No. 0 to 9. See the Monitor Mode sec-
tion too.
place part.
When the set temperature is
32.0 and the blow mode is set
3 32.0 ﾟC Go to Step 4 Go to Step 5
to foot mode, the blow temper-
ature rises.
Inspect the duct or eliminate Computer breakdown or in-
Warm air is flowing into the in-
4 the cause of the warm air side air sensor defect
side air sensor section.
infiltration. Inspect and replace.
The air mix damper is at the Inspect the warm coolant
5 Go to Step 6
HOTMAX position. lines.
If motor actuator operation
• Inspect motor actuator
stops midway, remove the
Motor actuator breakdown lever link section.
cause or correct the problem, 1.5 kgf or Repair or replace.
6 or controller breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?
The blower motor does not rotate.
Standard
Step Action Yes No
value
With the flow set to HI, battery
voltage is applied to the termi-
1 Replace the blower motor. Go to Step 2
nals (+ and -) of the blower mo-
tor. (Note: 1)
The battery voltage is applied
between the blower motor (+)
power supply red/blue and the
body.
Voltage of about 10 V is ap-
3 plied between the blower amp About 10 V Go to Step 4 Replace computer.
brown/yellow line and ground.
Remove the blower amp and
refer to the section on Blower
Eliminate the cause of the
Amp Inspection. Is there any Inspect and repair the wire
4 trouble, then replace the
abnormality? harness.
blower amp.
No abnormality → Yes
Abnormality → No
Inspect the blower motor relay.
When the blower motor relay
Inspect, repair, or replace
5 white/red and blue/red are di- Go to Step 6
the wire harness.
rectly connected, the blower
motor rotates. (Note: 2)
84551720B NA - August 2012
9006-41
Standard
Step Action Yes No
value
The battery voltage is applied
Inspect, repair, or replace
6 between the blower motor relay Go to Step 7
the wire harness.
white/red and the body.
When the blower motor re-
Inspect or repair the wire
lay purple/white is dropped to
7 harness or replace the com- Replace the relay.
ground, the blower motor ro-
puter.
tates.
NOTE:
1. Measure with the connector connected.
2. For the sake of safety, have the air conditioner, vehicle key, and light switches all OFF when working with direct
connections in place.
The blower motor speed does not change.
Part 1
Step Action Yes No

• Inside air sensor or harness
disconnection or short
• The inside air sensor connec-
HL. * is displayed on the panel set tor is disconnected or has a
contact defect. Replace the blower amp or
1 temperature display section.
computer.
* is No. 0 to 9. See the Monitor Mode section
too.
Inspect and repair or replace
part.
Part 2
Step Action Yes No

Does the blower motor fail to change
1 speed when the mode is other than Go to Step 2 See Part 1.
FACE?
While operating under restric-
2 Is the door or front window open? tive control by door switch or See Part 1.
front window switch.
The magnetic clutch does not engage.
Step Action Yes No

The snow mark flashes and E is
When the AUTO switch or AC switch
1 Go to Step 2 displayed on the panel display
is pressed, the snow mark lights up.
section.
Clutch defect. Replace the
2 Voltage is applied to the clutch. Go to Step 3
compressor.
Pressure switch defect or
coolant pressure abnormally
Voltage is applied between the har-
3 high or low Go to Step 4
ness and pressure switch.
See the cooling cycle trou-
bleshooting.
Voltage is applied between the vehicle
4 side harness connector blue/red and Go to Step 5 Inspect the clutch fuse.
ground (black).
Is there trouble in the air conditioner
5 Replace computer. Replace the harness.
harness?
Refresh/recirculate mode does not switch

84551720B NA - August 2012
9006-42
Step Action Yes No

The refresh/recirculate motor
actuator connector is discon-
The refresh/recirculate mode display
nected, there is a contact de-
1 on the operation panel LCD display Go to Step 2
fect, or there is trouble with the
section is flashing.
motor actuator or the main har-
ness.
There is foreign matter on the refresh/
recirculate motor actuator lever sec- Remove the foreign matter or
2 Replace the motor actuator.
tion or the motor actuator lever sec- replace the part.
tion is broken.
The mode is not switched.
Standard
Step Action Yes No
value
The refresh/recirculate mo-
tor actuator connector is dis-
The passenger icon display on connected, there is a con-
1 the operation panel LCD dis- tact defect, or there is trou- Go to Step 2
play section flashes. ble with the motor actuator
or the main harness.
Inspect or replace.
The motor actuator rod is cor-
2 Go to Step 3 Correction
rectly in place.
A damper lever is correctly in
3 Go to Step 4 Correction
place.
• Foreign matter or break-
age at cam section or
damper shaft section
• Operation defect due to
When the cam with the rod re- soiling with grease or the
2 kgf or like Replace the motor actuator
4 moved is moved by hand, it is
more or computer.
sluggish (2 kgf or more).
• Remove the foreign mat-
ter or replace the part.
• Clean the cam section,
then apply grease.
84551720B NA - August 2012

9006-43
Part Function and Good/Poor Judgment

Control Panel
Function of each switch
1 Main power switch 4 Air flow select switch 7 Diffuser select switch
Refresh/recirculate select
2 Auto control switch 5 Air conditioner ON/OFF switch 8
switch
3 Temperature control switch 6 Defrost switch
Through the operation of its internal microcomputer, the control panel compares, operates on, and processes the
sensor input signals and control panel switch input signals, switches the output side actuators (refresh/recirculate
switching, mode switching, air mix) and comprehensively controls the fan motor and compressor.
Also, it is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the air conditioner
troubleshooting.)
84551720B NA - August 2012

9006-44
Blower Amp
The power transistor receives the base current from the control unit and changes the speed of the fan motor.
Blower amp inspection
The blower amp can be easily judged by removing the blower amp connector and checking for continuity across
the blower amp terminals.
Terminal No.
Continuity
1 2 3
+ --- - Yes (4.7 kΩ)
Tester - + --- No
+ - --- Yes (diode parallel forward direction)
a Temperature fuse: 132 - 138 °C

( 275.0 - 280.4 °F )
84551720B NA - August 2012

9006-45
Relay
4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay
This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp
and the blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp compressor control.
Relay inspection contents
1. Relay
2. Coil resistor: 320Ω
3. Specification voltage: DC 20 - 30 V
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect for continuity between 3 and 4 under the conditions below.
20 - 30 V applied between term8inals 1 and 2 : Continuity

No voltage applied between terminals 1 and 2 : No continuity
84551720B NA - August 2012

9006-46
Air Mix Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.
The air mix actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and
closes the air mix damper via the link.
Built into the air mix actuator is the potentio-meter which switches linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit reads in the
potentio-meter position in the actuator and determines whether the motor turns forward or reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
Control panel Motor actuator
1 M/A 1 3 GND 5 5 VDC

2 M/A 2 4 Potentio-meter
Terminal
Direction of rotation 1 2
Clockwise (forward) + -
Counter-clockwise (reverse) - +
84551720B NA - August 2012

9006-47
Refresh/Recirculate Actuator
CAUTION
tions.
The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
door via the link.
Built into the refresh/recirculate switch actuator is the potentio-meter that switches linked with the actuator shaft.
When the refresh/recirculate door position is determined by the refresh/recirculate switch on the control panel, the
control unit reads in the signal of the potentio-meter in the actuator and determines whether the motor turns forward
or reverse.
The position detection switch also rotates linked with the motor and stops the refresh/recirculate door at the set po-
sition.
84551720B NA - August 2012

9006-48
Blow Mode Actuator
CAUTION
tions.
The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens
and closes the mode door via the link.
Built into the blow mode actuator is the potentio-meter which switches linked with the actuator shaft.
When blow mode is determined by the temperature control switch, the control unit reads in the potentio-meter position
in the actuator and determines whether the motor turns forward or in reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
Evaporator Sensor
In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor
ON/OFF is controlled.
• Evaporator sensor inspection method (specifications value)

Disconnect the evaporator sensor from the main harness and measure the resistance between the sensor side
connector terminals using the tester.
Resistance between When the sensor section detection temperature is 0 °C ( 32.0 °F ) : 7.2 kΩ
terminals When the sensor section detection temperature is 25 °C ( 77.0 °F ) : 2.2 kΩ
84551720B NA - August 2012

9006-49
Dual Pressure Switch
• The dual pressure switch is installed on the receiver dryer.

When there is pressure trouble in the coolant high-pressure side line (abnormally high pressure or abnormally low
pressure), the dual pressure switch contacts open up to cut off the compressor power and protect the cooling cycle.
Dual pressure switch specifications
1 (Low-pressure side)
2 (High-pressure side)
• Simple inspection method for dual pressure switch

1. With the cooling cycle stopped, disconnect the connector from the switch and check the conductance between
the switch side connector terminals using the tester.
If there is conductance, the switch is normal. (When the outside air temperature is 0 °C ( 32.0 °F ) or higher)
2. Connect the gauge manifold high-pressure side hose to the high-pressure side charge port.
With the cooling cycle operating, the condenser front surface is covered with a plate shaped object and the high
pressure rises.
If the compressor stops around 3.14 MPa ( 455.4685 psi ), the switch is normal.
3. With the coolant removed, check the conductance between the switch side connector terminals using the tester.
If there is no conductance, the switch is normal.
84551720B NA - August 2012

9006-50
Solar Radiation Sensor

This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photodiode, converts
it into milli-amp and sends that to the controller.
• Solar radiation sensor inspection method

Disconnect the solar radiation sensor connector from the harness and measure the voltage between the sensor
side connector terminals using the tester's voltage measurement mode.
The voltage must be different when light is striking the photoreceiver section and when it is not. (The voltage is
about 0 V when absolutely no light is striking the photoreceiver.)
CAUTION
Always measure with the tester in voltage measurement mode (V mode).
Measuring in resistance mode (Ω mode) would destroy the sensor.
Inside Air Sensor
The inside air sensor is installed in the inside air side intake port of the air conditioner unit and switches the tempera-
ture inside the cab to the resistance.
This resistance value is converted into a voltage value in the control panel and processed.
Inside air sensor inspection method
Remove the inside air sensor connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Inside air sensor inspection details (specifications)
Resistance between terminals
For 0 °C ( 32.0 °F ): 7.2 kΩ ± 3％
For 25 °C ( 77.0 °F ): 2.2 kΩ ± 3％
84551720B NA - August 2012

9006-51
84551720B NA - August 2012

9006-52
Section
9007
Assembly and Disassembly of Air Conditioner Units
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Blower Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacement of Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heat Case Right/Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement of Evaporator and Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement of Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CAUTION Replacement of Blower Motor

• Be sure to stop the engine before beginning CAUTION
work.
Do not remove the fan from the blower motor.
CAUTION
1. Remove the cooling hose (2) from the air condi-
• When replacing the evaporator, re-supply tioner unit (1).
and check the compressor oil quantity.
• Remove the 3 Phillips screws (3) and remove the
blower motor (4).
Removal of Blower Unit Screw size
Phillips screws (3): M5 x 14 ( 0.551 )
1. Remove the connectors connected to the refresh/
recirculate motor actuator connector (1), blower mo- • The installation procedure is the reverse of the
tor connector (2), inside air sensor connector (3), removal procedure.
evaporator sensor connector (4) and relay connec-
tor (5).
2. Remove the filter cover (1) and inside air filter (2).
intake case (4).
Screw size
Phillips screws (3): M5 x 16 ( 0.630 )(T1)
84551720B NA - August 2012

9007-3
Replacement of Blower Amp Removal of Heater Core

CAUTION CAUTION
Never disassemble the blower amp. Remove while being careful not to apply exces-
Removing with the power on can suddenly in- sive force to the pipe.
crease the blower amp temperature, damaging
the part. 1. Drain the coolant.
Also, touching the surface could cause burns.
1. Remove the connector (1) from the blower amp (2). link cover (2).
Screw size
• Remove the 2 Phillips screws (3) and remove the Phillips screws (1): M5 x 16 ( 0.630 )
blower amp (2).
Screw size • Remove the mode actuator connector (3), and re-
Phillips screws (3): M4 x 16 ( 0.630 ) move the heater core (4).
• The installation procedure is the reverse of the • The installation procedure is the reverse of the
removal procedure. removal procedure.
84551720B NA - August 2012

9007-4
Removal of Heat Case Right/Left Replacement of Evaporator and

CAUTION Expansion Valve
At this time, perform work with the heater core CAUTION
removed from the heater case.
The evaporator sensor cord is sandwiched in Be careful of the O-rings getting caught, etc.
the groove of the HVAC unit, so carefully check when installing the expansion valve.
it and remove it while making sure not to dam- The evaporator sensor cord is sandwiched in
age it. the groove of the HVAC unit, so carefully check
it and remove it while making sure not to dam-
age it.
1. Remove the 10 Phillips screws (1) and remove the
heater case right (2) and heater case left (3).
Screw size 1. Turn the HVAC unit upside down and place it on a
Phillips screws (1): M4 x 16 ( 0.630 ) stand.
drain case (2).
• Remove the 1 Phillips screw (1) and remove the
evaporator pipe stay (3).
• Remove the evaporator sensor connector (4), and
remove the evaporator (5).

then remove the expansion valve (2).
• Install O-rings (3) on the new evaporator (4) (1 NF
O-ring 5/8 and 1 NF O-ring 1/2).
Bolt (1) tightening torque: 6.9 N・m ( 5.09 lbf・
ft. )
84551720B NA - August 2012

9007-5
Installation of Evaporator Sensor Make sure to install the harness holder (1) and thermis-
tor holder (2) in the original position of the evaporator (4)
CAUTION as shown in the diagram.
Be careful that the sensor cord does not get • Install the evaporator sensor (3) end and thermistor
squeezed in the case when the case is assem- holder (2) as shown in the diagram.
bled.
a Thermistor holder position d 9th row

b 20 mm ( 0.787 in. ) e 27th row
c 73 mm ( 2.874 in. )
84551720B NA - August 2012

9007-6
Replacement of Motor Actuator 3. Replacement of refresh/recirculate motor actuator

Remove the link cover.
1. Replacement of mode motor actuator Remove the connector (2) from the motor actuator
Remove the link cover. (1).
Remove the connector (2) from the motor actuator Remove the 3 Phillips screws (3) securing the motor
(1). actuator (1), remove the lever pin (4) attached to
Remove the 3 Phillips screws (3) securing the mo- the motor actuator (1) from the slot hole, and then
tor actuator (1), remove the rod (4) attached to the install the new motor actuator (1). The installation
motor actuator (1) from the rod hole on the mode procedure is the reverse of the removal procedure.
cam, and then install the new motor actuator (1). Screw size
The installation procedure is the reverse of the re- Phillips screws (3): M4 x 16 ( 0.630 ) (T1)
moval procedure.
Screw size
Phillips screws (3): M4 x 16 ( 0.630 ) (T1)
2. Replacement of air mix motor actuator
Remove the link cover.
Remove the connector (2) from the motor actuator
(1).
Remove the 3 Phillips screws (3) securing the mo-
tor actuator (1), remove the rod (4) attached to the
motor actuator (1) from the rod hole on the damper
lever, and then install the new motor actuator (1).
The installation procedure is the reverse of the re-
moval procedure.
Screw size
Phillips screws (3): M4 x 16 ( 0.630 ) (T1)
84551720B NA - August 2012

9007-7
84551720B NA - August 2012

9007-8
Section
9009
Removal and Installation of Compressor
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AA26 Removal of Compressor

WARNING
• Be careful when loosening the lines. The air
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying
out.
CAUTION
work.
• When removing and installing the compres-
sor, check the compressor oil quantity.
Items to prepare
2. Use a box wrench [ 13 mm ( 0.512 in. ) ] to loosen
• Wrench [ 13 mm ( 0.512 in. ) ] the bolts (1) on the lines in the 2 locations, and then
• Box wrench [ 13 mm ( 0.512 in. ) ] remove the 2 lines (2) (3).
• Rag
• Cleaning fluid • Always remove the low-pressure side line (2) first.
• Attach caps or plugs to the compressor and lines
Tightening torque for bolt (1) installation: 19.6 -
24.5 N・m ( 14.459 - 18.073 lbf・ft. )

4 bolts (1), and then remove the compressor (2).
N・m ( 14.459 - 21.688 lbf・ft. )
84551720B NA - August 2012

9009-3
Installation of Compressor 2. Check the compressor oil quantity.

The compressor contains 135 cc of oil.
1. To install, perform the reverse of the removal pro- The oil quantity being low will cause compressor
cedure. seizing and a reduction in durability. The oil quantity
When installing the bolts, tighten them to the spec- being high will cause a reduction in cooling capabil-
ified torque. ities.
Make sure to check the oil quantity and adjust if
needed.
Measure the oil quantity of the removed compres-
sor. Only this oil quantity is necessary, so subtract
this quantity from 135 cc to determine the amount by
which the oil quantity of the new compressor should
be reduced.
Example)
If the remaining oil quantity of the removed com-
pressor is 30 cc:
Remove 135 cc - 30 cc = 105 cc from the new com-
pressor to be installed.
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
3. Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".
84551720B NA - August 2012

9009-4
Section
9010
Removal and Installation of Condenser
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AK72 Removal of Condenser

1. Use a wrench [ 17 mm ( 0.669 in. ) ] to press the
WARNING lower line on the condenser side (1), and then use a
wrench [ 19 mm ( 0.748 in. ) ] to loosen and remove
• Be careful when loosening the lines. The air the sleeve nut of the low-pressure side line (2).
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying • Always remove the low-pressure side line first.
out. • Attach caps or plugs to the condenser and line to
CAUTION • Clean the lines by spraying with a parts cleaner to
• Be sure to stop the engine before beginning lating on the connectors.
work. Tightening torque for line (1) installation: 11.8 -
14.7 N・m ( 8.70 - 10.84 lbf・ft. )
CAUTION
• When removing and installing the condenser,
resupply and check the compressor oil quan-
tity.
Items to prepare
19 mm ( 0.748 in. ), 22 mm ( 0.866 in. ) ]
• Cap
• Plug
• Rag
• Cleaning fluid
2. Use a wrench [ 22 mm ( 0.866 in. ) ] to press the
upper line on the condenser side (1), and then use a
wrench [ 22 mm ( 0.866 in. ) ] to loosen and remove
the sleeve nut of the high-pressure side line (2).
• The "H" cap indicates the high-pressure side line.
• Attach caps or plugs to the condenser and line to
• Clean the lines by spraying with a parts cleaner to
lating on the connectors.
Tightening torque for line (1) installation: 19.6 -
24.5 N・m ( 14.46 - 18.07 lbf・ft. )
84551720B NA - August 2012

9010-3
3. Use a wrench [ 13 mm ( 0.512 in. ) ] to remove the Installation of Condenser

4 bolts (1), and then remove the condenser (2).
• To install, perform the reverse of the removal proce-
• Bolt (1) tightening torque: 17.7 - 21.6 N ・ m ( dure.
13.06 - 15.93 lbf・ft. ) Tighten the lines and bolts to the specified torque.
If the torque is not specified for a bolt, see the "Bolt
Size and Torque Table".
• Make sure to resupply and check the compressor oil
quantity.
The oil quantity being low will cause compressor seiz-
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
needed.
Resupply quantity: 40 cc
• Perform air conditioner gas charging.
84551720B NA - August 2012

9010-4
Section
9011
Removal and Installation of Receiver Dryer
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Removal of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AN92 Removal of Receiver Dryer

WARNING
• Be careful when loosening the lines.
The air conditioner circuit is filled with high-
pressure gas, so there is the danger of gas
splaying out.
CAUTION
work.
CAUTION
• When replacing the receiver dryer, resupply
and check the compressor oil quantity. 2. Use a wrench [ 10 mm ( 0.394 in. ) ] to remove the
2 bolts (2) from the line (1).
Items to prepare • Attach caps or plugs to the receiver dryer and line
• Wrench [ 10 mm ( 0.394 in. ) ]
Cap • Clean the receiver dryer and line by spraying them
•
• Plug
• Rag
Cleaning fluid • Bolt (2) tightening torque: 7.8 - 11.8 N・m ( 5.75
•
- 8.70 lbf・ft. )
* When connecting the hoses, be sure not to mis-

take the IN and OUT sides.
IN: Hose from the condenser

1
outlet (LIQUID1 hose)
OUT: Hose that goes to the
2 air conditioner unit (LIQUID2
hose)
84551720B NA - August 2012

9011-3
3. Use a wrench [ 10 mm ( 0.394 in. ) ] to remove the Installation of Receiver Dryer

1 bolt (1), and then remove the receiver dryer (2).
• To install, perform the reverse of the removal proce-
dure.
When installing the lines and bolts, tighten them to the
specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
• Check the compressor oil quantity.
The oil quantity being low will cause compressor seiz-
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
needed.
Resupply quantity: 20 cc
• Perform air conditioner gas charging.
84551720B NA - August 2012

9011-4
Section
9015
Air Conditioning Gas Vacuum and Filling Operations
84551720B NA - August 2012

84551720B NA - August 2012
CONTENTS
Air Conditioning Gas Vacuum and Filling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Work Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation". . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging Hose Connection Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gauge Manifold Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vacuuming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas Filling Operation, High-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Filling Operation, Low-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10


WARNING
• Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a experi-
enced and qualified worker with the procedure performs this operation.
• Always wear protective eyewear.
• Gas entering the eyes may cause blindness.
• Refrigerant in the liquid state is very cold (about -26 °C ( -14.8 °F )), so be very careful during handling.
• Refrigerant coming in contact with skin may cause frostbite.
Always use R134a refrigerant.

• Storage
Keep service cans (hereinafter, cans) with refrigerant in them at 40 °C ( 104.0 °F ) or below.
The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises there is the
danger of internal pressure rising sharply and an explosion occurring.
Never store in direct sunlight, in a closed vehicle, or near open flames.
Be careful not to drop cans or have them collide with other objects.
• Filling operation
When cans are heated in order to fill them with refrigerant, make sure that the service can valve and gauge manifold
low-pressure valve are open and heat with water at 40 °C ( 104.0 °F ) or below.
Direct heating or heating to 40 °C ( 104.0 °F ) or higher may cause explosions, so use caution.
If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure valve.
This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a can or charging
hose explosion.
Be careful not to allow the entry of dust or dirt into the air conditioner circuit.
Air, moisture and dirt are very bad for the cooling cycle.
Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter.
Be careful not to overfill with gas.
84551720B NA - August 2012

9015-3
Work Procedures
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation".
1. The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during operation such
as freezing in the small hole of the expansion valve causing the circuit to clog and rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation consists of eliminating
moisture inside the circuit through boiling and evaporation.
2. The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life of the parts
which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and this will cause
reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor will be poor and
this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the operation using an
incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrigerant filling.
Operation Chart
Vacuuming start 30 min. or longer (750 mmHg or less)
↓
Vacuuming Vacuuming stop Let sit for 5 min.
operation ↓
Airtightness check Gauge display abnormality (connectors check and repair)
↓
Refrigerant filling Fill with refrigerant gas up to a gauge pressure of 0.098 MPa ( 14.21525 psi ).
↓
Refrigerant fill-
Gas leak check
ing operation
↓
Refrigerant filling
84551720B NA - August 2012

9015-4
Tools
No. Part name Q'ty Shape Application
1 Gauge manifold 1
Red: high-pressure
side
Blue: low-pressure
2 Charging hose 3
side
Yellow: vacuum
pump side
3 Quick joint 1
4 Quick joint 1 Low-pressure side
5 T joint 1 For service can valve
6 Service can valve 2 For service can
Vacuum pump
7 1 For vacuum pump
adapter
84551720B NA - August 2012

9015-5
Filling Procedures
CAUTION
• Because gauge manifold specifications such as hose color are different depending on the manufac-
turer, read the operator's manual for the gauge manifold to be used for details.
Charging Hose Connection Positions
High-pressure side (DIS) ser-

1 3 Air conditioner compressor 5 Receiver dryer
vice valve
Low-pressure side (SUC) ser-
2 4 Condenser 6 Air conditioner unit
vice valve
84551720B NA - August 2012

9015-6
Gauge Manifold Connection

1. Close the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13).
2. Connect the charging hoses (red and blue) to the service valve.
Red hose (14)：Gauge manifold high-pressure side (HI) → compressor high-pressure side (DIS) service valve
(1)
Blue hose (15)：Gauge manifold low-pressure side (LO) → compressor low-pressure side (SUC) service valve
(2)
Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to make sure they
are secure and in the correct position.
3. Connect the charging hose (yellow) (7) to the vacuum pump (8).
9 Low-pressure gauge
10 High-pressure gauge
84551720B NA - August 2012

9015-7
Vacuuming
1. Open the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13).
2. Turn the vacuum pump (8) switch on and vacuum for at least 30 min.
3. After the prescribed vacuuming time has elapsed (degree of vacuuming achieved: -750 mmHg or less), close
the gauge manifold (13) high-pressure valve (12) and low-pressure valve (11).
4. Next, turn the vacuum pump (8) switch off.
5. Perform a check of air-tightness.
Let the gauge manifold (13) sit for at least 5 min. with the high-pressure valve (12) and low-pressure valve (11)
closed, and check that the gauge indicator does not go back to 0.
If the gauge indicator starts to swing back to 0, this indicates there is a leak. Tighten the line connections, perform
vacuuming again, and check to see if there is still a leak.
84551720B NA - August 2012

9015-8
Gas Filling Operation, High-pressure Side

First, prepare the regulation amount of refrigerant, then start the filling operation from the high-pressure side.
1. After repeating vacuuming, switch the charging hose (yellow) (7) of the gauge manifold (13) from the vacuum
pump to the service can (16).
2. Air purging
Open the valve for the service can (17). (However, keep the gauge manifold high-pressure and low-pressure
valves closed.)
Next, press the air purge valve (18) of the side service port on the gauge manifold low-pressure side with a
screwdriver to discharge the air inside the charging hose using the refrigerant pressure. (Complete after the
swooshing sound stops.)
3. Open the high-pressure valve (12) of the gauge manifold (13), and fill with coolant. (Fill with refrigerant gas up
to a gauge pressure of 0.098 MPa ( 14.21525 psi ).)
After filling, close the gauge manifold high-pressure valve and valve for the service can (17).
Never operate the compressor. (This is very dangerous, as the refrigerant will flow in the opposite direction and
may cause a service can or hose explosion.)
4. Gas leak check
Check for gas leaks in the cycle using the gas leak tester.
If there are leaks, eliminate them through tightening.
Always use the tester for R134a.
84551720B NA - August 2012

9015-9
Gas Filling Operation, Low-pressure Side

CAUTION
• Never open the gauge manifold high-pressure valve.
• Never tip over the service can. This may cause damage to the compressor.
After finishing the high-pressure side filling operation, perform the operation for the low-pressure side.
1. Check that the high-pressure valve (12) and low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17) are closed.
2. Start the engine, increase speed to 1400 - 1600 min-1 ( 1400 - 1600 rpm ), and completely open the cab door
and window.
3. Turn the air conditioner switch on, move the fan switch to the maximum position, and move the temperature
adjustment switch to the maximum cooling position.
4. During filling, set the degree of discharge for the compressor at 1.37 - 1.57 MPa ( 198.72 - 227.73 psi ).
5. Open the low-pressure valve (11) of the gauge manifold (13) and valve for the service can (17), and fill with the
regulation amount of refrigerant until the air bubbles in the receiver sight glass (19) are gone.
• Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air bubbles are visible.
When the amount is
The glass then becomes transparent and turns to a
correct
pale, milky-white color.
When overfilling oc- After the AC is turned ON, no air bubbles at all are
curred visible.
When filling was in- After the AC is turned ON, air bubbles are seen con-
sufficient tinuously.
(Total gas filling amount: 950 - 1050 g ( 2.094 - 2.314 lb ))
6. After refrigerant filling is complete, close the low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17), and stop the engine.
84551720B NA - August 2012
9015-10
• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging effect on the
compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insufficient cooling
and there is the danger of pressure in the circuit becoming abnormally high.
Be sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (12).
• Never invert the service can.
(Gas is suctioned in liquid form, so this may cause damage to the compressor valve.)
7. After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (15) from the low-pressure side (SUC) service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98 MPa ( 142.15
psi ) or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure side charge hose
(red) (14) from the high-pressure side (DIS) service valve.
84551720B NA - August 2012

9015-11
BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)
8R 105 8R 105 2 8R 105
5RW 103 5RW 103 1 5RW 103
F34 F41 F42 F43 F44
3R 105d
3R 105b
3R 105e
3R 105c
3R 105a
180,215,242,250,260,267
400,410,411,412,413,414,415,416,419,420,430,444,445,446,450,490,492,532,534,535,538,559,660,800,801,802,803,805,0806,807,812,813,900,901,902,903,904,905,906,907,908,909,910,911
5RW 020
DIESEL ENGINE
(CN.A50
YAZAKI
1
2
(F20)
(F19)
(F18)
(F17)
(F16)
(F15)
(F14)
(F13)
(F12)
(F10)
FUSIBLE LINK FUSE FUSIBLE LINK FUSIBLE LINK
(F11)
58L
(F9)
(F8)
(F7)
(F6)
(F5)
(F4)
(F3)
(F2)
(F1)
10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 BACK UP CONT FUSE BOX SAFTY RL
10A
15A
10A
15A
10A
10A
20A
15A
ALTERNATOR
5A
5A
10A
15A
15A
15A
15A
10A
10A
10A
10A
10A
20 19 18 17 16 15 14 13 12 11 20 19 18 17 16 15 14 13 12 11
50A 1 15A 1 65A 1 50A 1 8B 797 E 24V 50A
SUMITOMO SUMITOMO 2
(CN.A41) (CN.A42) 2 2 2 YAZAKI M6
YAZAKI YAZAKI YAZAKI
BLOWER MOTOR
YAZAKI M8 (CN.D15)
WIPER/WASHER
CIGAR LIGHTER
TRAVEL ARALM
(BOOM,HOUSE)
1 2 3 1 2 3 1 2 3
COMPRESSOR
REFUEL PUMP
2
1
2
1
1
2
58L 58L 58L
CONTROLLER
CONTROLLER
1.25BG 600 8 2BG 600 CN-A
2
1
AIRCON UNIT
LEVER LOCK
CONVERTOR
KEY SWITCH
4 5 6 4 5 6 4 5 6 (CN.D23) (CN.D26) (CN.D25) (CN.D24) IC
SOLENOID
1.25B 700 2B 700 YAZAKI
SEAT SUS
7
BACK UP
REGULATOR
BEACON
10
12
13
14
15
16
17
18
19
20
10
12
13
14
15
16
17
18
19
20
11
11
AIRCON
AIRCON
OPTION
ENGINE
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
6
5
4
3
2
1
1
2
3
4
5
6
YAZAKI YAZAKI YAZAKI (CN.D16)
SPARE
SPARE
(GATE)
DC/DC
HORN
6
LAMP
LAMP
(CAB)
5RW 103
5RW 102
8R 105
8R 104
5R 002
5R 003
M M M
GPS
1.25W 107
1.25W 106
(CN.A38) (CN.A39) (CN.A40) 5
PG 41b
PG 41d
PG 41g
PG 41h
BG 630
BG 637
BG 640
PG 41a
PG 41c
PG 41e
P 40b
P 40d
P 40g
P 40h
P 40a
P 40c
P 40e
RL 160
RL 161
RL 162
RL 163
RL 164
PG 41f
PG 41i
PG 41j
P 40f
P 40i
P 40j
1.25W 109
1.25W 108
1.25W 107
1.25Y 870 1.25Y 870
1.25WR 141
1.25WR 142
1.25WR 145
1.25WR 146
1.25WR 147
1.25WR 148
G2
1.25W 112
1.25W 110
1.25G 510 0.75R R
1.25W 111
0.85G 502
0.85G 503
0.85G 504
0.85G 505
0.85G 506
1.25BG 600
1.25BG 601
1.25BG 602
0.85BG 603
1.25BG 609
1.25BG 610
0.85BG 620
1.25B 700
0.85B 701
0.85B 702
1.25B 703
0.85B 704
0.85B 720
4 1
WB 245
WL 260
2W 250
GR 180
LgW 190
VR 230
RL 160
0.85GW 215
WL 267
1.25WR 235
1.25RW 140
1.25W 205
0.85VW 170
1.25Br 515 0.75L L
0.85OR 225
1.25LW 200
0.85R 130
3 2
1.25RB 150
0.85YR 220
0.85LR 240
1.25GrR 195
0.85BrR 210
WL 266
WL 267
0.85GW 216
0.85GW 215 2 0.85GW 215
0.85YR 221
0.85LR 242
(CN.D14)
SWP
YAZAKI
B 749 2W 250 1 2W 250
1 2
0.85B 708
RL 166 0.85G 507 K7
(CN.D17)
(CN.D19)
(CN.D18)
1 2 3 4
5 6 7 8
YAZAKI
YAZAKI
YAZAKI
0.5μF
(CN.A51)
8R 030 B
YAZAKI
108,109,110 YAZAKI M6
58M
RELAY BATTERY
A1 601,602,603,701,702,703 G1 (CN.D13)
STARTER MOTOR
CONTROLLER A 503,504,505,515,520,521,530,536,537,539,558,804,808,809 60R 100 60R 101 60R 001 B
(CN.A09) K63 (CN.A13) K64 (CN.A11) K65 (CN.A12) K66 (CN.A10) K67 (CN.A14) K68 (CN.A15) K34 M8 M8
YAZAKI M10
M
10 11 12 13 14 15 16 17 18 19 20
6 7 8 9
POWER 24V 1.25W 108 V 097
X37 RELAY RELAY RELAY RELAY RELAY RELAY RELAY (CN.D21) 5Y 004 S
M1
0.85BG 660
1 1
ECM KEY ON BATTERY RL IDLE STOP DPF NEUTRAL START STARTER CUT M10 M10 M10 M10
12 1.25W 108a VG 098 2 M4 YAZAKI M5
_ _
7 8 9 10 11 12 13 14
4 5 6
YAZAKI
(CN.D11)
58Y
YAZAKI
+ +
(CN.D12)
(CN.C21)
SDL
YAZAKI
POWER 24V 11 G 099 3 (CN.D20)
6 5 4 3
2
1
24V 5.0kw
VR 595 M4
P1
(CN.C3)
YAZAKI
22 4
(CN.A44)
60B 799
YAZAKI
2
1
SDL
GND_2 2 1.25BG 601 Br 596 5 5L 021 1 5BW
1.25WR 511
1.25G 501
1 2 3 4 5
SDL
GLOW PLUG
1 2 3
B
13 1.25BG 601a BG 612 6 1 4 2 1
YR 882a
LR 881a
GND_3 0.85B 701 MONITOR DISPLAY 12V 12V
14 13 12 11
(CN.D9)
SWP
YAZAKI
5 5
7 6 5 4
YAZAKI
10 9 8
R1
3 2 1
1
16 0.85B 701a 3 M8 CN-A
GND BZ. BATT. 0.85RL 161 0.85RL 161 0.85RL 161 RL 161 SUMITOMO (CN.D22)
9 1 1 1
VGS TURBO
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
20 IGN 2 1.25W 111 2 1.25W 111 1.25W 111 2 1.25W 111 1.25W 107 1 1.25W 107 0.85B 751
GND_A 10 D-IN8 ALTERNATOR 4 0.85BrW 519 4 0.85BrW 519 0.85BrW 519 3 0.85BrW 519 0.85G 501 2 1.25G 501 0.75GR 389 1 0.75GR 5
U
P4 M
0.85GW 303
P 040b P 040b 0.85LR 881 LR 881 0.85WR 511 1.25WR 511 0.75Y 390 0.75YR
1.25WR 141
1.25WR 146
1.25WR 147
1.25WR 145
1.25RW 140
0.85W 112
0.85W 113
0.85W 114
0.85W 115
0.85WR 511
CAN H
0.85G 501
0.85O 804
0.85GR 845
0.85B 704
0.85B 705
0.85B 706
21 5 5 4 3 2 6
0.85YR 370
0.85LR 890
0.85LR 891
0.85LR 890
0.85Y 011
0.85Y 011
0.85LR 373
0.85YL 808
0.85LgR 500
0.85LY 824
0.85GrR 012
0.85BrR 010
V
NPN_OUT1 SOL SWING BRAKE 6 W 800 H1 CAN L 6 PG 041b 6 PG 041b 0.85YR 882 5 YR 882 0.85Br 515 4 1.25Br 515 0.75WR 391 3 0.75LR 7
W
NPN_OUT2 SOL 2STAGE TRAVEL 4 L 801 CAN GND 18 18 V 809 6 V 809 0.85GrR 012 5 0.85GrR 012 0.75R 357 8 0.75R 4 VCC
M23
LCD DISPLAY
NPN_OUT3 SOL 2STAGE RELIEFE 7 Y 802 TxD(RS232C) 8 WL 061b 8 WL 061b P 040b 7 P 040b 373 0.85RY 840 6 0.75RY 840
K69 0.75W 358 5 LW 1 U
(CN.E1)
DL090
SUMITOMO
(CN.D30)
CN-A
YAZAKI
5 6 7 8
1 2 3 4
CPU RELAY GLOW 1 2 RELAY STARTER
NPN_OUT4 FREE SWING 3 Br 803 TFT FULL COLOR RxD(RS232C) 9 W 060b 9 W 060b PG 041b 8 PG 041b 303 7
K2 0.75G 359 6 Br 2 V
508
509
118
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
SUMITOMO
1
NPN_OUT5 RL BATTERY 8 0.85O 804 GND(RS232C) 19 BL 064b 19 BL 064b WL 061b 9 WL 061b 142 8 0.85B 779 MT090 0.75L 360 7 L 3 W
517
519
I/O
1
2
NPN_OUT6 SOL OPT 2SPEED 14 YR 805 5V-OUT PGM_WRITE 3 V 097 3 V 097 W 060b 10 W 060b 140 370 (CN.D82) 1 5R 003 0.75B 361 9 0.75B 8 GND
NPN_OUT7 SOL OPT SELECT 15 LY 806 PGM_WRITE SW 12 VG 098 12 VG 098 BL 064b 11 BL 064b 804,808 301 5RW 020 1 1 5L 021 2 5Y 004 0.75BW 693b 4 0.75BW
(CN.D28)
SWP
YAZAKI
070MIULTI
NPN_OUT8 TRAVEL ALARM 18 WL 807 RESET 7 G 099 7 G 099 WB 949 12 WB 949 500 501 10
(CN.C1)
2 3
4 5 6 7 8
0.85B 776
INTAKE THROTTLE
1 2
0.85GrR 013
AMP
NPN_OUT9 RL DPF 17 0.85YL 808 8V-OUT CAMERA+ 10 R 960 10 R 960 BW 950 13 BW 950 112 511 0.75BR 392 12 RW
(CN.A52)
YAZAKI
DC-MOTOR
1 2 3 4
NPN_OUT10 SIG WASHER 19 V 809

P10 CAMERA GND 11 B 961 11 B 961 1.25BG 610 14 1.25BG 610 515 515 0.85G 509 1 0.75GR 393 13 G
(CN.D27)
SDL
1 2
YAZAKI
(CN.D31)
YAZAKI
A/D-IN THERMO SN 010 012 0.85L 372 0.85GrR 012 0.75P 326 VW RW
M
1
13 13 2 1 11 2
1
040/070HYBRID I/O
CN-A
58
AGND 14 14 840 840 0.85B 750 2 14 G 1
SWITCH PANEL
1 2 3 4 5
(CN.E2)
AMP
PWM_OUT1 PUMP POWER(OUT) 3 0.85Y 900 SCL(12C) 16 16 845 6
9 10 11 12 13 14 15 16 17 18
5 6 7 8
S11 0.85Br 516 2 M24
(CN.D29)
CN-A
YAZAKI
PWM_RTN1 PUMP POWER(RTN) 6 0.85BY 901 SDA(12C) 17 17 824 L 5 Vcc
WIPER 0.85WR 512 1
AMP
PWM_OUT2 BOOM DOWN(OUT) 0.85O 902 GND 1.25BG 611 1.25BG 611 VW OUT
2
1
1 15 15 3
S12
(CN.A45)
PWM_RTN2 BOOM DOWN(RTN) 4 0.85BO 903 GND 20 1.25BG 610 20 1.25BG 610 704 508,372 LW 4 GND
YAZAKI
16 15 14 13
12 11 10 9
(CN.D8)
SWP
YAZAKI
8 7 6 5
4 3 2 1
(CN.A30)
MT090
SUMITOMO
WASHER
22 21 20 19 18 17 16 15 14 13 12
11 10 9 8 7 6 5 4 3 2 1
PWM_OUT3 P1 FLOW(OUT) 0.85L 904
SDL
2
S10
1 2
1 2 3 4
(CN.D38)
MT090
SUMITOMO
K37 K36 K35 K5 K3 K11
PWM_RTN3 P1 FLOW(RTN) 0.85BL 905 1.25W 119
5
K10 1
520
521
EGR VALVE
BG 613
BG 614
W.LAMP
1 2
SHLD GND 8 CAMERA1 SIG 1 Y 962 1 Y 962 (CN.A21) (CN.A22) (CN.A20) (CN.A19) (CN.A16) (CN.A18) (CN.A17) 1.25G 754 2
7 S2 CAMERA1 GND 11 W 963 11 W 963 RELAY RELAY RELAY RELAY RELAY RELAY RELAY 0.75WR 386 5 0.75WR 5
(CN.A4)
U
S-G BOOT_CNT 11 WR 062
TRAVEL MODE
CAMERA2 SIG 2 YB 967 2 YB 967 0.85BrR 210 1 0.85BrR 210 SPEAKER:R SPEAKER:L ROOM LAMP BEACON HORN LAMP:CAB LAMP:UPPER
M20 0.75WB 387 6 0.75WB 6 M
FWE 12 WR 063 S4 CAMERA2 GND 12 WB 968 12 WB 968 0.85YR 220 2 0.85YR 220 M8 FUEL PUMP 0.75WL 388 7 0.75WL 7
V
W
IDLE MODE
SW_IN12 LM MAG SW 9 YR 541 CAMERA3 SIG 3 YR 972 3 YR 972 0.85WR 282 3 0.85WR 282 0.75RG 356 8 0.75LW 8 GND
S86 YAZAKI
(CN.D37)
58W
YAZAKI
SW_IN13 LM MODE 10 O 542 CAMERA3 GND 13 WR 973 13 WR 973 0.85WY 829 4 0.85WV 829 (CN.D81) SOLENOID VALVE 1.25W 118 1 2BY
M
0.75GB 353 1 0.75GB 1 U
M25
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
(CN.E3)
DL090
SUMITOMO
DPF CLEAN
1 2
5 6 7 8
1 2 3 4
D-IN1 F-WINDOW SW 4 O 590 4 O 590 1.25GR 875 5 1.25GR 875 1.25G 753 2 2B 0.75GW 354 2 0.75GW 2 V
SUMITOMO
S87 (SP) 24V
6 5 4 3 2 1
12 11 10 9 8 7
LEVER
0.85GR 838
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
(CN.D59)
SWP
YAZAKI
(CN.A59)
0.85LR 837
D-IN2 MUTE SW YL 591 YL 591 VG 822 VG 822 0.75RY 840 0.75R 0.75GR 355 0.75GY W
1 2
5 5 6 1 4 2 1 3 3
MT090
ATT SELECT
Y2
1 2
TXD 4 PW 055 D-IN3 CAMERA SW 6 V 592 6 V 592 WG 823 7 WG 823 0.75B 752 2 0.75B 0.75RW 352 4 0.75L 4 VCC
(CN.A3)
E2
5 LOCK
S88
(CN.A55)
RXD 12 PL 056 D-IN4 DOOR SW 7 OL 593 7 OL 593 LY 824 8 0.85LY 824 3 9
YAZAKI
(BLUE TAPE)
040MIULTI
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
MENU
SDL
RS232C_TXD 3 W 060a D-IN5 ONE TIME WIPER 8 YG 594 8 YG 594 LG 825 9 LG 825 SUMITOMO 10
(CN.C2)
S89 SWING (S2) CRANK ANG(MRE)
(CN.D60)
SWP
YAZAKI
1 2 3 4
AMP
2
1
RS232C_RXD 10 WL 061a D-IN6 SPARE1 9 VR 595 9 VR 595 OR 826 10 OR 826 0.75R 181 1 0.75R 1.25Y 871 1 1.25Y 871 1 0.85R 11
24V
WG 831
WG 823
SENSOR
G 888
OR 826
LW 841
LgW 190
LgW 191
LG 825
LG 832
LG 842
LR 880
RL 164
RL 165
DIAPLAY SEL
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Y3
1 2
0.85GW 216
0.85GW 217
RS232C_GND BL 064a D-IN7 SPARE2 Br 596 Br 596 G 888 G 888 0.75W 800 0.75B 1.25B 758 1.25B 758 0.85B
1.25GR 875
1.25LW 200
1.25LW 201
0.85R 885
2 10 10 11 2 2 2 12
0.85RB 292
0.85RB 293
0.85RB 290
0.85Y 980
0.85YB 984
1.25Y 870
0.85L 981
0.85LB 985
BRAKE
S90
1.25GrR 195
1.25GrR 196
D-OUT1 WIPER-INT GR 820 GR 820 YL 591 YL 591
70W Vcc
GND 5 14 14 12 (WHITE TAPE) 13 1
(CN.E4)
YAZAKI
TRIP/CAMERA
B49
(CN.A2)
1 2 3
GND 13 D-OUT2 WIPER-CNT 15 Lg 821 15 Lg 821 V 592 13 14 3 OUT(PULSE)
(CN.D66)
SWP
YAZAKI
(S1)
(CN.G2)
CN-A
YAZAKI
LR 881
2STAGE LAMP
(CN.D61)
SWP
YAZAKI
CAN_H 6 P 040c D-OUT3 RL FUEL PUMP 16 VG 822 16 VG 822 YG 594 14 YG 594 GR 180 1 0.75GR 180 0.75R 182 1 0.75R 15 2 GND
1 2
2
1
(BOOM)
Y4
1 2
CAN_L 14 PG 041c D-OUT4 RL LAMP 17 WG 823 17 WG 823 0.85YB 984 15 0.85YB 984 833 W 800 2 0.75W 800 0.75L 801 2 0.75B TRAVEL 16
+5V_OUT 11 D-OUT5 RL IDLE STOP 18 LY 824 18 LY 824 0.85LB 985 16 0.85LB 985 164,190,195,200,216 L 801 3 0.75L 801 (RED TAPE)
D-OUT6 RL MUTE LG 825 LG 825 0.85BY 982 0.85BY 982 Y 802 0.75Y 802 COMMON RAIL PRESS
FREQUENCY_IN 1 19 19 17 4
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
2STAGE (S3)
E1 SENSOR
(CN.D62)
SWP
YAZAKI
FREQUENCY_GND 9 D-OUT7 RL ROOM LAMP 20 OR 826 20 OR 826 0.85BL 983 18 0.85BL 983 829,834,850,851,852,853,880,882,885,943 Br 803 5 0.85Br 803 0.75R 183 1 0.75R 1.25Y 870 1 0.85R
24V LAMP
1 2
AVcc 7 0.85Y 408 11 WB 949 G 812 6 0.75G 812 0.75Y 802 2 0.75B RELIEFE Y5 1.25B 757 2 0.85B
70W 1
(CN.E5)
AMP
(HOUSE)
1 2 3
B52
SW_1 IDLE SW 15 L 530 22 BW 950 Lg 813 7 0.75W 310 1 VW 2
(CN.D65)
CN-A
YAZAKI
(YELLOW TAPE)
SW_2 ANTI-THEFT 16 VG 531 WL 807 8 0.85WL 807 0.75R 311 6 GrB 3
(CN.A1)
S1
2
1
POWER (S4)
CAMERA
R3 S51
(CN.D63)
SWP
YAZAKI
12 13 14 15 16 17 18 19 20 21 22
SUNLOAD SENSOR
1 2 3 4 5 6 7 8 9 10 11
SW_3 COOLANT 8 GrR 532 VG 822 9 0.85VG 822 0.75R 184 1 0.75R 0.75G 312 15 WB
(See page 2/2)
7 8 9 10 11 12 13
1 2
4 5 6
0.85R 130 1 0.85R 130 KEY SWITCH LR 880 10 0.85LR 880 0.75G 812 2 0.75B 0.75B 690b 11 0.75B
1 WB 949 0.85RB 290 2 0.85RB 290
CONNECTION YR 882 11 0.85YR 882
SAVE
Y6 0.85WL 807 1 B TRAVEL 12
A4 TO CAMERA 3 (GREEN TAPE)
THROTTLE VOL. LIMIT SWITCH OFF ACC
B61 ALARM
H2 BOOST PRESS
(CN.C6)
SN_IN1 SN HYD.TEMP 2 0.85YB 490 2 BW 950 R 970 1 0.85VW 170 3 0.85VW 170 0.85WV 829 12 0.85WV 829 0.85GW 215 2 R 0.75W 313 5 L
(BLUE TAPE) B G1 G2 ACC M ST
AMP
(GATE) 24V,107dB SENSOR

(CN.C4)
YAZAKI
1 2 3
0.85GL 492 0.85LgR 500 0.85LgR 500 0.85R 885 0.85R 885 0.75L 314 LW
ON
(CN.D69)
SWP
YAZAKI
SN_IN2 SN FUEL LEVEL 15 B 971 4 13 10
1.0Ⅲ
2
HEAT
(CN.C20)
1 2
3 4
0.85Y 410 0.85BrR 010 0.85BrR 010 0.85GW 943 0.85GW 943 0.75G 315 Br 0.75RW
1 2
POT_IN1 SN_P P1 YR 972 SOLENOID VALVE
YAZAKI
21 WIPER 3 5 14 17 1
(CN.E6)
SUMITOMO
ST
SWP
OFF
1 2 3
0.85L 411 0.85RY 840 0.85RY 840 0.85LR 242 0.75BW 691b 0.75BW 0.75L
POT_IN2 SN_P P2 9 CONTROLER WR 973 4 6 15 14 2
B47
(CN.C5)
1 2
FREE
(CN.D64)
SWP
YAZAKI
POT_IN3 SN_P N1 0.85Lg 412 0.85GR 845 0.85GR 845 0.75R 187 0.75R 2W 250 0.75RL
22 7
ACC 16 1 1 16 3
AMP
Y18
040
1 2
POT_IN4 SN_P N2 10 0.85G 413 WIPER SW.IN(INT) 11 GR 820 0.85G 507 8 0.85G 507 17 0.85Br 803 2 0.75B 0.85VG 822 3 0.75RW 319 29 0.75RW
X30 ON SWING
REFUEL PUMP
Br 834
POT_IN5 SN_P SWING 23 0.85GR 414 WIPER SW.IN(CNT) 12 Lg 821 0.85B 720 9 0.85B 720 18 (NO TAPE) 2B 764 2 0.75GW 320 24 0.75L
ST (See page 2/2) OIL PRESS
0.85B
A/D
0.85Y
0.85L
0.85V 415 WASHER SW. IN V 809 0.85BG 620 0.85BG 620 0.75RG 321 0.75RL
(CN.D76)
58W
YAZAKI
POT_IN6 SN_P UPPER 12 13 10 19 19
0.85YG 416 POWER (24V) IN 0.85BrR 210 0.75GR 180
SENSOR
1 2
POT_IN7 SN_P TRAVEL 24 1 20 1 18
TO CAMERA 2
3
ROOM LAMP 3 2 1 1 2
5 6 7 8 9 10
1 2
0.85LR 417 WASHER CONT.(+) 0.85WY 829
E4 0.75R 181 0.75WB 322 0.75WB 0.75WB
(CN.B6)
MT090
SUMITOMO
POT_IN8 SN_P HYD.FILTER 13 2 R 965 2 30 1
(CN.A46)
SDL
YAZAKI
1 (RED TAPE)
(CN.E7)
SUMITOMO
YAZAKI
(CN.C8)
1
2
3
YAZAKI
1 2
1
2
YAZAKI
(CN.D68)
MT090
SUMITOMO
1 2 3
0.85LY 418 WASHER CONT.(-) 0.75R 182 0.85WV 830 0.75YB 323 0.75LY
B21
0.75LY
1 2
POT_IN9 SN_ANG THROTTLE 25 3 24V,10W B 966 2 SDL 1 2 3 3 1 25 2
090
SWP
4
2
5
3
6
1
1 2
(CN.D58)
SWP
YAZAKI
(CN.B2)
(CN.C19)
POT_IN10 SN_P OVER LOAD 0.85Gr 419 WINDOW CONTROL 4 5 6 0.75R 183 0.85B 756 0.75BY 324 0.75BY 0.75BY
1 2
3 4
26 9 YB 967 4
5 6 7 8
1 2 3 4
(CN.B3) 2 20 3
YAZAKI
3
9 10 11 12 13 14 15 16 17 18
5 6 7 8
3 4
SWP
OFF
(CN.C22)
0.85G 503 REV. SIG. 0.85G 485 G 888 G 888 0.75R 184
0.85VW 170
COMP_IN1 KEY ON
0.85BO 428
7 7 2 1 WB 968 5 21
0.85Y 408
YAZAKI
0.85RY 840
4
0.85LY 418
YAZAKI
1
2
CN-A
COMP_IN2 SW GATE LEVER 0.85RY 520 STOP SIG. 0.85L 486 Y 843 Y 843 0.85RY 844 CN-A 0.75R 185 0.75YG 342 0.75YG
0.85R 130
20 1 2 2 6 31
0.85RB 290
DOOR
0.85LgR 500
0.85BrR 010
0.85Br 515 WINDOW LIMIT SW. L 530 0.85L 530 0.85GR 845 (CN.B1) WASHER
COMP_IN3 BATTERY CHARGE 8 4 1 1 7 22
(CN.A56)
ON
X29
YAZAKI
SW_IN1 AVcc 11 0.85W 400 WIPER MOTOR(CW) 8
5 0.85LR 827 YG 594 2 0.85YG 594 0.75R 187 8 0.75BR 344 9 0.75BR FUEL TEMP.SENSOR
SDL
1 2 3 4
0.85BO 428 WIPER MOTOR(CCW) 0.85LB 828 G 850 0.85G 850 0.85WV 829 0.75G 345 0.75RL 0.75YG
SW_IN2 AGND
M
(CN.E8)
ECO-J
AMP
1 6 LIMIT SW 3 1 13 1
(CN.C9)
YAZAKI
M4
1 2
3 4
B3
1 2
SW_IN3 AGND 14 0.85BW 420 GND 10 1.25B 710 (DOOR) TO CAMERA 1 O 851 4 0.85O 851 0.85B 755 2 23 0.75LW 2
LW 533 R 960 LW 841 0.85LW 841 24V
(CN.D67)
CN-A
YAZAKI
SW_IN4 SW AIR CLEANER 16 1 (NO TAPE) 5 0.75WR 365 7 0.75WR
VY 534
M3 S53 OL 593 OL 593 B 961 YL 591 0.85YL 591 RADIO AM/FM STEREO 0.75Y 366 0.75GY
SW_IN5 P-SW OPT1 3 1 2 2 6
P15 HYD.OIL TEMP SENSOR 2
2
1
KNOB(RIGHT) 24V,2A
(CN.C18)
B2
1 2 3
4 5 6
1 2
3 4
SW_IN6 P-SW OPT2 GY 535 Y 843 Y 843 Y 962 GL 852 0.85GL 852 0.85Y 900 0.75Y 900
YAZAKI
17 2 4 3 7 1 26
(CN.C7)
YAZAKI
BOOST TEMP.SENSOR
CN-A
SWP
SW_IN7 SW FREE SWING GW 536 WIPER MOTOR BG 613 BG 613 W 963 OL 853 0.85OL 853 IDLE SW P3 0.85O 902 0.85O 902 0.75YB 490 0.75R 340 0.75RB
(CN.C23)
4 3 1 4 8 2 2 3
I/O
YAZAKI
BUCK UP
HORN LOW
1
2
3
S16
(CN.D56)
SWP
YAZAKI
WG 537 0.85L 530 L 0.85L 904 0.75L 904 0.75BW 491 0.85LR 880 0.75R 0.75BR
CN-A
SW_IN8 SW HBCV/TRVL ALM
(CN.E9)
PACKARD
18 3 6 3 1 8 1
(LEFT)
B51
GND
4 5 6 7 8
1
ACC
1 2
(CN.A47)
SDL
YAZAKI
R(+)
1 2
L(+)
YL 538 0.85LR 0.85LR 827 0.85BG 625 L 0.85G 906 0.85G 906 0.75RL
R(-)
B92
L(-)
SW_IN9 SW FILTER IND 5 1 7 4 YAZAKI(CN.D70) 27 2
SW_IN10 SW ENG STOP 19 LB 539 M 0.85LB 3 0.85LB 828 DOOR OPEN:CLOSE X28 0.85YG 594 4 Y WIPER 0.85W 908 5 0.85B 760
24V,370Hz
4 0.75G
DOOR CLOSE:OPEN
U1 S11 FUEL LEVEL SENSOR 111dB
4 5 6 7 8
1
2 3
0.85BG 626 Y 0.85V 910 0.85VR 910
(CN.B4)
62C
YAZAKI
SW_IN11 6 2 5 6 28
GrR
YAZAKI(CN.D71)
OW
R5
(CN.C10)
GR
1 2
3 4
Gr
YAZAKI
G
R
B
SW_IN12 0.85G
0.85L
4 0.85G 485
0.85L 486
H4 SPEAKER(R)
RL 167
0.85G 850
0.85B 723
3 G
G
1ST.ACT
S/V(R)
7 0.85GL 492 2 0.75Y 32
EGR INTAKE TEMP.SENSOR
2 3
SW_IN13 6 8 8 0.85BG 660 1 0.75B
DC/DC(24V/12V)
(CN.D57)
SWP
YAZAKI
S31 HORN HIGH
1
2
3
4
5
6
7
8
9
(CN.E10)
YAZAKI
0.85B 5 1.25B 711 1 0.85BY 982 3 0.85BY 982 RL 162 1 RL 162 0.85O 851 1 O 0.85BY 901 9 0.75BY 901 0.85YR 882 0.75WR 1
CONVERTER (RIGHT) B86
1 2
(CN.C24)
1 2
R
YAZAKI
0.85YB 984 0.85YB 984 0.85YR 221 0.85YR 221 0.85B 724 O 1ST.ACT 0.85BO 903 0.85BO 903 0.75GY
2 1 2 2 10 YAZAKI(CN.D72)
B93 2
1
2
(CN.D7)
NMW
MITSUBISHI
PRESS. SENSOR 24V,370Hz
32
27
22
17
14
10
5
CN-A
24V 0.85BL 983 24V IN (MAIN) 0.85OR 225 GW 536 0.85GW 536 S/V(L) 1 2 3 4 0.85BL 905 0.75BL 905 0.85B 761
0.85RB 291
1.25B 728
4 6 3 11
0.85Y 980
0.85L 981
RL 162
0.85BY 982
0.85BL 983
31 30 29 28
26 25 24 23
21 20 19 18
13
9 8 7 6
4 3 2 1
5 6 7 8 9 (HYD.FILTER) 111dB
2 0.85LB 985 24V IN (BACKUP) 2 RL 163 WG 537 4 0.85WG 537 S32 YAZAKI
0.85GB 907 12 0.85GB 907 YAZAKI(CN.D73)
16 15
12 11
A13 GND 5 0.85B 708 YL 558 5 0.85YL 558 PA 0.85YL 818 13 0.85YL 818 0.85W 407 1
WATER TEMP.SENSOR
(CN.D54)
ECO-J
AMP
ACC
X15 H5 B97
1 2 3
12V OUT(BACKUP) 3 0.85RY 280 YB 570 6 0.85YB 570 (CN.B13) 0.85LR 417 14 0.85LR 417 0.85LR 417 2
SOCKET SPEAKER(L)
(CN.E11)
SUMITOMO
CONTROLLER B KNOB(LEFT)
(CN.D74)
SWP
YAZAKI
12V OUT(MAIN) 1 0.85WR 281 V 571 7 0.85V 571 0.85WB 909 15 0.85BW 427 3 0.85R 885 1 0.75RB 1
BEACON
X2
1 2
HORN
P2
3
B1
1 2
0.85B 712 0.85WR 282 1 0.85BL 983 GND 4 0.85BW 709 Br 834 8 0.85Br 834 0.85VG 911 16 0.85VG 911 0.85B 762 2 0.75BY 2
12V S15 M8 YAZAKI
(CN.C25)
L
YAZAKI
POWER 24V 1 1.25W 109 YAZAKI YAZAKI 2 0.85LB 985 SHUT OFF 7 LG 842 9 0.85LG 842 0.85LW 841 6 L 17 0.75R 3
1
2
(CN.B22)
CN-A
12 1.25W 109a (CN.C16) (CN.C15) 0.85Y 980 10 0.85Y 980 0.85B 725 7 L 0.85RY 280 18 PRESS. SENSOR (P1)
RADIO
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
YAZAKI(CN.B14)
(CN.D75)
SWP
YAZAKI
POWER 24V 0.85L 981 0.85L 981 0.85YL 591 Y MUTE 0.85WR 281 0.75W 400 0.75R 886
11 11 4
X36 1 1 BEACON
E69
(CN.D45)
ECO-J
AMP
YAZAKI(CN.B15)
CIGAR LIGHTER S69
4 5 6 7 8
1
B42
1 2
1 2 3
0.85BY 982 0.85BY 982 0.85BG 627 Y 0.85BW 709 0.75Y 410 0.75B 763
(CN.B5)
62C
YAZAKI
22 12 5 2 2 OVER HEAT SW.
E51 24V,5A YAZAKI(CN.B16) (FOR CRANE) CAM ANG(MRE)
4 5 6 7
2 3
GND_2 2 1.25BG 602 0.85BL 983 13 0.85BL 983 0.85GL 852 3 G 2ND.ACT 0.75BW 420 3 M4
(CN.A28)
LIMIT SW 12V OUTPUT SENSOR

YAZAKI
S/V(R)
(CN.A54)
1.25BG 602a 0.85B 713 0.85YR 220 0.85RY 280 0.85RY 280 0.85B 726 G
2 3
13 14 8
YAZAKI
ISUZU(CN.E19)
(WINDOW) (FOR RADIO) DUAL SWITCH
S33 X35
PA
P-G
1
GND_3 0.85B 702 YAZAKI(CN.A30F) 0.85WR 281 0.85WR 281 0.85OL 853 O Vcc
S52
SDL
5 YAZAKI YAZAKI 15 1 1
(CN.E12)
SUMITOMO
X6 (RECIVER DRYER)
1 2 3 4 5
(CN.C14) (CN.C13) PRESS. SENSOR (P2)
1 2 3
B87
16 0.85B 702a O 590 6 O 590 0.85BW 709 16 0.85BW 709 0.85B 727 2 O 2ND.ACT 3 OUT(PULSE)
S54
(CN.B17)
SWP
YAZAKI
N-G S/V(L)
(CN.D77)
090
SUMITOMO
GND 9 HORN VOL.SW BG 614 3 BG 614 17 0.75W 401 1 0.85GW 943 2 2 GND
(CN.D46)
ECO-J
AMP
S34
1 2
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 2
B44
1 2 3
20 YAZAKI(CN.A31F) 2 18 AIR SUSPENSION 0.75L 411 2 1.25W 944 1 0.75R 316 17 Y
9 10
L-G GND_A 10 5 0.75BW 421 3 0.75L 317 18 T
6 3
(CN.A49)
SDL
YAZAKI
5 2 WINDOW OPEN:CLOSE 1.25GR 875 0.85YR 221 1.25R 0.85W 400 0.75W 400 0.75G 318 OB
21
S70 WINDOW CLOSE:OPEN
1 1
M 1 19
SUCTION CONT.VALVE
(CN.D78)
SWP
YAZAKI
A-G 4 1 1.25B 714 0.85B 720 1.25B 0.85BW 420 0.75BW 420 0.75BL 692b 0.75BW
NPN_OUT1 6 4 2 2 MAGNET CLUTCH 15
7 8
PRESS. SENSOR (N1)
Y8
(CN.E13)
MT090
SUMITOMO
0.85Y 410 0.75Y 410
1
NPN_OUT2 4 3 (COMPRESSOR) 3 2
5 6 7 8
E3 Y35
10
1
2
3
4
5
6
7
8
9
CARLING
(CN.B18)
MT090
SUMITOMO
1 2
NPN_OUT3 SOL POWER SAVE 7 G 812 YAZAKI(CN.A26F) 0.85YR 222 1 0.85L 411 4 0.75L 411 0.85W 402 1 7 1
(CN.D47)
ECO-J
AMP
X23
VC2 24V
B43
1 2
1 2 3
NPN_OUT4 SOL FAN REVERSE 3 Lg 813 (CN.C12) 0.85R 1.25GR 875 0.85B 721 2 0.85Lg 412 5 0.85Lg 412 0.85Lg 412 2 1.25W 944 1 1.25G 0.75RG 394 20 0.75RB
24V
1 2 3
4 5 6
(CN.C11)
YAZAKI
NPN_OUT5 8 0.85LR 881 0.85W 1.25B 714 0.85G 413 6 0.75G 413 0.85BW 422 3 0.75RW 396 16 0.75RW
LAMP 70W
CN-A
I/O
NPN_OUT6 14 0.85YR 882 VR 230 1 VR 230 0.85GR 414 7 0.85GR 414 10

(CAB) YAZAKI(CN.A27F) MEMORY CLEAR INJ1 (#1)
NPN_OUT7 15
YAZAKI(CN.A37M)
BG 635 1.25WR 235 2 1.25WR 235 S9 S85 0.85V 415 8 0.85V 415
PRESS. SENSOR (N2)
11
(CN.E14)
MT090
SUMITOMO
NPN_OUT8 18 BrY 084 0.85LR 240 3 0.85LR 240 ENG STOP BEACON<EU> 0.85YG 416 9 0.85YG 416 1.25B 374 5 1.25BW 4 1
YAZAKI(CN.A37F) PUMP
Y63
1 2
NPN_OUT9 BACKET CLOSE(PWM) 17 0.85YL 818 1.25WR 148 4 0.85WR 148 0.85Gr 419 10 0.85Gr 419 0.75W 403 1 1.25W 375 1 1.25L 8 2
E3
(CN.D48)
ECO-J
AMP
PUMP
(CN.D39)
SWP
YAZAKI
B40
1 2 3
NPN_OUT10 19 WL 819 YAZAKI(CN.A28F) 0.85LG 302 5 0.85LG 302 0.85WL 430 11 0.85WL 430 0.75G 413 2 0.75Y 900 1 1.25RB 378 6 1.25R 1
DIAG SW
X24 Y7
1 2
0.85R 1.25GR 876 BG 634 LB 539 6 0.85LB 539 0.85BL 450 12 0.85BL 450 0.75BW 423 3 0.75BY 901 2 1.25RL 379 2 1.25WB 5
IMMOBILIZER 24V POWER
040/070HYBRID I/O
YAZAKI(CN.A36M) INJ3 (#4)

VG 531 0.85W 1.25B 715 PB 083 0.85Y 408 0.85Y 408 0.85GW 444 0.85GW 444 1.25Y 376 1.25B
YAZAKI(CN.A33F) X9 LAMP 70W YAZAKI(CN.A36F)
7 9 10 9 10 13 8 2
(CN.E15)
MT090
SUMITOMO
PWM_OUT1 ARM CLOSE(OUT) 3 0.85G 906 BG 637 0.85LY 418 8 0.85LY 418 6 3 6 3 0.85VG 445 14 0.85VG 445 1.25L 377 4 1.25WL 6 1
(CAB)
10
10
YAZAKI(CN.A33M) YAZAKI(CN.A29F)
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
PRESS. SENSOR(PILOT SWING)
5 2 5 2
Y65
1 2
PWM_RTN1 ARM CLOSE(RTN) 6 0.85GB 907 M8 M8 0.85BO 428 9 0.85BO 428 0.85LR 446 15 0.85LR 446 1.25B 380 13 1.25LR 3 2
A BG 631 1 BG 631 4 1 4 1 P1
(CN.D40)
ECO-J
AMP
AMP
PWM_OUT2 FAN SPEED(OUT) 1 0.85W 908 P 040g 10 P 040g 7 8 7 8 0.85YB 490 16 0.75YB 490 0.85W 404 1 0.75L 904 1 1.25BW 381 9 1.25BR 7
TO CONTROLLER C
(CN.D49)
ECO-J
AMP
B RL 166 2 RL 166
Y11
1 2
B22
0.85WR 148
YAZAKI YAZAKI
1 2 3
0.85WB 909 PG 041g PG 041g 0.85GL 492 0.85GL 492 0.85GR 414 0.75BL 905
0.85BG 620
0.85LG 302
PWM_RTN2 FAN SPEED(RTN)
0.85LB 539
0.85B 722
4 11 17 2 2 12
0.85LG 842
CARLING CARLING FLOW
(CN.C17) (CN.C32) C P 040 3 P 040h INJ2 (#3)
22 21 20 19 18 17 16 15 14 13 12
11 10 9 8 7 6 5 4 3 2 1
PWM_OUT3 OPT PRESS(OUT) 2 0.85V 910 1.25W 110 1 WB 949 12 WB 949 0.85BG 660 18 0.85BG 660 0.85BW 424 3 14
EST CONNECTOR A
VC2 VC2
X25 D PG 041 4 PG 041h
(CN.E18)
YAZAKI
(CN.D10)
D
SUMITOMO
(CN.E16)
MT090
SUMITOMO
0.85VG 911 WL 266 BW 950 BW 950 (CN.B7) (CN.B10) GrR 532 0.85GrR 532
20 19 18 17
16 15 14 13
12 11 10 9
PWM_RTN3 OPT PRESS(RTN)
5 6 7 8
1 2 3 4
5 2 13 19 1
8 7 6 5
4 3 2 1
PL 081 PL 081
Y64
F A B
X5
(CN.52)
HD10
DEUTSCH
E 5
1 2
SHLD GND 0.85G 505 0.85GW 943 0.85GW 943 LW 533 0.85LW 533
G
8 3 14 20 2
F 6 PRESS. SENSOR (PILOT UPPER)
H
7 0.85RY 521 4 YL 538 21 0.85YL 538

(CN.A8)
PROPORTIONAL S/V
C
J
G
7 8 9 10 11 12 13 14
1 2 3
S-G BOOT_CNT 11 YR 067 YB 570 5 LB 559 22 0.85W 405 1

CAN
(CN.D50)
ECO-J
AMP
S22 INJ4 (#2)
3 2 1
14 13 12 11 10 9 8 7
H
B26 BOOM
(CN.D41)
SWP
YAZAKI
X31
1 2 3
YR 068 V 571 P 040j 0.85V 415 0.85O 902
(CN.A48)
SDL
YAZAKI
FWE 12 6 2 1
YAZAKI(CN.A34F) SOL3
Y59
(CN.A26)
SDL
YAZAKI

CX210C Crawler Excavator Tier 4

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CX210C Crawler Excavator Tier 4

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CX210C

Printed in U.S.A. Part number 84551720B

Safety, general information and standard torque data

84551720B NA - August 2012

84551720B NA - August 2012 Copyright © 2011 CNH FRANCE

84551720B NA - August 2012

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

84551720B NA - August 2012

84551720B NA - August 2012

ROPS Judgment Method

Machine body total weight Class

Machine body total weight Class

Machine body total weight Class

Machine body total weight Class

Machine body total weight Class

[X3 Cab (SH120-6/SH150-6)]

[X3 Cab (SH200-6/SH240-6/SH290-6)]

84551720B NA - August 2012

[X2 Cab (SH200-5/SH240-5/SH290-5)]

84551720B NA - August 2012

Bolt and Nut Tightening

84551720B NA - August 2012

84551720B NA - August 2012

84551720B NA - August 2012 Copyright © 2011 CNH FRANCE

84551720B NA - August 2012 Copyright © 2011 CNH FRANCE

Main Unit Dimensions

Upper Side Work System

Work mode select status SP/H/A

Travel Lower Body

Hydraulic pump drive type Direct engine link (no transmission)

Control Valve and Cylinder

Coolant 28.7 L (7.582 gal)

Hydraulic Oil Filters

Suction filter (inside tank) 105 μm

84551720B NA - August 2012

Main Unit Dimensions

Upper Side Work System

Work mode select status SP/H/A

Travel Lower Body

Hydraulic pump drive type Direct engine link (no transmission)

Control Valve and Cylinder

Coolant 28.7 L (7.582 gal)

Hydraulic Oil Filters

Suction filter (inside tank) 105 μm

84551720B NA - August 2012

Operating weight 23100 kg (50927.049 lb)

Standard weight 5.5 kN (1236.661 lbf)

Main Unit Dimensions

Main unit length 4960 mm (195.276 in)

Swing radius (rear end) 2750 mm (108.268 in)

Upper Side Work System

Minimum swing radius at front 5190 mm (204.331 in)

Travel Lower Body

Travel hydraulic motor Variable displacement piston motor x 2

Hydraulic pump drive type Direct engine link (no transmission)

Control Valve and Cylinder

Coolant 28.7 L (7.582 gal)

Hydraulic Oil Filters

Suction filter (inside tank) 105 μm

84551720B NA - August 2012

84551720B NA - August 2012

Main Equipment Table

84551720B NA - August 2012

Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3