Yanmar Crawler Carrier C30R-3 Service Manual 0BKC200EN60

SERVICE MANUAL
CRAWLER CARRIER
C30R-3
SERVICE MANUAL CRAWLER CARRIER C30R-3
C30R-3 SVM.book 1 ページ２０１８年３月８日木曜日午前１１時４４分
California California
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Battery posts, terminals and related
constituents are known to the State of accessories contain lead and lead
California to cause cancer, birth defects compounds, chemicals known to the
and other reproductive harm. State of California to cause cancer and
reproductive harm.
Wash hands after handling.
CONTENTS
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work ...........................................................................................................................................................................1-1
1-2 Safety Precautions ..................................................................................................................................................................1-1
1-3 Preparations ............................................................................................................................................................................1-1
1-4 Cautions for Disassembly and Reassembly............................................................................................................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............................................................................................1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping......................................................................................................1-2
1-7 Cautions for Handling Seals....................................................................................................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................................................................................................1-3
1-9 Specifications of Hydraulic Hose.............................................................................................................................................1-6
1-10 Air Release of Hydraulic Equipment......................................................................................................................................1-8
CHAPTER 2
TECHNICAL DATA
2-1 Specifications ...................................................................................................................................................................... 2-1-1
2-2 Outline Drawing and Working Area ..................................................................................................................................... 2-2-1
2-3 Weight List of Main Parts .................................................................................................................................................... 2-3-1
2-4 Power Transmission............................................................................................................................................................ 2-4-1
2-5 List of periodic inspection and servicing.............................................................................................................................. 2-5-1
2-6 Fuel, Lube Oil and Grease Recommended......................................................................................................................... 2-6-1
2-7 Hydraulic Circuit Schematic ................................................................................................................................................ 2-7-1
2-8 Wiring Diagram.................................................................................................................................................................... 2-8-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance ......................................................................................................................................................... 3-1-1
3-1-1 Three-side flaps wagon type ...................................................................................................................................... 3-1-1
3-1-2 Swing wagon type ...................................................................................................................................................... 3-1-4
3-2 Engine ................................................................................................................................................................................. 3-2-1
3-2-1 Nominal and Allowable Values................................................................................................................................ 3-2-1
3-3 Undercarriage ..................................................................................................................................................................... 3-3-1
3-4 Controls ............................................................................................................................................................................... 3-4-1
3-5 Hydraulic Cylinder ............................................................................................................................................................... 3-5-1
3-6 Work Implement .................................................................................................................................................................. 3-6-1
3-7 List of Tightening Torque .................................................................................................................................................... 3-7-1
3-7-1 Machine...................................................................................................................................................................... 3-7-1
3-7-2 Engine ........................................................................................................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts.......................................................................................................... 3-7--6
3-7-4 Hydraulic Fitting.......................................................................................................................................................... 3-7-7
3-8 Pressure Adjustment ........................................................................................................................................................... 3-8-1
3-8-1 Measuring the pressure.............................................................................................................................................. 3-8-1
3-8-2 Measuring the main pressure (effective differential pressure) ................................................................................... 3-8-1
3-8-3 Charge pressure measurement.................................................................................................................................. 3-8-2
3-8-4 Dump pressure measurement.................................................................................................................................... 3-8-3
3-8-5 Pilot pressure measurement ...................................................................................................................................... 3-8-3
3-8-6 Wagon swing pressure measurement........................................................................................................................ 3-8-4
CHAPTER 4
ENGINE
4-1 Safety .................................................................................................................................................................................. 4-1-1
4-1-1 Safety Statements ...................................................................................................................................................... 4-1-1
4-1-2 Safety Precautions ..................................................................................................................................................... 4-1-2
4-2 Engine ................................................................................................................................................................................. 4-2-1
4-2-1 Before You Begin Servicing ....................................................................................................................................... 4-2-1
4-2-2 Introduction................................................................................................................................................................. 4-2-2
4-2-3 Special Service Tools................................................................................................................................................. 4-2-3
4-2-4 Measuring Instruments............................................................................................................................................... 4-2-6
4-2-5 Cylinder Head............................................................................................................................................................. 4-2-8
4-2-6 Measuring and Adjusting Valve Clearance .............................................................................................................. 4-2-24
4-2-7 Crankshaft and Camshaft Components ................................................................................................................... 4-2-26
4-2-8 EGR System............................................................................................................................................................. 4-2-52
4-3 Fuel System ........................................................................................................................................................................ 4-3-1
4-3-2 System Structure........................................................................................................................................................ 4-3-2
4-3-3 Fuel System Diagram................................................................................................................................................. 4-3-4
4-3-4 Fuel System Components .......................................................................................................................................... 4-3-5
4-4 Cooling System ................................................................................................................................................................... 4-4-1
4-4-2 Introduction................................................................................................................................................................. 4-4-2
4-4-3 Cooling System Diagram............................................................................................................................................ 4-4-2
4-4-4 Engine Coolant Pump Components ........................................................................................................................... 4-4-3
4-4-5 Engine Coolant System Check................................................................................................................................... 4-4-4
4-4-6 Engine Coolant Pump ................................................................................................................................................ 4-4-4
4-5 Lubrication System.............................................................................................................................................................. 4-5-1
4-5-2 Introduction................................................................................................................................................................. 4-5-2
4-5-3 Lubrication System Diagram ...................................................................................................................................... 4-5-2
4-5-4 Checking Engine Oil Pressure ................................................................................................................................... 4-5-3
4-5-5 Oil Pump Components ............................................................................................................................................... 4-5-3
4-6 Starter Motor ....................................................................................................................................................................... 4-6-1
4-6-2 Introduction................................................................................................................................................................. 4-6-1
4-6-3 Starter Motor Specifications ....................................................................................................................................... 4-6-2
4-6-4 Starter Motor Troubleshooting.................................................................................................................................... 4-6-3
4-6-5 Starter Motor Components ......................................................................................................................................... 4-6-4
4-6-6 Starter Motor .............................................................................................................................................................. 4-6-5
4-7 Alternator............................................................................................................................................................................. 4-7-1
4-7-2 Introduction................................................................................................................................................................. 4-7-2
4-7-3 Alternator Specifications............................................................................................................................................. 4-7-2
4-7-4 Alternator Troubleshooting ......................................................................................................................................... 4-7-3
4-7-5 Alternator Components .............................................................................................................................................. 4-7-4
4-7-6 Alternator Wiring Diagram .......................................................................................................................................... 4-7-5
C30R-3 SVMTOC.fm 3 ページ２０１８年３月８日木曜日午後４時４８分
4-7-7 Alternator Standard Output ........................................................................................................................................ 4-7-6

4-7-8 Alternator.................................................................................................................................................................... 4-7-7
4-8 Electronic Control System ................................................................................................................................................... 4-8-1
4-8-2 System Structure........................................................................................................................................................ 4-8-2
4-8-3 Electronic Engine Speed Control ............................................................................................................................... 4-8-3
4-8-4 Diesel Particulate Filter (DPF).................................................................................................................................... 4-8-5
4-8-5 How to Remove and Reattach the Diesel Particulate Filter (DPF) ........................................................................... 4-8-10
4-8-6 SF and DPF Maintenance Kit................................................................................................................................... 4-8-20
4-8-7 Troubleshooting of Electronic Control System ......................................................................................................... 4-8-21
4-8-8 Replacement of Components................................................................................................................................... 4-8-25
4-8-9 Installation Position of Sensors ................................................................................................................................ 4-8-29
4-9 Electric Wiring .................................................................................................................................................................... 4-9-1
4-9-1 Electric Wiring Precautions ....................................................................................................................................... 4-9-1
4-10 Failure Diagnosis ............................................................................................................................................................ 4-10-1
4-10-1 Special Service Tools............................................................................................................................................. 4-10-1
4-10-2 Troubleshooting by Measuring Compression Pressure ......................................................................................... 4-10-2
4-10-3 Measured Value and Troubleshooting ................................................................................................................... 4-10-4
4-10-4 Quick Reference Table for Troubleshooting........................................................................................................... 4-10-4
CHAPTER 5
ELECTRIC SYSTEM
5-1 Electric Equipment of Machine............................................................................................................................................ 5-1-1
5-1-1 Parts Layout of Electrical Equipment ......................................................................................................................... 5-1-1
5-1-2 LCD Monitor and Alarm Systems ............................................................................................................................. 5-1-10
5-2 Circuit Description of Engine Start and Stop ....................................................................................................................... 5-2-1
5-3 Circuit Description of Engine Start and Stop ....................................................................................................................... 5-3-1
5-4 Engine ECU (engine controller)........................................................................................................................................... 5-4-1
5-4-1 Engine ECU................................................................................................................................................................ 5-4-1
5-4-2 Circuit Description of Auto Deceleration Mode........................................................................................................... 5-4-3
5-4-3 Circuit Description of Eco Mode ................................................................................................................................. 5-4-4
5-4-4 Control Functions ....................................................................................................................................................... 5-4-5
5-5 Error Code........................................................................................................................................................................... 5-5-1
CHAPTER 6
HYDRAULIC SYSTEM
6-1 Outline ................................................................................................................................................................................. 6-1-1
6-2 Component Parts ................................................................................................................................................................ 6-2-1
6-2-1 Arrangement of the main hydraulic equipment........................................................................................................... 6-2-1
6-2-2 Oil Flow ...................................................................................................................................................................... 6-2-3
6-2-3 Description of hydraulic main circuit........................................................................................................................... 6-2-5
6-3 Circuit Operation ................................................................................................................................................................. 6-3-1
6-3-1 Traveling and controlling direction.............................................................................................................................. 6-3-1
6-3-2 Wagon control ............................................................................................................................................................ 6-3-6
6-4 Hydraulic Pump (HST) ........................................................................................................................................................ 6-4-1
6-4-1 Main specifications ..................................................................................................................................................... 6-4-1
6-4-2 Operation theory......................................................................................................................................................... 6-4-1
6-4-3 Exploded view and Parts comprised .......................................................................................................................... 6-4-7

6-4-4 Disassembly and Reassembly ................................................................................................................................. 6-4-12
6-5 Travel motor ........................................................................................................................................................................ 6-5-1
6-6 Swing Motor ........................................................................................................................................................................ 6-6-1
6-7 Control Valve....................................................................................................................................................................... 6-7-1
6-8 Pilot Valve ........................................................................................................................................................................... 6-8-1
6-8-1 Wagon control lever (pilot valve R) ............................................................................................................................ 6-8-1
6-8-2 Travel lever (pilot valve L) ........................................................................................................................................ 6-8-31
6-9 Proportional solenoid valve ................................................................................................................................................. 6-9-1
6-9-1 Single solenoid valve.................................................................................................................................................. 6-9-1
6-9-2 Triple solenoid valve................................................................................................................................................... 6-9-2
6-10 Selector valve.................................................................................................................................................................. 6-10-1
6-11 Hydraulic cylinder ............................................................................................................................................................ 6-11-1
6-11-1 Sectional View and Parts (Three-side flaps wagon type) ....................................................................................... 6-11-1
6-11-2 Sectional View and Parts (Swing wagon type) ....................................................................................................... 6-11-2
6-11-3 Disassembling and assembling.............................................................................................................................. 6-11-3
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Engine and Electric Equipment ........................................................................................................................................... 7-1-1
7-1-1 Removal and Reinstallation of Engine ....................................................................................................................... 7-1-1
7-1-2 Removal and Reinstallation of Diesel Particulate Filter (DPF) ................................................................................. 7-1-12
7-1-3 Removal and Reinstallation of Starter Motor............................................................................................................ 7-1-18
7-1-4 Removing and reinstalling the fan belt ..................................................................................................................... 7-1-20
7-1-5 Removal and Reinstallation of Radiator and Hydraulic Oil Cooler ........................................................................... 7-1-22
7-1-6 Removing and installing the fuel cooler.................................................................................................................... 7-1-27
7-1-7 Removing and installing the fuel tank....................................................................................................................... 7-1-29
7-1-8 Removing and installing the LCD monitor ................................................................................................................ 7-1-33
7-1-9 Removal and Reinstallation of Engine ECU............................................................................................................. 7-1-34
7-2 Undercarriage ..................................................................................................................................................................... 7-2-1
7-2-1 Removal and Reinstallation of Crawler ...................................................................................................................... 7-2-1
7-2-2 Removal and Reinstallation of Travel Motor .............................................................................................................. 7-2-8
7-2-3 Disassembly and Reassembly of Idler and Grease Adjuster ................................................................................... 7-2-11
7-2-4 Disassembly and Reassembly of Carrier Roller ....................................................................................................... 7-2-17
7-2-5 Disassembly and Reassembly of Track Roller......................................................................................................... 7-2-21
7-2-6 Installation of Floating Seal ...................................................................................................................................... 7-2-30
7-3 Controls ............................................................................................................................................................................... 7-3-1
7-3-1 Travel lever, wagon control lever, and lock lever components................................................................................... 7-3-1
7-3-2 Accelerator pedal components................................................................................................................................... 7-3-5
7-3-3 Adjustment of Boom Swing Pedal .............................................................................................................................. 7-3-6
7-4 Hydraulic equipment ........................................................................................................................................................... 7-4-1
7-4-1 Removing and Reinstalling the hydraulic pump ......................................................................................................... 7-4-1
7-4-2 Removing and Reinstalling the control valve (Three-side flaps wagon type) ............................................................. 7-4-7
7-4-3 Removing and Reinstalling the control valve (Swing wagon type) ........................................................................... 7-4-10
7-4-4 Removal and Reinstallation of Pilot Valves.............................................................................................................. 7-4-13
7-4-5 Removing and installing the solenoid valve (single/triple)........................................................................................ 7-4-19
7-4-6 Removing and Reinstalling the selector valve.......................................................................................................... 7-4-23

7-4-7 Removing and installing the line filter....................................................................................................................... 7-4-26
7-4-8 Removing and installing the charge filter ................................................................................................................. 7-4-28
7-4-9 Removing and Reinstalling the accumulator ............................................................................................................ 7-4-31
7-4-10 Removing and Reinstalling the dump cylinder (Three-side flaps wagon type)....................................................... 7-4-33
7-4-11 Removing and Reinstalling the dump cylinder (Swing wagon type)....................................................................... 7-4-35
7-4-12 Removing and Reinstalling the hydraulic oil tank ................................................................................................... 7-4-37
7-4-13 Disassembly and Reassembly of wagon swing motor ........................................................................................... 7-4-40
7-4-14 Removal and Reinstallation of Swivel Joint............................................................................................................ 7-4-42
7-4-15 Disassembly and Reassembly of swing bearing .................................................................................................... 7-4-45
7-4-16 Piping Layout.......................................................................................................................................................... 7-4-51
7-5 Wagon ................................................................................................................................................................................. 7-5-1
7-5-1 Wagon components (Three-side flaps wagon type)................................................................................................... 7-5-1
7-5-2 Wagon components (Swing wagon type)................................................................................................................... 7-5-6
7-5-3 Removing and installing the canopy........................................................................................................................... 7-5-8
CHAPTER 8
TROUBLESHOOTING
8-1 Troubleshooting .................................................................................................................................................................. 8-1-1
8-1-1 Machine and Engine................................................................................................................................................... 8-1-1
8-1-2 HST relationship......................................................................................................................................................... 8-1-8
8-1-3 Electrical Equipment................................................................................................................................................. 8-1-16
APPENDIX
C30R-3 Wiring Diagram
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work...........................................................................................1-1

1-2 Safety Precautions..................................................................................1-1
1-3 Preparations ...........................................................................................1-1
1-4 Cautions for Disassembly and Reassembly ...........................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping .....................1-2
1-7 Cautions for Handling Seals ...................................................................1-3
1-8 Correct Installation of Hydraulic Hose ....................................................1-3
1-9 Specifications of Hydraulic Hose ............................................................1-6
1-10 Air Release of Hydraulic Equipment .....................................................1-8
1. GENERAL CAUTIONS FOR

MAINTENANCE WORK
1. General Cautions for Maintenance Work
1-1 Correct Work
Correct work means the quickest possible completion of according to the correct procedures and the specified stan-
dards.
It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil
and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions
to watch out for.
1-2 Safety Precautions
(1) Never attempt servicing while engine is running or immediately after stopping operation.
(2) Wear work cloths, safety shoes and helmet.
(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
(4) When working together with other persons, allocate everyone's share of job, arrange the signals and act in con-
cert with the other persons.
(5) The operation of the crane and slinging work must be performed by qualified persons.
(6) Do not enter or pass under the raised load.
(7) Lift and support the massive parts by crane before removing the installation bolts.
(8) Disconnect cables from battery before repairing the electric system.
(9) Remove the battery when welding the machine.
(10) Use explosion-proof lighting equipment when inspecting fuel, oil, cooling water and battery electrolyte.
(11) Always relieve the internal pressure in the implement hydraulic circuit before carrying out inspection or mainte-
nance work.
1-3 Preparations
(1) Check the service record of the machine. (That is, check how many months or hours the machine has been
used since the preceding overhaul, what was the trouble then and what parts were replaced.)
(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), con-
tainers, oil & grease, etc.
(3) Have the service literature (operation manual, parts catalog, etc.) ready.
1-4 Cautions for Disassembly and Reassembly
(1) Clean the machine before disassembly.

(2) Check and record the condition of the machine before disassembly :
• Model, machine number, operation hours
• Reasons for repair, history of repair
• Contamination of filters
• Fuel and oil condition
• Damage to parts, etc.
(3) Place alignment marks on the necessary parts to facilitate reassembly.
1-1 172663 0BKC2-EN0060


MAINTENANCE WORK
(4) Clean all the removed parts and new replacement parts and put them in order.
(5) Use new seals, split pins, etc. for reassembly.
(6) Keep the parts apt to be damaged by water or oil apart from the oily or wet parts.
e.g.: Electrical parts, rubber parts, V-belts, etc.
(7) Use the jig for press-fitting the bearings, bushes and oil seals. When Sealing tape
using a hammer, use a pad block.
(8) Clean the joint surface of all parts and keep them free from dust.
(9) Wind the sealing tape securely, leaving a space of one or two
threads from the tip of the male screw. The tape should have an
overlap of about 0.4 in. (10 mm).
One and a half threads
1-5 Cautions for Removal and Installation of Hydraulic Equipment
(1) Check that the hydraulic oil temperature is low enough.

(2) Release air from the hydraulic tank to prevent the hydraulic oil from flowing out.
(3) Be sure to plug open the ends of hydraulic components to prevent dust from entering.
(4) Be sure to wipe hydraulic oil from the hydraulic components so that it will not be mistaken for an oil leak.
(5) Take care not to damage the plating on the cylinder rod.
(6) Remove or install cylinders with rods fully retracted.
(7) Be sure to release air after installing the hydraulic cylinders.
• Run the engine at a low speed. Extend and retract the cylinders 4 to 5 times up to 2.0 to 3.9 in. (50 to 100 mm)
from the end of the stroke. Then, fully extend and retract.
(8) Be sure to pressurize the hydraulic tank after installing the hydraulic components (in the case of the sealed
hydraulic tank). Otherwise, hydraulic pumps might suffer cavitation and their life will be shortened.
• To pressurize the hydraulic tank, fully extend each cylinder and tighten the oil filter port plugs.
1-6 Cautions for Removal and Installation of Hydraulic Piping
(1) Installation of hydraulic hose

Take care not to twist the hoses. (Judge whether or not the hose is twisted by Metal fitting
the hose mark.) For hoses with a metal fitting, use two wrenches to prevent
twisting.
Pipe or
Use one to fix the hose, and the other to tighten the fitting to the specified Hose connector
tightening torque. Carefully check that the hoses do not come in contact after Fixed side
tightening. If any contact is found, correct it or use tubes.
(2) When installing hoses, first tighten to the specified torque and then loosen
them a little. Then retighten to the specified torque.
• Break in the installed parts before tightening (except those using seal tapes).
(3) When installing pipes, turn the nuts more 1/4 to 1/2 turn after they reach the sharp torque rise point.
(4) When installing or removing hoses, use two wrenches, one to fasten the hose and the other to tighten or loosen
the hose to prevent twisting.
(5) Check for oil leakage by applying max. pressure 5 to 6 times after attaching hydraulic hoses or pipes.
1-2 172663 0BKC2-EN0060


MAINTENANCE WORK
1-7 Cautions for Handling Seals
(1) Clean out grooves of O-rings. Remove burrs or dust if any.
Burrs
Dust
(2) Take care not to twist O-rings. Correct by your finger if it is twisted.
(3) Take care not to damage seals when inserting.
(4) Handling of floating seals :
• Completely wipe off all the oil from the O-ring and housing after detaching the floating seals.
• Before installing, apply a little gear oil to the matching face of the housing.
• Turn the seals two or three times after installation to break them in.
(5) Apply grease to the lip of the oil seals to prevent wear.
Grease
1-8 Correct Installation of Hydraulic Hose
In order to mount the hydraulic hose most effectively and economically, observe the following cautions.
(1) When a hose is used at the minimum bending radius, use elbows to avoid sharp bending.
Not good Good
(2) To prevent twisting, the hose should be bent in the same direction as it moves.
Not good Good
1-3 172663 0BKC2-EN0060


MAINTENANCE WORK
(3) When the hose is pressurized, the hose length varies slightly at the bend. Allow this change to occur and do not
try to fasten the bend.
Not pressurized
When pressurized
(4) It is necessary for the hose to have ample slackness for elongation and contraction, because its length will
change by +2 % to -4 % when used at high pressure.
Not good
Good
(5) Use the proper adapters, not pipes, in order to reduce the number and length of joints and improve the external
appearance.
Not good Good
(6) Use an elbow to prevent excessive twisting or bending of the hose.
Not good Good
(7) Use adapters to make the hose as straight as possible. The outside appearance can be improved by avoiding
the use of hoses that are too long.
Not good Good
1-4 172663 0BKC2-EN0060


MAINTENANCE WORK
(8) The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the
hose and prevents sharp bending.
Not good Good
(9) When a bent hose is attached to two different planes, fix as shown in the diagram to prevent twisting.
Not good Good
(10) Use the marking on the hose as a guide to prevent twisting during installation.
Twisting of metal fitting with union nuts should be with a wrench on the hexagonal parts.
Hose mark Hose mark

Not good Good
1-5 172663 0BKC2-EN0060


MAINTENANCE WORK
1-9 Specifications of Hydraulic Hose
Specifications of the hydraulic hoses can be known by the part descriptions as explained below. (For the parts num-
ber, please refer to our Parts Catalog.)
Description ..................... Hose P 2 06 AB 075 W

1 2 3 4 5 6 7 8
8 Other accessories
1 Part name No accessories...Blank
O-ring ....................... 1
2 Hose material
Rubber hose ........... G 6 Total length 7 Hose protector
Wear-resistant high (Unit : cm) Coil spring ............... W
pressure rubber Coil tube .................. S
hose ....................... H Wire braid ................ B
5 Combination of fitting Tube (Rubber) ......... R
Plastic hose ............ P
Tube (Vinyl) ............. V
Wear-resistant Fitting type Code Sponge rubber ......... P
plastic hose ............ F Hose cover ............... K
R(PT)
Taper pipe No protection ..... Blank
A
3 Recommended thread R (PT)
working pressure
G(PF) Straight pipe
PSI(Mpa) thread G (PF)
Over 2986 (20.6) ..................... 1 with male 30 B
30°
2489 to 2986 (17.2 to 20.6) ..... 2 degrees seat
1991 to 2489 (13.7 to 17.2) ..... 3 90 degrees
1564 to 1991 (10.8 to 13.7) ..... 4 90° bent type.
995 to 1564 (6.9 to 10.8) ......... 5 Straight pipe
427 to 995 (2.9 to 6.9) ............. 6 thread G (PF) C
with male 30
213 to 427 (1.5 to 2.9) ............. 7 G(PF) 30° degrees seat
Below 213 (1.5) ....................... 8
4 Nominal dia. (inch)

1 / 8" ......................... 02
Without fitting Y
3 / 16" ....................... 03 List of pipe threads
1 / 4" ......................... 04 Symbol Name
3 / 8" ......................... 06 *For the combination of fitting,
refer to the list on the following G (PF) Straight pipe thread
1 / 2" ......................... 08 page. R (PT) Male taper pipe thread
5 / 8" ......................... 10
Rc (PT) Female taper pipe thread
3 / 4" ......................... 12
1" .............................. 16
The example hose, P 2 06 AB 075 W stands for :

2 3 4 5 6 7
2 Material : Plastic
3 Working pressure : 2489 to 2986 PSI (17.2 to 20.6 MPa)
4 Nominal dia. : 3 / 8"
5 Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat.
6 Length : 29.5 in. (75 cm)
7 Hose protector : Coil spring
1-6 172663 0BKC2-EN0060


MAINTENANCE WORK
5 Combination of fitting
Fitting type Code Fitting type Code

90°
R (PT) 90 degrees bent type.
Taper pipe thread R (PT) A UNF thread with female P
UNF 37 degrees seat
37°
G (PF)
Straight pipe thread G 60° 60 degrees bent type.
(PF) with male 30 B UNF thread with female Q
30° degrees seat 37 degrees seat
UNF
90 degrees bent type.
90°
Straight pipe thread G 45° 45 degrees bent type.
(PF) with male 30 C UNF thread with female R
degrees seat 37 degrees seat
UNF
G (PF) 30°
60° 60 degrees bent type. UNF UNF, thread with O-ring

Straight pipe thread G groove
D S
(PF) with male 30
G (PF) degrees seat O-ring
45° 45 degrees bent type.

Straight pipe thread G O-ring One-touch fitting (male)
E T
(PF) with male 30
G (PF) degrees seat
G (PF) Straight pipe thread G
30°
(PF) with male 30 F 90°
degrees seat
90 degrees elbow straight
pipe thread male 30 V
degrees seat
O-ring flange type G
G (PF)
30°
90° 90 degrees bent O-ring

flange type H
Eyejoint with O-ring
W
45 degrees bent O-ring O-ring groove groove
45°
flange type J
Straight pipe thread with

PF nut
G (PF) Straight pipe thread, jam nut female 30
30°
30° female 30 degrees seat K degrees seat X
with O-ring groove G (PF)
30° 30 degrees bent type.

Straight pipe thread G 90° Gauge port
L
(PF) with male 30 90 degrees elbow straight
G (PF) degrees seat G (PF) pipe thread with gauge Z
NPTF
port plug male 30
Taper pipe thread NPTF M degrees seat
30°
Without fitting Y
UNF
37° UNF, thread with female Note :
37 degrees seat N
According to the combination of bending or elbow fittings, some
hoses require drawings or original hoses to locally manufacture.
1-7 172663 0BKC2-EN0060


MAINTENANCE WORK
1-10 Air Release of Hydraulic Equipment
When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be
sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic
equipment. If the air is left in the hydraulic system, the air is compressed or expanded depending on the load, having
an adverse effect on the smooth operation of the hydraulic equipment and shortening the service life.
1. Air Release of Variable Displacement Piston Pumps

Be sure to release air from the HST below after supply of hydraulic oil following the replacement or repair of the HST
pump.
If any excessive internal wear is found during disassembly of the pump, always replace the hydraulic oil and return
filter.
1) Disconnect harness 1 connected to the solenoid valve for the

parking brake mounted on the track frame under the operator's
seat so that the parking brake is not released even when the travel
lever is moved.
Solenoid valve for parking brake
105413-00EN00
2) Remove the connector from drain port 2 of the hydraulic pump, fill
the front case housing with hydraulic oil, and then reinstall and
tighten the connector.
105725-00X00
1-8 172663 0BKC2-EN0060


MAINTENANCE WORK
3) Loosen air breathers 3 and 5 on the front case and air breathers 4
and 6 on the rear case.
4) After starting the engine, run it at idle speed and move the travel
lever repeatedly.
5) Once hydraulic oil begins to overflow through the air breathers,
tighten air breathers 3, 4, 5 and 6.
6) Stop the engine and check for oil leaks and the oil level in the
3 4
hydraulic oil tank.
5 6
105726-00X00
7) Reconnect harness 1 connected to the solenoid valve for the park-

ing brake that was disconnected in step 1.
8) After starting the engine again, run it at 1800 to 2200 rpm and move
the machine forward and backward 5 or 6 times.
Then, run the engine at maximum speed and check whether the
machine moves straight when starting traveling.
Solenoid valve for parking brake

If the machine does not move straight when starting traveling, follow
steps 9 to 11 below.
9) Disconnect harness 1 connected to the solenoid valve for the park-
ing brake again.
1
105413-00EN00
10)Start the engine again and run it at 2000 to 2500 rpm. Move the
travel lever in the direction (forward or backward) in which the
machine does not move straight when starting traveling and hold it
in that position for one to one and a half minutes.
11)Reconnect harness 1 connected to the solenoid valve for the park-
ing brake and check whether the machine moves straight when
starting traveling. If the machine does not move straight, repeat
steps 9 to 11 until the problem is resolved.
12)After the problem has been resolved, run the engine at rated speed
for approximately 1 to 2 minutes and then stop the engine.
13)Check the oil level in the hydraulic oil tank.
1-9 172663 0BKC2-EN0060


MAINTENANCE WORK
Note :
After removal and reinstallation of any of the hydraulic hoses, the
travel lever or the selector valve of the travel control system
Travel lever
shown in the figure at the right, the machine may not move
straight when starting traveling. In such cases, follow steps 1 and
3 to 12 above and then perform air bleeding.
The machine will not move straight at low hydraulic oil tempera- Hydraulic
tures if it is moved forward or backward immediately after it has Hydraulic pump
hoses
made a turn. In such cases, perform warm-up before travel.
Hydraulic hoses
Selector valve 105727-00EN00
2. Air Release of Each Hydraulic Component

Run the engine at medium speed and activate the respective circuits for about 10 to 15 minutes.
3. Air Release of Hydraulic Cylinders

1) Set the Engine Speed at Low Idling Range.
2) Extend and Retract the Cylinder Up to 1.97 to 3.9 in. (50 to 100 mm) from Each Stroke End Slowly 4 or 5 Times.
1.97 to 3.9 in. 1.97 to 3.9 in.

(50 to 100 mm) (50 to 100 mm)
Retraction stroke end Retraction stroke end
3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times.
1-10 172663 0BKC2-EN0060


MAINTENANCE WORK
4. Air Release of Hydraulic Oil tank

Replace the oil supply cap of the hydraulic tank with the vacuuming cap.
Connect the vacuuming cap to the vacuum compressor, vacuum the air in the hydraulic oil tank.
ø8 (Unit: mm)
ø6 25
R2
7
16
HEX41 can be used R1
Note:
*55
" " dimensions
* be changed
3.5
can
*35
R0.7
M40×1.5
*11
ø4
29±0.1
O-ring: P29
ø41 and over
Material: SS or Aluminum
Vacuuming Cap
044068-01EN00
1-11 172663 0BKC2-EN0060

CHAPTER 2
TECHNICAL DATA
2-1 Specifications...................................................................................... 2-1-1

2-2 Outline Drawing and Working Area .................................................... 2-2-1
2-3 Weight List of Main Parts .................................................................... 2-3-1
2-4 Power Transmission ........................................................................... 2-4-1
2-5 List of periodic inspection and servicing ............................................. 2-5-1
2-6 Fuel, Lube Oil and Grease Recommended ........................................ 2-6-1
2-7 Hydraulic Circuit Schematic ................................................................ 2-7-1
2-8 Wiring Diagram ................................................................................... 2-8-1
2. TECHNICAL DATA
2. Technical Data
2-1 Specifications
C30R-3
Item Unit Three-side flaps
Swing wagon type
wagon type
Main specifications of machine
Dimensions/Weight
Overall length in. (mm) 129.1 (3280) 143.3 (3640)
Overall width in. (mm) 62.6 (1590) 61.6 (1565)
Overall height in. (mm) 90.9 (2310)
Tumbler center distance in. (mm) 77.2 (1960)
Crawler center distance in. (mm) 48.4 (1230)
Minimum ground clearance in. (mm) 10.4 (265) 11.0 (280)
Operating mass lbs. (kg) 5842 (2650) 6316 (2865)
Ground pressure JIS (Empty/Loaded) PSI (kPa) 4.0 / 7.6 (27.5 / 53.5) 4.3 / 8.1 (29.8 / 55.7)
Traveling performance
Low MPH (km/hr) 0 to 3.5 (0 to 5.7)
Forward
High MPH (km/hr) 0 to 6.8 (0 to 11.0)
Travel speed
Low MPH (km/hr) 0 to 3.5 (0 to 5.7)
Backward
High MPH (km/hr) 0 to 6.8 (0 to 11.0)
Minimum turning radius in. (mm) 82.7 (2100) 90.6 (2300)
Work performance
Max. load capacity lbs. (kg) 5512 (2500)
66.3 × 55.3 × 14.6 79.1 × 54.7 × 19.9
Carrier (Length × width × height) in. (mm)
(1685 × 1410 × 370) (2010 × 1390 × 505)
Struck capacity cu.ft. (cu.m) 31.1 (0.88) 39.9 (1.13)
Carrier capacity
Heaped capacity cu.ft. (cu.m) 43.8 (1.24) 53.0 (1.5)
Floor height above ground in. (mm) 32.3 (820) 36.2 (920)
Dump angle degrees 58 85
Dump clearance in. (mm) 17.9 (455) 28.7 (730)
Maximum dumping capacity lbs. (kgf) 7275 (32.3)
Maximum dumping inclination angle degrees 20
Height to top of wagon at dumping in. (mm) 94.7 (2405) 111.0 (2820)
Hydraulic implement
Hydraulic pump
Variable displacement and swash plate type
Type -
piston pump + gear pump
Drive method - Engine → CF coupling → Pump (Direct drive)
Theoretical discharge volume cu.in. (cc)/rev 1.34 (22.0) × 2
Maximum number of revolutions rpm 2830
Maximum working pressure PSI (MPa) 4978 (34.3)
System relief set pressure PSI (MPa) 4978 (34.3)
Charge relief set pressure PSI (MPa) 406 (2.8)
Type - External gear pump
Charge pump
Discharge volume cu.in. (cc)/rev 0.73 (11.9)
Max. charge pump system pressure PSI (MPa) 406 (2.8)
Type - External gear pump
Pilot pump
Discharge volume cu.in. (cc)/rev 0.49 (8.1)
2-1-1 172663 0BKC2-EN0060

2. TECHNICAL DATA
C30R-3
Swing wagon type
wagon type
Hydraulic implement
Travel motor (Hydraulic motor)
Type - Variable displacement piston motor
in3/rev
Motor displacement (Low/High) 2.06 (33.8)/1.03 (16.9)
(cm3/rev)
High pressure relief valve set pressure PSI (MPa) -
Reduction gear ratio - 1:25.526
Parking brake torque (Hydraulic motor) ft•lbf (N•m) 3617 (4900)
Brake
Brake release pressure PSI (MPa) 406 (2.8)
Swing motor
Fixed displacement
Type - -
piston motor
cu.in./rev
Displacement - 1.67 (27.4)
(cu.cm/rev)
Type - - Cross relief valve
Brake valve
Relief set pressure PSI (MPa) - 1450 (10)
Brake - - Negative brake
Control valve
Number of series pcs 1 2
System relief set pressure PSI (MPa) 2489 (17.2) 2988 (20.6)
Cylinder
Stroke in. (mm) 16.5 (418.5) 25.8 (656)
Inner diameter in. (mm) Ø 2.36 (60) Ø 2.56 (65)
Piston rod diameter in. (mm) Ø 1.18 (30) Ø 1.38 (35)
Extension sec. 3.3 6.2
Cycle time (Full stroke)
Retraction sec. 2.5 4.4
Swivel joint
Swivel joint port diameter×Number in.×pcs. - Rc 1/4×17, Rc 1/8×7
Hydraulic oil tank
10.0 (38) <7.4 (28), 10.6 (40) <7.4 (28),
Capacity Gal. (L)
Tank, 2.6 (10): Others> Tank, 3.2 (12): Others>
2-1-2 172663 0BKC2-EN0060

2. TECHNICAL DATA
C30R-3
Swing wagon type
wagon type
Hydraulic implement
Undercarriage
Installation - Fixed type
Quantity (One side) pcs. 1
Carrier roller Bearing - Ball bearing
Sealing - Oil seal on shaft
Lubrication - -
Installation - Rigid and oscillating
Quantity (One side) pcs. (Rigid × 2, Oscillating × 4)
Track roller Bearing - Ball bearing
Sealing - Oil seal
Lubricating oil quantity Qts. (cc) 0.095 (90):Rigid, 0.127 (120):Oscillating
Quantity (One side) pcs. 1
Bearing - Ball bearing
Idler
Sealing - Water seal
Lubricating oil quantity Qts. (cc) 0.137 (130)
Sprocket Number of teeth pcs. 15
Type - Endless rubber track
Shoe width in. (mm) 12.6 (320)
Rubber track
Grouser height in. (mm) 1.2 (30)
Core pitch  Number of links in (mm) × pcs 3.54 (90) × 58
Track tension adjustment mechanism - Grease adjuster
Engine
Main specifications
Engine model - 4TNV88C-KFW
Vertical type series water-cooled
Type -
4 cycle diesel engine
Combustion system - Direct injection
pcs. - in.×in.
Number of cylinders - Bore×Stroke 4 - Ø3.46×3.54 (Ø88×90)
(mm × mm)
Total displacement cu.in. (cu.cm) 133.6 (2189)
HP/rpm
Rated output / engine speed (GROSS) 46.6/2800 (34.3/2800)
(kW/rpm)
ft•lbf/rpm
Maximum torque / engine speed 99.2 to 107.8 (134.5 to 146.2) / 1795 to 1845
(N•m/rpm)
lbs./HP•h
Specific fuel consumption 0.401 (244) or less
(g/kW•h)
Maximum idling speed rpm 2820 to 2840
Minimum idling speed rpm 1190 to 1210
Engine dry mass (excluding air cleaner and silencer) lbs. (kg) 421 (191)
Lubricating method Forced lubrication by trochoid pump
lbs./HP•h
Specific lubricating oil consumption 0.00005 to 0.00033 (0.05 to 0.20)
(g/kW•h)
Compression pressure PSI (MPa) 484 (3.34) at 250 rpm
2-1-3 172663 0BKC2-EN0060

2. TECHNICAL DATA
C30R-3
Swing wagon type
wagon type
Engine
Cylinder head
Open bTDC degrees 10 to 20
Intake valve
Close aBDC degrees 40 to 50
Open bBDC degrees 51 to 61
Exhaust valve
Close aTDC degrees 13 to 23
Intake valve clearance (Cold engine) in. (mm) 0.0059 to 0.0098 (0.15 to 0.25)
Exhaust valve clearance (Cold engine) in. (mm) 0.0059 to 0.0098 (0.15 to 0.25)
Intake valve seat angle degrees 120
Exhaust valve seat angle degrees 90
Piston
Ring shape - Rectangular
First compression ring
Ring quantity pcs. 4
Ring shape - Taper face
Second compression ring
Ring shape - Bevel (with coil expander)
Oil-ring
Governor
Name - Electronic control (common rail system)
Type - Electronic control
Fuel feed system
Fuel filter - Filter paper with automatic air release device
Fuel filter filtration area sq.in. (sq.cm) 310 (2000)
Oil/water separator - Float type
Feed pump - Plunger type
Lubrication system
Lubrication pump - Trochoid pump
LO pressure regulating valve opening pressure PSI (MPa) 42.1 to 56.7 (0.29 to 0.39)
LO filter - Full flow filter
LO filter filtration area sq.in. (sq.cm) 180 (1160)
Filter valve opening pressure PSI (MPa) -
Operating pressure of alarm switch PSI (MPa) 5.7 to 8.5 (0.04 to 0.06)
Cooling device
Cooling system - Water-cooling (Radiator)
Fan belt size - A42
Thermostat opening temperature ºF (ºC) 159.8 (71)
Thermostat full-open temperature ºF (ºC) 185 (85)
Radiator cap pressure PSI (MPa) 12.80 (0.09)
pcs.×Øin.
Radiator fan 7 × Ø15.0 (380)
(mm)
Operating temperature of water temperature alarm
ºF (ºC) 224.6 to 235.4 (107 to 113)
switch
Air cleaner
Type - Cyclone type
Filtration area sq.ft. (sq.m) 12.8 (1.19)
2-1-4 172663 0BKC2-EN0060

2. TECHNICAL DATA
C30R-3
Swing wagon type
wagon type
Engine
Fuel injection pump
Injection pump type - CR-Bosch
Injection pump plunger diameter in. (mm) -
Injection pump cam lifting height in. (mm) -
Fuel injection timing (FIT) degrees -
Firing order - 1→3→4→2→1
Nozzle
Type - DRI2.2
Øin.
Nozzle hole diameter×Number of holes Ø 0.0053 (0.134) × 6
(mm)×pcs.
Spray angle degrees 156
Fuel injection pressure PSI (MPa) MAX. 23206 (160)
Turbocharger
Type - -
Revolution speed rpm -
Boost pressure PSI (Pa) -
Starting device
Cold starting aids - Glow plug
Starting aids capacity V-A 11-7
Battery type - 115D31R
Battery voltage - 5 hrs rate capacity V-Ah 12-72
Electrical equipment
Type - AC generator
Alternator Nominal output V-A 12 - 55
Rated speed rpm 5000
Type - IC type
Regulator
Regulation voltage V 14.2 to 14.8
Type - Reduction type
Starter motor Nominal output V-kW 12 - 1.7
Engagement - Magnet shift
LCD monitor V-W 12 - 0.45
Horn V-dB 12 - 103
Blade fuse A × pcs. 5×8, 10×4, 15×3, 20×3
Fuse
Slow blow fuse A × pcs. 60×2, 80×1, 120×1
Headlight V-W 12-25
Beacon lamp V-W 12-9.6
External power socket V-W 12-120
Rear working lamp V-W 12-55
2-1-5 172663 0BKC2-EN0060

2. TECHNICAL DATA
2-2 Outline Drawing and Working Area

Unit: in. (mm)
Three-side flaps wagon type
55.5 (1410)
66.3 (1685)
62.6 (1590)
14.6 (370)
94.7 (2405)
90.9 (2310)
°
58
68.7 (1745)
46.9 (1190)
32.3 (820)
17.9 (455)
(265)
10.4
12.6 (320)
48.4 (1230) 29.1 (740) 77.1 (1960) 22.8 (580)
61.0 (1550) 129.1 (3280)
078692-00X01
2-2-1 172663 0BKC2-EN0060

2. TECHNICAL DATA
Unit: in. (mm)
Swing wagon type
79.1 (2010)
53.1 (1350)
54.7 (1390)
(730)
28.7
61.6 (1565)
19.9 (505)
111.0 (2820)
85°
90.9 (2310)
68.7 (1745)
56.1 (1425)
36.2 (920)
28.7 (730)
（280）
11.0
34.3 (870) 77.2 (1960) 31.9 (810)

12.6 (320) 143.3 (3640)
48.4 (1230)
61.0 (1550)
106562-00X01
2-2-2 172663 0BKC2-EN0060

2. TECHNICAL DATA
2-3 Weight List of Main Parts

Qty Weight lbs. (kg)
No. Part name Three-side flaps wagon
Swing wagon type
type
Engine
1 Engine 1 421 (191)
2 Silencer 1 (Included in the weight above)
3 Fuel oil tank 1 13 (6)
4 Air cleaner 1 3.3 (1.5)
5 Radiator & mount 1 40 (18)
Power transfer equipment
6 Sprocket 2 33 (15) each
7 Flywheel case 1 13 (6)
Hydraulic equipment
8 Control valve assembly 1 11 (5) 18 (8)
9 Dump cylinder assembly 1 22 (10) 46 (21)
10 Pump assembly 1 121.5 (55)
11 Swing motor 1 - 70.5 (32)
12 Travel motor assembly 2 121.5 (55) each
13 Hydraulic oil tank 1 81.5 (37)
Chassis frame & canopy
14 Front frame CMP. 1 24.5 (11)
15 Frame CMP. 1 963.5 (437) 999 (453)
16 Turning frame CMP. 1 - 361.5 (164)
17 Swing bearing 1 - 64 (29)
18 Swivel joint 1 - 18 (8)
19 Bumper CMP. 1 24.5 (11)
20 Canopy roof CMP. 1 42 (19)
21 ROPS canopy CMP. 1 66 (30)
22 Front ROPS mount CMP. 1 31 (14)
23 ROPS mount CMP. 1 64 (29)
Outfittings
24 Bonnet B CMP. 1 44 (20)
25 Bonnet L CMP. 1 26.5 (12)
26 Bonnet A CMP. 1 15.5 (7)
27 Front cover CMP. 1 13 (6)
28 Operator seat 1 57.3 (26)
29 Seat bracket CMP. 1 22 (10)
30 Seat mount CMP. 1 17.5 (8)
31 Step 1 39.5 (18)
32 Floor mat 1 11 (5)
33 Bottom cover CMP. 1 24.5 (11)
2-3-1 172663 0BKC2-EN0060

2. TECHNICAL DATA
Qty Weight lbs. (kg)

No. Part name Three-side flaps wagon
Swing wagon type
type
Undercarriage
34 Rubber track 2 379 (172) each
35 Idler assembly 2 73 (33) each
36 Track roller (A) CMP. 8 26.5 (12) each
37 Track roller (B) CMP. 4 35.5 (16) each
38 Track carrier roller assembly 2 13 (6) each
Wagon
39 Rear flap CMP. 1 77 (35) -
40 Side flap CMP. 2 73 (33) each -
41 Wagon CMP. 1 582 (264) 763 (346)
2-3-2 172663 0BKC2-EN0060

2. TECHNICAL DATA
2-4 Power Transmission
The hydraulic pump driven by the engine discharges oil to drive the hydraulic motors and the return oil from the
motors is directly returned to the hydraulic pump. This is how the power transmission system is comprised by the
hydraulic closed circuits.
Hydraulic Reduction
Sprocket
motor gear
Travel motor (R)
Hydraulic pump Hydraulic pump

Engine Gear pump
for Travel motor (L) for Travel motor (R)
Travel motor (L)
Hydraulic Reduction
Sprocket
motor gear
104585-01EN00
2-4-1 172663 0BKC2-EN0060

2. TECHNICAL DATA
2-5 List of periodic inspection and servicing

 : Check  : Supply  : Replace  : Adjust (clean)  : Oil & grease
Every Every Every Every Every Every Every Every
Check & service items Daily
50 hrs 100 hrs 250 hrs 500 hrs 1000 hrs 1500 hrs 2000 hrs 3000 hrs
General Check falling off, breakage of parts 
Check loosened bolts & nuts, retighten 
Check engine condition 
Clean 
Fuel oil Check & supply of oil to the tank ()
Drain the fuel tank 
Water separator Check, drain 
Replace 
Replace the fuel filter element 
Lube oil Engine oil Check, resupply 

Replace 
Replace the engine oil filter element 
Travel reduction gear Check, resupply 

oil Replace 

1st time
Coolant Check & supply of coolant 
Check coolant leakage 
Check & clean radiator fins 
Check & adjust the fan-belt tension ()
Clean & check the coolant system, and within
replace the coolant two years
Rubber Check & replace fuel oil pipe, cooling within

hose water pipe two years
Air cleaner Clean air cleaner 
Replace air cleaner element 
Hydraulic Hydraulic oil Check, resupply 

system Replace 
Clean suction filter 


1st time
Replace line filter 

1st time
Replace charge filter 

1st time
Check for abnormality of hydraulic pump 
Check function of accumulator 
Grease Check grease-up positions, grease before
use
Grease the swing bearing (swing wagon

type)
Undercar- Check, adjust track tension ()
riage Check for abnormality of upper/lower roll-

ers and idlers
Check for wear or damage of rollers 
Control Check operation of wagon 
equipment Check the accelerator pedal 
Check engine control dial function 
Check travel lever for operation and loose-

ness
Check performance and play of dump

lever
2-5-1 172663 0BKC2-EN0060

2. TECHNICAL DATA
 : Check  : Supply  : Replace  : Adjust (clean)  : Oil & grease

Every Every Every Every Every Every Every Every
Check & service items Daily
50 hrs 100 hrs 250 hrs 500 hrs 1000 hrs 1500 hrs 2000 hrs 3000 hrs
Electric Check work lights, horn 
equipment Check hour meter function 
Check function of LCD monitor 
Check LED lamps 
Check wire breakage, short-circuits, loos-

ened terminals retighten
Check, resupply battery fluid 
Engine Check & adjust the intake and exhaust

valve clearance
Lap the intake and exhaust valve seats As
required
Check, clean and test EGR valve 
Clean EGR cooler 
Check crankcase breather system 
Check & test intake throttle valve 
Check & clean fuel injector 
Check & clean DPF soot filter*1
*1: Inspect the DPF soot filter when the relevant error code is displayed. For details, refer to the Operation Manual.
Note :
• When machine is used at dusty work sites, clean and replace filter element twice as often as specified in the table.
• Execution of periodic inspection and servicing is indispensable to assuring conformance to EPA emission control
regulations.
Keep a record of the results.
2-5-2 172663 0BKC2-EN0060

2. TECHNICAL DATA
2-6 Fuel, Lube Oil and Grease Recommended

Capacity
Item Recommended type Three-side flaps Swing wagon
wagon type type
Fuel oil Diesel fuel oil (Ultra low sulfur) 15 Gals (58 L)
Engine oil Engine oil SAE 10W30, CJ-4 class 7.8 Qts. (7.4 L)
In the tank: 7.4 In the tank: 7.4
Gals (28 L) Gals (28 L)
Other parts: 2.6 Other parts: 3.2
Hydraulic oil Hydraulic oil ISO VG46
Gals (10 L) Gals (12 L)
Total: 10 Gals (38 Total: 10.6 Gals
L) (40 L)
Travel reduction gear oil Gear oil SAE90 (GL-4) 1.0 Qt (0.9 L)
Idler 0.137 Qts. (0.13 L)
Track roller A Engine oil SAE 30, CC class 0.126 Qts. (0.12 L)
Track roller B 0.095 Qts. (0.09 L)
Radiator: 5.6 Qts. (5.3 L)
Coolant Soft water + antirusting & antifreeze long-life coolant (LLC) Subtank: 0.4 Qts. (0.4 L)
Total: 6.0 Qts. (5.7 L)
Lithium soap group (extreme pressure type)
Grease -
multi-purpose grease NLGI No.2
■ Mixture ratio of water and antifreeze

°F 23 14 5 -4 -13 -22 -31 -40
Lowest temperature
(°C) (-5) (-10) (-15) (-20) (-25) (-30) (-35) (-40)
Qts. 1.0 1.5 2.35 2.74 3.13 3.52 3.91 4.3
Amount of anti-freeze
(L) (0.9) (1.4) (2.2) (2.6) (3) (3.3) (3.7) (4.1)
Qts. 5.0 4.5 5.47 5.08 4.69 4.3 3.91 3.52
Amount of water
(L) (4.8) (4.3) (5.2) (4.8) (4.4) (4.1) (3.7) (3.3)
Note :
• Decide the antifreeze mixing ratio for lower temperature by around 18 °F (10 °C) than the lowest temperature at
job-site.
• At the delivery from the factory, water and antifreeze are mixed at the ratio for -31 °F (-35 °C) temperature above.
2-6-1 172663 0BKC2-EN0060

2. TECHNICAL DATA
2-7 Hydraulic Circuit Schematic

Travel lever Wagon control lever

ȝ
ȝ
Control valve
(Pilot valve L) (Pilot valve R)
P T P T Relief valve set pressure
B1 C30R-3
1 34.3Mpa (350kgf/cm²)
Dump
A1
2 2.8Mpa (29kgf/cm²)
Up
Down
1 2
Pb1
(1) (2) (3) (4) 3 17.2Mpa (175kgf/cm²)
Dump Cylinder 4 0.5Mpa (5.1kgf/cm²)
3 (ø60×ø30-418.5)
1 2 3 4 Pa1
ø0.6 ø0.6 ø0.6 ø0.6
P T
Selector valve
P1 T1 P2 T2
a1 Pf P3
Travel automatic dual Implement Traveling ø2.5
speed switching A Parking brake B1 Cut off B2 Cut off B3
ø2.0
Drain block
P1
R/G
ø1.3
T P2
Drain block
A1 B1 A2 B2 P3 P T A1 A2 A3
Pressure Switch Single solenoid valve Triple solenoid valve T1,T2

Accumulator
ø0.5
ø0.35
Drain block
Charge Filter L

a2 Ps
ȕ Travel motor (R)
Pp3 Pp4 Pp6 Pp5
Hydraulic pump FPñUHY
T2 B2 Pp1
3 FPñUHY
3 FPñUHY 2
3 FPñUHY
ø3.8
3 FPñUHY a1 Pf P3
6 FPñUHY PgC
ø1.2
ø2.5
ø2.0
6 FPñUHY Pg1 Pg3 B1 B3
P3 P1
P1
R/G
ø1.3
P2
Engine
1 1
4TNV88C-KFW P2 P1 P3 P4 S1 S3
Gross rated output
34.3kW/2800min¯1 T1,T2
(46.6PS/2800rpm) 1 1
ø0.5
ø0.35
P2 P4
Pg2 T1 Pg4 S
HST pump
HST pump
Charge pump Implement pump
L
a2 Ps
Travel motor (L)
FPñUHY
Check Valve
4 Oil cooler
ȝ
14.8kW (15L/min)
Line filter
Suction filter
ȝ
Hydraulic Oil Tank
101399-00EN00
2-7-1 172663 0BKC2-EN0060

2. TECHNICAL DATA
Swing wagon type

'XPS&\OLQGHU 6ZLQJPRWRU
&RQWUROYDOYH B2 L
7UDYHOOHYHU :DJRQFRQWUROOHYHU (ø65×ø35-656) FP3/rev
ȝ ȝ A2
P T
3LORWYDOYH/ P T
3LORWYDOYH5 Pa2
6ZLYHOMRLQW
Swing
PB DB
Pb2 F F
D D
B B
C C
B1
E E
1 3 2 4 Pa1 A A
Right Left Up Down A1
(1) (2) (3) (4)
'XPS
G
Dr
G
5
Dr
Pb1
ø2.3
1 2 3 4
ø0.6 ø0.6 ø0.6 ø0.6 GB B M A GA
3 Left Right
P T
6HOHFWRUYDOYH
P1 T1 P2 T2
a1 Pf P3
ø2.5
7UDYHODXWRPDWLF 3DUNLQJEUDNH ,PSOHPHQW Traveling ø2.0
GXDOVSHHGVZLWFKLQJ 'UDLQEORFN
A B1 &XWRII B2 &XWRII B3 P1
R/G
ø1.3
T P2
'UDLQEORFN
A1 B1 A2 B2 P3 P T A1 A2 A3
3UHVVXUH6: 6LQJOHVROHQRLGYDOYH 7ULSOHVROHQRLGYDOYH T1,T2

$FFXPXODWRU
ø0.5
ø0.35
'UDLQEORFN
L
&KDUJH)LOWHU
a2 Ps
ȕ 7UDYHOPRWRU 5
Pp3 Pp4 Pp6 Pp5
+\GUDXOLFSXPS FP3/rev)
T2 B2 Pp1
3 FP3/rev
3 FP3/rev 2
3 FP3/rev
ø3.8
3 FP3/rev a1 Pf P3
6 FP3/rev
PgC ø2.5
6 FP3/rev ø1.2 ø2.0
Pg1 Pg3 B1 B3
P1 P3 P1
R/G
ø1.3
Engine P2
1 1
4TNV88C-KFW
*URVVUDWHGRXWSXW P2 P1 P3 P4 S1 S3
N:PLQ-1 T1,T2
36USP
1 1 &KDUJHSXPS ø0.5
ø0.35
P2 P4 5HOLHIYDOYHVHWSUHVVXUH
Pg2 T1 Pg4 S
+67SXPS ,PSOHPHQWSXPS
+67SXPS C30R-3
L 1 0SD NJIFP2)

a2 Ps
7UDYHOPRWRU / 2 0SD NJIFP2)
FP3/rev)
3 0SD NJIFP2)
&KHFN9DOYH
4 0SD NJIFP2)
4 2LOFRROHU 5 0SD NJIFP2)
ȝ .: /PLQ
/LQHILOWHU
6XFWLRQILOWHU
ȝ
+\GUDXOLF2LO7DQN
109593-00EN00
2-7-2 172663 0BKC2-EN0060

2. TECHNICAL DATA
2-8 Wiring Diagram

■ How to Read Wiring Diagrams  Reference numbers
 Intersections and Wire Connections <Example>
<Example>
Branch wire 2. TECHNICAL DATA
G50A B/W AVSS 0.5 f
1
A
Main wire 1) Seat mount harness
G50 B/W AVSS 1.25 f 1/2
2 3
060851-00EN00
The point of arrow A on the main wire shown in the figure above represents an intersection of the branch wire and the A-1
Power supply Connector
A-2
(Option 2) (LCD monitor data)
main wire.
A
D
C
B
2 fA
B
A
2A
2 f
The direction of the arrow indicates which one is the branch wire (the arrowed line represents the branch wire) and also
Y/G AVSS 0.75 f

AVSS 0.75 f
AVSS
R/Y AVSS
AVSS 0.5 f
AVSS 0.5 f
AVSS 0.5 f
AVSS 0.5 f
f
AVSS 0.5 f
Lg/B
L10C O/W
E44A P/G
M15A O/B
F03A O/L
0.5
0.5
0.5
W
Y
L
G10H B
AVSS
AVSS
AVSS
M40
M39
M38
F10
shows the division between the branch wire and the main wire.
F16
G10BK B
A
AL
P
T
B
AN
AM
Back up
ACC
High speed travel signal
Work lamp signal
Glow signal
GND (TTL)
RX
TX
S70B
LCD monitor
In the example above, the wires are divided as follows.
A-24
to the point of arrow A : Branch wire G50A B/W AVSS 0.5 f
Intake air temp. sensor
Hyd. oil temp. sensor
Terminating resistor
Engine oil pressure switch
Battery charge
Sensor GND
: Main wire G50 B/W AVSS 1.25 f
Fuel sensor
to
CAN H
CAN L
Buzzer
GND
AG
AC
AD
AH
AA
AB
AE
AK
AF
AJ
W
AI
M
G
C
H
E
Y
F
Z
L
J
I
f
0.5 f
f
0.5 f
0.5 f
0.5 f
Lg/W
W/G
Y/Br
B/W
L/W
B/L
B/L
0.5
0.5
0.5
0.5
0.5
CAVST 0.5
CAVST 0.5
Y
G10AB B
L
 How to Read Wiring Symbols
AVSS
AVSS
AVSS
AVSS
AVSS
AVSS
AVSS
AVSS
AVSS
C01E
M04
M07
M08
M13
M31
M23
C01
C02
K15
Each reference number (e.g., A-1) for
electric equipment in the wiring diagram
G50 B/W AVSS 1.25 f corresponds to the numbers described in
Section "5-1-1 Parts Layout of Electrical
Equipment".
Circuit symbol Wire type and size (The reference numbers in "APPENDIX
Wiring Diagram" are also the same.)
5. ELECTRIC SYSTEM
Wire color (Ground color/stripe color)
2) Seat Mount
1/2
Wire color: B/W means: Wire color: B means:
A-17 A-19
A-16
A-18
Stripe color: White Ground color: Black Ground color: Black
A-15
A-20
A-6
A-14 A-1
Band symbol Band symbol

A-21
(No relation to the color) (No relation to the color)
A-24
Wire color codes

W ：White P ： Pink
R ：Red Br ： Brown
B ：Black Lg ： Light green
Y ：Yellow Sb ： Sky blue Ref. No. Part Ref. No. Part
G ：Green Or ： Orange
A-1 Power supply (Option 2) A-13 Horn switch
L ：Blue Gr ： Gray
V ： Violet A-2 Connector (LCD monitor data) A-14 Quick coupler controller
A-3 Power supply A (option 1) A-15 Wiper switch
060860-00EN00
062753-00EN00
2-8-1 172663 0BKC2-EN0060

1/2
1) Main harness
(rear)
(front)
Diode
Diode
Diode
A-61
A-62
A-63
A-64
A-65
A-66
2A
G00 B SEBB 60
K90
K90 12v output
(accelerator VCC)
(accelerator GND)
Accelerator sensor
Accelerator sensor
(accelerator signal)
Earth
K75
C00 Y CAVST 0.5 K75 CAN-H2
Resister (accelerator)
1A
A-67
Engine ECU
K53
C10 L CAVST 0.5 K53 CAN-L2
SIG
VCC
GND
VCC
SIG
GND
B C A B C A B C A B A C B A C
2A
G01 B SEBB 60
K65
K65 sensor gnd
Z11
Z10
Z15
Z14
Z13
Z12
Z14
Z13
Z15
K55
K58
Z11A
Z10A
B A
A-60
Battery
Z16
L/R
O/L
O/L
L/W
L/W
W/L
O/W
W/L
K43 W/R AVSSX 0.5 f K43 accelerator sensor 1
A-59
1A
G10AF
Battery
A33 injector #4 A33 L/W CAVST 1.25
cut off switch

L AVSS
L AVSS
W AVSS
Br AVSS
K43 K61
W AVSS
K61 Br AVSSX 0.5 f K61 accelerator sensor 1 TWIST
AVSS
AVSS
AVSS
L/W
AVSS
AVSS
AVSS
B
AVSS
AVSS
B01
A16 injector #4 A16 R CAVST 1.25
0.5
0.5
0.5
0.5
0.5
B00
B00
0.5
0.5
0.5
f
f
0.5
0.5
0.5
0.5
0.5
R
f
f
A47 injector #1 A47 W CAVST 1.25
f
f
f
f
f
f
f
K62
K62 L/W AVSSX 0.5 f K62 accelarator sensor 1
AVSS
AVSS
R
R
TWIST
A17 injector #1 A17 L CAVST 1.25
SEBB
AV
AV
0.5
0.5
A33 A16 A47 A17 A31
K46 accelerator sensor A31 injector #2 A31 Y CAVST 1.25
5
5
60
TWIST
f
f
K46 K83
K83 accelerator sensor 2 A01 injector #2 A01 O CAVST 1.25
J
A1 A32
A32 injector #3 A32 G CAVST 1.25
G
TWIST
A2
K84 accelerator sensor 2 A02 injector #3 A02 Br CAVST 1.25
K84
B00
B00A
Cir
E
A04A Y/G CAVST 1.25
A4
A-58
K58
R
R
K58 Br AVSS 0.5 f K58 accelarator sensor A04 supply pump A04 Y/G CAVST 1.25
IG
L
B
Generator
TWIST
A5
A05 supply pump
Z11
A05 P CAVST 1.25
<yellow 12 pin connector>
Connect to engine harness
AVS
AVS
Fuse box
Slow blow
1A
K22
K22 accele pedal sw1(no) A05A P CAVST 1.25
5
5
2A F02
W/L
2B K66
AVSS
AVSS
K89
K89 accele pedal sw(no)
W/L
R/G
0.5
0.5
AVSS
Z10 W AVSS 0.5 f
A
K55
60A K55 L/R AVSS 0.5 f K55 accelerator sensor 3
Glow
f
f
A-57
0.5
B
K44 W/R AVSS 0.5 f K44 accelerator sensor 3
f
A07 rail pressure sensor A07 R/Y AVSS 0.5 f
K44 K36
K36 analog reserve
A
60A B30 R/B AVS 3 B30 R/B AVS 3 A26 rail pressure sensor A26 G/R AVSS 0.5 f
B40 R/L AVS 3 B40 R/L AVS 3
A-56
Starter
2-8-2
B
A7 A26 A25
B10B R/W AVS 3 A25 rail pressure sensor A25 B/W AVSS 0.5 f
K60
B11 R/L AVS 2 K60 analog reserve
K35
B12 Br AVS 3
K73
K56 exh gas temp. Sensor K56 Y/Br AVSS 0.5 f
B13 W AVS 3
A
80A
Y/R
B20 W AEX 8 f A11 fuel temp. Sensor A11 L/B AVSS 0.5 f
L/G
A-55
K28 B/L
Charge
K29
K29 W/B AVSS 0.5 f K29 12v output A51 fuel temp. Sensor A51 Br AVSS 0.5 f
M21 Y/B
AVSS
I
F02C
F03 Br
F06 W/B
AVSS
A
M20 Lg
A39 crank speed sensor A39 W CAVSAS 0.5
1 2 3 4 5 6 7 8 9 10 11 12
AVSS
0.5
Z17 L/Y
120A
R06 R/L
TWIST
R/G
A30
AVSS
0.5
B10 R/W AVS 5 A30 R/L AVSS 0.5 f A30 12v output A54 crank speed sensor A54 B CAVSAS 0.5
AVSS
45 44 43 42 41 40 39 38 37 36 35 34 33
Y01 Lg/Y
B
f
0.5
Main
AVSS
AVSSX
A-54
Y02 G/W
P16
K86 Gr/R
f
K56 A11 A51 A39 A54 A38
A38 crank speed sensor A38 Lg AVSS 0.5 f
0.5
S
ASW1
K68 L AVSS
M26
AVSS
AVSS
f
AVSS
1.25
Z05
0.5
A15
S01 R/W
Gr
A15 buzzer A08 cam speed sensor A08 R/W AVSS 0.5 f
E01 W AVX
1.25
f
AVSS
E02
13 14 15 16 17
AVSS
<gray 12 pin connector>
0.5
Refer to "Details of relay"
0.5
0.5
K70
0.5
f
f
AVSS
3
Br
A37 cam speed sensor A37 L/W AVSS 0.5 f
AVX
f
0.5
f
f
f
0.5
f
R/W
AVSSX
K47
A8 A37 A52
O AVSSX
K47load ratio monitor A52 cam speed sensor A52 B/L AVSS 0.5 f
0.5
W/G
f
2. TECHNICAL DATA
AVSS
f
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
f
0.5
0.5
AVSS
Fuse box
AVSS
K17
0.5
K17 high idle
172663 0BKC2-EN0060
f
Z01
T07
T05
T03
T02
T01
V01
P14
M11
M04
M06
M23
Fuse
T06A
F12B
f
G10H
1.25
0.5
(engine)
K14
A-53
R/L
f
K45 egr pressure sensor
P
f
B10 R/W AVS 5 K14 Y/B K45 R AVSS 0.5 f
Br
K14 starter permission 1
O/L
Br/W
Y/R
R/W
W/R
B
G/B
Sb
G/W
L/W
L/W
W/R
A
20A AVSS 0.5 f
F04 R AVSS 2 f K39 egr pressure sensor K39 W AVSS 0.5 f
B
AVSS
AVSS
AVSS
AVSS
AVSS
Fuse
K93
AVSSX
AVSSX
AVSS
AVSS
AVSS
AVSS
AVSS
K93 speed selection lamp K85 egr pressure sensor K85 Y AVSS 0.5 f
AVSSX
AVSSX
AVSSX
(EGR valve) K74 egr pressure sensor K74 B AVSS 0.5 f
0.5
0.5
0.5
0.5
0.5
0.5
0.75
A-52
0.5
A
0.5
0.5
0.5
0.5
0.75
0.75
0.75
15A
K72
K72 amber warning lamp K79 ambient temp. Sensor

H
F03 Br AVSS 1.25 f K79 G/R AVSS 0.5 f
f
f
f
f
f
f
f
B
f
f
f
f
f
f
f
f
K21 ambient temp. Sensor K21 B/W AVSS 0.5 f
Fuse
K48
(immobilizer) K48 red engine stop lamp A28 cw temp. Sensor A28 G AVSS 0.5 f
B10A R/W AVS 5
A
K45 K39 K85 K74 K79 K21 A28 A29
5A A29 cw temp. Sensor A29 L AVSS 0.5 f

<red 8 pin connector>
F05 Br/Y AVSS 0.5 f

A34
B
A34 reserve
Fuse
(key switch)
A-51 A-50
A
5A
F01 R AVSSX 0.5 f
B
A60
F02C
A60 Gr A60 12v output
Fuse AVSSX 0.5 f
(LCD monitor-2)
R/G
A-49
A
K51
5A K51 Y/G K51 12v output K23 intake throttle K23 O AVSS 0.5 f
F09 P AVSSX 0.5 f AVSS 0.5 f
B
K20 intake throttle K20 G AVSS 0.5 f
AVSS
Fuse
K86
K86 Gr/R K52 intake throttle K52 Br/R AVSS 0.5 f
0.5
K86 regeneration
(parking) AVSS 0.5 f
B11 R/L AVS 2 A19 intake throttle motor A19 Y AVSS 0.5 f
A-48
f
A
15A TWIST
K31
F06 W/B AVSSX 1.25 f K31 dpf regeneration A20 intake throttle motor A20 L/R AVSS 0.5 f
B
Fuse A59 int mani temp. Sensor A59 L/Y AVSS 0.5 f
K86A
K66A
F06A
G
(controler -1)
F06B
K18
K18 dpf regeneration K33 egr temp. Sensor K33 P/B AVSS 0.5 f
F02B
A-47
A
5A
W/L
Gr/R
K18
W/B
F02 R/G AVSS 0.5 f K54 CAN-H1 K54 P CAVST 0.5
F02A
W/B
B
R/G
TWIST
K23 K20 K52 A19 A20 A59 K33 K54 K76
K71
K71 dpf regen K76 CAN-L1 K76 L CAVST 0.5
F02D
B/R
Fuse AVSS
R/G
AVSS
AVSSX
G10GA B AVSS 1.25 f
<red 12 pin connector>
AVSSX
(LCD monitor -1)
AVSS
B11A R/L AVS 2
0.5
R/G
A
K69
5A 0.5 K69 egt lamp E02 R/W AVSS 1.25 f

AVSSX
AVSS
0.75
F10 O AVSSX 0.5 f
f
0.5
0.75
B
f
AVSS
Fuse
f
f
0.5
0.5
f
K27
(controller-2) K27 dpf regen
f
f
0.5
A
5A
F14 R/W AVSS 0.5 f
f
K25
B
K25 dpf regen req lamp K77B B/Y AVSS 0.5 f GND
E
Fuse
K25
K24 R/L AVSS 0.5 f VCC

D
(lamp)
A-46 A-45 A-44

B12 Br AVS 3 Voa(P1)
Lg
A
A
10A
A-1
K24 dpf diffrential pressure sensor Voa(P2)

K87
F07 G/R AVSSX 0.75 f K87 sensor gnd A12 G/W AVSS 0.5 f
B
C
Fuse
AVSSX
K63 dpf differential pressure sensor(low) K63 Lg AVSS 0.5 f Vob

B
DPF differential
pressure sensor
(option-1)
K24 K63 A12
K67
K67 engine stop 2 A12 dpf differential ressure sensor(high)
A-43
0.5
A
10A
F08 Y/B AVSSX 0.75 f
f
B
K42
Fuse K42 high idle limit K80 dpf inside temp. Sensor K80 O/W AVSS 0.5 f
A
(vessel) K77 dpf diffrential pressure sensor K77A B/Y AVSS 0.5 f
A-2
GND
A
5A
K80 K77 K81
K38
F11 G/Y AVSS 0.5 f K38 starter permission 2 K81 dpf inlet temp. Sensor
B
temperature sensor
Fuse
K37
(alarm and travel) K37 droop

B13 W AVS 3 K77 B/Y AVSS 0.5 f GND
A-42 A-41
B
A
10A
F12 Y/R AVSS 0.5 f K81 R/W AVSS 0.5 f
A-3
B
A
DPF inlet
K19
K19 speed 1
Fuse
K19
DPF intermediate temperature sensor
(power outlet)
A
K16
K16 speed 2
A-40
20A
F13 R/W AVSS 1.25 f
G10GB B AVSS 0.5 f
B
K16
O AVSSX
B01
Earth
K13
K13 speed selection

R
K13
0.5
P AVSS
K70
K70 graw plug relay K70 W/G AVSS 0.5 f

f
Gr
K49 cwt warning lamp

K49
SEBB
0.5
60
K88B
K88b key sw F02B R/G AVSS 0.5 f

f
AVSSX
M B
K26
K26 isochronous lamp

1A
S01 R/W AVX 3

S
Starter
A-39
2A
0.5
K28
K28 starter relay K28 B/L AVSS 0.5 f

f
A50
A50 12v output

K73
E01 W AVX 3 K73 12v output K73 L/G AVSS 0.5 f

A50
A-38
K94
K94 speed monitor

Glow plug
K66
R/G
K35
K35 key sw K35 Y/R AVSS 0.5 f

W/L
G10 B AVS 5
AVSS
K32
K32 engine stop 1

Earth
K68
K68 12v output K68 L AVSS 0.5 f

K32
0.5
AVSS
K92
K92 failure lamp

f
O/B
0.5
K29 W/B AVSS 0.5 f

A
f
K16 P AVSS 0.5 f

K66
AVSS
B
Earth
K66 charge lamp

A-37
Resister
0.5
(A/D restraint)
K16A
K6
K06 GND G02B B AVSS 2 f

K50
K50 pre-heat lamp

f
P
K4
K04 GND G02A B AVSS 2 f

A30 R/L AVSS 0.5 f
A
K2
K02 GND G02 B AVSS 2 f

AVSS
K41
Z09 Br AVSS 0.5 f K41 air cleaner lamp

B
A-36
Resister
0.5
(eco, A/D)
K40
K40 water separator

K1
K01 ECUVB F04 R AVSS 2 f

K3
K03 ECUVB F04A R AVSS 2 f

K15
K5
K15 G/W AVSS 0.5 f K15 oilpressure lamp K05 ECUVB F04B R AVSS 2 f
A
A-35
Engine oil
pressure switch
K15A
G/W
K19A O AVSS 0.5 f

C
AVSS
Diode
K13A Gr AVSS 0.5 f

A-34
A
(eco, A/D)
0.5
K35A
K70A
f
G10GA
G10GB
Y/R
W/G
G10H
AVSS
R : Red
B AVSS
B AVSS
L : Blue
AVSSX
B : Black
W : White
0.5
G : Green
Y : Yellow
B AVSS
f
0.5
0.5 f
f
1.25 f
0.75
V:
Lg :
Br :
Gr :
P:
O:
Sb :
f
Wiring color
Pink
Gray
Violet
Brown
Orange
Sky blue
Light green
8
6
4
2
60
58
56
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
9
7
5
3
1
61
59
57
55
53
51
49
47
45
43
41
39
37
35
33
31
29
27
25
23
21
19
17
15
13
11
Band marking
Example: W/B
Base color: White
Stripe: Black
(No relation with wiring color.)
101417-00EN00
2/2
8
6
4
2
60
58
56
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
9
7
5
3
1
61
59
57
55
53
51
49
47
45
43
41
39
37
35
33
31
29
27
25
23
21
19
17
15
13
11
K66A W/L AVSS 0.5 f
A
K86A Gr/R AVSS 0.5 f
C
Z02A P AVSS 0.5 f G10G B AVSS 2 f
Diode
A-33
-
A
(charge,
DPF lock)
F06A W/B AVSSX 0.75 f
+
A-4
B
Feed
pump
TWIST
G10GD
K16A P AVSS 0.5 f
B
B
Z17 L/Y AVSS 0.5 f

C
AVSS
K51 Y/G AVSS 0.5 f
A-5
A
Diode
Z05 Br AVSS 0.5 f

A
B
0.75
A-32
Z17A
(A/D resistant)
Resister
DPF lock)
Z05A
(charge, oil,
L/Y
Br
K35A Y/R AVSS 0.5 f
A
K14A Y/B AVSS 0.5 f

C
AVSS
AVSS
Diode
A-6
Z07 L/B AVSS 0.5 f

B
Z02 P AVSS 0.5 f
0.5
0.5
A
(starter restraint)
K15A G/W AVSS 0.5 f
B
F06B W/B AVSSX 0.75 f
Diode
A-31
M11 R/L AVSS 0.5 f
(engine oil)
M20 Lg AVSS 0.5 f
M21 Y/B AVSS 0.5 f
M23 Br AVSS 0.75 f
K32 O/B AVSS 0.5 f
F
A50 R/G AVSS 0.5 f
2-8-3
F11 G/Y AVSS 0.5 f
<10 pin connector>
M06 G/W AVSS 0.5 f Y01 Lg/Y AVSS 0.5 f

Connect to seat harness
F
K18A B/R AVSS 0.5 f
S10 W/G AVSSX 0.5 f
A
F13 R/W AVSS 1.25 f
F02A R/G AVSS 0.5 f
G
F12 Y/R AVSS 0.5 f
F05 Br/Y AVSS 0.5 f T05 Br/W AVSS 0.75 f
I
T07 G/B AVSS 0.75 f
G10GD B AVSS 0.75 f H01 P AVSS 0.5 f
L
C10A L CAVST 0.5
E
TWIST C00A Y CAVST 0.5

P40 B/W AVSS 0.5 f
M04 O/L AVSS 0.5 f P39 V AVSS 0.5 f
D
P38 W AVSS 0.5 f
T06A
G10AA B AVSS 2 f
F05A
G10GC
<12 pin connector>
K14 Y/B AVSS 0.5 f

Connect to seat harness
E
L/W
F12A
H01A
Br/Y
G10AD
G10AB
2. TECHNICAL DATA
Z07 L/B AVSS 0.5 f
AVSS
A
K
P
Y/R
B
B
AVSSX
G10AC B AVSS 0.5 f
172663 0BKC2-EN0060
A-7
J
AVSS
0.5
Resister
H01 P AVSS 0.5 f
AVSS
AVSS
AVSS
AVSS
0.5
H
0.5
(starter restraint)
M02 G AVSSX 0.5 f
G10AF
0.5
0.5
B
0.5
0.5
f
G10AA
M03 Br AVSSX 0.5 f T06 L/W AVSSX 0.5 f
f
f
f
B
A
C
T08 L AVSS 0.5 f
B
A-8
AVSS
Travel pilot
AVSS
B
0.5
2
A
f
f
+
G10A B G10AE B AVSS 0.5 f

Single
A-9
AVSS 2 f
pressure switch solenoid valve
G10 B AVS 5
G10AG
T03 R/W AVSS 0.5 f
+
Earth
1B
B
G10B B AVSS 0.75 f
-
G10C
G10D
1A
T03D
SOL1
Y02 G/W AVSS 0.5 f
AVSS
B
B
+
2B
G10GC B AVSS 0.5 f G10BA B AVSS 0.5 f

R/W
-
0.5
A
2A
AVSS
SOL2
A-10
AVSSX
F02D R/G AVSS 0.5 f T03E R/W AVSS 0.5 f
f
+
Diode
3B
A-30
2
AVSSX
G10BB B AVSS 0.5 f
2
-
f
3A
f
SOL3
(surge ACC1)
0.5
F14 R/W AVSS 0.5 f

F05A Br/Y AVSS 0.5 f
f
R06 R/L AVSS 0.5 f K61 Br AVSSX 0.5 f SIG

B
Z17A L/Y AVSS 0.5 f

Z05A Br AVSS 0.5 f K62 L/W AVSSX 0.5 f GND
D
A
C10B L CAVST 0.5

C00B Y CAVST 0.5 TWIST K43 W/R AVSSX 0.5 f
A-11
2
1
G10AB B AVSS 0.5 f VCC

OFF
POSITION
F01 R AVSSX 0.5 f
<12 pin connector>

1A
V01 W/R AVSSX 0.5 f

B
Connect to option harness

2A
G10F B AVSSX 0.5 f

2B
3
S10 W/G AVSSX 0.5 f

A-12
BR1 BR2 C1
G10CB B AVSS 0.5 f

BATT
2C
P14A Sb AVSSX 0.5 f P14A Sb AVSSX 0.5 f
A
C2
2D
T06B L/W AVSSX 0.5 f T06B L/W AVSSX 0.5 f
C
Z20 Lg AVSS 0.5 f
Diode
A-29
B
BR1 BR2 C2
L11A Y/B AVSSX 0.5 f

A
Starter switch diagram
L10A W/R AVSSX 0.5 f

C
C1
GND
C
A
G10FA B Battery F09 P L13D Lg AVSSX 0.5 f

A-13
AVSSX 0.5 f AVSSX 0.5 f

Triple solenoid valve Engine control dial Starter switch Diode (head light)
B
B
ACC F10 O
G10AD B AVSS 0.5 f AVSSX 0.5 f
A
L13 Lg AVSSX 0.5 f
+
A-28
G
Resister
-
1st speed sig.In P14 Sb G10D B AVSSX 2 f

H
AVSSX 0.5 f
L15 Y AVSSX 0.75 f
L13B
L13A
L13E
L13C
B
G10E
F
O
2nd speed sig. In T06 L/W

G10EB
G10EA
G10DF
G10DB
G10DD
A
Lg
Lg
Lg
Lg
Z01 L/W AVSS 0.5 f AVSSX 0.5 f
A
L11 Y/B AVSSX 0.75 f
B
B
B
B
B
B
C
G10CB B AVSS 0.5 f
Diode
Hydraulic oil temp.
B
P
P07 Y/B Parking lamp sig. P16 Gr
A-27
AVSSX
AVSSX
AVSSX
AVSSX
D

A-14
L10 W/R AVSSX 0.75 f

AVSSX
AVSSX
AVSSX
AVSSX
AVSSX
AVSSX
F
Light switch
P16A
0.5
0.5
0.5
0.5
Fuel gauge Illumi lamp sig. In

H
Q
P08 Br L13 Lg F07 G/R AVSSX 0.75 f

E
0.5
0.5
0.5
0.5
0.5
0.5

f
f
f
f
Gr
-
G10DA B AVSSX 0.5 f

J
f
f
f
f
f
f
T04A L AVSS 0.5 f

I
A
R
L10C W/R AVSSX 0.5 f

+
G10AG B AVSS 0.5 f

AVSSX
A-26
Resister
J
S
G10DC B AVSSX 0.5 f

0.5
(speed signal) (speed signal) (prevent reverse) (travel alarm)

B
K13 Gr AVSSX 0.5 f

f
C
Glow sig. In K70A W/G L13C Lg AVSSX 0.5 f

switch
AVSSX 0.5 f
A-15
G10DB B AVSSX 0.5 f

G
Auto deceleration
L
U
High beam sig. In L10B W/R

AVSSX 0.5 f
P07 Y/B AVSSX 0.5 f G10DE B AVSSX 0.5 f
B
A
M
V
P13A B/R AVSSX 0.5 f P13 B/R Sensor GND K19 O AVSSX 0.5 f
GND
C
AVSSX 0.5 f
A-25
L13B Lg AVSSX 0.5 f

Hydraulic oil
H
switch
A-16
Z
AN
GND (for ttl communication) P40 B/W G10DD B AVSSX 0.5 f

ECO mode
AVSS 0.5 f
temperature sensor
AA
P08 Br AVSSX 0.5 f RX

AM
P39 V L13A Lg AVSSX 0.5 f

A
F
RX AVSS 0.5 f
P13 B/R AVSSX 0.5 f M26 O AVSSX 0.5 f
B
B
GND
A-24
AB
AL
ON
TX P38 W T01 W/R AVSSX 0.5 f
C
Fuel gauge
TX AVSS 0.5 f
T02 P AVSSX 0.5 f
A
OFF
A-17
AC
P16A Gr AVSSX 0.5 f

H
G10DF B AVSSX 0.5 f

Parking switch
AD
F08A Y/B AVSSX 0.75 f

B
AE
L20 W/G AVSSX 0.5 f

C
G10EA B AVSSX 0.5 f

switch
AF
H
A-18
Option
L13F Lg AVSSX 0.5 f

Beacon lamp
AG
G10F B AVSSX 0.5 f T03D R/W AVSSX 0.5 f

B
2A
Buzzer output
W
P23 R AVSSX 0.5 f T04 L AVSSX 0.5 f

A-23
C
Buzzer
1A
A-22
G10EB B AVSSX 0.5 f

switch
H
A-19
Option
X
LCD monitor
L13G Lg AVSSX 0.5 f

Travel alarm
L11
L20
L21
L10
T04
F12A
Y
H01A
G10A
G10C
G10CA
F08 Y/B AVSSX 0.75 f

B
B
G/R
L
Y/B
Y/R
B
P
W/G
W/R
L21 G/R AVSSX 0.75 f

Termination resistor
C
AK
C10C L
AVSS 0.5 f G10E B AVSSX 0.5 f
AVSS
AVSSX
H
AVSSX
AVSS
AVSS
AVSS
AVSS
AVSSX
AVSSX
AVSSX
A-20
Option
L13E Lg AVSSX 0.5 f

lamp switch
Rear working
AJ
G
0.5
0.5
0.5
0.5
0.5
0.75
2
0.75
0.75
A60 Gr AVSSX 0.5 f

f
f
f
f
f
f
f
f
f
f
AI
B
C10 L CAVST 0.5 CAN L

R : Red
L : Blue
K18 B/R AVSSX 0.5 f

B : Black
W : White
G : Green
Y : Yellow
C
K25 Lg AVSSX 0.5 f

G
AH
C
B
A
C00 Y CAVST 0.5 CAN H

A-21
V:
Lg :
Br :
Gr :
P:
O:
Sb :
A60A Gr AVSSX 0.5 f

DPF manual
Wiring color
regeneration switch
Pink
Gray
Violet
Brown
Orange
Sky blue
Light green
< 2 pin connector>
< 3 pin connector>
< 6 pin connector>
Band marking
Example: W/B
Connect to front harness
Connect to optional part harness

Connect to optional part harness
Base color: White

Stripe: Black
101417-00EN00
B30 R/B AVS 3
B40 R/L AVS 3 Z10 W AVSS 0.5 f
B10B R/W AVS 3 Z11 W/L AVSS 0.5 f
B11 R/L AVS 2 K44 W/R AVSS 0.5 f
B12 Br AVS 3
B13 W AVS 3
K35
K73
Y/R AVSS 0.5 f
L/G AVSS 0.5 f
Details of relay
F03 Br AVSS 1.25 f K28 B/L AVSS 0.5 f
F02C R/G AVSS 0.5 f M21 Y/B AVSS 0.5 f
R06 R/L AVSS 0.5 f F06 W/B AVSSX 1.25 f
K68 L AVSS 0.5 f M20 Lg AVSS 0.5 f
Connect to
Connect to
main harness
K86 Gr/R AVSS 0.5 f Z17 L/Y AVSS 0.5 f
main harness
E01 W AVX 3 Y01 Lg/Y AVSS 0.5 f
S01 R/W AVX 3 Y02 G/W AVSS 0.5 f
45 44 43 42 41 40 39 38 37 36 35 34 33
1 2 3 4 5 6 7 8 9 10 11 12
M25 R/W AVSS 0.75 f

M23 Br AVSS 0.75 f
E B
M24 G AVSS 0.75 f
D
A-68
G10HA B AVSS 0.5 f
Relay box
-
A
Relay (forward)
[No:CM1-R-12V]
M21 Y/B AVSS 0.5 f

+
C
F06 W/B AVSSX 1.25 f

E B
S01 R/W AVX 3
D
M23A Br AVSS 0.75 f
D
B40 R/L AVS 3
2-8-4
A-69
G10HG B AVSS 0.5 f

-
A
K73 L/G AVSS 0.5 f
A-86
C
[No:CM1-R-12V]
Relay (rearward)
M20 Lg AVSS 0.5 f

+
C
Relay (starter)
K28 B/L AVSS 0.5 f
[No:CB1aH-12V]
B
K44 W/R AVSS 0.5 f
E01 W AVX 3 Z10 W AVSS 0.5 f
E B
D
B30 R/B AVS 3 Z11 W/L AVSS 0.5 f
D
A
A-70
K70 W/G AVSS 0.5 f G10HM B AVSS 0.5 f
A-85
-
A
C
2. TECHNICAL DATA
Relay (glow)
[No:CM1-R-12V]
G10K B AVSS 0.5 f M23B Br AVSS 0.5 f

Relay (accelerator)
[No:CB1aH-12V]
+
C
172663 0BKC2-EN0060
K86 Gr/R AVSS 0.5 f M25 R/W AVSS 0.75 f
G10KB B AVSS 0.5 f M06 G/W AVSS 0.5 f
E B
E B
M26A O AVSS 0.5 f
D
D
A-84
A-71
G10KC B AVSS 0.5 f G10HH B AVSS 0.5 f

-
-
A
A
Relay (safety)
[No:CM1-R-12V]
[No:CM1-R-12V]
Relay (inter lock)
M11A R/L AVSS 0.5 f M11 R/L AVSS 0.5 f
+
+
C
C
F03 Br AVSS 1.25 f Y01 Lg/Y AVSS 0.5 f
E B
E B
E02 R/W AVSS 1.25 f Y02 G/W AVSS 0.5 f
D
D
A-83
A-72
G10KA B AVSS 0.5 f G10HC B AVSS 0.5 f

-
-
A
A
Relay (wagon)
[No:CM1-R-12V]
[No:CM1-R-12V]
K68 L AVSS 0.5 f M26B O AVSS 0.5 f
Relay (EGR valve)

+
+
C
C
M04 O/L AVSS 0.5 f Z17 L/Y AVSS 0.5 f

E B
E B
K35 Y/R AVSS 0.5 f G10HL B AVSS 0.5 f
D
A-82
A-73
R06 R/L AVSS 0.5 f G10HB B AVSS 0.5 f

-
-
A
A
[No:CM1-R-12V]
[No:CM1-R-12V]
F02C R/G AVSS 0.5 f Y02A G/W AVSS 0.5 f
+
+
C
Relay (engine control)

Relay (A/D 1: wagon)
B10B R/W AVS 3 Z05 Br AVSS 0.5 f
E B
E B
B13 W AVS 3 G10HD B AVSS 0.5 f
D
D
A-81
A-74
Z01B L/W AVSS 0.5 f G10HE B AVSS 0.5 f

-
-
A
A
Relay (ACC3)
[No:CM1-R-12V]
[No:CM1-R-12V]
V01B W/R AVSS 0.5 f T03A R/W AVSS 0.5 f
+
+
C
C
B10D R/W AVS 3 F12C Y/R AVSS 0.5 f

P16 Gr AVSSX 0.5 f
E B
E B
B12 Br AVS 3
D
A-80
A-75
Z01A L/W AVSS 0.5 f G10HF B AVSS 0.5 f

-
-
A
Relay (ACC2)
[No:CM1-R-12V]
[No:CM1-R-12V]
V01A W/R AVSS 0.5 f T03C R/W AVSS 0.5 f
+
+
C
B10C R/W AVS 2 M26 O AVSSX 0.5 f

E B
E B
B11 R/L AVS 2 T03B R/W AVSS 0.5 f

D
A-79
A-76
Z01 L/W AVSS 0.5 f G10HK B AVSS 0.5 f

-
-
A
Relay (ACC1)
[No:CM1-R-12V]
[No:CM1-R-12V]
V01 W/R AVSSX 0.5 f T02A P AVSS 0.5 f

+
+
C
C
G10HF B AVSS 0.5
G10HA B AVSS 0.5

G10HB B AVSS 0.5
G10HC B AVSS 0.5
G10HD B AVSS 0.5
G10HM B AVSS 0.5
G10K B AVSS 0.5 f

f
f
f
f
f
T02 P AVSSX 0.5 f

T03 R/W AVSS 0.5 f
E B
D
T05 Br/W AVSS 0.75 f

A
A-77
G10H B AVSS 0.75 f

-
A
T07 G/B AVSS 0.75 f

D
[No:CM1-R-12V]
T01 W/R AVSSX 0.5 f

+
C
T06A L/W AVSSX 0.5 f

Relay (A/D 2: parking) Relay (parking 1: signal) Relay (parking 2: release) Relay (parking 3: lock)
A-78
P14 Sb AVSSX 0.5 f

F
[No:CA1-DC12V-N]
F12B Y/R AVSS 0.5 f

B
Relay (travel dual speed)

Relay box
T02 P AVSSX 0.5 f

M23 Br AVSS 0.75 f
M11 R/L AVSS 0.5 f

T03 R/W AVSS 0.5 f
M06 G/W AVSS 0.5 f

F12B Y/R AVSS 0.5 f
T01 W/R AVSSX 0.5 f
R : Red
L : Blue
B : Black
W : White
G : Green
Y : Yellow
P14 Sb AVSSX 0.5 f
Z01 L/W AVSS 0.5 f

M04 O/L AVSS 0.5 f
G10H B AVSS 0.75 f
P16 Gr AVSSX 0.5 f

T07 G/B AVSS 0.75 f
V01 W/R AVSSX 0.5 f

T05 Br/W AVSS 0.75 f
T06A L/W AVSSX 0.5 f
M26 O AVSSX 0.5 f

V:
Lg :
Br :
Gr :
P:
O:
Sb :
Z05 Br AVSS 0.5 f

Wiring color
E02 R/W AVSS 1.25 f

Pink
Gray
Violet
K70 W/G AVSS 0.5 f

Brown
13 14 15 16 17
Orange
Sky blue
Light green
Connect to
main harness
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
Connect to
Connect to
Band marking
main harness
main harness
Example: W/B
Base color: White
Stripe: Black

101410-00EN00
2) Seat harness
F06 W/B AVSS 0.75 f F06B W/B AVSS 0.75 f
A
M11 R/L AVSS 0.75 f
B-1
M20 Lg AVSS 0.75 f M10 G AVSS 0.75 f
B
M21 Y/B AVSS 0.75 f
Cut off lever (right)
M23 Br AVSS 0.75 f
F
K32 O/B AVSS 0.75 f
A50 R/G AVSS 0.75 f
F11 G/Y AVSS 0.75 f
Y01 Lg/Y AVSS 0.75 f
<10 pin connector>

A
K18 B/R AVSS 0.5 f
Connect to main harness

B-2
M11 R/L AVSS 0.75 f

B
F13 R/W AVSS 1.25 f

Cut off lever (left)
F12 Y/R AVSS 0.75 f

T05 Br/W AVSS 0.75 f F06A W/B AVSS 0.75 f
B
2-8-5
T07 G/B AVSS 0.75 f
H01 P AVSS 0.75 f M20 Lg AVSS 0.75 f
D
E
C10 L CAVST 0.5
C00 Y CAVST 0.5
B-3
P40 B/W AVSS 0.5 f

P39 V AVSS 0.5 f
<12 pin connector>

P38 W AVSS 0.5 f

C
Seat direction switch (rearward)
G10 B AVSS 2 f
2. TECHNICAL DATA
172663 0BKC2-EN0060
F06 W/B AVSS 0.75 f
B
M21 Y/B AVSS 0.75 f

D
B-4
TWIST
C
Seat direction switch (forward)
M23 Br AVSS 0.75 f

+
B
B-5
G10A B AVSS 0.5 f

A
-
Selector valve
K18 B/R AVSS 0.5 f
A
K32A O/B AVSS 0.5 f K32 O/B AVSS 0.75 f
C
B
B-14
B-6
Z03 L AVSS 0.5 f A50 R/G AVSS 0.75 f
B
C
Diode (engine stop, DPF)

Engine stop switch
F12A Y/R AVSS 0.75 f POWER

D
G10B B AVSS 0.75 f GND

C
T05 Br/W AVSS 0.75 f OUTPUT

A
B-7
T07 G/B AVSS 0.75 f RETURN

TRAVEL
Lever (left)
B-13
G10C B AVSS 0.5 f G10D B AVSS 0.75 f HORN -

F
H01 P AVSS 0.75 f HORN +

G
Resister (engine stop, DPF)
F11A G/Y AVSS 0.75 f

A
B-8
TX P38 W AVSS 0.5 f Y01A Lg/Y AVSS 0.75 f

B
C
Swing wagon type
RX
B-12
P39 V AVSS 0.5 f

B
Lever (swing wagon type)
GND P40 B/W AVSS 0.5 f

D
Connector (LCD monitor data)
F11 G/Y AVSS 0.75 f

R : Red
L : Blue
B : Black
1A
W : White
G : Green
Y : Yellow
B-9
F12 Y/R AVSS 0.75 f Y01 Lg/Y AVSS 0.75 f

V:
Lg :
Br :
Gr :
P:
O:
Sb :
A
2A
VCC
Wiring color
Pink
Gray
Violet
Brown
B
Orange
Sky blue
Light green
CAN_H
Lever (three-side flaps wagon type)
C00 Y CAVST 0.5

C
B-11
D
CAN_L
Band marking
C10 L CAVST 0.5 F13 R/W AVSS 1.25 f Vcc

Example: W/B
E
B
Base color: White

Stripe: Black
GND
Connector (SMARTASSIST-Direct)
B-10
G10E B AVSS 0.5 f G10 B AVSS 2 f GND

F
A
Power outlet
101411-01EN00
2. TECHNICAL DATA
3) Front harness
F12 Y/R AVSS 0.5 f
1A
C-1
H01 P AVSS 0.5 f Horn
A 2A
< 6 pin connector>
G10A B AVSS 0.5 f

A
L10A W/R AVSS 0.5 f High beam C-2

B Head light (L)
L11A Y/B AVSS 0.5 f Low beam
G10 B AVSS 0.75 f

A Wiring color Example: W/B
W : White P: Pink Base color: White

L10 W/R AVSS 0.75 f Hight beam C-3 R : Red Br : Brown Stripe: Black
B : Black Lg : Light green
B Head light (R) Y : Yellow Sb : Sky blue
G : Green O: Orange
L : Blue Gr : Gray
L11 Y/B AVSS 0.75 f Low beam V: Violet Band marking
C
101412-00EN00
2-8-6 172663 0BKC2-EN0060

2. TECHNICAL DATA
4) Option harness

<12 pin connector>
F14 R/W AVSS 0.5 f
F05 Br/Y AVSS 0.5 f
R06 R/L AVSS 0.5 f
1B 1O 1C 1P 2A 3A 1A 1M 1R 1Z 1F 1S
GPS
COM
A02
A15
A03
A16
A01
A13
A18
A26
A06
A19
Z17 L/Y AVSS 0.5 f
Z05 Br AVSS 0.5 f
G10 B AVSS 0.5 f

C10 L CAVST 0.5
C00 Y CAVST 0.5

Option harness
TWIST
A04
A05
A17
A10
A12
A23
A24
A25
A14
A07
A08
A09
A20
A21
A22
A11
1D 1E 1Q 1J 1K 1L 1W 1X 1Y 1N 1G 1H 1I 1T 1U 1V
Z17 L/Y AVSS 0.5 f
Z05 Br AVSS 0.5 f
C10 L CAVST 0.5
C00 Y CAVST 0.5
G10A B AVSS 0.5 f
G10 B AVSS 0.5 f
Wiring color Example: W/B

R : Red Br : Brown Stripe: Black
Y : Yellow Sb : Sky blue
G : Green O: Orange
L : Blue Gr : Gray
V: Violet Band marking
101413-00EN00
2-8-7 172663 0BKC2-EN0060

2. TECHNICAL DATA
5) Optional part harness
Connect to main harness Connect to main harness Connect to main harness Connect to main harness
< 2 pin connector> < 3 pin connector> < 3 pin connector> < 3 pin connector>
C B B B
G10 B AVSS 0.5 f
L20 W/G AVSS 0.5 f
G10 B AVSS 0.75 f
L21 G/R AVSS 0.75 f
T04 L AVSS 0.5 f
G10 B AVSS 0.75 f
L21 G/R AVSS 0.75 f
T04 L AVSS 0.5 f
G10 B AVSS 0.75 f
L21 G/R AVSS 0.75 f
T04 L AVSS 0.5 f

L21 G/R AVSS 0.75 f
L21 G/R AVSS 0.75 f
L21 G/R AVSS 0.75 f

L20 W/G AVSS 0.5 f
G10A B AVSS 0.5 f
G10A B AVSS 0.5 f

G10 B AVSS 0.75 f
G10 B AVSS 0.75 f
G10 B AVSS 0.75 f

G10 B AVSS 0.5 f
T04 L AVSS 0.5 f
T04 L AVSS 0.5 f

B A A B A A B A
- + - +
Body earth Body earth W : White P: Pink Base color: White

(buzzer) R : Red Br : Brown Stripe: Black
Beacon lamp Rear working lamp Travel buzzer Rear working lamp Travel buzzer G : Green O: Orange
D-1 D-2 D-3 D-4 D-5 L : Blue Gr : Gray
Beacon lamp specification Rear working lamp specification Travel alarm specification Travel alarm & rear working lamp specification
101414-00EN00
2-8-8 172663 0BKC2-EN0060

2. TECHNICAL DATA
6) Engine harness
Harness C Harness B
E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-15

E-1 E-2 E-3 E-4 E-5 Rail pressure Exhaust manifold Fuel temperature Crank speed Cam speed EGR pressure Intake temperature Coolant E-14 Intake manifold E-17
Injector #4 Injector #1 Injector #2 Injector #3 Supply pump sensor temperature sensor sensor sensor sensor sensor sensor temperature sensor Intake throttle temperature sensor Resistor
B
Voa (P2)
Voa (P1)
A
INJ-H
INJ-H
INJ-H
INJ-H
Vout2
Vout1
INJ-L
INJ-L
INJ-L
INJ-L
SIG1
SIG2
GND
GND
GND
GND
GND
GND
GND
GND
GND
VCC
VCC
VCC
High
Vout
Vout
Vout
Vout
Low
SIG
SIG
SIG
Vin
M+
M-
+ -
+ - + - + - + -
A B A B A B A B 2A 2B C B A A B 1B 1A B A C B A D C B E A B A B E D C F B A B A E-18
E-16 EGR Valve
EGR gas CAN_H
temperature sensor D
TWIST
TWIST
TWIST
TWIST
TWIST
CAN_L
C
GND
Vout
GND
B A
B
Vcc
A
TWIST
TWIST
TWIST
B00B B AVSSX 1.25 f

A05A P AVSSX 1.25 f
A04A Y AVSSX 1.25 f
A47 W AVSSX 1.25 f
A01 O AVSSX 1.25 f
A32 G AVSSX 1.25 f
B42 O AVSSX 1.25 f

A16 R AVSSX 1.25 f
A02 Br AVSSX 1.25 f
A05 P AVSSX 1.25 f

A31 Y AVSSX 1.25 f
A04 Y AVSSX 1.25 f
A19 Y AVSSX 1.25 f

A33 L AVSSX 1.25 f
A17 L AVSSX 1.25 f
A20 L AVSSX 1.25 f

A39 W AVSSX 0.5 f
K39 W AVSSX 0.5 f

A26 G AVSSX 0.5 f
A28 G AVSSX 0.5 f
K20 G AVSSX 0.5 f

A07 R AVSSX 0.5 f
A51 Br AVSSX 0.5 f
A08 R AVSSX 0.5 f
K45 R AVSSX 0.5 f
K23 R AVSSX 0.5 f
K52 Br AVSSX 0.5 f
K33 R AVSSX 0.5 f

A25 B AVSSX 0.5 f
A54 B AVSSX 0.5 f
A52 B AVSSX 0.5 f
K74 B AVSSX 0.5 f
K21 B AVSSX 0.5 f

K79 P AVSSX 0.5 f
K54 P AVSSX 0.5 f

K56 Y AVSSX 0.5 f
K85 Y AVSSX 0.5 f

A37 L AVSSX 0.5 f
A29 L AVSSX 0.5 f
A59 L AVSSX 0.5 f
K76 L AVSSX 0.5 f

A11 L AVSSX 0.5 f
seal plug
seal plug
F E D C B A L K J I H G 3F 3E 3D 3I 3H 3G 3L 3K 3C 3B 3A 3J 1D 1B 1C 1A 1H 1G 1F 1E 2B 2A 2L 2K 2J 2I 2H 2E 2D 2C 2F 2G
J I H G
Connect to main harness Connect to main harness Connect to main harness Connect to main harness
<yellow 12 pin connector> <gray 12 pin connector> <red 8 pin connector> <red 12 pin connector>

R : Red Br : Brown Stripe: Black
G : Green O: Orange
L : Blue Gr : Gray
101409-00EN00
2-8-9 172663 0BKC2-EN0060

CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance......................................................................... 3-1-1

3-1-1 Three-side flaps wagon type...................................................... 3-1-1
3-1-2 Swing wagon type...................................................................... 3-1-4
3-2 Engine................................................................................................. 3-2-1
3-2-1 Nominal and Allowable Values................................................... 3-2-1
3-3 Undercarriage ..................................................................................... 3-3-1
3-4 Controls .............................................................................................. 3-4-1
3-5 Hydraulic Cylinder............................................................................... 3-5-1
3-6 Work Implement.................................................................................. 3-6-1
3-7 List of Tightening Torque .................................................................... 3-7-1
3-7-1 Machine ..................................................................................... 3-7-1
3-7-2 Engine........................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts .......................... 3-7-6
3-7-4 Hydraulic Fitting ......................................................................... 3-7-7
3-8 Pressure Adjustment .......................................................................... 3-8-1
3-8-1 Measuring the pressure ............................................................. 3-8-1
3-8-2 Measuring the main pressure (effective differential pressure) ... 3-8-1
3-8-3 Charge pressure measurement ................................................. 3-8-2
3-8-4 Dump pressure measurement ................................................... 3-8-3
3-8-5 Pilot pressure measurement ...................................................... 3-8-3
3-8-6 Wagon swing pressure measurement ....................................... 3-8-4
3. SERVICING STANDARDS
3. Service Standards
3-1 Machine Performance
3-1-1 Three-side flaps wagon type
Applicable model C30R-3

Item Measuring condition Unit Standard Allowance
Machine performance
Traveling speed Machine position
High
6.2 to 7.0 -
speed
sec.
104762-00X00
• Engine: Rated speed

• Load: Empty Low
11.5 to 13.9 -
• Site: Firm, flat ground speed
• Measure traveling time for 65.6 ft (20
m) after an approach run of over 16.5
ft (5 m).
Track deviation Machine position
104762-00X00
20
• Engine: Rated speed in.
(500) -
• Hydraulic oil temp.:122 to 140°F (50 to 60°C) (mm)
or less
• Site: Firm, flat ground
• Measure the deviation (X) in a traveling dis-
tance of 65.6 ft (20 m) after an approach run of
over 16.5 ft (5 m).
65.6 ft (20m)
32.8 ft
(10 m)
013961-00X01
3-1-1 172663 0BKC2-EN0060


Machine performance
Dump speed Machine position
No load Up time
-
Up 3.1 to 3.5
sec.
Down
Down time
104763-00EN01 -
2.3 to 2.7
• Hydraulic oil temp.:122 to 140°F (50 to 60°C)
Dumping drift Machine position
No load
0.2
in.
(5) -
(mm)
or less
104763-00EN01
• Engine : Stopped
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Measure the cylinder retraction for 5 minutes
in the posture above.
Max. slope angle to dump Machine position
vessel
deg. 20 -
d
104763-01X00
• Engine : Rated speed

• Load : 5513 lbs. (2500 kg)
Note: Load should be evenly centered on the
vessel.
• Measure the maximum angle d where dump-
ing is started.
3-1-2 172663 0BKC2-EN0060


Machine performance
Breaking distance Machine position
ft. (m) 9.8 (3.0) or less -

104762-01X00

• Speed : Forward, high-speed
• Load : 5513 lbs. (2500 kg)
• Run in max. speed on a dry paved ground and
measure the distance between the point
where the travel lever is moved to the neutral
position and the carrier stopping point.
3-1-3 172663 0BKC2-EN0060

3-1-2 Swing wagon type

Machine performance
Traveling speed Machine position
High
6.2 to 7.0 -
speed
109594-00X00
sec.

• Load: Empty Low
11.5 to 13.9 -
• Site: Firm, flat ground speed
• Measure traveling time for 65.6 ft (20
m) after an approach run of over 16.5
ft (5 m).
Track deviation Machine position
109594-00X00
20
• Engine: Rated speed in.
(500) -
• Hydraulic oil temp.:122 to 140°F (50 to 60°C) (mm)
or less
• Measure the deviation (X) in a traveling dis-
tance of 65.6 ft (20 m) after an approach run of
over 16.5 ft (5 m).
65.6 ft (20m)
32.8 ft
(10 m)
013961-00X01
3-1-4 172663 0BKC2-EN0060


Machine performance
Dump speed Machine position
No load
5.8 to 6.6 -
Up
sec.
Down
109595-00EN00 4.1 to 4.7 -
Swing time Machine position
180°
sec. 5.3 to 6.7 -

109596-00X00

• Turn the wagon 90° to the left (or right) to hit
the left (or right) stopper.
• Then turn the wagon 180° to the right (or left)
to hit the right (or left) stopper, and measure the
time required for the wagon to travel between
the two stoppers.
Dumping drift Machine position
No load
0.2
in.
(5) -
(mm)
or less
109595-00EN00
• Engine : Stopped
• Measure the cylinder retraction for 5 minutes
in the posture above.
3-1-5 172663 0BKC2-EN0060


Machine performance
Max. slope angle to dump Machine position
wagon
deg. 20 -
d
109597-00X00

• Load : 5513 lbs. (2500 kg)
vessel.
• Measure the maximum angle d where dump-
ing is started.
Max. slope angle to swing Machine position
wagon
deg. 20 -
d
109597-00X00

• Load : 5513 lbs. (2500 kg)
vessel.
• Measure the maximum angle d where swing-
ing is started, when the wagon is turned 90° to
the left (or right) to hit the left (or right) stopper.
3-1-6 172663 0BKC2-EN0060


Machine performance
Breaking distance Machine position
ft. (m) 9.8 (3.0) or less -

104762-01JA00

• Speed : Forward, high-speed
• Load : 5513 lbs. (2500 kg)
• Run in max. speed on a dry paved ground and
measure the distance between the point
where the travel lever is moved to the neutral
position and the carrier stopping point.
3-1-7 172663 0BKC2-EN0060

3-2 Engine
3-2-1 Nominal and Allowable Values
Applicable model 4TNV88C-KFW

Item Unit Standard Allowable limit
Cylinder head
0.006 to 0.010
Adjustment of valve clearance in. (mm) -
(0.15 to 0.25)
Cylinder head distortion (Flatness) in. (mm) 0.0020 (0.05) or less 0.0059 (0.15)
0.0118 to 0.0197
Intake in. (mm) 0.0315 (0.8)
(0.30 to 0.50)
Valve sinkage
0.0118 to 0.0197
Exhaust in. (mm) 0.0315 (0.8)
(0.30 to 0.50)
Intake degrees (°) 120 -
Valve seat angle
Exhaust degrees (°) 90 -
Valve seat correction angle degrees (°) 40, 150 -
0.3154 to 0.3159
Guide inside diameter in. (mm) 0.3189 (8.10)
(8.010 to 8.025)
0.3132 to 0.3140
Intake valve Valve stem outside diameter in. (mm) 0.3110 (7.90)
(7.955 to 7.975)
0.0014 to 0.0028
Valve stem bend in. (mm) 0.0071 (0.18)
(0.035 to 0.070)
0.3156 to 0.3161
Guide inside diameter in. (mm) 0.3189 (8.10)
(8.015 to 8.030)
0.3132 to 0.3134
Exhaust valve Valve stem outside diameter in. (mm) 0.3110 (7.90)
(7.955 to 7.960)
0.0018 to 0.0030
Valve stem bend in. (mm) 0.0071 (0.18)
(0.045 to 0.075)
0.5791 to 0.5905
Projection from cylinder head in. (mm) -
Valve guide (14.71 to 15.00)
Insertion method in. (mm) Cold-fitted -
0.736 to 0.748
Vavle stem seal projeciton from cylinder head in. (mm) -
(18.7 to 19.0)
Less than 0.0012
Push rod bend in. (mm) 0.0012 (0.03)
(0.03)
0.6299 to 0.6307
Arm shaft hole diameter in. (mm) 0.6327 (16.07)
(16.000 to 16.020)
0.6286 to 0.6293
Rocker arm and shaft Shaft outside diameter in. (mm) 0.6276 (15.94)
(15.966 to 15.984)
0.0006 to 0.0021
Oil clearance in. (mm) 0.0051 (0.13)
(0.016 to 0.054)
Free length in. (mm) 1.6535 (42.0) 1.6339 (41.5)
Valve spring
Squareness in. (mm) - 0.0551 (1.4)
3-2-1 172663 0BKC2-EN0060


Cam shaft and timing gear train
0.0020 to 0.0079
End play in. (mm) 0.0118 (0.030)
(0.05 to 0.20)
0 to 0.0008
Bend (1/2 the dial gauge reading) in. (mm) 0.0020 (0.05)
(0 to 0.02)
1.5197 to 1.5276
Cam lobe height in. (mm) 1.5098 (38.350)
(38.600 to 38.800)
1.7713 to 1.7738
Bush inside diameter in. (mm) 1.7768 (45.130)
(44.990 to 45.055)
1.7687 to 1.7697
Gear end Cam shaft outside diameter in. (mm) 1.7673 (44.890)
(44.925 to 44.950)
0.0016 to 0.0051
(0.040 to 0.130)
Cam shaft
1.7716 to 1.7726
Bore inside diameter in. (mm) 1.7756 (45.100)
(45.000 to 45.025)
Intermedi- 1.7681 to 1.7691
Cam shaft outside diameter in. (mm) 1.7667 (44.875)
ate (44.910 to 44.935)
0.0026 to 0.0045
(0.065 to 0.115)
1.7716 to 1.7726
Bore inside diameter in. (mm) 1.7756 (45.100)
(45.000 to 45.025)
Flywheel 1.7687 to 1.7697
Cam shaft outside diameter in. (mm) 1.7673 (44.890)
end (44.925 to 44.950)
0.0020 to 0.0039
(0.50 to 0.100)
1.8091 to 1.8100
Shaft outside diameter in. (mm) 1.8071 (45.900)
(45.950 to 45.975)
1.8110 to 1.8120
Idler gear A Bush inside diameter in. (mm) 1.8140 (46.075)
(46.000 to 46.025)
0.0010 to 0.0030
Idler gear (0.025 to 0.075)
shaft 1.6909 to 1.6919
Shaft outside diameter in. (mm) 1.6890 (42.900)
(42.950 to 42.975)
1.6929 to 1.6939
Idler gear B Bush inside diameter in. (mm) 1.6959 (43.075)
(43.000 to 43.025)
0.0010 to 0.0030
(0.025 to 0.075)
Crank gear, cam gear, idler gear, fuel 0.0031 to 0.0055
Timing gear backlash in. (mm) 0.0063 (0.16)
injection pump drive gear and P.T.O. gear (0.08 to 0.14)
3-2-2 172663 0BKC2-EN0060


Crank shaft and piston
Bend (1/2 the dial gauge reading) in. (mm) - 0.0008 (0.02)
1.8879 to 1.8883
Journal outside diameter in. (mm) 1.8859 (47.902)
(47.952 to 47.962)
1.8898 to 1.8909
Bearing inside diameter in. (mm) -
Connecting (48.000 to 48.026)
rod journals 0.0587 to 0.0591
Bearing insert thickness in. (mm) -
(1.492 to 1.500)
0.0015 to 0.0029
Crank Oil clearance in. (mm) 0.0059 (0.150)
(0.038 to 0.074)
shaft
1.9666 to 1.9670
Journal outside diameter in. (mm) 1.9646 (49.902)
(49.952 to 49.962)
1.9685 to 1.9693
Bearing inside diameter in. (mm) -
Main bear- (50.000 to 50.020)
ing journal 0.0785 to 0.0791
Bearing insert thickness in. (mm) -
(1.995 to 2.010)
0.0015 to 0.0027
(0.038 to 0.068)
Thrust 0.0051 to 0.0091
Crank shaft end play in. (mm) 0.0110 (0.28)
bearing (0.13 to 0.23)
Piston outside diameter 3.4622 to 3.4634
in. (mm) 3.4604 (87.895)
(measured at 90° to the piston pin) (87.940 to 87.970)
Piston diameter measure location
in. (mm) 0.9449 (24) -
(upward from the bottom of the piston)
1.0236 to 1.0240
Piston Hole inside diameter in. (mm) 1.0252 (26.039)
(26.000 to 26.009)
1.0234 to 1.0236
Piston pin Pin outside diameter in. (mm) 1.0222 (25.965)
(25.995 to 26.000)
0.0000 to 0.0006
(0.000 to 0.014)
0.0807 to 0.0817
Ring groove width in. (mm) -
(2.050 to 2.075)
0.0776 to 0.0783
Ring width in. (mm) 0.0768 (1.950)
(1.970 to 1.990)
Top ring
0.0028 to 0.0041
Side clearance in. (mm) -
(0.070 to 0.105)
0.0079 to 0.0157
End gap in. (mm) 0.0193 (0.490)
(0.200 to 0.400)
0.0797 to 0.0803
Ring groove width in. (mm) 0.0843 (2.140)
(2.025 to 2.040)
0.0776 to 0.0783
Ring width in. (mm) 0.0768 (1.950)
(1.970 to 1.990)
Piston ring Second ring
0.0014 to 0.0028
Side clearance in. (mm) 0.0075 (0.190)
(0.035 to 0.070)
0.0079 to 0.0158
End gap in. (mm) 0.0193 (0.490)
(0.20 to 0.40)
0.1581 to 0.1587
Ring groove width in. (mm) 0.1626 (4.130)
(4.015 to 4.030)
0.1563 to 0.1571
Ring width in. (mm) 0.1555 (3.950)
(3.970 to 3.990)
Oil ring
0.0010 to 0.0024
Side clearance in. (mm) 0.0071 (0.180)
(0.025 to 0.060)
0.0079 to 0.0157
End gap in. (mm) 0.0193 (0.490)
(0.200 to 0.400)
3-2-3 172663 0BKC2-EN0060


Crank shaft and piston
1.0234 to 1.0251
Wrist pin bush inside diameter in. (mm) 1.0263 (26.068)
(26.025 to 26.038)
Connecting
1.0234 to 1.0236
rod small Wrist pin outside diameter in. (mm) 1.0223 (25.967)
Connect- (25.995 to 26.000)
end
ing rod 0.0010 to 0.0017
(0.025 to 0.043)
Connecting 0.0079 to 0.0157
Side clearance in. (mm) -
rod big end (0.20 to 0.40)
0.4724 to 0.4734
Tappet bore (block) inside diameter in. (mm) 0.4742 (12.045)
(12.000 to 12.025)
0.4715 to 0.4720
Tappet Tappet stem outside diameter in. (mm) 0.4707 (11.955)
(11.975 to 11.990)
0.0004 to 0.0020
(0.010 to 0.050)
Cylinder block
3.4646 to 3.4657
Cylinder inside diameter in. (mm) 3.4724 (88.200)
(88.000 to 88.030)
Roundness
Cylinder bore in. (mm) 0.0004 (0.01) or less 0.0012 (0.03)
Taper
Lubricating oil pump
0.0035 to 0.0059
Outer rotor outside clearance in. (mm) 0.0098 (0.25)
(0.09 to 0.15)
0.0020 to 0.0035
Outer rotor side clearance in. (mm) 0.0059 (0.15)
(0.05 to 0.09)
Outer rotor to inner rotor tip clearance in. (mm) - 0.0063 (0.16)
Gear case bearing inside diameter in. (mm) - -
0.3945 to 0.3952
Plate bearing inside diameter in. (mm) 0.3962 (10.063)
(10.020 to 10.038)
Rotor shaft clearance 0.3928 to 0.3932
Rotor shaft outside diameter in. (mm) 0.3922 (9.963)
(9.978 to 9.987)
0.0013 to 0.0024
Rotor clearance in. (mm) 0.0039 (0.100)
(0.033 to 0.060)
Others
0.006 to 0.010
Intake/Exhaust valve clearance in. (mm) -
(0.15 to 0.25)
455 to 485 355 to 385
Compression pressure at 250 rpm PSI (MPa)
(3.14 to 3.34) (2.45 to 2.65)
29 to 43
Deviation between cylinders PSI (MPa) -
(0.2 to 0.3)
5.8 to 8.8
Oil pressure switch operating pressure PSI (MPa) -
(0.04 to 0.06)
degree F 157 to 163
Valve opening temperature -
(degree C) (70 to 73)
Thermostat 0.32 (8) or above
Full opening lift temperature in. (mm) [at 185 degree F (85 -
degree C)]
3-2-4 172663 0BKC2-EN0060

3-3 Undercarriage
[Unit : in. (mm)]

Measuring
Part Standard Wear limit
position
(1) Track roller, track roller shaft
A Ø2.441 (Ø62) Ø2.439 (Ø61.69)
Track roller D
B Ø2.60 (Ø66) Ø2.20 (Ø55.90)
C Ø6.70 (Ø170) Ø6.50 (Ø165)
D 3.54 (90) 3.82 (97)

A
B
C
E
Track roller shaft 104751-00EN00

E Ø1.181 (Ø30) Ø1.180 (Ø29.98)
(2) Carrier roller, carrier roller shaft

A Ø1.850 (Ø47) Ø1.852 (Ø47.03)
Carrier roller
B Ø2.047 (Ø52) Ø2.048 (Ø52.03)
C
C Ø6.81 (Ø173) Ø6.50 (Ø165)

B
A
D Ø0.984 (Ø25) Ø0.983 (Ø24.98)

Carrier roller shaft 104752-00EN00
(3) Sprocket
B A
A 1.30 (33) 0.91 (23)
80
B 1.38 (35) 0.32 (8)
104753-00X00
(4) Rubber track
A 1.18 (30) 0.32 (8)

A
104754-00X00
3-3-1 172663 0BKC2-EN0060


Measuring
Part Standard Wear limit
position
(5) Idler, idler shaft
C A Ø12.99 (Ø330) Ø12.60 (Ø320)
Idler
B Ø3.150 (Ø80) Ø3.148 (Ø79.96)

A
C 1.97 (50) 1.65 (42)

B
D
D Ø1.378 (Ø35) Ø1.377 (Ø34.98)

Idler shaft 104755-00EN00
3-3-2 172663 0BKC2-EN0060

3-4 Controls

Item Measuring conditions Unit Standard Allowable limit
Control levers and pedals
Operating force
• Engine : stopped
Wagon control lever
• Hydraulic oil temp. : Ordinary temperature 2.0 to 4.2
(Three-side flaps -
• Lever operating force : Set the push-pull scale to the mid- (8.7 to 18.7)
wagon type)
point of the lever grip to measure operation forces for mov-
ing lever forward and rearward.
Wagon control lever 0.6 to 2.9
lbs. (N) -
(Swing wagon type) (2.8 to 12.8)
Press Press
1.5 to 3.7
Travel lever -
104756-00EN00
(6.8 to 16.8)
Full stroke of control lever

Wagon control lever • Hydraulic oil temp. : Ordinary temperature
1.7 to 2.4
(Three-side flaps • Play of each control lever and pedal : Stroke -
(42 to 62)
wagon type) Measure the stroke length and free play (in the
center position) on the end of the lever grip..
Full stroke
Wagon control lever 3.0 to 3.8
Stroke in. -
(Swing wagon type) (77 to 97)
(mm)
2.8 to 3.6
Travel lever Stroke -
(71 to 91)
104757-00EN00
Tread force
• Measure force to press the push-pull scale at the end of
the pedal. The pedal operating force should be the one
which measured through the range of whole stroke.
4.4 to 8.8
Accelerator pedal lbf (N) 1.4 (6)
(19.4 to 39.4)
104759-00X01
3-4-1 172663 0BKC2-EN0060


Item Measuring conditions Unit Standard Allowable limit
Control levers and pedals
Play and full stroke of pedal
• Measure free play and full stroke at the end of the
pedal.
0.2 to 0.6
Play 0.79 (20)
(5 to 15)
Fu
ll s
Pla
tro
y
ke
in.
Accelerator pedal
(mm)
2.7 to 3.5
Stroke 4.3 (110)
(68 to 88)
104759-00EN00
3-4-2 172663 0BKC2-EN0060

3-5 Hydraulic Cylinder
6 6
7
7
4
8
3 2
1 (Length fully retracted)
104760-00EN00
)
Unit: in (mm)
Cylinder Dump cylinder Dump cylinder
No. (Three-side flaps wagon type) (Swing wagon type)
1 23.5 (597) 33.9 (860)
2 16.5 (418.5) 25.8 (656)
3 1.77 (45) 2.24 (57)
4 Ø1.18 (Ø30) Ø1.37 (Ø35)
5 Ø2.4 (Ø60) Ø2.6 (Ø65)
6 PF1/4
Standard Ø1.19 (Ø30.3)
7
Allowable limit Ø1.22 (Ø31)
Thread size M20×1.5 M27×2
8 Tightening torque 217 to 253 543 to 615
ft•lbf (N•m) (294 to 343) (736 to 834)
3-5-1 172663 0BKC2-EN0060

3-6 Work Implement
2
1 1
3 104761-00X00
Unit : in. (mm)

Applicable model : C30R-3 Wear limit
No. Standard
Measuring point Pin outside dia. Bore of bush or hole
1 Platform pivot Ø1.19 (Ø30.3) Ø1.17 (Ø29.8) Ø1.24 (Ø31.5)
2 Dump cylinder, rod Ø1.19 (Ø30.3) Ø1.17 (Ø29.8) Ø1.24 (Ø31.5)
3 Dump cylinder, bottom Ø1.19 (Ø30.3) Ø1.17 (Ø29.8) Ø1.24 (Ø31.5)
Note :
• Allowable clearance is 0.04 in. (1.0 mm).
• Pins, inner diameter of pin bushings and pin bores of the three-side flaps wagon are the same as those of the
swing wagon.
3-6-1 172663 0BKC2-EN0060

3-7 List of Tightening Torque
3-7-1 Machine

Equipment Tightening torque
Thread size Adhesive
No Tightening part ft•lbf (N•m)
Engine / Electrical equipment
Engine mount vibroisolating rubber 152 to 173
1 M16 × 150 (10.9T) ThreeBond 1324
(fan side) (205.8 to 235.2)
Engine mount vibroisolating rubber 138 to 151
2 M14 × 130 (10.9T) ThreeBond 1324
(flywheel side) (186 to 206)
48 to 54
3 Engine × Engine mount M10 × 40 (10.9T) ThreeBond 1324
(63.4 to 73.5)
2.9 to 3.6
4 Lube oil hose Hose clip 41 -
(3.9 to 4.9)
14 to 15
5 Exhaust pipe × Clamp M10 × 65 -
(19 to 21)
18 to 20
6 Air cleaner M8 × 20 -
(23.5 to 27.5)
1.9 to 2.5
7 Air cleaner intake hose Hose clip 75 -
(2.5 to 3.4)
3.3 to 3.6
8 Indicator hose Elbow 1/8 Seal tape
(4.4 to 4.9)
Barbed hose 5.1 to 6.5
9 Indicator hose Seal tape
connector 1/8 (6.9 to 8.8)
5.1 to 6.5
10 Indicator Rc 1/8 Seal tape
(6.9 to 8.8)
2.9 to 3.6
11 Cooling water hose Hose clip 41 -
(3.9 to 4.9)
3.7 to 4.3
12 Cooling water hose Hose clip 48 -
(4.9 to 5.9)
6.4 to 7.0
13 Shroud CMP M6 × 16 -
(8.6 to 9.6)
M5 × 12 0.9 to 1.1
14 Fuel level gauge -
(Pan head screw) (1.18 to 1.47)
0.7 to 1.1
15 Fuel oil gauge hose Hose clip 13 -
(0.98 to 1.47)
14.5 to 21.7
16 Fuel oil drain valve R 3/8 Seal tape + Loctite 577
(19.6 to 29.4)
1.9 to 2.1
17 Fuel tank holding band (Tank holding) Nut 10 -
(2.5 to 3.0)
18.1 to 23.8
18 Fuel tank holding band (Lock nut) Nut 10 -
(24.5 to 32.3)
5.2 to 5.9
19 Battery terminal Nut 8 -
(7 to 8)
4.4 to 7.2
20 Generator Nut 6 -
(5.9 to 9.8)
0.7 to 1.1
21 LCD monitor × Accelerator stay CMP M5 × 20 -
(1.0 to 1.5)
2.9 to 3.6
22 Monitor cover CMP Binding screw M6×16 -
(3.9 to 4.9)
1.02 to 1.08
23 Accelerator volume Fine thread nut M9 -
(1.33 to 1.47)
3-7-1 172663 0BKC2-EN0060


Engine / Electrical equipment
2.9 to 3.6
24 4-piece slow blow fuse box M6 × 16 -
(4 to 5)
2.6 to 3.0
25 Battery switch M6 × 20 -
(3.4 to 4.1)
3.4 to 4.7
26 Battery cut cable Nut 8 -
(4.5 to 6.5)
5.8 to 7.2
27 CA relay type C M6 × 12 -
(7.8 to 9.8)
15 to 18
28 Push switch Nut 20 -
(19.6 to 24.5)
5.2 to 5.9
29 Key cylinder (Standard) Ring nut -
(7 to 8)
3.0 to 4.4
30 Key cylinder (Multi) Ring nut -
(4 to 6)
M5 × 20 3.7 to 4.3
31 Limit switch -
(Pan head screw) (4.90 to 5.88)
3.7 to 4.3
32 Battery holding rod (Locknut) Nut 8 -
(4.90 to 5.88)
1.5 to 2.1
33 Battery holding rod (Holding) Nut 8 -
(1.96 to 2.94)
5.5 to 7.2
34 Harness × Starter motor terminal Nut 8 -
(7.4 to 9.8)
2.1 to 2.9
35 Slow blow fuse M5 -
(2.9 to 3.9)
3.6 to 4.4
36 Slow blow fuse M5 -
(4.9 to 5.9)
Travel device
6.5 to 7.2
1 Idler screw plug PT 1/8 Loctite 572
(8.83 to 9.81)
2 Nipple valve M16 36.2 (49) -
138 to 151
3 Sprocket M14 × 35 ThreeBond 1324
(186 to 206)
254 to 325
4 Idler Nut M24 ThreeBond 1324
(343 to 441)
290 to 325
5 Track roller Nut M24 Locktite 262 or K-965
(393 to 441)
290 to 325
6 Oscillation shaft Nut M24 Locktite 262 or K-965
(393 to 441)
Controls
Vessel knob CMP M4 × 6 1.3 to 1.8
1 ThreeBond 1324
(Three-side flaps wagon type) (Binding screw) (1.77 to 2.55)
Frame
87 to 94
1 Swing bearing × Frame M12 × 60 Locktite 262 or K-965
(117.7 to 127.5)
87 to 94
2 Swing bearing × Turning frame M12 × 55 Locktite 262 or K-965
(117.7 to 127.5)
3-7-2 172663 0BKC2-EN0060


Rigging
5.8 to 8.6
1 Key lock plate × Key cylinder U-nut 10 -
(7.9 to 11.8)
33 to 43
2 Seat belt anchor nut M10 × 1.5 -
(44.1 to 58.9)
87 to 108
3 Canopy mount × Frame M12 × 35 (10.9T) ThreeBond 1324
(117.7 to 147.1)
87 to 108
4 Canopy mount × Frame M12 × 45 (10.9T) ThreeBond 1324
(117.7 to 147.1)
116 to 151
5 Canopy × Canopy mount M14 × 40 (10.9T) ThreeBond 1324
(157 to 206)
Hydraulic equipment
M12 × 40 62 to 67
1 CF coupling ThreeBond 1324
(Hexagon socket head screw) (83.3 to 92.2)
10.9 to 11.5
2 Oil level gauge × Reservoir M10 × 30 -
(14.7 to 15.7)
80 to 87
3 Drain plug × Reservoir M24 -
(107.9 to 119.3)
15 to 17
4 Cooling water temp. sensor × Reservoir M12×1.5 (Fine) Seal washer
(20 to 24)
87 to 108
5 Travel motor × Frame M14 × 35 ThreeBond 1324
(117.7 to 147.1)
87 to 108
6 Main pump × Flywheel cover M14 × 40 ThreeBond 1324
(117.7 to 147.1)
87 to 94
7 Swing motor × Turning frame M14 × 35 ThreeBond 1324
(117.7 to 127.5)
33 to 43
8 Swivel joint M10 × 30 -
(44.1 to 58.9)
2.9 to 3.6
9 Suction hose Hose clip 41 -
(3.9 to 4.9)
1.9 to 2.5
10 Hydraulic hose Hose clip 13 -
(2.5 to 3.4)
1.9 to 2.5
(2.5 to 3.4)
2.9 to 3.6
(3.9 to 4.9)
2.9 to 3.6
(3.9 to 4.9)
2.9 to 3.6
(3.9 to 4.9)
3-7-3 172663 0BKC2-EN0060

3-7-2 Engine
1) Tightening torque for major bolts and nuts

Unit: ft•lbf (N•m)
4TNV88C-KFW
No. Item
Thread size X Pitch Tightening torque Lubricating oil
1 Cylinder head bolt M10 X 1.25 63 to 67 (85.3 to 91.1) Yes
2 Connecting rod bolt M9 X 1.0 33 to 36 (44.1 to 49.0) Yes
3 Flywheel bolt M10 X 1.25 61 to 65 (83.3 to 88.2) Yes
4 Main bearing cap bolt M12 X 1.5 70.8 to 73.8 (96.0 to 100) Yes
Cast metal (FC300): 62 to 69

(83.3 to 93.1)
5 Crankshaft pulley bolt M14 X 1.5 Yes
Steel metal (S45C): 83 to 91
(112.7 to 122.7)
6 Flywheel speed sensor M6 X 1.0 4.4 to 7.4 (6.0 to 10.0) No
7 Camshaft speed sensor M6 X 1.0 5.5 to 6.3 (7.5 to 8.5) No
8 EGR valve pipe M8 X 1.25 14.0 to 18.2 (18.9 to 24.7) No
9 Fresh air temperature sensor M5 X 0.5 3.0 to 3.7 (4.0 to 5.0) No
10 Fresh air temperature sensor M14 X 1.5 8.1 to 12.5 (11.0 to 17.0) No
11 DPF temperature sensor M12 X 1.25 18.4 to 29.5 (25.0 to 40.0) No
12 Differential pressure sensor M6 X 1.0 4.9 to 6.2 (6.6 to 8.4) No
13 Differential pressure sensor M12 X 1.25 33.2 to 40.5 (45.0 to 55.0) No
14 Valve cover nut - - -
15 Glow plug M10 X 1.25 11.1 to 14.8 (15 to 20) No
16 Glow connector nut M4 X 0.7 0.7 to 1.1 (1 to 1.5) No
3-7-4 172663 0BKC2-EN0060

2) Tightening torque for fuel system

No. Item Thread size X Pitch Tightening torque Lubricating oil
1 Fuel injector bolt M8 X 1.25 18 to 21 (24.4 to 28.4) No
2 Supply pump drive gear nut M18 X 1.5 55 to 63 (75 to 85) No
3 High-pressure fuel line nut (common rail) M12 X 1.5 21.7 to 25.3 (29.4 to 34.3) No
4 High-pressure fuel line nut (injector) M12 X 1.5 19.5 to 23.2 (26.5 to 34.3) No
5 High-pressure fuel line nut (supply pump) M16 X 1.0 21.7 to 25.3 (29.4 to 34.3) No
3-7-5 172663 0BKC2-EN0060

3-7-3 Tightening Torque for General Bolts and Nuts

Tightening torque
Item Thread size × Pitch Remarks
[Unit: ft•lbf (N•m)]
7.23 to 8.68
M6 × 1
(9.8 to 11.8)
16.6 to 21.0
M8 × 1.25
(22.5 to 28.4)
32.6 to 43.4
M10 × 1.5
(44.1 to 58.8)
57.9 to 72.3
M12 × 1.75
Coarse (78.4 to 98.0)
1) Apply 80% of tightening torque
thread 86.8 to 108.5 when tightened to aluminum.
M14 × 2
Hexagon head bolt (7T) (117.6 to 147.0) 2) Apply 60% of tightening torque
Nut 123.0 to 151.9 for 4T bolts and lock nuts.
M16 × 2 3) Use fine screw threads for
(166.6 to 205.8)
engine only.
173.6 to 209.8
M18 × 2.5
(235.2 to 284.2)
238.7 to 296.6
M20 × 2.5
(323.4 to 401.8)
94.0 to 108.5
M14 × 1.5
Fine (127.4 to 147.0)
thread 155.5 to 177.2
M16 × 1.5
(210.7 to 240.1)
1/8 7.23 (9.8)
1/4 14.5 (19.6)
PT plug
3/8 21.7 (29.4)
1/2 43.4 (58.8)
M8 9.4 to 12.3 (12.7 to 16.7)
M12 18.1 to 25.3 (24.5 to 34.3)
Pipe joint bolt
M14 28.9 to 36.2 (39.2 to 49.0)
M16 36.2 to 43.4 (49.0 to 58.8)
3-7-6 172663 0BKC2-EN0060

3-7-4 Hydraulic Fitting

(1) Tightening torque of parallel pipe thread Example G
For 30° sheet type joint and the O-ring sheet type joint. Parallel pipe thread (female)
(male 30° sheet)
30°
Nominal designation of Tightening torque
screw thread
G (PF) Material: Steel, Cast iron
Parallel pipe thread (female)
G
1/8 10.1 to 12.3 (13.7 to 16.7)
1/4 16.6 to 20.3 (22.6 to 27.5) 30°
3/8 32.5 to 39.8 (44.1 to 53.9)

1/2 39.1 to 47.7 (53.0 to 64.7)
3/4 78.1 to 95.5 (106 to 129) O-ring
1 91.1 to 111.4 (124 to 151)
1 1/4 110.7 to 135.3 (150 to 183)
1 1/2 137.4 to 166.4 (186 to 226) 017498-00E
(2) Tightening torque of taper pipe thread

Apply seal tape
screw thread
Example R
1/8 5.1 to 6.5 (6.9 to 8.8) Parallel pipe thread (female)
1/4 7.2 to 10.8 (9.8 to 14.7)

3/8 21.7 to 28.9 (29.4 to 39.2) 017501-00E
1/2 28.9 to 36.2 (39.2 to 49.0)

3/4 36.2 to 47.0 (49.0 to 63.7)
1 50.6 to 65.1 (68.6 to 88.3)
1 1/4 72.3 to 86.8 (98.1 to 118)
(3) Tightening torque of unified screw thread Example Unified

For 30° sheet type joint and the O-ring sheet type joint. Unified screw thread (female)
37°
(male 37° sheet)
screw thread
Example
Unified screw thread (female) Unified
7/16-20UNF 13.0 to 15.9 (17.7 to 21.6)
(male 37° sheet)
9/16-18UNF 26.0 to 31.8 (35.3 to 43.1)
37°
3/4-16UNF 32.5 to 39.8 (44.1 to 53.9)
7/8-14UNF 39.1 to 47.7 (53 to 64.7)
1 1-16-12UN 78.1 to 95.5 (106 to 129) O-ring
1 5/16-12UN 91.1 to 111.4 (124 to 151)
1 5/8-12UN 110.7 to 135.3 (150 to 183)
017502-00E
3-7-7 172663 0BKC2-EN0060

3-8 Pressure Adjustment
3-8-1 Measuring the pressure

WARNING:
• Do not allow anyone except service persons to enter the measurement area as the engine is rotated when mea-
suring the pressure.
Also, make sure your co-workers are safe.
• The hydraulic oil and the tank are hot and under pressure at operating temperature.
• Do not allow hot oil and components to contact your skin.
• When removing the hydraulic hose, slowly loosen the hydraulic hose.
• Be sure to install the wagon stopper to hold the wagon when inspecting or servicing the machine with the wagon in
the dump position.
3-8-2 Measuring the main pressure (effective differential pressure)

Measure the actual pressure and the back pressure, and determine the effective differential pressure as the criteria
by subtracting the measured back pressure value from the measured actual value.
1) Measuring conditions
(1) Engine: Rated speed
(2) Hydraulic oil temperature: 122 to 140 °F (50 to 60 °C)
(3) Pressure gauge capacity: 8532 PSI (58.8 MPa)
2) Relief Valve Specification

3)
Port Set pressure PSI (MPa)

P1 4975 (34.3)
Main P2 4975 (34.3)
port P3 4975 (34.3)
P4 4975 (34.3)
(1) Disconnect the wire harness of the solenoid valve 1 for the park-
ing brake. Make sure the parking brake is not released even if
the travel lever is operated.
(2) Install the oil pressure gauge onto the pressure pickup port of the
travel motor 2.
(3) Actuate the circuit to be measured to measure its pressure.
104764-00X00
3-8-1 172663 0BKC2-EN0060

Pressure pickup port View from the left side of machine

Circuit Relief valve P2 P4
Port location Size
Right travel
a2 of RH motor G1/2 P3
Actual pres- (Forward)
sure value Left travel
a1 of LH motor G1/2 P1
(Forward)
Right travel
a1 of RH motor G1/2 P4
Back pres- (Reverse)
View from the right side of machine
sure value Left travel P3 P1
a2 of LH motor G1/2 P2
(Reverse)
104765-00EN00
2
a1
a2
104766-00X00
3-8-3 Charge pressure measurement
1) Measuring conditions View from the right side of machine

(3) Mount pressure gauge on the pressure detection port and mea-
sure the charge pressure.
Port Set pressure PSI (MPa)

PgC
Charge port PgC 2.8 (0.02) 105048-00EN00
3-8-2 172663 0BKC2-EN0060

3-8-4 Dump pressure measurement
(3) Install the oil pressure gauge onto the pressure pickup
port and actuate the dump cylinder circuit to measure R3
its system relief pressure.
Port Set pressure PSI (MPa) 104767-00X00
Main relief valve B3 2495 (17.2)

View from the right side of machine
B3
3) Adjustment
(1) Loosen locknut 1, then begin adjusting pressure by

turning setting screw 2.
Turning clockwise.................... raises the set pressure.
Turning counterclockwise........ lowers the set pressure. 105048-00EN02
(2) In order to keep the setting screw from turning after

pressure has been adjusted, tighten the locknut while
Locknut
at the same time holding the setting screw firmly in
place.
Adjust screw
(3) Operate the relief valve once more to confirm that the
pressure that has been set it stabilized.
068841-00EN01
3-8-5 Pilot pressure measurement
(1) Engine : Rated speed View from the right side of machine
(2) Hydraulic oil temp.: 122 to 140°F (50 to 60°C)
(3) Mount pressure gauge on the pressure detection port
and measure the pilot relief pressure.
Pressure pickup port

Pilot valve
Port location Size
PgC Pp1
Right PgC G1/4 105048-00EN01
Left Pp1 G1/4
3-8-3 172663 0BKC2-EN0060

3-8-6 Wagon swing pressure measurement
(1) Engine : Rated speed
(2) Hydraulic oil temp.: 122 to 140°F (50 to 60°C)
(3) Install the oil pressure gauge onto the pressure pickup
port and actuate the circuit to measure its system relief
pressure.
Pressure pickup port Set pressure

Relief valve
Port location Size PSI (MPa)
Right swing R1 GA G1/8
1450 (10.0)
Left swing R2 GB G1/8
3) Adjustment
(1) Loosen locknut 1, then begin adjusting pressure by

GA
turning setting screw 2. R1 GB
1 R2
Turning clockwise.................... raises the set pressure. 2
Turning counterclockwise........ lowers the set pressure.
(2) In order to keep the setting screw from turning after
pressure has been adjusted, tighten the locknut while
at the same time holding the setting screw firmly in
place. 109599-00X00
(3) Operate the relief valve once more to confirm that the
pressure that has been set it stabilized.
3-8-4 172663 0BKC2-EN0060

CHAPTER 4
ENGINE
4-1 Safety ........................................................................ 4-1-1 4-6-5 Starter Motor Components ............................... 4-6-4
4-1-1 Safety Statements ............................................ 4-1-1 4-6-6 Starter Motor .................................................... 4-6-5
4-1-2 Safety Precautions ........................................... 4-1-2 4-7 Alternator................................................................... 4-7-1
4-2 Engine ....................................................................... 4-2-1 4-7-1 Before You Begin Servicing ............................. 4-7-1
4-2-1 Before You Begin Servicing ............................. 4-2-1 4-7-2 Introduction....................................................... 4-7-2
4-2-2 Introduction....................................................... 4-2-2 4-7-3 Alternator Specifications................................... 4-7-2
4-2-3 Special Service Tools....................................... 4-2-3 4-7-4 Alternator Troubleshooting ............................... 4-7-3
4-2-4 Measuring Instruments ..................................... 4-2-6 4-7-5 Alternator Components .................................... 4-7-4
4-2-5 Cylinder Head................................................... 4-2-8 4-7-6 Alternator Wiring Diagram ................................ 4-7-5
4-2-6 Measuring and Adjusting Valve Clearance .... 4-2-24 4-7-7 Alternator Standard Output .............................. 4-7-6
4-2-7 Crankshaft and Camshaft Components ......... 4-2-26 4-7-8 Alternator .......................................................... 4-7-7
4-2-8 EGR System................................................... 4-2-52 4-8 Electronic Control System ......................................... 4-8-1
4-3 Fuel System .............................................................. 4-3-1 4-8-1Before You Begin Servicing ............................. 4-8-1
4-3-1 Before You Begin Servicing ............................. 4-3-1 4-8-2System Structure .............................................. 4-8-2
4-3-2 System Structure.............................................. 4-3-2 4-8-3Electronic Engine Speed Control ..................... 4-8-3
4-3-3 Fuel System Diagram....................................... 4-3-4 4-8-4Diesel Particulate Filter (DPF) .......................... 4-8-5
4-3-4 Fuel System Components ................................ 4-3-5 4-8-5How to Remove and Reattach the
4-4 Cooling System ......................................................... 4-4-1 Diesel Particulate Filter (DPF)........................ 4-8-10
4-4-1 Before You Begin Servicing ............................. 4-4-1 4-8-6 SF and DPF Maintenance Kit ......................... 4-8-20
4-4-2 Introduction....................................................... 4-4-2 4-8-7 Troubleshooting of Electronic Control System ... 4-8-21
4-4-3 Cooling System Diagram.................................. 4-4-2 4-8-8 Replacement of Components ......................... 4-8-25
4-4-4 Engine Coolant Pump Components ................. 4-4-3 4-8-9 Installation Position of Sensors ...................... 4-8-29
4-4-5 Engine Coolant System Check......................... 4-4-4 4-9 Electric Wiring .......................................................... 4-9-1
4-4-6 Engine Coolant Pump ...................................... 4-4-4 4-9-1 Electric Wiring Precautions ............................. 4-9-1
4-5 Lubrication System.................................................... 4-5-1 4-10 Failure Diagnosis................................................... 4-10-1
4-5-1 Before You Begin Servicing ............................. 4-5-1 4-10-1 Special Service Tools ................................... 4-10-1
4-5-2 Introduction....................................................... 4-5-2 4-10-2 Troubleshooting by Measuring
4-5-3 Lubrication System Diagram ............................ 4-5-2 Compression Pressure................................... 4-10-2
4-5-4 Checking Engine Oil Pressure ......................... 4-5-3 4-10-3 Measured Value and Troubleshooting ......... 4-10-4
4-5-5 Oil Pump Components ..................................... 4-5-3 4-10-4 Quick Reference Table for
4-6 Starter Motor ............................................................. 4-6-1 Troubleshooting .......................................... 4-10-4-4
4-6-1 Before You Begin Servicing ............................. 4-6-1
4-6-2 Introduction....................................................... 4-6-1
4-6-3 Starter Motor Specifications ............................. 4-6-2
4-6-4 Starter Motor Troubleshooting.......................... 4-6-3
4. ENGINE
4. Engine
DANGER
4-1 Safety DANGER indicates a hazardous situation
which, if not avoided, will result in death or
4-1-1 Safety Statements serious injury.
Yanmar is concerned for your safety and your WARNING

machine’s condition. Safety statements are one of
WARNING indicates a hazardous situation
the primary ways to call your attention to the
which, if not avoided, could result in death or
potential hazards associated with Yanmar TNV
serious injury.
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance CAUTION
procedures for your safety, the safety of others and CAUTION indicates a hazardous situation
to protect the performance of your engine. Keep which, if not avoided, could result in minor or
the labels from becoming dirty or torn and replace moderate injury.
them if they are lost or damaged. Also, if you need
to replace a part that has a label attached to it, NOTICE
make sure you order the new part and label at the
same time. NOTICE indicates a situation which can cause
damage to the machine, personal property and/or
This safety alert symbol appears the environment or cause the equipment to
operate improperly.
A
with most safety statements. It
means attention, become alert,
your safety is involved! Please read
and abide by the message that
follows the safety alert symbol.
4-1-1 172663 0BKC2-EN0060

4. ENGINE
4-1-2 Safety Precautions

DANGER
DANGER Explosion Hazard!
• Keep the area around the battery
High Pressure Hazard! well-ventilated. While the engine
• This engine uses a high-pressure is running or the battery is
common rail system. For charging, hydrogen gas is
disassembly of the high pressure produced which can be easily
parts (e.g. the high-pressure ignited.
pipe) in particular, be sure to wait
• Keep sparks, open flame and any other form
approximately 10 to 15 minutes
of ignition away while the engine is running
before performing disassembly.
or battery is charging.
• Do not loosen the high-pressure fuel
• Never check the remaining battery charge by
injection lines while the engine is running,
shorting out the terminals. This will result in
even in low idle. This is dangerous because
a spark and may cause an explosion or fire.
fuel under high pressure will blow out.
Use a hydrometer to check the remaining
• Failure to comply will result in death or battery charge.
serious injury.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it.
Scald Hazard! • Failure to comply will result in death or
• Never remove the radiator cap if serious injury.
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the Crush Hazard!
engine to cool down before you • When you need to transport an
attempt to remove the radiator engine for repair, have a helper
cap. assist you to attach it to a hoist
and load it on a truck.
• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out
during engine operation if the cap is loose. • Never stand under a hoisted engine. If the
hoist mechanism fails, the engine will fall on
• Always check the level of the engine coolant
you, causing death or serious injury.
by observing the reserve tank.
• Failure to comply will result in death or
• Failure to comply will result in death or
serious injury.
serious injury.
4-1-2 172663 0BKC2-EN0060

4. ENGINE
DANGER DANGER (Continued)
Fire and Explosion Hazard! • Be sure to place the diesel fuel container on
• Diesel fuel is flammable and the ground when transferring the diesel fuel
explosive under certain from the pump to the container. Hold the
conditions. hose nozzle firmly against the side of the
container while filling it. This prevents static
electricity buildup which could cause sparks
and ignite fuel vapors.
• When you remove any fuel system
component to perform maintenance (such as • Never place diesel fuel or other flammable
changing the fuel filter) place an approved material such as oil, hay or dried grass close
container under the opening to catch the fuel. to the engine during engine operation or
shortly after shutdown.
• Never use a shop rag to catch the fuel.
Vapors from the rag are flammable and • Before you operate the engine, check for fuel
explosive. leaks. Replace rubberized fuel hoses every
two years or every 2000 hours of engine
• Wipe up any spills immediately. operation, whichever comes first, even if the
• Wear eye protection. The fuel system is under engine has been out of service. Rubberized
pressure and fuel could spray out when you fuel lines tend to dry out and become brittle
remove any fuel system component. after two years or 2000 hours of engine
operation, whichever comes first.
• Only use the key switch to start the engine.
• Never remove the fuel cap with the engine
• Never jump-start the engine (by shorting the
running.
battery terminal and the starter terminal).
This will result in a spark and may cause a • Never use diesel fuel as a cleaning agent.
fire or explosion. • Failure to comply will result in death or
• The fuel oil transfer pump is electromagnetic serious injury.
type. Turn the starter switch key to the ON
position for 10 to 15 seconds to prime the
fuel oil system. Air in fuel oil is automatically
purged.
• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine.
• Never refuel with the engine running.
• Keep sparks, open flames or any other form
of ignition (match, cigarette, static electric
source) well away when refueling.
• Never overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.
4-1-3 172663 0BKC2-EN0060

4. ENGINE
WARNING WARNING
Sever Hazard! Exhaust Hazard!
• Keep hands and other body parts • Never operate the engine in an
away from moving/rotating parts enclosed area such as a garage,
such as the cooling fan, flywheel tunnel, underground room,
or PTO shaft. manhole or ship’s hold without
proper ventilation.
• Wear tight-fitting clothing and keep your hair • Never block windows, vents, or other means
short or tie it back while the engine is of ventilation if the engine is operating in an
running. enclosed area. All internal combustion
• Remove all jewelry before you operate or engines create carbon monoxide gas during
service the machine. operation. Accumulation of this gas within an
enclosure could cause illness or even death.
• Never start the engine in gear. Sudden
movement of the engine and/or machine • Make sure that all connections are tightened
could cause death or serious personal injury. to specifications after repair is made to the
exhaust system.
• Never operate the engine without the guards
in place. • Failure to comply could result in death or
serious injury.
• Before you start the engine make sure that all
bystanders are clear of the area.
Alcohol and Drug Hazard!
• Keep children and pets away while the engine
is operating. • Never operate the engine while
you are under the influence of
• Check before starting the engine that any alcohol or drugs.
tools or shop rags used during maintenance
have been removed from the area.
• Failure to comply could result in death or • Never operate the engine when you are
serious injury. feeling ill.
• Failure to comply could result in death or
serious injury.
4-1-4 172663 0BKC2-EN0060

4. ENGINE
WARNING WARNING
Exposure Hazard! Burn Hazard!
• Wear personal protective •Batteries contain sulfuric acid.
equipment such as gloves, work Never allow battery fluid to come
shoes, eye and hearing in contact with clothing, skin or
protection as required by the task eyes. Severe burns could result.
at hand. Always wear safety goggles and
protective clothing when
• Never wear jewelry, unbuttoned cuffs, ties or servicing the battery. If battery
loose-fitting clothing when you are working fluid contacts the eyes and/or
near moving/rotating parts such as the skin, immediately flush the
cooling fan, flywheel or PTO shaft. affected area with a large amount
of clean water and obtain prompt
• Always tie back long hair when you are medical treatment.
working near moving/rotating parts such as a
cooling fan, flywheel, or PTO shaft. • Failure to comply could result in death or
serious injury.
• Never operate the engine while wearing a
headset to listen to music or radio because it
will be difficult to hear the alert signals. High-Pressure Hazard!
• Failure to comply could result in death or •While the engine is running or
serious injury. right after the engine has
stopped, there is still high
pressure fuel left in the fuel piping
Burn Hazard! system. When you need to
• If you must drain the engine oil disassemble the fuel system, wait
while it is still hot, stay clear of for 10 to 15 minutes after stopping
the hot engine oil to avoid being the engine.
burned. • Avoid skin contact with the high-pressure
diesel fuel spray caused by a fuel system leak
• Always wear eye protection. such as a broken fuel injection line. High-
pressure fuel can penetrate your skin and
• Wait until the engine cools before you drain
result in serious injury. If you are exposed to
the engine coolant. Hot engine coolant may
high-pressure fuel spray, obtain prompt
splash and burn you.
medical treatment.
• Keep your hands and other body parts away
• Never check for a fuel leak with your hands.
from hot engine surfaces such as the muffler,
Always use a piece of wood or cardboard.
exhaust pipe, turbocharger (if equipped) and
Have your authorized YANMAR dealer or
engine block during operation and shortly
distributor repair the damage.
after you shut the engine down. These
surfaces are extremely hot while the engine • Failure to comply could result in death or
is operating and could seriously burn you. serious injury.
serious injury.
4-1-5 172663 0BKC2-EN0060

4. ENGINE
WARNING WARNING
Shock Hazard! To prevent possible eye injury,
• Turn off the battery switch (if always wear safety glasses while
equipped) or disconnect the servicing the engine.
negative battery cable before
servicing the electrical system.
• Check the electrical harnesses for cracks, Fume/Burn Hazard!

abrasions, and damaged or corroded • Always read and
connectors. Always keep the connectors and follow safety related
terminals clean. precautions found on
• Failure to comply could result in death or containers of
serious injury. hazardous
substances like parts
cleaners, primers,
Sudden Movement Hazard! sealants and sealant
• Before engaging the transmission or PTO, removers.
warm up the engine for at least 5 minutes and
then set the speed back to normal. Engaging
serious injury.
the transmission or PTO at an elevated
engine speed could result in unexpected
movement of the equipment. • Never inject fuel toward you. Since the fuel is
• Failure to comply could result in death or injected at high pressure from the nozzle, it
serious injury. may penetrate the skin, resulting in injury.
• Never inject fuel toward a fire source.
Entanglement Hazard! Atomized fuel is highly flammable and may
cause a fire or burn skin.
• Stop the engine before you begin
to service it.
Precaution regarding the ECU
(Engine Controller)
• Never use the E-ECU for other purposes than
• Never leave the key in the key switch when intended or in other ways than specified by
you are servicing the engine. Someone may YANMAR. Doing so could result in the
accidentally start the engine and not realize violation of emission control regulations and
you are servicing it. This could result in a will void the product warranty.
serious injury. • Improper use or misuse of the E-ECU may
• If you must service the engine while it is result in death or serious injury due to an
operating, remove all jewelry, tie back long abrupt and unexpected increase in engine
hair, and keep your hands, other body parts speed.
and clothing away from moving/rotating
parts.
serious injury.
4-1-6 172663 0BKC2-EN0060

4. ENGINE
WARNING CAUTION
• Be sure to use the E-ECU in conjunction with DPF Regeneration
the engines whose models or serial numbers During reset regeneration, post-injection is
are specified by YANMAR. used and fuel is burned directly inside the DPF
Other E-ECU/engine combinations than (burned by chemical reaction inside the DOC).
specified will void the engine warranty. Through this heat, regeneration occurs inside
• Improper use or misuse of the E-ECU may the SF, but the combustion increases the
result in death or serious injury due to an temperature of the exhaust gas to close to 600
abrupt and unexpected increase in engine °C (1112 °F). Stay away from the exhaust gas.
speed. Extremely hot exhaust gas may burn you. Be
careful that neither people nor flammable
materials are near the exhaust gas outlet.
• When replacing the fuel injector, you need to Never operate the engine in an enclosed area
rewrite the fuel injection quantity adjustment without proper ventilation.
data in the ECU. You will need YANMAR’s Observe the following conditions when
genuine SMARTASSIST-DIRECT (SA-D) for performing stationary regeneration.
rewriting the data. Always contact the
• Never operate the engine in an enclosed area.
authorized YANMAR dealer that handles the
Accumulation of gas may cause carbon
SA-D. ECU that does not have the proper fuel
monoxide poisoning.
injection quantity adjustment data written will
void the engine warranty. • Regeneration causes the exhaust gas
temperature to increase. To prevent fire,
• Improper use or misuse of the E-ECU may
make sure that there are no flammable
result in death or serious injury due to an
materials around the exhaust gas outlet.
abrupt and unexpected increase in engine
speed. • Never touch the exhaust pipe. The
temperature of the exhaust gas can be
extremely high. Never stand near or around
• When replacing the ECU, it is necessary to the exhaust gas outlet.
transfer the data from the old ECU to the new
ECU using SMARTASSIST-DIRECT (SA-D).
Contact your authorized YANMAR dealer who Coolant Hazard!
can handle SMARTASSIST-DIRECT (SA-D). • Wear eye protection
If the data is not correctly transfered to the and rubber gloves
new ECU, the engine performance can not be when you handle long
ensured. life or extended life
• Improper use or misuse of the E-ECU may engine coolant. If
result in death or serious injury due to an contact with the eyes
abrupt and unexpected increase in engine or skin should occur,
speed. flush eyes and wash
immediately with
clean water.
• Failure to comply may result in minor or
moderate injury.
4-1-7 172663 0BKC2-EN0060

4. ENGINE
CAUTION NOTICE
Flying Object Hazard! Diesel Fuel
• Always wear eye protection when • Poor quality fuel can reduce engine performance
servicing the engine and when and cause damage. Only use diesel fuels
using compressed air or high- recommended by YANMAR for the best engine
pressure water. Dust, flying performance. The recommended fuel complies
debris, compressed air, with the U.S. EPA and ARB protection guidelines.
pressurized water or steam may
injure your eyes. • The common rail system installed as this
engine’s fuel injection device is very high in
• Failure to comply may result in minor or pressure and sprays fuel into the cylinder. If any
moderate injury. impurities or water mixes into the fuel, the sliding
parts of the fuel system causes friction and may
Be sure to secure the engine solidly to prevent degrade the engine’s exhaust gas property
injury or damage to parts due to the engine durability. Only use clean diesel fuel.
falling during work on the engine. • Keep the fuel tank and fuel-handling equipment
clean at all times. Be careful not to let any
contaminants or even dust from the outside into
Pinch Hazard! the filler port when supplying fuel.
Carefully rotate the alternator
toward the cylinder block while • Never remove the primary strainer (if equipped)
loosening the V-belt. Failure to from the fuel tank filler port. If removed, dirt and
comply may result in minor or debris could get into the fuel system causing it to
moderate injury. clog.
If any oil pump component clearance exceeds Engine Lubricating Oil

its limit, the oil pump must be replaced as an • Only use the engine oil specified. Other engine
assembly. oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick
and the surrounding area before you remove the
cap.
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.
• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
4-1-8 172663 0BKC2-EN0060

4. ENGINE
NOTICE NOTICE
Engine Coolant Engine Break-in Period
• Only use the engine coolant specified. Other New engine break-in:
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale and/ • On the initial engine start-up, allow the engine to
or shorten engine life. idle for approximately 15 minutes while you
check for proper engine oil pressure, diesel fuel
• Prevent dirt and debris from contaminating the leaks, engine oil leaks, engine coolant leaks, and
engine coolant. Carefully clean the radiator cap for proper operation of the indicators and/or
and the surrounding area before you remove the gauges.
cap.
• During the first hour of operation, vary the engine
• Never mix different types of engine coolants. speed and the load on the engine. Short periods
This may adversely affect the properties of the of maximum engine speed and load are
engine coolant. desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads for the
next four to five hours.
Inspecting and Starting
• During the break-in period, carefully observe the
If any problem is noted during the visual check, the
engine oil pressure and engine temperature.
necessary corrective action should be taken before
you operate the engine. • During the break-in period, check the engine oil
and engine coolant levels frequently.
Never hold the key in the START position for longer

than 15 seconds. Make sure the engine is installed on a level
Take a pause of at least 30 seconds until the surface. If a continuously running engine is
restart. installed at an angle greater than (30°) in any
The starter motor may overheat and cause direction or if an engine runs for short periods of
damage. time (less than three minutes) at an angle greater
than (35°) in any direction, engine oil may enter the
combustion chamber causing excessive engine
If the engine fails to start: speed and white exhaust smoke. This may cause
Wait until the engine comes to a complete stop serious engine damage.
before you attempt to start it again. Engaging the
starter while the engine is still rotating will result in
damage to the starter and flywheel.
Never use an engine starting aid such as ether.

Engine damage will result.
Never engage the starter motor while the engine is

running. This may damage the starter motor pinion
and/or ring gear.
4-1-9 172663 0BKC2-EN0060

4. ENGINE
NOTICE NOTICE
Alarm System • Further, for engines with turbochargers, be
If there is a problem with the engine and/or its aware that leaving them idling or working in low
control components, the engine failure lamp load in an environment with ambient temperature
comes on and indicates the status. If the engine below -15 °C (+5 °F) may freeze the intake pipe.
failure lamp illuminates during engine operation, If this continues, load-operate the engine every
stop the engine immediately. Do not keep running three hours to prevent freezing.
the engine while the engine failure lamp is on. It
will not only void the engine warranty, but could
• When the engine is operated in dusty conditions,
result in a serious malfunction of or damage to the
clean the air cleaner element more frequently.
engine.
Determine the cause and repair the problem • Never operate the engine with the air cleaner
before you continue to operate the engine. element(s) removed. This may allow foreign
material to enter the engine and damage it.
The illustrations and descriptions of optional The maximum air intake restriction, in terms of
equipment in this manual, such as the operator’s differential pressure measurement, must not
console, are for a typical engine installation. Refer exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean or
to the documentation supplied by the optional replace the air cleaner element if the air intake
equipment manufacturer for specific operation and restriction exceeds the above mentioned value.
maintenance instructions.
Engine Stop
For maximum engine life, YANMAR recommends
Environment Conditions for Operation that when shutting the engine down, you allow the
Observe the following environmental operating engine to idle, without load, for five minutes. This
conditions to maintain engine performance and will allow the engine components that operate at
avoid premature engine wear: high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
• Avoid operating in extremely dusty conditions. before the engine itself is shut down.
• Avoid operating in the presence of chemical
gases or fumes. Battery and Electrical Equipment
• Avoid operating in a corrosive atmosphere such Always keep the battery in a best charged state.
as salt water spray. Electronic controlled engines may not be able to
start.
• If the ambient temperature exceeds +45 °C
(+113 °F) or falls below -15 °C (+5 °F), there are
possibilities of: Use a specialized battery charger to recharge a
• If the ambient temperature exceeds +45 °C battery with a voltage of 8 volts or less. Booster
(+113 °F), engine lubricating oil degrades due starting a battery with a voltage of 8 volts or less
to the overheating of the engine. will generate an abnormally high voltage and
destroy electrical equipment.
• If the ambient temperature falls below -15 °C When unavoidably using a rapid charger to
(+5 °F), parts degrade and shortens its life due recharge, do not insert and turn the starter key to
to the hardening of the rubber parts. ON position while the battery is being charged.
If you need to use it in the above temperatures, Avoid using a charger equipped with a boost
please change to applicable parts and function (cell start support) to start the engine.
specification. The ECU may be damaged by applied excessive
voltage.
4-1-10 172663 0BKC2-EN0060

4. ENGINE
NOTICE NOTICE
Removing the battery cables or the battery while ECU (Engine Controller)
the engine is operating may cause damage to the • Do not plug or unplug the ECU for a period of at
current limiter depending on the electrical least 60 seconds after power to the unit has been
equipment being used. This situation could cause turned on or off.
loss of control of output voltage. The continuous
high voltage of 23 - 24 volts (for 5000 min-1 (rpm) • Do not touch connector pins of the ECU with
dynamo) will damage the current limiter and other bare hands. Doing so may result in corrosion of
electrical equipment. the connector pins and/or damage to the internal
circuits of the ECU due to static electricity.
Reversing the battery cable connections at the • Do not force a measuring probe into the female
battery or on the engine will destroy the SCR diode coupler. Doing so may cause contact failure of
in the current limiter. This will cause the charging the connector pins, resulting in malfunction of the
system to malfunction and may cause damage to ECU.
the electrical harnesses. • Take care to prevent water from entering the
couplers when plugging or unplugging the
connector. Water inside the couplers may cause
Do not remove the positive (+) battery cable from
corrosion, resulting in malfunction of the ECU.
alternator terminal B while the engine is operating.
Damage to the alternator will result. • Avoid plugging/unplugging the connector more
Do not turn the battery switch OFF while the than approx. 10 times.
engine is operating. Damage to the alternator will Frequent plugging/unplugging of the connector
result. may cause contact failure of the connector pins,
resulting in malfunction of the ECU.
Do not reverse the positive (+) and negative (-) • Do not use the ECU that has ever suffered drop
ends of the battery cable. The alternator diode and impact.
stator coil will be damaged.
High-Pressure Cleaning
Protect the air cleaner, turbocharger (if equipped)
When the battery indicator goes out, it should not and electric components from damage when you
come on again. The battery indicator only comes use steam or high-pressure water to clean the
on during operation if the alternator fails. However, engine.
if an LED is used in the battery indicator, the LED
will shine faintly during normal operation.
Never use high-pressure water or compressed air
at greater than 28 psi (193 kPa; 19686 mmAq) or a
Using a non-specified V-belt will cause inadequate wire brush to clean the radiator fins. Radiator fins
charging and shorten the belt life. Use the damage easily.
specified belt.
• Do not use a high-pressure cleaner directly on

Agricultural or other chemicals, especially those the alternator. Water will damage the alternator
with a high sulfur content, can adhere to the IC and result in inadequate charging.
regulator.
• The starter motor is water-proofed according to
This will corrode the conductor and result in
JIS D 0203, R2 which protects the motor from
battery over-charging (boiling) and charging
rain or general cleaning. Do not use
malfunctions.
highpressure cleaner or submerse the starter
Consult YANMAR before using the equipment in
motor in water.
such an environment or the warranty is voided.
4-1-11 172663 0BKC2-EN0060

4. ENGINE
NOTICE NOTICE
• Avoid using high-pressure cleaner for electronic • Never attempt to modify the engine’s design or
or electric devices installed in, on or around the safety features such as defeating the engine
engine, including the E-ECU, relays and harness speed limit control or the diesel fuel injection
couplers. quantity control.
Otherwise such devices may suffer malfunction • Modifications may impair the engine’s safety and
due to water ingress into them. performance characteristics and shorten the
engine’s life. Any alterations to this engine may
void its warranty. Be sure to use YANMAR
Periodic Maintenance genuine replacement parts.
Establish a periodic maintenance plan according to
the engine application and make sure you perform
the required periodic maintenance at intervals If the oil pump must be replaced, replace it as an
indicated. Failure to follow these guidelines will assembly only. Do not replace individual
impair the engine’s safety and performance components.
characteristics, shorten the engine’s life and may
affect the warranty coverage on your engine.
If the engine coolant pump must be replaced,
Periodic maintenance prevents unexpected replace the engine coolant pump as an assembly
downtime, reduces the number of accidents due to only. Do not attempt to repair the engine coolant
poor machine performance and helps extend the pump or replace individual components.
life of the engine.
The tightening torque in the Standard Torque Use a new special O-ring between the engine
Chart in the Periodic Maintenance Section of this coolant pump and the joint. Be sure to use the
manual should be applied only to the bolts with a special O-ring for each engine model. Although the
“7” head. O-ring dimensions are the same as a commercially
(JIS strength classification: 7T) available O-ring, the material is different.
• Apply 60 % torque to bolts that are
not listed.
Remove or install the high-pressure fuel injection
• Apply 80 % torque when tightened to lines as an assembly whenever possible.
aluminum alloy. Disassembling the high-pressure fuel injection
lines from the retainers or bending any of the fuel
lines will make it difficult to reinstall the fuel lines.
• Always be environmentally
responsible.
After marking the position of the pump drive gear,
do not rotate the engine crankshaft. Rotating the
crankshaft will cause the fuel supply pump to
become misaligned.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel Do not short-circuit the charging system between
fuel and engine coolant. Consult the local alternator terminals IG and L. Damage to the
authorities or reclamation facility. alternator will result.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on Do not connect a load between alternator
the ground, or into ground water or waterways. terminalsL and E. Damage to the alternator will
• Failure to follow these procedures may seriously result.
harm the environment.
4-1-12 172663 0BKC2-EN0060

4. ENGINE
NOTICE NOTICE
Do not operate the engine if the alternator is Operating the Engine or the Attachment
producing unusual sounds. Damage to the • Never permit anyone to operate the
alternator will result. engine or driven machine without
proper training.
Make sure that the combined total resistance of
the battery cable in both directions between the
starter motor and the battery is within the value • Read and understand this Service Manual before
indicated in the Battery Cable Resistance chart in you operate or service the machine to ensure
the Electric Wiring Section of this manual. The that you follow safe operating practices and
starter motor will malfunction and fail if the maintenance procedures.
resistance is higher than the specified value.
• Machine safety signs and labels are additional
reminders for safe operating and maintenance
Identify all parts and their location using an techniques.
appropriate method. It is important that all parts
are returned to the same position during the
reassembly process.
Keep the piston pin parts, piston assemblies, and

connecting rod assemblies together to be returned
to the same position during the reassembly
process. Label the parts using an appropriate
method.
Do not allow the honing tool to operate in one

position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in constant
up-and-down motion.
Any part which is found defective as a result of

inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.
Any part determined to not meet the service

standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.
Never use a steel wire brush to clean fuel injectors.

Damage to the nozzle and other components is
likely to result.
4-1-13 172663 0BKC2-EN0060

4. ENGINE
4-2 Engine
4-2-1 Before You Begin Servicing
Before performing any service procedures within

this section, read the following safety information
and review the Safety section on page 4-1-1.
4-2-1 172663 0BKC2-EN0060

4. ENGINE
4-2-2 Introduction Required EPA / ARB Maintenance -

USA Only
The Importance of Periodic
Maintenance To maintain optimum engine performance and
compliance with the Environmental Protection
Engine deterioration and wear occurs in proportion Agency (EPA) Regulations Non-road Engines and
to length of time the engine has been in service the California Air Resources Board (ARB,
and the conditions the engine is subject to during California), it is essential that you follow the
operation. Periodic maintenance prevents "Maintenance" section in Operation manual.
unexpected downtime, reduces the number of
accidents due to poor machine performance and EPA / ARB Installation
helps extend the life of the engine. Requirements - USA Only
Performing Periodic Maintenance The following are the installation requirements for
the EPA / ARB. Unless these requirements are
WARNING met, the exhaust gas emissions will not be within
the limits specified by the EPA and ARB.
Exhaust hazard!
• Never operate the engine in an Maximum Exhaust Gas Restriction shall be:
enclosed area such as a garage, • 4TNV88C, 4TNV86CT: 1.84psi (12.7kPa,
tunnel, underground room, 1300mmAq) or less
manhole or ship’s hold without
proper ventilation. Maximum air intake restriction shall be 0.90 psi
(6.23 kPa; 635 mm Aq) or less. Clean or replace
• Never block windows, vents, or other means the air cleaner element if the air intake restriction
of ventilation if the engine is operating in an exceeds the above mentioned value.
enclosed area. All internal combustion
engines create carbon monoxide gas during
operation. Accumulation of this gas within an
enclosure could cause illness or even death.
• Make sure that all connections are tightened
to specifications after repair is made to the
exhaust system.
serious injury.
Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind, or
snow, from damaging the machine.
Yanmar Replacement Parts

Yanmar recommends that you use genuine
Yanmar parts when replacement parts are needed.
Genuine replacement parts help ensure long
engine life.
4-2-2 172663 0BKC2-EN0060

4. ENGINE
4-2-3 Special Service Tools
No. Tool name Applicable model and tool size Illustration
Model L1 L2 d1 d2 L2
Valve guide tool d2
0.787 in. 2.953 in. 0.295 in. 0.433 in.
1 (for removing 4TNV88C L1
(20 mm) (75 mm) (7.5 mm) (11 mm)
valve guide)
Locally manufactured
d1
010932-00X
Model L1 L2 d1 d2 L2
Valve guide tool 0.591 in. 2.559 in. 0.551 in. 0.787 in.
2 (for installing 4TNV88C L1
(15 mm) (65 mm) (14 mm) (20 mm)
valve guide)
d1
d2 001421-00X
Connecting rod
bushing Model L1 L2 d1 d2 L2
replacer (for 0.787 in. 3.937 in. 1.024 in. 1.142 in. d2
4TNV88C L1
3 removal/ (20 mm) (100 mm) (26 mm) (29 mm)
installation of
connecting rod
bushing) d1
010933-00X
Valve spring
compressor
4 (for removal/ YANMAR Part No. 129100-92630
installation of
valve spring) 010931-00X
Model d1 d2 d3 L1 L2 L3 L2
0.638 0.866 0.531 0.740 2.559 L1
0.157
in. in. in. in. in.
4TNV88C in.
(16.2 (22 (13.5 (18.8 (65
(4 mm) d1
mm) mm) mm) mm) mm)
d2 001421-00X
Stem seal Locally manufactured
installer
5 (for installing
valve stem
seal)
L2
d3 L3
d1 L1
d2
001422-00X
Filter wrench
(for removal/
6 Available locally
installation of
engine oil filter)
002829-01X
4-2-3 172663 0BKC2-EN0060

4. ENGINE
Camshaft Model L1 L2 d1 d2 L2
bushing tool 0.709 in. 2.756 in. 1.772 in. 1.890 in.
7 (for extracting 4TNV88C L1
(18 mm) (70 mm) (45 mm) (48 mm)
camshaft
bushing) d1
d2 001421-00X
Model YANMAR Part No. Cylinder bore

Flex-hone
3.268 - 3.740 in.
(for preparation 4TNV88C 129400-92430
8 (83 - 95 mm)
of cylinder
walls)
010930-00X
Piston ring
YANMAR Part No. 95550-002476
compressor
9 The piston insertion tool is applicable for
(for installing
2.362 - 4.921 in. (60 - 125 mm) diameter pistons
piston)
007236-00X
Piston ring
expander
10 (for removal/ Available locally
installation of
piston ring)
001411-00X
6.3
0.05 A 0.1 A
(16) 36
20
5 M14 × 1.5
0.
C
0.
16 C
5
Pulley installing 1
11 4TNV88C C
ø 35.4 -0.05
-0.15
tool
ø6
1
C
A
3
52
Knurling 109874-00EN00
4-2-4 172663 0BKC2-EN0060

4. ENGINE
13 -0.1
0
16mmx18/1inch
(Whitworth screw thread)
13
ø13
25
82
Compression
18
(5)
gauge adapter
12
(129A00-
(141)
92950)
(1)
(ø16)
68
ø17
R0
.2
17
0
ø7.2 -0.1
043931-00E00
4-2-5 172663 0BKC2-EN0060

4. ENGINE
4-2-4 Measuring Instruments
No. Instrument Name Application Illustration
1 Dial Indicator Locally Available Measure shaft bend and end play
0000831
Measurements of narrow or deep portions that

2 Test Indicator Locally Available
cannot be measured by dial gauge
0000832
3 Magnetic Stand Locally Available For holding the dial gauge when measuring
0000833
For measuring the outside diameters of

4 Micrometer Locally Available
crankshaft, pistons, piston pins, etc.
0000834
Cylinder Bore For measuring the inside diameters of cylinder

5 Locally Available
Gauge liners, bearing bores, etc.
0000835
For measuring outside diameters, depth,

6 Calipers Locally Available
thickness and width
0000836
7 Depth Micrometer Locally Available For measuring of valve recession
0000837
For measuring valve spring inclination and

8 Square Locally Available
straightness of parts
0000838
4-2-6 172663 0BKC2-EN0060

4. ENGINE
No. Instrument Name Application Illustration
9 V-Block Locally Available For measuring shaft bend
0000839
For tightening nuts and bolts to the specified

10 Torque Wrench Locally Available
torque
0000840
For measuring piston ring gaps, piston ring

11 Feeler Gauge Locally Available
clearance, and valve adjustment clearance
0000841
4-2-7 172663 0BKC2-EN0060

4. ENGINE
4-2-5 Cylinder Head
Cylinder Head Components
3
1 4
2 5
6
34 7
33
37
36 9
35 12
10
11
13
30 17
18 14
31
19 15
20
32 16
29
21
28 22
27
23
26
25
24
071817-00X00
Figure 4-2-1
4-2-8 172663 0BKC2-EN0060

4. ENGINE
1 – Valve cover nut Disassembly of Cylinder Head

2 – Valve cover nut O-ring
3 – Crankcase breather cover Prepare a clean, flat working surface on a
4 – Diaphragm spring workbench large enough to accommodate the
5 – Diaphragm plate cylinder head assembly. Discard all gaskets,
6 – Crankcase breather diaphragm O-rings and seals. Use new gaskets, O-rings and
(non-turbocharged engines only) seals on reassembly of the cylinder head.
7 – Oil fill cap
8 – Valve cover gasket 1. Drain the coolant from the engine into a
9 – Rocker arm shaft spring suitable container.
10 – Valve adjusting screw lock nut
11 – Valve adjusting screw NOTICE
12 – Rocker arm
13 – Rocker arm shaft
Identify all parts and their location using an
14 – Rocker arm shaft aligning stud appropriate method. It is important that all parts
15 – Support bolt are returned to the same position during the
16 – Rocker arm shaft support reassembly process.
17 – Valve cap
18 – Valve keepers
19 – Spring retainer 2. Remove the DPF (1, Figure 4-2-2). See How
20 – Valve spring to remove the DPF unit on page 4-8-15.
21 – Valve stem seal
3. Remove the breather hose (1, Figure 4-2-3)
22 – Valve guide
that connects the intake manifold and the
23 – Cylinder head
24 – Intake valve
cylinder head cover.
25 – Exhaust valve 4. Remove electric wirings of the EGR gas
26 – Cylinder head gasket temperature sensor (equipped to the EGR
27 – Fuel injector retainer valve side end of the EGR pipe), and remove
28 – Washer the EGR pipe (4, Figure 4-2-2). Remove the
29 – Fuel injector retainer bolt cooling water pipes (both inlet and outlet)
30 – Fuel injector nozzle protector
(5, Figure 4-2-2) of the EGR cooler. Here,
31 – Fuel injector nozzle seat
remaining water may spill. Prepare waste
32 – Push rod
33 – Crankcase breather components
cloths or the like under the EGR cooler.
34 – Valve cover 5. Alternator (6, Figure 4-2-2). See Removal of
35 – Glow plug Alternator on page 4-7-7.
36 – Glow plug connector
6. Remove the electric wirings for the
37 – Glow plug wire harness
temperature sensor of the coolant, and then
remove the cooling fan ans the coolant pump.
See Engine Coolant Pump Components on
page 4-4-3.
4-2-9 172663 0BKC2-EN0060

4. ENGINE
DPF flywheel housing-mounted type 7. Remove electric wirings from each of intake
3 2 1 throttle (1, Figure 4-2-4), ambient air
temperature sensor (2, Figure 4-2-4), and
EGR valve (3, Figure 4-2-4).
043927-01X00
6 5 4 044740-00X01
Figure 4-2-4
DPF Exhaust manifold-mounted type 8. If the fuel filter assembly (1, Figure 4-2-5) is
attached to the intake manifold, either remove
3 1 2
the filter bracket by removing the fuel pipe from
the fuel filter, or leave the fuel pipe and remove
the fuel filter assembly, and put it aside to the
engine side.
9. If necessary, remove the intake throttle
(2, Figure 4-2-5) on the intake manifold, and
the EGR valve (3, Figure 4-2-5) (Dispose all
the gaskets.).
2 3
6 5 4
044738-01X04
Figure 4-2-2
1 071818-00X00
1
Figure 4-2-5
072637-00X00
Figure 4-2-3
4-2-10 172663 0BKC2-EN0060
4. ENGINE
10. Remove the high-pressure fuel injection lines Remove the intake collector and the intake
(From rail to injector (18, Figure 4-2-6) and manifold as a unit, along with the common rail
from rail to supply pump (19, Figure 4-2-6). (9, Figure 4-2-6), intake throttle (2, Figure 4-
See Removal of Injector on page 4-3-6. 2-6), and EGR valve (3, Figure 4-2-6). Dispose
11. Remove the wiring coupler of the intake the exhaust manifold gasket (10, Figure 4-2-6).
temperature sensor (4, Figure 4-2-6) of the Cover the sheet part of the rail inlet of which the
intake manifold (1, Figure 4-2-6). Remove the high-pressure pipe is removed with plastic bags
intake manifold mounting bolts (5, Figure 4- after cleaning the part. Also cover the supply
2-6), and the mounting bolt (7, Figure 4-2-6) pump side too with a plastic bag.
and nut (8, Figure 4-2-6) of the intake collector
(6, Figure 4-2-6).
12
2 B 14*
13 A
17
10
6
4 11
5
9
8 7
18 5 1 16
18 15
19 B
* : If there is turbocharger 071819-00EN01
Figure 4-2-6
12. If there is an exhaust throttle (1, Figure 4-2-7) 13. Remove the exhaust manifold mounting bolts
equipped, remove the electric wirings (13, Figure 4-2-6), and then remove the
(2, Figure 4-2-7) from the driven machine side. turbocharger (14, Figure 4-2-6) (If there is
one.), exhaust throttle (If there is one), EGR
2 1
cooler (15, Figure 4-2-6), and EGR cooler
outlet vent (16, Figure 4-2-6), together with the
exhaust manifold. Dispose the exhaust
manifold gasket (17, Figure 4-2-6).
14. Remove the injector from the cylinder head.
See Removal of Injector on page 4-3-6.
071682-00X00
Figure 4-2-7
4-2-11 172663 0BKC2-EN0060
4. ENGINE
Removing the Glow Plugs

1. Remove the glow plug harness (2, 3, Figure 4- 1
2-8) from each glow plug (1, Figure 4-2-8). 2
2. Remove the glow plug from the cylinder head. 4

3
3
1
2
5
071820-00X00
Figure 4-2-9
4. Remove the cylinder head cover (4, Figure 4-
2-9) and the cylinder head cover gasket
(5, Figure 4-2-9).
Removal of Rocker Arm Assembly

061222-00X00
1. Remove the bolts (1, Figure 4-2-10) that retain
Figure 4-2-8 the rocker arm shaft supports.
Note: Removing the cylinder head from the 2. Remove the rocker arm shaft assembly from
engine requires that the glow plugs be the cylinder head.
removed in advance. Note: Identify the push rods so they can be
Failure to remove the glow plugs in reinstalled in their original locations.
advance could result in damages to the
glow plugs because their tips are 3. Remove the push rods and identify for
protruding from the cylinder head installation.
combustion chamber surface.
Removal of Cylinder Head Cover

1. Disconnect the electrical wire from sensor
(3, Figure 4-2-9) on the cylinder head cover.
2. Remove the cylinder head cover knobs
(1, Figure 4-2-9). 1
3. Remove the O-ring (2, Figure 4-2-9) on each
cylinder head cover knob.
K0001950
Figure 4-2-10
4-2-12 172663 0BKC2-EN0060

4. ENGINE
Disassembly of Rocker Arm Removal of Cylinder Head

Assembly 1. Loosen the cylinder head bolts following the
1. Remove the rocker arm shaft alignment stud sequence shown in (Figure 4-2-12).
(4, Figure 4-2-11) from support (5, Figure 4-
2-11). 2
Note: The rocker arm shaft fits tightly in the 1
7
9
16
18
14
12
6
4
rocker arm supports. Clamp the support 1
in a padded vise. Twist and pull out on 3 11 17 10 2
5 13 15 8
the rocker arm shaft to remove. Reverse K0001864-01
this process when you reinstall the
rocker arm shaft into the supports. 1 – Cooling fan end
2 – Camshaft side
2. Slide the rocker arm shaft (3, Figure 4-2-11)
out of the rocker arm supports (5, Figure 4- Figure 4-2-12
2-11), springs (1, Figure 4-2-11), and rocker 2. Remove the cylinder head bolts (1, Figure 4-
arms (2, Figure 4-2-11). 2-13).
Note: Mark the rocker arms so they can be 3. Lift the cylinder head away from the cylinder
reinstalled with the original matching block. Discard the cylinder head gasket
valve and pushrod. (2, Figure 4-2-13). Position the cylinder head
on the work bench to prevent damage to the
7 combustion surface.
6
1
2
1
3
4
K0001951
Figure 4-2-11
3. Remove the valve adjusting screw 2
(6, Figure 4-2-11) and the lock nut
(7, Figure 4-2-11) from the rocker arms.
K0001690
Figure 4-2-13
4-2-13 172663 0BKC2-EN0060

4. ENGINE
Removal of Intake/exhaust Valves 8. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
1. Place the cylinder head on the work bench with valves (6, Figure 4-2-15) from the cylinder
the combustion side down. head.
2. Remove the valve cap (1, Figure 4-2-15) and 9. Remove the valve stem seals (5, Figure 4-
keep with the valve it was installed on. 2-15).
3. Using the valve spring compressor tool,
compress one of the valve springs (Figure 4- Removal of Valve Guides
2-14). Note: Removal of the valve guides should be
postponed until inspection and
measurement procedures have been
performed. See Inspection of Valve Guides
on page 4-2-16.
1. If the valve guides were not within
specifications, use a drift pin and hammer to
K0000191
drive the valve guides (1, Figure 4-2-16) out of
the cylinder head.
Figure 4-2-14
4. Remove the valve keepers (2, Figure 4-2-15).
5. Slowly release the tension on the valve spring.
1
6. Remove the spring retainer (3, Figure 4-2-15)
and valve spring (4, Figure 4-2-15).
1
2
3
4
K001689X
5
Figure 4-2-16
K0001684
Figure 4-2-15
7. Repeat the procedure with all remaining
valves.
Note: If the valves are to be reused, identify
them so they can be installed in their
original location.
4-2-14 172663 0BKC2-EN0060

4. ENGINE
Cleaning of Cylinder Head Inspection of Push Rods

Components
■ Push rod bend
WARNING Determine if the bend of the push rods are within
the specified limit.
Fume/Burn Hazard!
• Always read and 1. Place the push rods on a flat inspection block
follow safety related or layout bed.
precautions found on 2. Roll the push rods until a gap can be observed
containers of between a portion of the push rod and the
hazardous surface of the block or layout bed.
substances like parts
3. Use a feeler gauge to measure the gap
cleaners, primers,
(Figure 4-2-17). See "3-2 Engine" section for
sealants and sealant
the service limit.
removers.
serious injury.
Thoroughly clean all components using a non-

metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other
debris.
Inspection of Cylinder Head

Components K0000204
Visually inspect the parts. Replace any parts that Figure 4-2-17
are obviously discolored, heavily pitted or
otherwise damaged. Discard any parts that do not
meet its specified limit.
NOTICE
Any part which is found defective as a result of
inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.
NOTICE
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.
4-2-15 172663 0BKC2-EN0060

4. ENGINE
Inspection of Rocker Arm Assembly Inspection of Valve Guides

Visually inspect the valve guides for distortions,
■ Rocker arm shaft hole diameter
scoring or other damage.
Use a test indicator and micrometer to determine if
the inside diameter of all the rocker arm support Note: Measure the valve guides while they are
brackets and the rocker arms (Figure 4-2-18) are installed in the cylinder head.
within the specified limits. See "3-2 Engine" section Use a telescoping gauge and micrometer to
for the service limit. measure the inside diameter at each end of the
Inspect the contact areas (1, Figure 4-2-18) for valve guide. Measure in three places and 90° apart
excessive wear or damage. (Figure 4-2-20). See "3-2 Engine" section for the
service limit. Replace valve guides if not within
specification.
K0001869
Figure 4-2-20
1
1
Inspection of Cylinder Head
■ Cylinder head distortion
K0001916
Place the cylinder head flat and inverted

Figure 4-2-18 (combustion side up) on the bench. Use a straight
edge and a feeler gauge to measure cylinder head
■ Rocker arm shaft outside diameter distortion (Figure 4-2-21). Measure diagonally and
Use a micrometer to measure the rocker arm shaft along each side. See "3-2 Engine" section for the
diameter. Measure at each rocker arm location in service limit.
two directions 90° apart (Figure 4-2-19). See "3-2
Engine" section for the service limit.
K0000192
Figure 4-2-21
If distortion exceeds the service limit, resurface or
replace the cylinder head. Remove only enough
material to make the cylinder head flat, but do not
remove more than 0.008 in. (0.20 mm).
K0001952
Figure 4-2-19
4-2-16 172663 0BKC2-EN0060

4. ENGINE
Inspection of Intake and Exhaust ■ Valve recession

Valves Note: The valve guides must be installed to
perform this check.
Visually inspect the intake and exhaust valves.
Replace any valves that are obviously discolored, Insert the valves into their original locations and
heavily pitted or otherwise damaged. press them down until they are fully seated. Use a
depth micrometer (Figure 4-2-24) to measure the
■ Valve stem diameter difference between the cylinder head gasket
Use a micrometer to measure the valve stem surface and the combustion surface of each
diameter. Measure the valve stem near the exhaust and intake valve (Figure 4-2-25). See "3-2
combustion end and near the opposite end Engine" section for the service limit.
(1, Figure 4-2-22). See "3-2 Engine" section for
the service limit.
K0000197
Figure 4-2-22
■ Valve stem bend K0000193
Place the valve stem on a flat inspection block or Figure 4-2-24

layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 4-2-23). See "3-2
K0001755
Figure 4-2-25
K0000199
Figure 4-2-23
4-2-17 172663 0BKC2-EN0060

4. ENGINE
■ Valve face and valve seat

Always check the clearance between the valve and 1
150° 40°
valve guide before grinding or lapping the valve
seats. See "3-2 Engine" section for the service
limit. If the clearance exceeds the limit, replace the 3
valve and/or valve guide to bring the clearance 2
within the limit.
Roughness or burrs will cause poor seating of a K0001862
valve. Visually inspect the seating surfaces of each

valve and valve seat to determine if lapping or Figure 4-2-27
grinding is needed. The valve seat diameter can be adjusted by top-
Visually inspect all valve faces and valve seats for grinding with a 150° stone to make the seat
pitting, distortion, cracking, or evidence of diameter smaller, and bottom-grinding using a 40°
overheating. Usually the valves and the valve seats stone to make the seat diameter larger. Once the
can be lapped or ground to return them to seat location has been corrected, grind and lap the
serviceable condition. Severely worn or damaged seat angle (1, Figure 4-2-27) to specification. See
components will require replacement. "3-2 Engine" section for the service limit.
Coat the valve seat with a thin coat of bluing Grind the valve face and/or valve seat only enough
compound. Install the valve and rotate it to to return them to serviceable condition. Grinding is
distribute bluing onto the valve face. The contact needed if the valve and the valve seat do not
pattern should be approximately centered on the contact correctly. Check the recession after
valve face (1, Figure 4-2-26) and even in width. grinding.
If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.
Inspection of Valve Springs

Inspect the valve springs. If damage or corrosion is
1 seen, or if measurements exceed the specified
limits, replace the springs.
■ Fractures
K0001691B
Check for fractures on the inside and outside
Figure 4-2-26 portions of the springs. If the valve spring is
fractured, replace the valve spring.
Also visually inspect the valve seat for even
contact. ■ Corrosion
Light cutting can be performed by the use of a Check for corrosion of the spring material caused
hand-operated cutter (3, Figure 4-2-27). by oxidation.
■ Squareness
Use a flat surface and a square to check each
spring for squareness (Figure 4-2-28). See "3-2
4-2-18 172663 0BKC2-EN0060

4. ENGINE
Reassembly of Cylinder Head

Use new gaskets, O-rings and seals for the
reassembly of the cylinder head.
NOTICE
Liberally oil all components during reassembly to
prevent premature wear or damage.
K0000201
Figure 4-2-28 ■ Reassembly of valve guides

■ Free length 1. The valve guides are installed into the cylinder
head with an extremely tight press fit. Before
Use a caliper to measure the length of the spring
installing the valve guides, place the valve
(Figure 4-2-29). See "3-2 Engine" section for the
guides in a freezer for at least twenty minutes
service limit.
This will cause the valve guides to contract, making
it easier to install the valve guides into place.
2. Immediately after removing the valve guides
from the freezer, insert the valve guides
(1, Figure 4-2-30) in their proper positions.
2
3
1
4
0
5
9
6
8
7
K0000200
Figure 4-2-29
K001689X
Figure 4-2-30
3. Finish installing the valve guides (1, Figure 4-
2-31) into the cylinder head to the proper
height (3, Figure 4-2-31) using the valve guide
installation tool (2, Figure 4-2-31). See "3-2
1
K0001756A
Figure 4-2-31
4-2-19 172663 0BKC2-EN0060

4. ENGINE
■ Reassembly of intake and exhaust

valves
NOTICE
Always install new valve stem seals. 2
1
The exhaust valve stem seals are different than the
intake valve stem seals and can be identified by
either the paint marks on the outside of the seals
or by the color of the seal spring (4, Figure 4-
2-32). Ensure they are installed in the correct
locations. K0001874
Figure 4-2-33
Marking 3. Place the cylinder head assembly on its
Engine model
Intake Exhaust exhaust port side.
White (Paint on 4. Place all the valves (6, Figure 4-2-34) in their
All models None
outside of seal) proper location in the cylinder head.
1. Oil the lip of the valve stem seal (2, Figure 4-
2-32). Using the valve stem seal installation 1
tool (1, Figure 4-2-32), install a new valve 2
stem seal on each of the valve guides 3
(3, Figure 4-2-32).
4
5
2
6
3
K0001684
K0001873B
Figure 4-2-34
5. Place the cylinder head on the workbench with
Figure 4-2-32
the combustion side down to install the valve
2. Measure the distance (1, Figure 4-2-33) from springs. Install the valve spring (4, Figure 4-
the cylinder head to valve stem seal to ensure 2-34) and the spring retainer (5, Figure 4-
proper clearance (2, Figure 4-2-33) between 2-34).
the guide and the seal. See "3-2 Engine" 6. Using the valve spring compressor tool,
section for the service limit. compress the valve spring.
7. Insert the valve keepers (2, Figure 4-2-34) and
slowly release the tension on the valve spring.
Install the valve cap (1, Figure 4-2-34). Repeat
the steps on all the remaining valves.
4-2-20 172663 0BKC2-EN0060

4. ENGINE
■ Reassembly of cylinder head 4. Insert the push rods in their respective

1. Carefully clean both the combustion surface of positions.
the cylinder head and the top surface of the
2
cylinder block. Then place a new cylinder head
gasket (2, Figure 4-2-35) on the cylinder block. 18
12
10
3
1
5
7
13
15
2. Position the cylinder head on the cylinder head 1

16 8 2 9 17
gasket. 14 6 4 11
K0001875-01
1 – Fan end
1 2 – Camshaft side
Figure 4-2-36
■ Reassembly of rocker arm reassembly
NOTICE
Ensure the lubrication holes (1, Figure 4-2-37) in
the rocker arm shaft are oriented correctly with
respect to the rocker arms (2, Figure 4-2-37).
1 2
2
1 045200-00X00
K0001690
Figure 4-2-37
Figure 4-2-35
1. Lubricate the rocker arm shaft. Slide the rocker
3. Lightly oil the threads of the cylinder head bolts arm supports (5, Figure 4-2-38), springs
(1, Figure 4-2-35). Tighten the bolts to the (1, Figure 4-2-38) and rocker arms
specified torque in two steps as shown in the (2, Figure 4-2-38) onto the shaft.
chart below. Tighten in the sequence shown in Note:
(Figure 4-2-36). See "3-7-2 Engine Tightening
Torque" section for tightening torque. • The rocker arm shaft fits tightly in the rocker
arm supports. Clamp the support in a padded
First step 1/2 of final torque vise. Twist and push on the rocker arm shaft to
Second step Final torque reinstall.
• To properly align the rocker arm shaft with the
rocker arm shaft supports, first reinstall a
rocker arm support (5, Figure 4-2-38) having
a hole for the shaft alignment stud
(4, Figure 4-2-38). Align the hole in the rocker
arm shaft and the hole in the rocker arm
support. Reinstall the alignment stud.
4-2-21 172663 0BKC2-EN0060

4. ENGINE
7
■ Assembling the parts around the
6 cylinder head
1 1. Attaching the glow plug
2
Install the glow plug (1, Figure 4-2-39) and
tighten with the specified torque.
3
4 Glow plug (M10) 11.1 - 14.8 ft·lb
tightening torque (15 - 20 N·m; 1.5 - 2.0 kgf·m)
5 Attach the glow plug connector (2, Figure 4-

2-39) and glow plug harness (3, Figure 4-2-39)
to the glow plug with a specified torque.
K0001951
0.7 - 1.1 ft·lb
M4 nut tightening torque
Figure 4-2-38 (1 - 1.5 N·m; 0.1 - 0.2 kgf·m)
Note: Figure 4-2-38 shows components for

one cylinder. Components for all 3 4
remaining cylinders are assembled in
the same order. 1
2
2. Place the rocker arm shaft assembly onto the
cylinder head.
3. If removed, reinstall the valve adjusting screws
(6, Figure 4-2-38) and the lock the nuts
(7, Figure 4-2-38).
4. Align the push rods with their respective rocker
arms.
5. Reinstall and tighten the rocker arm shaft
retaining bolts (M10 × 65) to the specified
torque. 061222-00X01
6. Tighten the rocker arm shaft alignment studs. Figure 4-2-39

7. Adjust the valve clearance. See Measuring and
Adjusting Valve Clearance on page 4-2-24. 2. Attaching the injector
Attach the injector. See Reassembly of injector
on page 4-3-7.
3. Attaching the exhaust manifold
Reinstall the exhaust manifold using a new
gasket (17, Figure 4-2-6). Here, attach the
EGR cooler, the EGR cooler outlet vent, a
turbocharger (if there is one), and an exhaust
throttle (if there is one), as a unit to the cylinder
head. Tighten it with specified torque.
Tightening torque
59.3 - 60.4 ft·lb
for M10 (10.9T) bolts
(80.3 - 81.8 N·m; 8.2 - 8.3 kgf·m)
and nuts
Connect the cooling water pipes (both inlet and

outlet) of the EGR cooler.
4-2-22 172663 0BKC2-EN0060

4. ENGINE
4. Attaching the intake manifold 9. Attaching the cylinder head cover

Attach the exhaust manifold and intake collector Apply grease to a new cylinder head cover
as a unit using a new gasket (10, Figure 4-2-6). packing (2, Figure 4-2-40) and insert the
Here, attach the intake collector with the EGR packing to the cylinder head cover groove
valve and the intake throttle in a attached state, (1, Figure 4-2-40). Place the cylinder head
and attach the intake manifold with the common cover on the cylinder head. Tighten the cylinder
rail in a connected state. Tighten it with specified head cover with a mounting knob (3, Figure 4-
torque. If the EGR valve and the intake throttle 2-40). Here, replace the O-ring with a new one
were removed, attach them to the intake (4, Figure 4-2-40). Connect the electric wirings
collector. Replace the gasket with a new one. of the pressure sensor (5, Figure 4-2-40).
For turbocharged engines, attach the removed
Tightening torque 7.2 - 8.7 ft·lb intake duct (2, Figure 4-2-2) and the breather
for M6 bolts (9.8 - 11.8 N·m; 1.0 - 1.2 kgf·m)
hose (3, Figure 4-2-2). For models without
Tightening torque 16.7 - 21.0 ft·lb turbocharger, attach the breather hose
for M8 bolts and nuts (22.6 - 28.4 N·m; 2.3 - 2.9 kgf·m)
(1, Figure 4-2-3).
Tightening torque 32.5 - 39.8 ft·lb
for M10 bolts (44.1 - 53.9 N·m; 4.5 - 5.5 kgf·m
3
5. Installing the high-pressure fuel injection lines 4
Install the high-pressure piles and fuel return 1
lines from injector to common rail and from 5
supply pump to common rail. See Reassembly
of Common Rail on page 4-3-9.
CAUTION
2
For high-pressure fuel injection line, use a
new one. If you reuse it, the displacement of
the working face may occur, causing the fuel 071820-00X02
to leak.
Figure 4-2-40
6. Attaching the EGR pipe 10. Installing the alternator

Attach the EGR pipe (4, Figure 4-2-2). Install the alternator. See Installation of
Replace the gasket with a new one on both Alternator on page 4-7-11.
ends. 11. Attaching the fuel filter assembly
7. Connecting the electric wiring If the fuel filter assembly was removed, attach
Connect the coupler of the removed electric it to the intake manifold.
wirings. 12. Installing the DPF
• Intake temperature sensor Install the DPF. See How to reattach the DPF
on page 4-8-17.
• Exhaust temperature sensor
• Exhaust throttle (if equipped)
• EGR valve
• EGR gas temperature sensor
• Intake throttle
• Ambient temperature sensor
• Glow plug wire harness
8. Attaching the coolant pump
Attach the coolant pump. See Removal of
Engine Coolant Pump on page 4-4-4.
Connect the electric wirings of the coolant
pump temperature sensor.
4-2-23 172663 0BKC2-EN0060

4. ENGINE
4-2-6 Measuring and Adjusting Valve Clearance
Measure and adjust while the engine is cold. • If adjusting each cylinder individually, the cylinder
to be adjusted first does not have to be the No. 1
Note: cylinder. Select and adjust the cylinder where the
• The No. 1 piston position is on the flywheel end piston is nearest to the top dead center after
of the engine, opposite the radiator. The firing turning. Make adjustment for the remaining
order is 1-3-4-2. cylinders in the order of firing by turning the
crankshaft each time.
• The engine fires every 180° of crankshaft
rotation. • To decrease the number of rotations required to
check all cylinders, other cylinders can also be
• Valve clearance of both the intake and exhaust checked as indicated in the chart below.
valves can be checked with the piston for that
cylinder at top dead center (TDC) of the On an engine, with the No. 1 piston at TDC on the
compression stroke. When a piston is at TDC of compression stroke (both valves closed), the four
the compression stroke, both rocker arms will be valves indicated on the top line of the chart can be
loose and the cylinder TDC mark on the flywheel adjusted without rotating the crankshaft. To adjust
will be visible in the timing port of the flywheel the remaining four valves, rotate the crankshaft
housing. until the No. 4 piston is at TDC on the compression
stroke (both valves closed).
• If there is no valve clearance, and the cylinder is
at TDC of the compression stroke, extreme wear,
or damage to the cylinder head or valves may be
possible.
Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 cylinder at TDC compression • • • •
No. 4 cylinder at TDC compression • • • •
4-2-24 172663 0BKC2-EN0060

4. ENGINE
1. Remove the valve cover. See Removal of

Cylinder Head Cover on page 4-2-12.
Note: If adjusting each cylinder individually, 2
the cylinder to be adjusted first does not
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is
nearest to the top dead center after
turning, and make adjustment for other
cylinders in the order of firing by turning
the crankshaft.
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to 1
TDC on the compression stroke while watching
the rocker arm motion and timing grid on the Figure 4-2-42
flywheel. (Position where both the intake and
exhaust valves are closed.) 6. Insert a feeler gauge of the correct thickness
(1, Figure 4-2-43) (See "3-2 Engine" section
3. Insert a feeler gauge (1, Figure 4-2-41)
for the service limit.) between the rocker arm
between the rocker arm and valve cap, and
and valve cap. Turn the valve adjustment screw
record the measured valve clearance. (Use the
to adjust the valve clearance so there is a slight
data for estimating the wear.)
“drag” on the feeler gauge when sliding it
between the rocker arm and the valve cap.
1 Hold the adjusting screw while tightening the
valve adjusting screw lock nut (1, Figure 4-
2-42). Recheck the clearance.
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that you make
the initial clearance adjustment slightly
on the “loose” side before tightening the
lock nut.
1
K0001782A
Figure 4-2-41
4. If adjustment is required, proceed to the next
step.
5. Loosen the valve adjusting screw lock nut
(1, Figure 4-2-42) and valve adjusting screw
(2, Figure 4-2-42) on the rocker arm and check
Figure 4-2-43
the valve for inclination of the valve cap,
entrance of dirt, or wear. 7. Apply oil to the contact surface between the
adjusting screw and push rod.
8. Rotate the crankshaft. Measure and adjust the
valves on the next cylinder. Continue until all
the valves have been measured and adjusted.
4-2-25 172663 0BKC2-EN0060

4. ENGINE
4-2-7 Crankshaft and Camshaft Components
41 1
42 3
4
2
40 6
39
38 7
36
37 35 8
9
10 5
34
33
30 13
18 12
32
19 11
31
17
16
20 15
21 14
22
23
24
29
25
26
27
28
043952-00X00
Figure 4-2-44
4-2-26 172663 0BKC2-EN0060

4. ENGINE
1 – Cylinder block Disassembly of Engine

2 – Camshaft bushing
3 – Gear case Prepare a clean, flat working surface on a
4 – Gear case cover workbench large enough to accommodate the
5 – Front crankshaft seal engine components. Discard all used gaskets,
6 – Tappets O-rings and seals. Use new gaskets, O-rings and
7 – Camshaft seals on reassembly of engine.
8 – Camshaft gear key
9 – Camshaft end plate
10 – Camshaft gear
NOTICE
11 – Idler gear shaft (A) Identify all parts and their location using an
12 – Idler gear (A) appropriate method. It is important that all parts
13 – Idler gear bushing (A) are returned to the same position during the
14 – Idler gear plate (B) reassembly process.
15 – Idler gear shaft (B)
16 – Idler gear (B)
17 – Idler gear bushing (B)
If the engine will be completely disassembled, the
18 – Oil pickup gasket
following preliminary steps should be performed:
19 – Oil pickup
20 – Crankshaft 1. Disconnect the battery cables at the battery.
21 – ball Always disconnect the negative (-) cable first.
22 – Crankshaft gear key
23 – Crankshaft gear 2. Remove the throttle cable, electrical
24 – Crankshaft pulley connections, intake and exhaust system
25 – Main bearing inserts connections, and fuel supply lines from the
26 – Main bearing cap engine.
27 – Oil pan spacer
3. Remove the alternator. See Removal of
28 – Oil pan
Alternator on page 4-7-7.
29 – Thrust bearings
30 – Flywheel 4. Drain the engine coolant from the radiator and
31 – Connecting rod cap cylinder block. Remove the cooling system
32 – Connecting rod bearing inserts components from the engine.
33 – Connecting rod
5. Remove the engine from the machine. Mount
34 – Wrist pin bushing
35 – Circlip
the engine to a suitable engine repair stand
36 – Wrist pin having adequate weight capacity.
37 – Piston
38 – Oil ring NOTICE
39 – Second compression ring Be sure to secure the engine solidly to prevent
40 – Top compression ring
injury or damage to parts due to the engine
41 – Crankshaft rear seal housing
falling during work on the engine.
42 – Crankshaft rear seal
6. Clean the engine by washing with solvent, air

or steam cleaning. Carefully operate so as to
prevent any foreign matter or fluids from
entering the engine or any fuel system or
electrical components remaining on the
engine.
7. Drain the engine oil into a suitable container.
Remove the oil filter.
8. Remove the cylinder head. See Cylinder Head
on page 4-2-8.
4-2-27 172663 0BKC2-EN0060

4. ENGINE
9. Remove fuel supply pump if necessary. ■ Checking timing gear backlash

See Removal of Supply Pump on page 4-3-10 Prior to removing the timing gears, measure the
if necessary. gear backlash and determine the gear wear.
10. Remove the starter motor. See Removal of
Starter Motor on page 4-6-5. Check the backlash between each pair of mating
gears (Figure 4-2-46). If not within specification,
Disassembly of Camshaft and replace both mating gears. See "3-2 Engine"
section for the service limit.
Timing Components
Discard all gaskets, O-rings and seals. Use new Note: Do not allow the gear being checked to
gaskets, O-rings and seals on reassembly of the move axially as excess end play could
camshaft and timing components. cause a false reading.
■ Removal of timing gear case cover 1 2 3 4

1. Remove the bolt and washer retaining the
crankshaft pulley.
NOTICE
Use care not to damage the threads in the end of
the crankshaft when removing the crankshaft
pulley.
5
6
2. Remove the crankshaft pulley using a gear
7 043953-00X00
puller.
3. Remove the bolts that retain the gear case 1 – Supply pump gear
cover to the cylinder block and oil pan. 2 – Idler gear (B)
3 – Idler gear (A)
4. Remove the gear case cover (1, Figure 4- 4 – Camshaft gear
2-45). 5 – Crankshaft gear
6 – Lubricating oil pump gear
7 – Direction of rotation
Figure 4-2-46
073697-00X00
Figure 4-2-45
4-2-28 172663 0BKC2-EN0060

4. ENGINE
■ Measuring idler gear-to-crankshaft gear ■ Removal of timing gears

backlash 1. Remove the bolts from the idler gear shaft
1. Install a dial indicator as shown in Figure 4- (1, Figure 4-2-48). Remove the idler gear
2-47. shaft, idler gear (2, Figure 4-2-48) and bushing
(3, Figure 4-2-48).
2
3
1
6
043954-00X00 5
4
3
1
043957-01X00
1 – Idler gear shaft

3 – Idler gear bushing
5 – Plate, idle shaft
6 – Packing
Backside engagement
clearance (backlash)
007778-00E
Figure 4-2-48
2. Do not remove the crankshaft gear unless it is
Figure 4-2-47 damaged and requires replacement. If the gear
must be removed, remove it using a gear
2. Rotate the idler gear back and forth to check
puller.
the idler gear-to-crankshaft gear backlash. The
total indicator reading is the backlash. Record 3. Removal of the camshaft gear requires the
the measurement. camshaft be removed and placed in a press.
Do not remove the camshaft gear unless it or
■ Measuring idler gear-to-camshaft gear the camshaft is damaged and requires
backlash replacement. See Removal of camshaft on
page 4-2-31.
1. Drive a small wooden wedge between the
crankshaft gear and idler gear to prevent the 4. Remove the supply pump drive gear using a
idler gear from rotating. gear puller.
2. Install the dial indicator to read the camshaft
gear backlash. Rotate the camshaft drive gear
against the idler gear to measure the backlash.
Record the measurement.
3. Check the idler gear-to-fuel injection pump
drive gear backlash in the same manner as the
camshaft drive gear. Record the measurement.
4-2-29 172663 0BKC2-EN0060

4. ENGINE
3. Remove the oil pickup tube (1, Figure 4-2-51)

and O-ring (2, Figure 4-2-51).
043958-00X00
Figure 4-2-49
2
■ Removal of oil pan 1
1. Invert the engine (oil pan up) on the engine
stand.
2. Remove the oil pan (1, Figure 4-2-50).
K0001696A
Figure 4-2-51
K0001695A
Figure 4-2-50
4-2-30 172663 0BKC2-EN0060

4. ENGINE
■ Removal of camshaft 2. Remove the two bolts (3, Figure 4-2-54)

1. Before removing the camshaft, check the retaining the camshaft thrust plate
camshaft end play. (1, Figure 4-2-54).
• Method A: Install a dial indicator (1, Figure 4-

2-52) on the cylinder block. Move the camshaft
(2, Figure 4-2-52) back and forth to measure
the end play. Record the measurement. See 2 5
"3-2 Engine" section for the service limit.
1
3 4
K0001966
Figure 4-2-54
3. Rotate the engine in the engine stand so that
2 gravity causes the tappets (5, Figure 4-2-54)
043959-00X00
to drop away from the camshaft lobes.
Figure 4-2-52 Note: Rotate the camshaft at least two turns to
“bump” any sticking tappets away from
• Method B: Use a feeler gauge to measure the
the camshaft.
clearance between the thrust plate
(1, Figure 4-2-53) and front camshaft bearing 4. Slowly pull the camshaft (2, Figure 4-2-54)
(2, Figure 4-2-53). See "3-2 Engine" section assembly out of the engine being careful not to
for the service limit. damage the front camshaft bushing.
Note:
1
• If the engine is not installed on an engine
repair fixture, stand the engine upright on the
2
flywheel end mounting flange. Rotate the
camshaft at least two turns to bump the
tappets out of the way to prevent the tappets
from interfering with the removal of the
camshaft.
• The tappets are “mushroom” shaped and must
be removed from inside the engine crankcase.
K0001710B
5. Remove the tappets. Mark the tappets so they
can be reinstalled in the same location.
Figure 4-2-53 6. Remove the camshaft drive gear (4, Figure 4-
2-54) only if the gear or camshaft require
replacement. Use a knife-edge puller and a
press to remove the gear. The gear is a shrink-
fit and will need to be heated to 356 - 392 °F
(180 - 200 °C) to remove.
4-2-31 172663 0BKC2-EN0060

4. ENGINE
■ Removal of gear case or front plate Disassembly of Crankshaft and

Note: The camshaft must be removed before the Piston Components
gear case can be removed. See Inspection
of camshaft on page 4-2-40. ■ Removal of pistons
1. Remove the oil pump.
NOTICE
Note: It is not necessary to remove the fuel
supply pump from the gear case to Keep the piston pin parts, piston assemblies, and
remove the gear case. If the fuel supply connecting rod assemblies together to be returned
pump does not need to be repaired, to the same position during the reassembly
leaving it mounted to the timing gear process. Label the parts using an appropriate
case will eliminate the need to re-time it method.
during assembly. See Removal of
Supply Pump on page 4-3-10. NOTICE
2. Remove the bolts (4, Figure 4-2-55). Engines with high operating hours may have a
ridge near the top of the cylinders that will catch
3. Remove the gear case (1, Figure 4-2-55) from
the piston rings and make it impossible to remove
the cylinder block. Thoroughly clean all old
the pistons. Use a suitable ridge reamer to remove
sealant from the mating surfaces.
ridges and carbon prior to removing the pistons.
4. Inspect and measure the camshaft bushing.
See "3-2 Engine" section for the service limit. If
damaged or worn beyond service limits, Note: Pistons can fall from cylinder block if the
remove the camshaft bushing (3, Figure 4- engine is inverted. Rotate the engine so the
2-55). connecting rods are horizontal before
5. Remove the O-ring (2, Figure 4-2-55) and removing the connecting rod caps.
dowels (4, Figure 4-2-55). 1. Using a feeler gauge, measure the connecting
rod side clearance as shown (Figure 4-2-56).
See "3-2 Engine" section for the service limit.
3 If the measurement is out of specification,
4 replace the crankshaft, connecting rod, or both.
1
2
4
043961-00X02
Figure 4-2-55
K0000219
Figure 4-2-56
2. Measure bearing oil clearance prior to
removing the pistons and connecting rods to
determine extent of wear. Record the
measurements.
4-2-32 172663 0BKC2-EN0060

4. ENGINE
7- Repeat with remaining connecting rods.

NOTICE
Mark the connecting rod caps and connecting NOTICE
rods so the caps and connecting rods stay Do not allow the connecting rod to contact the
together. crankshaft journal during piston removal.
Damage to the bearing journal may result.
1- Remove the bearing cap. Do not remove
the bearing inserts at this time. 3. Use a wooden dowel against the connecting
2- Wipe oil from the bearing insert and rod and tap the piston/connecting rod
crankshaft journal surfaces. assembly out of the cylinder.
3- Place a piece of PLASTIGAGE® 4. Mark the cylinder number on the piston and
(1, Figure 4-2-57) along the full width of the connecting rod.
bearing insert. 5. Remove the bearing inserts (2, Figure 4-2-59).
6. Remove the compression rings (3, Figure 4-
1 2-59) from the piston using a piston ring
expander.
7. Remove the oil ring (4, Figure 4-2-59) from the
piston using a piston ring expander.
3
K0001898
4
Figure 4-2-57 5
NOTICE 9 6
5
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result.
8
7
4- Reinstall bearing cap and tighten to
specification. See "3-7-2 Engine Tightening
2
Torque" section for tightening torque.
5- Remove bearing cap. 1
6- Compare the width of the flattened
PLASTIGAGE to the graduation marks on
K0001960
the package (1, Figure 4-2-58). The mark
that most closely matches the width of the Figure 4-2-59
flattened PLASTIGAGE will indicate the
bearing oil clearance. 8. Remove the circlips (5, Figure 4-2-59) from
the wrist pin.
9. Remove the wrist pin (6, Figure 4-2-59) and
connecting rod (8, Figure 4-2-59) from the
1 piston (9, Figure 4-2-59).
10. Repeat the steps until all pistons are removed
and dissembled.
K0001899
Figure 4-2-58
4-2-33 172663 0BKC2-EN0060

4. ENGINE
■ Removal of crankshaft
1. Remove the flywheel (1, Figure 4-2-60) from
the crankshaft.
2. Remove the bolts from the rear oil seal
assembly (2,3, Figure 4-2-60). Remove the
assembly from the engine.
1
2
2
3
3
K0001962
1
Figure 4-2-62
4. Remove the main bearing caps (3, Figure 4-
2-63). Be sure to note the markings on the
main bearing caps, or mark them yourself, so
they can be reinstalled in the same order as
K0001707A they were removed. Do not remove the bearing
inserts at this time.
Figure 4-2-60
Note: The “arrows” on the main bearing caps
3. Before removing the main bearing caps, point to the flywheel end of the engine.
measure the crankshaft end play. Use either of
the following two methods.
• Method A: Install a dial gauge (1, Figure 4-
2-61) on the cylinder block. Move the
crankshaft (2, Figure 4-2-61) in and out to
measure the end play. Record the
measurement. 2
1 3
073703-00X00
2 K0001961
Figure 4-2-63
Figure 4-2-61 5. Measure bearing oil clearance prior to
• Method B: Use a feeler gauge to measure the removing the crankshaft to determine extent of
clearance (3, Figure 4-2-62) between the wear. Record the measurements.
thrust bearing (1, Figure 4-2-62) and 1- Wipe oil from the bearing insert and
crankshaft (2, Figure 4-2-62). Record the crankshaft journal surfaces.
measurement. See "3-2 Engine" section for
the service limit.
4-2-34 172663 0BKC2-EN0060
4. ENGINE
2- Place a piece of PLASTIGAGE 8. If necessary, remove the crankshaft gear

(1, Figure 4-2-64) along the full width of (1, Figure 4-2-66), parallel pin (2, Figure 4-
each bearing insert. 2-66) and key (3, Figure 4-2-66). If using a
gear puller, be careful not to damage the
threads in the end of the crankshaft.
1
2
3
K0001898
K0001731A
Figure 4-2-64
Figure 4-2-66
NOTICE
Inspection of Crankshaft and
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result. Camshaft Components
WARNING
3- Reinstall bearing caps and tighten to Fume/Burn Hazard!
specification. See "3-7-2 Engine Tightening
• Always read and
follow safety related
4- Remove bearing caps. precautions found on
5- Compare the width of the flattened containers of
PLASTIGAGE to the graduation marks on hazardous
the package (1, Figure 4-2-65). The mark substances like parts
that most closely matches the width of the cleaners, primers,
flattened PLASTIGAGE will indicate the sealants and sealant
bearing oil clearance. removers.
serious injury.
1 Thoroughly clean all components using a brush

and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
debris.
K0001899
Figure 4-2-65
6. Remove the crankshaft from the engine.
7. Remove the bearing inserts (1, Figure 4-2-63)
and thrust bearings (2, Figure 4-2-63).
Note: Do not remove the crankshaft gear
unless the gear or crankshaft are
damaged and require replacement.
4-2-35 172663 0BKC2-EN0060

4. ENGINE
■ Replacement of crankshaft oil seals ■ Measure crankshaft bearing oil

1. Remove the seal (2, Figure 4-2-67) from the clearance
cover (1, Figure 4-2-67). Oil clearance should be checked during
2. Apply a continuous bead of ThreeBond Liquid disassembly to determine the extent of wear, and
Gasket No. 1207F, YANMAR Part No. 977770- during assembly to ensure long engine life. The
1207F to the outside diameter of a new oil seal same procedure is done for both connecting rods
(2, Figure 4-2-67), and install in the gear case and main bearings.
cover. Apply lithium grease to the lip of the
seal. ■ Inspection of cylinder block
1. Ensure that oil passages are clear and
unobstructed.
2. Check for discoloration or evidence of cracks. If
a fracture is suspected, use the color check
method or the Magnaflux method to determine
if the cylinder block is fractured.
3. Inspect cylinders for roundness, taper, or
1 evidence of scoring. Collect and record the
measurements. Consider honing, reboring or
replacing the cylinder block if the
measurements are not within specification.
2 • Take measurements at three places
(Figure 4-2-69) (a, b, c), and in two directions
(d and e) in each cylinder.
073703-01X00
Figure 4-2-67 a 20 mm
(0.75 in.)
d
3. Remove the rear oil seal (3, Figure 4-2-68) e
from the seal housing (2, Figure 4-2-68). b
4. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, YANMAR Part No. 977770- c
1207F to the outside diameter of a new oil seal 20 mm
(2, Figure 4-2-68), and install in the housing. (0.75 in.) K0000230B
Apply lithium grease to the lip of the seal.

Figure 4-2-69
■ Inspection of pistons, piston rings and

wrist pin
2
Note:
3
• On an engine with low hours, the pistons, piston
1 rings may be reused if they are found to be within
specifications. The pistons and piston rings must
be reinstalled in the same cylinders from which
they were originally removed.
• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed (See
K0001707A
Honing and Boring on page 4-2-42) or replaced.
The piston should be replaced as necessary.
Figure 4-2-68
4-2-36 172663 0BKC2-EN0060

4. ENGINE
1. Clean piston ring grooves using a piston ring 7. Measure the outside diameter of the wrist pin
groove cleaning tool. Follow manufacturer’s in three places and at 90° (Figure 4-2-72). See
instructions for correct operation. "3-2 Engine" section for the service limit.
2. Wash the pistons in an appropriate solvent Record the measurements.
using a soft brush.
3. Visually inspect each piston for cracks. Pay
particular attention to the ring lands between
the piston ring grooves.
4. Measure the diameter of the piston skirt at 90°
to the wrist pin bore as shown (Figure 4-2-70).
Measurements must be taken at a specified K0001889
distance (1, Figure 4-2-70) from the bottom of

the piston, based on engine model. Record the Figure 4-2-72
measurements. See "3-2 Engine" section for 8. Using a micrometer, measure the thickness of
the service limit. each piston ring. See "3-2 Engine" section for
the service limit. Record the measurements.
Note:
• On an engine with low hours, the pistons,
piston rings and cylinders may be reused if
they are found to be within specifications.
• On an engine with high hours, the pistons
1 rings should be replaced and the cylinder
honed (see Honing and Boring on page 4-
2-42) or replaced. The piston should be
K0000235 replaced as necessary.
Figure 4-2-70 9. Place each compression piston ring in the
groove as shown (Figure 4-2-73). Use a feeler
5. Subtract the piston measurement from the gauge to measure the clearance between the
greatest measurement acquired during piston ring and the piston ring land. Record the
cylinder inspection (see Inspection of cylinder measurements. See "3-2 Engine" section for
block on page 4-2-36) to obtain piston-to- the service limit. Replace the piston if not
cylinder clearance. Record the measurements. within specification.
6. Measure the diameter of the wrist pin bore on
both sides of the piston (Figure 4-2-71). See
Record the measurements.
K0001892
Figure 4-2-73
K0000237
Figure 4-2-71
4-2-37 172663 0BKC2-EN0060

4. ENGINE
10. To measure piston ring end gap, insert each ■ Inspection of connecting rod
compression piston ring (1, Figure 4-2-74), 1. Measure the wrist pin bushing bore using a
one at a time, into the cylinder. Use a piston bore gauge (1, Figure 4-2-75). Replace the
with the piston rings removed to slide the ring bushing if not within specifications. If the
into the cylinder bore until it is approximately bushing has been removed, measure the
1.18 in. (30 mm) (2, Figure 4-2-74) from the inside diameter of the connecting rod small end
bottom of the bore. Remove the piston. (2, Figure 4-2-75). See "3-2 Engine" section
Measure the end gap (3, Figure 4-2-74) of for the service limit.
each piston ring. Record the measurements.
2
1 K0001724A
2
Figure 4-2-75
2. Place the connecting rod bearing inserts into
the connecting rod and connecting rod cap.
3 K0001964 Install the rod cap and tighten the bolts to the
specified torque.
Figure 4-2-74 3. Measure the inside diameter. See "3-2 Engine"
Note: Always check the piston ring end gap section for the service limit.
when installing new piston rings. See "3-
2 Engine" section for the service limit.
Use a piston ring end gap filing tool to
adjust the piston ring end gap on new
piston rings.
11. Repeat the above steps for each cylinder and
piston assembly.
4-2-38 172663 0BKC2-EN0060

4. ENGINE
■ Inspection of tappets ■ Inspection of crankshaft

1. Inspect the tappet contact surfaces for 1. Place the crankshaft end journals (4, Figure 4-
abnormal wear (1, Figure 4-2-76). Normal 2-79) on V-blocks.
wear will be even as shown in (2, Figure 4-
2. Place a dial indicator (3, Figure 4-2-79) on a
2-76). Slight surface defects can be corrected
using an oilstone. center main bearing surface.
2
1
1 2 K0001725
3
Figure 4-2-76
2. Measure the outside diameter of the tappet
stem (1, Figure 4-2-77). See "3-2 Engine"
section for the service limit.
4 4 K0000232A
Figure 4-2-79
3. Rotate the crankshaft and observe runout. See
1 4. Use the color check method or Magnaflux® to
K0001726A
inspect the crankshaft for cracks. Replace the
Figure 4-2-77 crankshaft if evidence of fractures are found.
3. From the head side of the below illustration, 5. Measure the outside diameter of each crankpin
use the cylinder gauge (1, Figure 4-2-78) to (2, Figure 4-2-80) and main bearing journal
measure the tappet bore. See "3-2 Engine (1, Figure 4-2-80). See "3-2 Engine" section
Service Standard" section for the service limit. for the service limit. Take measurements at
several places around each bearing surface. If
1 not within specification, grind the journals and
install undersize bearings, or replace the
crankshaft.
073704-00X00
Figure 4-2-78
4-2-39 172663 0BKC2-EN0060
4. ENGINE
■ Inspection of camshaft
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 4-2-81). Place the
indicator on the center bearing journal.
K0001711
R Figure 4-2-81
R 2. Rotate the camshaft and observe the runout.

3. Measure the height of each lobe (1, Figure 4-
2-82). See "3-2 Engine" section for the service
1 limit.
2 K0001733A
Figure 4-2-80
1
K0001712A
Figure 4-2-82
4. Measure the diameter of the gear end
(1, Figure 4-2-83), intermediate (2, Figure 4-
2-83), and flywheel end (3, Figure 4-2-83)
bearing journals. See "3-2 Engine" section for
the service limit.
2
1
K0001713A
Figure 4-2-83
4-2-40 172663 0BKC2-EN0060

4. ENGINE
■ Inspection of camshaft bushing and ■ Inspection of flywheel

bores 1. Check for crack and wear on the flywheel
1. Measure the I.D. of the front bushing and the friction surface, and replace it if there is
remaining bores in the cylinder block. See "3-2 damage.
Engine" section for the service limit. 2. Check the ring gear tooth surface and replace
2. If the camshaft bushing is not within the ring gear if there is damage or excessive
specification, replace it using the appropriate wear.
service tool. If the remaining bores are not • Removal of ring gear
within specification, the cylinder block will Bring a rod into contact with the ring gear, and
require replacement as there are no bearing remove the gear while evenly hitting the
inserts used. circumference with a hammer.
■ Inspection of idler gear and shaft
1. Measure the outside diameter (1, Figure 4-
2-84) of the idler gear shaft (2, Figure 4-2-84).
2. Measure the inside diameter (3, Figure 4-
2-84) of the idler gear bushing (4, Figure 4-
2-84). See "3-2 Engine" section for the service
limit.
4
061228-00X00
Figure 4-2-85
1 3
• Evenly heat a new ring gear with a gas burner
(approximately 200 °C (392 °F)), quickly install
2 the ring gear with the chamfered side of the
tooth surface facing the block side. Completely
and closely contact the ring gear and the
K0001714A
flywheel.
Figure 4-2-84
061229-00X00
Figure 4-2-86
4-2-41 172663 0BKC2-EN0060

4. ENGINE
Honing and Boring

1
Pistons must move freely in the cylinders while
maintaining adequate compression and oil sealing.
If the cylinder walls are scuffed, scored,
out-of-round, or tapered beyond specifications,
rebore and hone to restore cylinders to usable
condition. Slight imperfections can be corrected by
honing alone.
1. Boring - Significant cylinder damage may be
corrected by boring the cylinder to an oversize
dimension. Refer to the appropriate parts
K0000248A
catalog for available oversize pistons and
piston rings. Figure 4-2-87
• Boring a cylinder should always be done in a
properly equipped machine shop. • Use a 50:50 mixture of diesel fuel and engine
oil as a honing fluid.
• A bored cylinder should always be finished
with a hone to properly prepare the cylinder • Use a 300-grit hone at 300 - 1200 min-1 (rpm)
surface so the new piston rings will seat (Figure 4-2-88).
properly.
1
• After the cylinder has been bored and honed,
install the appropriate oversize pistons and
2
piston rings.
2. Honing - Minor cylinder imperfections may be
corrected by using a rigid cylinder hone
(1, Figure 4-2-88). Be sure not to exceed the
maximum cylinder bore specification.
3. Deglazing - A used cylinder that did not K0000249B
require boring or honing, should always be

deglazed with a ball hone (2, Figure 4-2-88) Figure 4-2-88
before installing new piston rings. This will
properly prepare the cylinder surface to allow NOTICE
new piston rings to seat properly.
Solvents will not adequately remove honing
Note: When honing a cylinder, with either a residue, resulting in premature piston and ring
ridged hone or a ball hone (1, Figure 4- wear. Always wash cylinders using hot, soapy
2-87), move the rotating hone up and water.
down in the cylinder bore to accomplish
a 30° to 40° crosshatch pattern
(Figure 4-2-87). This will provide the • When honing is completed, wash the cylinder
ideal surface for the proper seating of block with hot water and soap. The cylinder
new piston rings. wall is adequately cleaned when a white rag
wiped in cylinder comes out clean. Use
NOTICE brushes to clean all passages and crevices.
Rinse with hot water and dry with compressed
Do not allow the honing tool to operate in one air. Apply clean engine oil to all steel surfaces
position for any length of time. Damage to the to prevent rusting.
cylinder wall will occur. Keep the tool in constant
up-and-down motion.
4-2-42 172663 0BKC2-EN0060

4. ENGINE
Reassembly of Crankshaft and NOTICE

Piston Components
The piston and connecting rod must be
Note: assembled together in the correct orientation.
• Proceed slowly. Make no forced assemblies The orientation of the piston and connecting rod
unless a pressing operation is called for. All parts are different depending on engine model.
must be perfectly clean and lightly lubricated
when assembled.
Piston to connecting rod orientation - by model
• Use new gaskets, seals and O-rings during Orient the piston identification mark stamped on top of
assembly. the piston on the same side as the rod and cap match
marks stamped on the connecting rod.
• Liberally apply clean engine oil to all internal
parts during assembly. Note: The actual appearance of the match
• All fasteners should be tightened to a given marks on the piston and connecting rod
torque. If a special torque is not provided in the may vary, but they will always be in the
Special Torque. See "3-7-2 Engine Tightening same locations.
■ Reassembly of pistons
1. Select the parts needed to reassemble the
piston and connecting rod for one cylinder.
2. If removed, install a new wrist pin bushing
(7, Figure 4-2-89) using a press and the
appropriate service tool. Be sure to align the oil
holes.
4
5
9 6
5
8
7
K0001960
Figure 4-2-89
3. Reinstall one circlip (5, Figure 4-2-89) into the
piston. Ensure the circlip is securely seated in
the groove.
4-2-43 172663 0BKC2-EN0060

4. ENGINE
Piston assembly - all TNV models

When correctly assembled, the piston
1
identification mark (2, Figure 4-2-91) stamped
into the top of the piston will be on the same side
ML↓844V of the connecting rod as the match marks
(4, Figure 4-2-91) stamped into the connecting
rod and connecting rod cap.
When installed in the cylinder, the piston
on the top of the piston must face the fuel
injection pump side (1, Figure 4-2-91) of the
engine and the embossed mark on the
K0002091 connecting rod (3, Figure 4-2-91) must face the
flywheel end (5, Figure 4-2-91) of the engine.
2
6 1
E106 R
2
5
K0002090
3
3
80 80 K0001967
K0002089 1 – Fuel injection pump side of engine

2 – Piston identification mark
1 – Piston identification mark 3 – Embossed mark on connecting rod
2 – Embossed mark on connecting rod 4 – Rod and cap match marks
3 – Rod and cap match marks 5 – Flywheel end of engine
Figure 4-2-90 6 – Camshaft side of engine
Figure 4-2-91
4. Lubricate and reinstall the wrist pin
(6, Figure 4-2-92) through the piston and
connecting rod.
5. Reinstall the second circlip (5, Figure 4-2-92)
and ensure it is securely seated in the groove.
4-2-44 172663 0BKC2-EN0060

4. ENGINE
NOTICE
Always use a piston ring installation tool
3 (expander) when installing piston rings. Never
attempt to install piston rings by hand.
4
5
6. Reinstall the oil ring expander (4, Figure 4-
9 6 2-94). Reinstall the oil ring (3, Figure 4-2-94)
5 with the end gap at 180° from the expander
end gap.
7. Reinstall the second compression ring
8
7 (2, Figure 4-2-94). This ring is identified by its
dark color and tapered face profile.
8. Reinstall the top compression ring
2
(1, Figure 4-2-94). This ring is identified by its
1 silver color and barrel-shaped face profile.
NOTICE
K0001960
The oil ring expander (4, Figure 4-2-94) end
gap must be located 180° from the oil ring
(3, Figure 4-2-94) end gap.
Figure 4-2-92
Note:
• If installing new piston rings the end gap must 1
be checked and adjusted as necessary. See
Inspection of pistons, piston rings and wrist pin
on page 4-2-36 for specifications. Use a piston 2
ring end gap filing tool to adjust the piston ring
end gap on new piston rings.
3
• Reinstall the top and second piston rings with
the stamped “makers mark” (1, Figure 4-
2-93) facing the top of the piston. The “makers
4
mark” may vary in appearance but will always
K0001722B
be located on the top surface of the piston ring
adjacent to the piston ring gap. The oil ring and Figure 4-2-94
oil ring expander can be installed either side
up. 9. Stagger the piston ring end gaps at 120°
intervals (1, 2, 3, Figure 4-2-95). Do not
1 position the top piston ring end gap in line with
the wrist pin.
K0000225A
Figure 4-2-93
4-2-45 172663 0BKC2-EN0060

4. ENGINE
5. Apply a light coat of clean engine oil to the

1 bearing cap bolts and tighten the bolts to the
specified torque in two stages (1/2 then full
torque). See "3-7-2 Engine Tightening Torque"
section for tightening torque.
2
1
K0001968
1 – Top compression ring end gap

2 – Second compression ring end gap
3 – Oil ring end gap
3
Figure 4-2-95
073703-00X00
■ Installation of crankshaft Figure 4-2-96

1. If removed, reinstall the keys and timing gear
on the crankshaft. 6. Rotate the crankshaft to assure it turns freely.
2. Reinstall new bearing inserts (1, Figure 4- 7. Apply ThreeBond Liquid Gasket No. 1207F,
2-96) and thrust bearing (2, Figure 4-2-96) in YANMAR Part No. 977770-1207F to the
the cylinder block and main bearing caps. mounting flange of the seal housing
Apply a liberal coat of clean engine oil to the (2, Figure 4-2-97).
bearings and crankshaft journals. 8. Align the seal housing with the two dowel pins.
3. Place the crankshaft into the engine. 9. Reinstall seal housing and seal assembly.
10. Reinstall the flywheel (1, Figure 4-2-97) and
NOTICE tighten the bolts to the specified torque. See
The main bearing caps are numbered and have "3-7-2 Engine Tightening Torque" section for
arrows for proper positioning. The No. 1 cap is at tightening torque.
the flywheel end. The arrows point toward the
flywheel end of the engine.
2
4. Reinstall the main bearing caps (3, Figure 4-
2-96). 3
Figure 4-2-97
4-2-46 172663 0BKC2-EN0060

4. ENGINE
■ Installation of pistons Piston installation - all TNV models
NOTICE When correctly assembled, the piston

Do not allow the connecting rod to contact the into the top of the piston will be on the same side
crankshaft journal during piston installation. of the connecting rod as the match marks
Damage to the crankshaft bearing journal may (4, Figure 4-2-99) stamped into the connecting
result. rod and connecting rod cap.
When installed in the cylinder, the piston
1. Lubricate the piston, piston rings, and cylinder identification mark (2, Figure 4-2-99) stamped
with clean engine oil or assembly lubricant. on the top of the piston must face the fuel
2. Rotate the crankshaft so the crankpin for the injection pump side (1, Figure 4-2-99) of the
piston being installed is near bottom dead engine and the embossed mark on the
center. connecting rod (3, Figure 4-2-99) must face the
flywheel end (5, Figure 4-2-99) of the engine.
NOTICE
Ensure the piston ring gaps are located correctly 6 1
(Figure 4-2-98).
2
1 5
3
2
4
3
K0001967
1 – Fuel injection pump side of engine

2 – Piston identification mark
1 – Top compression ring end gap 3 – Embossed mark on connecting rod
2 – Second compression ring end gap 4 – Rod and cap match marks
3 – Oil ring end gap 5 – Flywheel end of engine
Figure 4-2-98 6 – Camshaft side of engine
Figure 4-2-99
3. Using a piston ring compressor, compress the
piston rings.
NOTICE
The piston and connecting rod must be installed
in the correct orientation.
Piston orientation to cylinder

Orient the piston identification mark stamped
All TNV
on top of the piston on the fuel injection pump
models
side of the engine
4-2-47 172663 0BKC2-EN0060

4. ENGINE
4. Reinstall the bearing inserts (1, Figure 4- Reassembly of Camshaft and Timing
2-100) in the connecting rod and cap.
Components
5. Apply a liberal coat of clean engine oil to the
bearing inserts and crankshaft journal. ■ Installation of gear case
6. Apply a light coat of clean engine oil to the rod 1. If removed, install a new camshaft bushing
cap bolts. Reinstall the connecting rod cap (3, Figure 4-2-101) using the appropriate
(2, Figure 4-2-100). Tighten the connecting service tool.
rod bolts to the specified torque in two stages
(1/2 then full torque). See "3-7-2 Engine
Gasket No. 1207F, YANMAR Part No. 977770-
Tightening Torque" section for tightening
1207F to the mounting area of the gear case.
torque.
Be sure to circle each bolt hole.
3. Reinstall the dowels (4, Figure 4-2-101) and
two new O-rings (2, Figure 4-2-101).
3
4
1
2
2
4
043961-00X02
K0001965
Figure 4-2-101
4. Reinstall the front plate (1, Figure 4-2-101).
Figure 4-2-100
Tighten the bolts to the specified torque.
7. Reinstall the remaining pistons in their
respective cylinders.
4-2-48 172663 0BKC2-EN0060

4. ENGINE
■ Installation of camshaft ■ Installation of timing gears

Note: The gear housing or front plate must be 1. Set the piston of gear case side cylinder
reinstalled prior to installing the camshaft. (cylinder No. 4) to the top dead center position.
See Installation of gear case on page 4- 2. Rotate the camshaft until the mark
2-48. (C, Figure 4-2-103) is approximately at the 9
1. If removed, reinstall the camshaft end plate o’clock position.
(1, Figure 4-2-102), key, and timing gear
1 2 3 4
(4, Figure 4-2-102) onto the camshaft using a
press.
Note: Heat the gear to 356 - 392 °F (180 - 200 D D
°C) and press onto the end of the B
B C C
camshaft.
2. Rotate the cylinder block so that gravity will A
keep the tappets (5, Figure 4-2-102) in place A 5
and out of the way of the camshaft lobes when 6
the camshaft is being reinstalled.
Note: 7 043953-01X00
• If the engine is not installed on an engine 1 – Supply pump gear

repair fixture, stand the engine upright on the 2 – Idler gear (A)
flywheel end mounting flange. 3 – Idler gear (B)
4 – Camshaft gear
• The tappets are “mushroom” shaped and must 5 – Crankshaft gear
be installed from inside the engine crankcase. 6 – Lubricating oil pump gear
3. Lubricate the tappets with clean oil or 7 – Direction of rotation
assembly lube. Reinstall the tappets in their Figure 4-2-103
respective locations in the cylinder block. Push
the tappets fully into the tappet bores so they 3. Lubricate the idler gear (2, Figure 4-2-104),
will not interfere with the installation of the bushing (3, Figure 4-2-104) and idler gear
camshaft. shaft (1, Figure 4-2-104) with clean engine oil.
4. Lubricate the camshaft (2, Figure 4-2-102)
2
with clean engine oil or assembly lube. Slowly
insert the camshaft through the front of the 3
1
engine.
5. Reinstall and tighten the cap screws
(3, Figure 4-2-102).
6
5 5
2
4
1 3
1
043957-01X00
3 4
1 – Idler gear shaft
3 – Idler gear bushing
K0001966
5 – Plate, idle shaft
Figure 4-2-102 6 – Packing
Figure 4-2-104
4-2-49 172663 0BKC2-EN0060

4. ENGINE
4. Align the timing gears as shown in (Figure 4-

2-103). 1
2
5. Install the idler gear (A), idler gear shaft, and
idler gear bushing while aligning the timing
marks A and C. At this time, direct the punch
mark on the idler gear shaft end surface to the
upper part of the engine.
6. While aligning the timing marks B and D of the
idler gear (B), install the idler gear (B), idler
gear shaft, and idler gear bushing.
7. When all gears are properly aligned, tighten 3
the idler gear retaining bolts to specified
torque. See "3-7-2 Engine Tightening Torque"
■ Installation of gear case cover K0002133
1. Apply a continuous bead of ThreeBond Liquid Figure 4-2-106

Gasket No. 1207F, YANMAR Part No. 977770- 4. Reinstall the washer and bolt. Tighten the bolt
1207F to the mounting area of the gear case to the specified torque. See "3-7-2 Engine
cover (1, Figure 4-2-105). Be sure to circle the Tightening Torque" section for tightening
bolt holes. torque.
2. Reinstall and tighten the gear case cover bolts.
073697-00X00
Figure 4-2-105
3. Reinstall the crankshaft pulley.
NOTICE
Use the crankshaft pulley installation tool
(3, Figure 4-2-106) when reinstalling the pulley
(1, Figure 4-2-106). The tool will guide the
pulley hub and protect the front seal
(2, Figure 4-2-106) from damage.
4-2-50 172663 0BKC2-EN0060

4. ENGINE
■ Installation of oil pan Final Reassembly of Engine

1. Reinstall the oil pickup tube (1, Figure 4- 1. Reinstall the starter motor.
2-107) using a new O-ring (2, Figure 4-2-107).
2. Reinstall the cylinder head. See Reassembly
of cylinder head on page 4-2-21.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
5. Reinstall the alternator.
6. Reconnect all electrical connections.
7. Fill the engine with oil and coolant.
8. Reconnect the battery cables, negative (-)
cable last.
2
1
073698-00X00
Figure 4-2-107
Gasket No. 1207F, YANMAR Part No.
977770-1207F to the mounting surface of the
oil pan (1, Figure 4-2-108). Be sure to circle
each bolt hole.
3. Reinstall the oil pan and tighten the bolts
securely.
073720-00X00
Figure 4-2-108
4-2-51 172663 0BKC2-EN0060

4. ENGINE
4-2-8 EGR System
EGR (Exhaust Gas Recirculation) is a technology which has been widely used for automotive diesel
engines. EGR lowers the combustion temperature by introducing a part of exhaust gas into the intake air
and reduces NOx which is a composition subject to emission control regulations. By applying this EGR
technology, we can now comply with emission control regulations in each country, including the emission
control regulation Tier4 of the Environmental Protection Agency (EPA).
Figure 4-2-109 shows the schematic diagram of the equipment. There is an appropriate value for the
circulating exhaust gas volume (EGR rate), and it is controlled by the EGR valve which is installed
between the intake and exhaust flow. EGR valves are driven by DC motors and they adjust the EGR rate
according to the appropriate opening indicated by the ECU based on engine speed or load conditions.
ECU Speed and load

Intake Exhaust
EGR valve
Recycle gas
Injector
Cylinder liner Piston
037271-00E00
Figure 4-2-109
4-2-52 172663 0BKC2-EN0060

4. ENGINE
EGR System (Typical Model)
2
5
Flywheel side
8
Gear case side 071822-01EN00
1 – Exhaust manifold 6 – Intake manifold

2 – EGR cooler outlet vent 7 – EGR cooler
3 – EGR pipe 8 – EGR cooler inlet side coolant hose
4 – Intake throttle valve 9 – EGR cooler outlet side coolant hose
5 – EGR valve
Figure 4-2-110
4-2-53 172663 0BKC2-EN0060

4. ENGINE
Disassembly of EGR System 4. Loosen the flange bolt (5, Figure 4-2-111) that
mount the EGR pipe and EGR valve
WARNING (1, Figure 4-2-111), and remove the EGR pipe.
Burn Hazard! 5. Loosen the EGR valve mounting bolt
(6, Figure 4-2-111), and remove the EGR
• Keep your hands and other body valve.
parts away from hot engine
surfaces such as the muffler,
exhaust pipe, turbocharger (if 4
3
equipped) and engine block
during operation and shortly
after you shut the engine down. 6
These surfaces are extremely hot
while the engine is operating and
could seriously burn you. 5
2
• Failure to comply could result in death or 1
serious injury. 8
CAUTION 7
Only for engines
with turbocharger
Coolant Hazard!
• Wear eye protection
and rubber gloves 10
when you handle long
9
life or extended life
engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
071824-00EN00
moderate injury. Figure 4-2-111
Disassembling procedure of each components will NOTICE

be described for maintenance and parts
When it is necessary to replace an EGR valve, be
replacement of the EGR system.
sure to replace the entire EGR valve assembly.
■ EGR valve Neither attempt to disassemble and repair the
EGR valve, nor replace its individual components.
1. If there is any additional equipment (such as an
air cleaner) installed above the EGR valves,
remove it in advance.
NOTICE
2. Remove the connector from the EGR valve A steel gasket is used to the joint section of the
(1, Figure 4-2-111). (Leave the connector EGR system devices with the parts.
attached when checking or cleaning the EGR When reinstalling the EGR system devices and
valve.) parts, always use new and specified one.
3. Loosen the flange nut (4, Figure 4-2-111) that
mount the EGR cooler outlet vent (2, Figure 4-
2-111) and the EGR pipe (3, Figure 4-2-111).
4-2-54 172663 0BKC2-EN0060

4. ENGINE
■ EGR cooler 2. Disconnect the coolant inlet (2, Figure 4-

When removing the EGR cooler for cleaning, 2-112) and outlet hoses (3, Figure 4-2-112)
inspections of the EGR valve should be done at from the EGR cooler (1, Figure 4-2-112) by
the same time (every 3000 hours), so carry on loosening the hose clips. When loosening the
after removing the EGR valve. clips, put a waste cloth or the like beneath the
hose joints in case water leaks.
1. Drain the engine coolant. 3. Loosen the bolt (5, Figure 4-2-112) fixing the
EGR cooler outlet vent (4, Figure 4-2-112) to
the cylinder block, and the bolt (7, Figure 4-
2-112) fixing the EGR cooler to the exhaust
manifold (6, Figure 4-2-112), then remove the
EGR cooler along with the vent.
1
4
3 7
071825-00X00
Figure 4-2-112
4-2-55 172663 0BKC2-EN0060

4. ENGINE
Check, Clean, and Test EGR Valve Therefore, when removing the EGR valve from the
engine, leave the harness in a connected state.
WARNING If it is difficult to remove with the harness
connected, disconnect the harness once, and then
Fume/Burn Hazard! reconnect it after removing the EGR valve.
• Always read and
follow safety related ■ EGR active control
precautions found on First connect the interface box to the engine
containers of harness via the connector cable, and then turn on
hazardous SMARTASSIST-DIRECT (SA-D). Force open the
substances like parts EGR valve, and clean the valve.
cleaners, primers,
sealants and sealant • Before forcibly activating the EGR, check for
removers. errors that affect the fully closing process of the
EGR.
How to check: Press “Defect Display” and
serious injury.
“Current Defect”. If the error is displayed,
go to (1). If no error is displayed, go to (2).
CAUTION
(1)
Flying Object Hazard!
• Always wear eye protection when • Select “Diagnostic Codes” and select “Defect
servicing the engine and when History”
using compressed air or high- • Press “All Clear” button
pressure water. Dust, flying • Error information is cleared from the “Defect
debris, compressed air, History”
pressurized water or steam may
(2)
injure your eyes.
• Select “Diagnosis Tests” and select “Active
Control”
moderate injury.
• Press “Execute” button from “EGR Valve
Opening Control”
Because the EGR valve is in a closed state when
• Enter the user ID and password
the engine key switch is off, in order to check,
clean, and test the valve, connect the interface box • When “EGR Valve Opening Control” is displayed,
to forcibly send signal from the ECU to fully open enter “106” in “Desired” and press “Set”
the EGR valve by SMARTASSIST-DIRECT (SA-D), • Active control starts if no error is found
as shown in Figure 4-2-113.
4-2-56 172663 0BKC2-EN0060

4. ENGINE
Active control SA-D
Interface box
Connector cable
Engine harness
ECU
Engine
EGR valve
071908-00EN00
Figure 4-2-113
• Check that the desired value on the screen ■ Cleaning the EGR valves
indicates the set target value. EGR valve Clean the EGR valve every 3000 hours of
opening control lamp comes on. operation to prevent carbon deposits. This leads to
deterioration of EGR performance. Blow the
NOTICE carbon deposits with the compressed air
Do not end the SA-D while cleaning the EGR. (0.19 MPa (2 kg/cm2) or less). Use a soft brush
with carbon cleaner or kerosene to clean the EGR
valve if the EGR valve is excessively dirty. Be sure
For details on how to operate the EGR Active to remove all carbon deposits. (Figure 4-2-114)
Control, refer to the SMARTASSIST DIRECT
In this case, the motor portion and the coupler
(SAD) Operation Manual.
terminals should not be exposed to solvent or
cleaner. This may result in a malfunction.
If the carbon deposits can not be removed by a
brush, be sure to replace the entire EGR valve
assembly.
Remove the remaining carbon deposits by blowing
the compressed air. (Figure 4-2-114)
4-2-57 172663 0BKC2-EN0060

4. ENGINE
■ Precautions for installation

1. The valve and stopper must be installed in their
specific orientations. As shown in the figure
above, install the valve and stopper so that
they are located on the left-hand side of the
lead valve.
2. Install the valve by tightening the machine
screw while ensuring that it is evenly positioned
inside the case window.
3. The machine screw must be tightened with
torque of 1.37 ± 0.2 N·m (14 ± 2 kgf·cm).
4. After tightening the machine screw, mark it with
a marker to indicate that it has already been
tightened.
Carbon removal
■ Clean EGR cooler
The EGR cooler must be periodically cleaned
every 3000 hours because the exhaust gas
passage is subject to carbon deposition and the
cooling water transit portion to scale deposition
and these depositions gradually deteriorate the
cooling of recirculated gas, thus resulting in higher
gas temperatures and lower effective circulation
amounts (EGR ratio).
To remove deposited carbon from the gas
Care must be taken for the direction
of air blow not to catch the carbon passage, use compressed air (0.19 MPa (2 kg/
in this part.
055190-00EN00
cm2) or lower). Then dip the gas passage in
carbon cleaner, kerosene, or some other liquid
Figure 4-2-114 capable of removing carbon; leave it dry and blow
it with compressed air again.
■ Exit the EGR active control
To clean the water transit portion, dip it in a
You can exit the EGR Active Control from the
solution of descaling detergent diluted with water
SMARTASSIST DIRECT screen.
and wash it.
• Press the “Stop” button from “EGR Valve
Opening Control”.
• EGR valve opening control lamp goes off and
EGR Active Control exits.
■ Precautions for cleaning

• Do not disassemble the EGR valve.
• Do not use wash fluid.
• Do not use a hard brush made of metal.
• Clean entire circumference of the valve and the
valve seat, and blow with the compressed air.
• Do not put your fingers into the valve portion.
4-2-58 172663 0BKC2-EN0060

4. ENGINE
■ EGR pipe and other connecting elbows ■ Intake Throttle

The exhaust gas passage is subject to carbon The intake throttle is a device that controls the
deposition when used over time. To remove amount of the engine air intake. The TNV series
deposited carbon from the gas passage, use engines use it for the combustion of soot collected
compressed air (0.19 MPa (2 kg/cm2) or lower). If inside the DPF. The intake throttle is driven by the
the exhaust gas passage is heavily fouled, clean it DC motor. The ECU controls the appropriate
by dipping it in carbon cleaner, kerosene, or some degree of opening of the throttle depending on the
other liquid capable of removing carbon. engine speed and load conditions. Accordingly, the
engine takes in the minimum required amount of
NOTICE air to increase the exhaust temperature and burn
soot inside the DPF.
•Always be environmentally
responsible. Check the operation performance of the intake
throttle every 3000 hours of operation. It is
necessary to connect SMARTASSIST DIRECT for
the EGR valve cleaning. For details, refer to the
SMARTASSIST DIRECT Operation Manual.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of Precautions for handling the intake throttle
hazardous materials such as engine oil, diesel
• Do not use a throttle after you have dropped it.
fuel and engine coolant. Consult the local
Even if it appears okay on the outside, it may
authorities or reclamation facility.
have internal damage.
• Never dispose of hazardous materials
• Do not apply excessive impact or load to the
irresponsibly by dumping them into a sewer, on
throttle.
the ground, or into ground water or waterways.
• Do not touch the stop screw part, as it has
• Failure to follow these procedures may seriously
already been adjusted.
harm the environment.
• Prevent any foreign matter including oil, dust,
and water droplets from entering the air passage
■ Installing EGR related components/parts part.
To install these components/parts, reverse the • Do not remove the sensor cover installation rivet.
disassembly procedure described above: thus
install the lead valve, spacer, EGR valve, EGR • Consider static electricity and prevent static
pipe, EGR cooler, elbow, cooler cooling water electric charge of the human body when
hose, and EGR cooling water hose exactly in this handling the throttle.
order. • Do not touch the sensor cover terminal directly.
The EGR system uses steel gaskets at the joints • Do not touch the throttle valve with your hands
between its components/parts. When you remove when the throttle is energized.
the system’s components/parts and reinstall them, Your hands may get pinched in the valve and get
replace the steel gaskets between them with new injured.
correct ones.
• Do not check operation with the installation
surface of the throttle unit pointing down, as the
valve protrudes from the installation surface.
• Prevent water and foreign matter from entering
the connector connection part.
4-2-59 172663 0BKC2-EN0060

4. ENGINE
Characteristics of the intake throttle

Fully closed angle flow
rate before adjustment
Fully closed learning
Mechanical valve position Fully closed
operating angle adjustment angle
Mechanical valve Fully closed control
maximum 4° angle
operating angle 3.18° Excluding overshoot,
undershoot and the
1°MIN dispersion in the
5°
10
1.6 system side

2°
.8
°
8Max
2
94
.8
82
ax
9M
Valve R2
ø1
closing
0
ø55 + 0.1
direction
ø56± 0.5
0
5
0.
C
Fully open control

position
Maintain 9.88 degrees or more from Valve fly-out range
the fully open position of machine
(Excluding overshoot, undershoot and
the dispersion in the system side) 044868-00EN00
Figure 4-2-115
Characteristics graph
VT A 1 (0.040V/2)
(V)
Output voltage
5
DC5V impressed 4
Between VC-E2
3
2
1
0.600V 0
20 40 60 80 95
Fully open
Fully closed
Valve opening (°)
95°(Mechanical (98°: Before

operating angle) adjustment)
044867-00EN00
Figure 4-2-116
4-2-60 172663 0BKC2-EN0060

4. ENGINE
4-3 Fuel System

and review the Safety Statements section on
page 4-1-1.
4-3-1 172663 0BKC2-EN0060

4. ENGINE
4-3-2 System Structure
Rail pressure sensor Rail Relief valve
Supply pump Main filter
Intake metering
valve
Fuel feed pump

(electromagnetic)
Fuel cooler
(optional equipment
Pre-filter on the machine side) Injector
Crank speed sensor
ECU
Gear speed sensor
Fuel tank Accelerator sensor

(optional)
Flow of intake
Flow of injection fuel Flow of electrical signal
/return fuel
037193-00EN01
Figure 4-3-1
■ Supply pump
The fuel passes the pre-filter and is pressure-fed by a fuel feed pump to the main filter, then it arrives at the
supply pump. The ECU controls the opening of the intake metering valve and adjusts the fuel intake volume
so that the rail pressure is at the target value. The fuel pressurized in the supply pump is fed to the rail.
■ Rail
A pressure of up to 160 MPa is accumulated in the rail. The rail is equipped with a rail pressure sensor
and it sends information to the ECU. In the case of an abnormal increase in the rail pressure, the
mechanical relief valve (pressure limiter valve) opens to prevent the pressure increase.
■ Injector
The ECU controls the injector to maintain optimum injection volume and injection timing and injects the
high pressure fuel accumulated in the rail into the cylinder.
Each injector has its unique correction data to optimize the injection volume. The correction data can be
found on the top of the injectors. The correction data is written to the ECU, and the ECU corrects the
injection volume based on the correction data. Therefore, it is necessary to write the correction data to the
ECU when the injector or ECU is replaced. For details, refer to the SMARTASSIST DIRECT (SA-D)
Operation Manual. Never touch the electric wiring with your hands when the key switch is in the “ON”
position. High-voltage current flows in the injector.
4-3-2 172663 0BKC2-EN0060

4. ENGINE
■ Crank rotation sensor and gear speed sensor

The crank rotation sensor is equipped on the flywheel side and the gear speed sensor is equipped on the
gear side. Based on these 2 sensor outputs, the ECU recognizes the engine speed and each piston
position.
■ ECU
Based on the information from each sensor, ECU determines optimum injection volume, injection timing
and rail pressure, and controls the intake metering valve of the supply pump and injector. It also monitors
the occurrence of system abnormality at all times. If an abnormality is detected, it notifies the operator and
controls the safe running condition of the system.
4-3-3 172663 0BKC2-EN0060

4. ENGINE
4-3-3 Fuel System Diagram
Pressure sensor
Rail
Pressure control valve
Supplier pump
Fuel filter
Fuel feed pump
Injectors
Various sensors
Fuel filter/water
separator
Fuel tank
Engine Engine Accelerator Turbocharger Intake Cooling
ECU speed speed pedal boost temperature water
(crank) (cam) temperature
EGR Flow of fuel (intake)

Starting aid Flow of fuel (high pressure)
Starter Flow of fuel (return)
Instrument panel Flow of electrical signal
038347-00EN06
Figure 4-3-2
4-3-4 172663 0BKC2-EN0060

4. ENGINE
4-3-4 Fuel System Components
8 6
9
1
10
5 11
071922-00X00
1 – High-pressure fuel injection lines 6 – Common rail

(Common rail - Injector) 7 – High-pressure fuel injection lines
2 – Fuel injector (Supply pump - Common rail)
3 – Supply pump 8 – Pressure limiter valve
4 – Fuel filter 9 – Pressure sensor
5 – Fuel filter bracket 10 – Intake manifold
11 – Collector
Figure 4-3-3
4-3-5 172663 0BKC2-EN0060

4. ENGINE
Removal of Injector 2
1. If there is any additional equipment such as a 1
intake duct (for engines with turbocharger) or
electric wiring stay above the injectors, remove A
it in advance.
2. Remove the coupler (1, Figure 4-3-4) from the
upper part of the injectors and place them
aside.
1 045207-00X01
Figure 4-3-6
4. Removing the high-pressure fuel injection lines
(Injector - Common rail)
1- Clean around the cap nuts on both the
injector and rail sides, using a brush or
aspirator. (Figure 4-3-7)
043938-00X02
Figure 4-3-4
3. Remove the fuel return hose (1, Figure 4-3-5)
from the injector. Pull out the fuel return hose
connector (back leak rail connector)
(2, Figure 4-3-6) vertically while fully pressing
the retaining ring (clip) (1, Figure 4-3-6)
attached on the top of the injector in the
direction of the arrow A (Figure 4-3-6). Do not
hold the hose. This may damage the hose. Do 043942-00X02
not reuse the removed clips.

Figure 4-3-7
1 2- Loosen the cap nut (4, Figure 4-3-8) of the
high-pressure pipe (2, Figure 4-3-8) on the
injector side. Here, loosen the cap nut held
with a spanner (1, Figure 4-3-8) or the like
to prevent the inlet connector (3, Figure 4-
3-8) from rotating together.
1 2 3 4
043939-00X02
Figure 4-3-5
061319-00X00
Figure 4-3-8
4-3-6 172663 0BKC2-EN0060

4. ENGINE
3- Loosen the cap nut (Figure 4-3-7) of the Reassembly of injector

high-pressure pipe on the common rail side
in the same manner. 1. Reassembly of injector
Insert the injector into the head by using the
4- Loosen and remove the cap nut by hand new injector seat (gasket).
while pushing the high-pressure pipe on
both injector side and rail side against the NOTICE
mounting surfaces.
• If you reuse the injector, be sure to reinstall it
5- Remove the high-pressure pipe. to the original cylinder.
6- Cover the sheet part of the high-pressure • When replacing the injector, replace it in the
pipe on the injector side of which the high- assembly.
pressure pipe is removed with plastic bags
after cleaning the part using a vacuum or • If you replace the injector, it is required to
the like. write the correction value of each injector to
E-ECU.
5. Loosen the injector fixture retainer bolt
(1, Figure 4-3-9) (M8), and remove the • If rewriting is not correctly done, the engine
retainer (2, Figure 4-3-9). performance cannot be guaranteed.
6. Remove the injector (3, Figure 4-3-9) and • Rewrite the correction value using
injector seats (gaskets) (4, Figure 4-3-9). SMARTASSIST-DIRECT (SA-D).
• The correction value is written on the injector.
1
2. Reassembly of injector fixture retainer
2 1- Reinstall the injector fixture retainer.
Temporarily tighten the bolt by hand at this
time.
3
3. Reassembly of high-pressure fuel injection
lines (Injector - Common rail)
4
CAUTION
For high-pressure pipe, use a new one. If you
reuse it, the displacement of the working
face may occur, causing the fuel to leak.
1- Before reinstalling the high-pressure pipe,

apply fuel to the cap nut thread portion.
072427-00X00
2- Temporarily tighten the clamp of the high-

Figure 4-3-9 pressure pipe.
3- Be sure to fit and fix the high-pressure pipe
NOTICE on the injector side to the sheet part by
• Do not reuse the injector seats (gaskets). hand, and temporarily tighten the cap nut by
hand.
• Separate the injectors by each cylinder (mark
them). 4- Next, securely fit the high-pressure pipe on
the rail side to the sheet part by hand, and
• Clean the removed injectors and cover them temporarily tighten the cap nut so as to
with a vinyl bag. rotate smoothly by hand.
• Never disassemble the injector. If you change 5- Fully tighten the clamp.
the injector to the new one must be changed
with whole injector.
4-3-7 172663 0BKC2-EN0060

4. ENGINE
4. Tighten the injector fixture retainer bolt to • Rewrite the correction value using YANMAR
specification. Diagnostic Tool, SMARTASSIST-DIRECT
(SA-D).
18.0 - 20.9 ft·lb
Tightening torque • The correction value is written on the injector.
(24.4 - 28.4 N·m;
for M8 bolts
2.5 - 2.9 kgf·m) • If the correction value of the injector is not
correctly written, not only the engine
5. Tighten the cap nut of the high-pressure pipe performance cannot be guaranteed, but the
with a predetermined torque while holding the engine may also not comply with emission
inlet connector on the injector side using a control regulations.
spanner or the like.
6. Tighten the cap nut of the high-pressure pipe
on the rail side with a predetermined torque. Removal of Common Rail
19.5 - 23.2 ft·lb
1. Removal of high-pressure fuel injection lines
Tightening torque The procedure for removal of high-pressure
(26.5 - 31.4 N·m;
for cap nuts (injector side) pipe between the injector and common rail is
2.7 - 3.2 kgf·m)
as the same procedure as removal of injectors.
21.7 - 25.3 ft·lb
Tightening torque
(29.4 - 34.3 N·m;
However, it is not necessary to remove the
for cap nuts (rail side) wiring coupler above the injectors and the fuel
3.0 - 3.5 kgf·m)
return line when removing the common rail.
7. Reinstall the fuel return pipe. Follow the same procedure to remove the high-
Push the connector vertically with the retaining pressure fuel injection line between the
ring (clip) of the injector pushed in the direction common rail and the supply pump.
of arrow A. Here, apply diesel oil to the O-ring at 2. Remove the leak piping (2, Figure 4-3-11)
the mounting area of the connector to prevent it from the pressure limiter (1, Figure 4-3-11).
from being worn. (Do not use lubricating oil
since it contains metal composition such as 1
zinc.) 4
2
3
A 043940-00X03
Figure 4-3-11
3. Remove the wiring coupler of the pressure
sensor (3, Figure 4-3-11).
4. Removal of common rail
045206-00X01
Remove the 2 pieces of M8 (4, Figure 4-3-11)
Figure 4-3-10 bolts that attach the common rail, and remove
the rail body.
8. Reinstall the injector wiring coupler.
NOTICE
NOTICE • Loosen the bolts while securely holding the
• If you replace the injector, it is required to rail body by hand not to drop it.
write the correction value of each injector to • Hold the rail body without touching the
E-ECU. sensors.
• If rewriting is not correctly done, the engine
performance cannot be guaranteed.
4-3-8 172663 0BKC2-EN0060

4. ENGINE
Reassembly of Common Rail CAUTION

1. Reassembly of common rail body
Temporarily tighten the 2 pieces of M8 bolts by
reuse it, the displacement of the working
hand while securely holding the common rail
body by hand. Then, tighten the bolts to
specification.
16.7 - 20.9 ft·lb

Tightening torque
(22.6 - 28.4 N·m;
for M8 bolts
2.3 - 2.9 kgf·m)
apply fuel to the cap nut thread portion.
2. Installing the high-pressure fuel injection lines 2- Next, securely fit the high-pressure pipe
(1) (Common rail - injector) both on the pump side and rail side to the
sheet part by hand, and temporarily tighten
CAUTION the cap nut so as to rotate smoothly by
hand.
reuse it, the displacement of the working 3- Tighten the cap nuts to specification.
Tightening torque
for cap nut (rail side) 21.7 - 25.3 ft·lb
(29.4 - 34.3 N·m;
Tightening torque 3.0 - 3.5 kgf·m)
for cap nut (pump side)
apply fuel to the cap nut thread portion. 4. Reinstall the leak piping from the pressure
2- Temporarily tighten the clamp of the high- limiter.
pressure pipe.
NOTICE
3- Be sure to fit and fix the high-pressure pipe
on the injector side to the sheet part by Do not reuse the gaskets.
hand, and temporarily tighten the cap nut by
hand. 5. Reinstall the wiring coupler of the pressure
4- Next, securely fit the high-pressure pipe on sensor.
the rail side to the sheet part by hand, and 6. Replace attached parts of the rail
temporarily tighten the cap nut so as to Spare parts for the rail pressure sensor
rotate smoothly by hand. (1, Figure 4-3-12) and the pressure limiting
5- Fully tighten the clamp. valve (2, Figure 4-3-12) are available for
6- While holding the inlet connector of the replacement. See the below table for the part
injector side using a spanner or other tool, number and the tightening torque.
tighten the cap nut to the specified torque. Tightening
Part name Part No.
7- Finally tighten the cap nut of the rail side to torque
the specified torque. Rail pressure
66.4 - 73.8 ft·lb
129A00-57100 (90 - 100 N·m;
sensor
19.5 - 23.2 ft·lb 9.2 - 10.2 kgf·m)
Tightening torque
(26.5 - 31.4 N·m; 70.1 - 77.4 ft·lb
for cap nut (injector side) Pressure limiting
2.7 - 3.2 kgf·m) 129A00-57200 (95 - 105 N·m;
valve (with O-ring)
21.7 - 25.3 ft·lb 9.7 - 10.7 kgf·m)
Tightening torque
(29.4 - 34.3 N·m; O-ring for pressure
129A00-57210 –
for cap nut (rail side) limiting valve
3.0 - 3.5 kgf·m)
3. Installing the high-pressure fuel injection lines

(2) (Supply pump - common rail)
4-3-9 172663 0BKC2-EN0060

4. ENGINE
Removal of Supply Pump

2
1. Remove the wiring coupler of the fuel pressure
sensor.
2. Remove the wiring coupler of the suction
control valve (SCV).
3. Remove the fuel supply pipe (supply pump
inlet) from the fuel filter (supply pump intake).
1
055191-00X00
Figure 4-3-12
From fuel tank To fuel tank
Injector overflow
Rail overflow
Supply pump
intake
Supply pump
overflow
043943-00E00
Figure 4-3-13
NOTICE
The fuel in the pipe may possibly spill at this
time. Prepare a fuel container before its removal.
4. Remove the fuel return pipe (supply pump

outlet) to the fuel filter (supply pump overflow).
5. Remove the return pipes from the common rail
and injector (rail overflow and injector
overflow).
NOTICE
Do not reuse either gasket.
4-3-10 172663 0BKC2-EN0060

4. ENGINE
6. Remove the fuel filter together with the Reassembly of Supply Pump
mounting base from the engine as required.
1. Reassembly of supply pump body
7. Removal of high-pressure pipe Align the position of the supply pump drive
(Supply pump - common rail) shaft key (pin) to the drive gear position, and
1- Clean around the cap nuts on both the reinstall the supply pump to the gear case.
pump and rail sides, using a brush or Reinstall the supply pump with the 3 pieces of
aspirator. M8 nuts.
2- While pressing and holding the pipes of the
rail and pump sides respectively against the NOTICE
bearing surface by hand, loosen the cap nut
using a tool. Be sure to apply oil to the O-ring at the time of
installation so that is does not roll up.
3- After that, while pressing the pipes of the rail
and pump sides respectively against the
bearing surface by hand, loosen and
remove the cap nut by hand. 16.7 - 20.9 ft·lb
Tightening torque
(22.6 - 28.4 N·m
4- Remove the high-pressure pipe. for M8 nuts
; 2.3 - 2.9 kgf·m)
5- Clean the removed seat portions of the rail
inlet with an aspirator or the like and cover 2. With the special M18 nuts, reinstall the supply
them with a vinyl bag. pump drive gear to the supply pump drive
shaft.
8. Remove the supply pump cover (drive gear) of
the gear case. 55.3 - 62.7 ft·lb
Tightening torque
9. Remove the supply pump drive gear nut (M18). (75 - 85 N·m
for M18 nut
; 7.7 - 8.7 kgf·m)
NOTICE
Be sure to put an alignment mark between the NOTICE
supply pump drive gear and the idle gear. Do not
Make sure that the alignment mark with the idle
rotate the crankshaft of the engine after putting
gear is not misaligned.
the mark.
NOTICE
10. Extract the supply pump drive gear by using Make sure that painting does not get into the
the gear extraction tool. coupler while reinstalling the coupler.
NOTICE
Be sure to use the gear extraction tool. 3. Reinstall the supply pump cover
16.7 - 20.9 ft·lb

Tightening torque
(22.6 - 28.4 N·m
11. Remove the supply pump nut (M8 - 3 pieces), for M8 bolts
; 2.3 - 2.9 kgf·m)
and remove the supply pump.
NOTICE
• Never disassemble the supply pump.
• If you change the supply pump to the new
one must be changed with whole pump.
4-3-11 172663 0BKC2-EN0060

4. ENGINE
4. Reassembly of high-pressure pipe Part name Part No. Tightening torque

(Supply pump - common rail)
Fuel
19.2 - 22.1 ft·lb
CAUTION temperature
129A00-51200 (26 - 30 N·m
sensor (with
; 2.7 - 3.1 kgf·m)
For high-pressure pipe, use a new one. If you gasket)
reuse it, the displacement of the working Fuel metering
face may occur, causing the fuel leaks. valve (suction 2.2 - 3.0 ft·lb
control valve) 129A00-51100 (3.0 - 4.0 N·m
(with seal ring ; 0.31 - 0.41 kgf·m)
1- Before reinstalling the high-pressure pipe, and O-ring)
apply fuel to the cap nut thread portion. Fuel metering
129A00-51110 -
2- Securely seat and fix the pipes of the pump valve seal ring
and rail sides respectively on the seat part Fuel metering
by hand, and temporarily tighten the cap nut 129A00-51120 -
valve O-ring
so as to rotate smoothly by hand. Fuel metering
129A00-51130 -
3- Tighten the cap nuts to specification. valve fixing bolt
Tightening torque
for cap nuts (rail side) 21.7 - 25.3 ft·lb 1
(29.4 - 34.3 N·m
Tightening torque ; 3.0 - 3.5 kgf·m)
for cap nuts (pump side)
5. Reinstall the fuel filter (M10 - 2 pieces).

2
25.8 - 31.7 ft·lb
Tightening torque for
(35 - 43 N·m
M10 bolts
; 3.6 - 4.4 kgf·m)
6. Reinstall the common rail and the return pipe

from the injector.
7. Reinstall the return pipe from the supply pump.
8. Reinstall the fuel supply pipe (supply pump
inlet) from the fuel filter.
9. Reinstall the wiring coupler of the fuel
temperature sensor.
10. Reinstall the wiring coupler of the SCV.
NOTICE
055192-00X00
Figure 4-3-14
Be sure to perform priming the engine before
starting. If air is mixed to the fuel, seizure to the
supply pump and the injector may result.
11. Replace attached parts of the supply pump

Spare parts for the fuel temperature sensor
(1, Figure 4-3-14) and the fuel metering valve
(suction control valve) (2, Figure 4-3-14) are
available for replacement. See the below table
for the part number and the tightening torque.
4-3-12 172663 0BKC2-EN0060

4. ENGINE
4-4 Cooling System

page 4-1-1.
4-4-1 172663 0BKC2-EN0060

4. ENGINE
4-4-2 Introduction
This section of the Service Manual describes the procedures necessary to service the TNV engine
coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model
engines. For specific part detail, see the parts catalog for the engine you are working on.
4-4-3 Cooling System Diagram
10
11
8
9
3
5
FULL
LOW
071835-00X00
1 – Cylinder head 7 – Cylinder block

2 – Thermostat 8 – EGR cooler
3 – Engine coolant pump 9 – EGR cooler inlet side hose
4 – Radiator 10 – EGR cooler outlet side hose
5 – Coolant recovery tank 11 – Exhaust throttle*2
6 – Engine oil cooler*1
*1:Not standard on all models.
*2: Equipped to some of the engines.
Figure 4-4-1
4-4-2 172663 0BKC2-EN0060

4. ENGINE
4-4-4 Engine Coolant Pump Components
1
2
3
5
4
8 14
7
9
12
10
11
13
K0000031A-01X
1 – Thermostat cover 8 – Gasket

2 – Thermostat cover gasket 9 – Engine coolant pump gasket
3 – Thermostat 10 – V-belt
4 – Thermostat O-ring 11 – Engine coolant pump V-pulley
5 – Special O-ring 12 – Spacer
6 – Engine coolant pump 13 – Engine coolant fan
7 – Temperature switch 14 – Water temperature sensor
(Electronically controlled engine)
Figure 4-4-2
4-4-3 172663 0BKC2-EN0060

4. ENGINE
4-4-5 Engine Coolant System Check 4-4-6 Engine Coolant Pump
Check the engine coolant system for leakage. Removal of Engine Coolant Pump
1. With the radiator properly filled, install a cooling Verify the condition of the engine coolant pump
system tester (1, Figure 4-4-3). before disassembling it from the engine. Check the
engine coolant pump shaft bearing for abnormal
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these
conditions are present.
CAUTION
Pinch Hazard!
Carefully rotate the alternator
1 K0000577AX toward the cylinder block while
loosening the V-belt. Failure to
Figure 4-4-3 comply may result in minor or
moderate injury.
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05
kgf/cm²) to the cooling system. If the pressure
reading drops, the engine coolant system is
NOTICE
leaking. Identify the source of the leak and If the engine coolant pump must be replaced,
repair it. replace the engine coolant pump as an assembly
only. Do not attempt to repair the engine coolant
pump or replace individual components.
NOTICE
Make sure the engine and engine coolant are not
hot.
1. Before removing the engine coolant pump or

thermostat, it will be necessary to drain the
engine coolant. Drain the coolant into a clean
container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
2. Remove the radiator cap (1, Figure 4-4-4).
3. Remove the drain plug or open the drain cock
(2, Figure 4-4-4) at the lower portion of the
radiator and drain the coolant.
4-4-4 172663 0BKC2-EN0060

4. ENGINE
FULL
LOW
043936-00X00
2 K0000074A
Figure 4-4-6
Figure 4-4-4 5. Loosen the alternator mounting bolts. Loosen
and remove the V-belt and rotate the alternator
4. Drain the coolant from the engine block.
away from the engine and out of the way.
• On models equipped with an oil cooler,
6. Remove the engine coolant fan guard (if
remove the coolant hose (1, Figure 4-4-5) at
equipped), engine coolant fan (1, Figure 4-
the oil cooler.
4-7), spacer (2, Figure 4-4-7) and engine
coolant pump V-pulley (3, Figure 4-4-7).
2 1
4
043935-00X00
Figure 4-4-5
3
K0000163B
• On models not equipped with an oil cooler,
remove the coolant drain plug (1, Figure 4- Figure 4-4-7
4-6) from the engine block.
7. Disconnect the coolant hoses and the
temperature switch lead wire from the engine
coolant pump.
8. Remove the engine coolant pump (4, Figure 4-
4-7). Discard the gasket.
4-4-5 172663 0BKC2-EN0060

4. ENGINE
Disassembly of Engine Coolant Cleaning and Inspection

Pump
■ Temperature switch
1. Remove the thermostat cover (1, Figure 4-
1. Check for proper operation of the temperature
4-8). Discard the gasket.
switch. Connect a continuity light or ohmmeter
to the temperature switch. Connect one lead to
the terminal of the switch (1, Figure 4-4-9) and
the other lead to the metal portion of the switch
1
(2, Figure 4-4-9).
3 1
4 2
3
K0000576AX
Figure 4-4-9
2. Place the temperature switch and an accurate
thermometer (3, Figure 4-4-9) in engine
K0000267AX coolant.
3. Slowly increase temperature of the fluid using
Figure 4-4-8
an external heat source.
2. Remove the thermostat (2, Figure 4-4-8). 4. The temperature switch is operating properly if
Discard the O-ring. Remove the temperature the continuity light or ohmmeter indicates
switch (3, Figure 4-4-8) and gasket continuity when the fluid temperature reaches
(4, Figure 4-4-8). Discard the gasket. 225 °F - 235 °F (107 °C - 113 °C).
4-4-6 172663 0BKC2-EN0060

4. ENGINE
■ Water temperature sensor ■ Thermostat

1. Inspect the water temperature sensor to make 1. Check for proper operation of the thermostat.
sure that it is properly operating. As shown in Place the thermostat (1, Figure 4-4-11) and an
the following figure, connect an electric resistor accurate thermometer (2, Figure 4-4-11) in
to the coupler of the water temperature sensor warm water.
(1, Figure 4-4-10).
2 1
K0000578A
Figure 4-4-11
2. Slowly increase the temperature of the water
using an external heat source.
3. The thermostat is operating properly if it starts
Figure 4-4-10
to open at the temperature value stamped on
2. Dip the water temperature sensor and an the flange of the thermostat, and fully opens as
accurate thermometer (2, Figure 4-4-10) into the temperature of the water is increased.
the cooling water.
■ Radiator cap
3. Measure the electric resistance value while
slowly raising the cooling water temperature 1. Check for proper operation of the radiator cap.
using an external heat source. Install the radiator cap (1, Figure 4-4-12) on a
cooling system tester.
4. The resistance value at each of the following
temperatures is within the permissible range
specified, the water temperature sensor is
correctly operating.
Cooling water temperature

Resistance (kΩ)
(°C)
20 2.45 +0.14
-0.13 1 K0000579A
80 0.318 ± 0.008
100 (0.1836) Figure 4-4-12
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05
kgf/cm²) to the radiator cap. The radiator cap
relief valve must open within the specified
range.
4-4-7 172663 0BKC2-EN0060

4. ENGINE
Reassembly of Engine Coolant 3. Inspect and reinstall the coolant hoses and the
temperature switch lead wire.
Pump
4. Reinstall the engine coolant pump V-pulley
1. Reinstall the thermostat (1, Figure 4-4-13) and (1, Figure 4-4-14), spacer (2, Figure 4-4-14)
a new O-ring. engine coolant fan (3, Figure 4-4-14) and
engine coolant fan guard (if equipped).
2
2 3
5 1
4
3
1
K0000163C
Figure 4-4-14
5. Inspect the condition of the V-belt. There must
be clearance (1, Figure 4-4-15) between the
V-belt and the bottom of the pulley groove. If
K0001623AX
there is no clearance (2, Figure 4-4-15)
Figure 4-4-13 between the V-belt and the bottom of the pulley
groove, replace the V-belt.
2. Reinstall the thermostat cover (2, Figure 4-
4-13) and a new gasket. Tighten the
thermostat cover bolts.
3. Reinstall the temperature switch (3, Figure 4-
4-13) and a new gasket (4, Figure 4-4-13).
2
Installation of Engine Coolant Pump 1
1. Position the engine coolant pump on the
engine and install a new gasket. Install a new K0000584
special O-ring (5, Figure 4-4-13) on assembly

between the engine coolant pump and the Figure 4-4-15
joint.
6. Reinstall the V-belt. Tighten the V-belt to the
NOTICE proper tension.
7. Reinstall and tighten the drain plug or close the
Use a new special O-ring between the engine
drain cock in the radiator. Reinstall and tighten
coolant pump and the joint. Be sure to use the
the engine block drain plug or reconnect the
special O-ring for each engine model. Although
coolant hose at the oil cooler.
the O-ring dimensions are the same as a
commercially available O-ring, the material is
different.
2. Reinstall the engine coolant pump bolts.

Tighten the bolts.
4-4-8 172663 0BKC2-EN0060
4. ENGINE
8. Fill the radiator and engine with engine coolant.
NOTICE
• Only use the engine coolant specified. Other
engine coolants may affect warranty
coverage, cause an internal buildup of rust
and scale and / or shorten engine life.
• Prevent dirt and debris from contaminating
the engine coolant. Carefully clean the
radiator cap and the surrounding area before
you remove the cap.
• Never mix different types of engine coolants.
This may adversely affect the properties of
the engine coolant.
4-4-9 172663 0BKC2-EN0060

4. ENGINE
4-5 Lubrication System

4-5-1 172663 0BKC2-EN0060

4. ENGINE
4-5-2 Introduction
This section describes the procedures necessary to service Trochoid oil pumps.
4-5-3 Lubrication System Diagram
Oil Filter
Turbocharger*
Bypass Valve
Oil Cooler* Fuel

Injection Pump
Oil Pressure
Switch
Cylinder Body - Main Gallery

Pressure
Regulator Valve
Idle Gear Camshaft Crank
Oil Pump Shaft Bearing Journal
Piston Cooling Rocker Arm Crank Pin

Oil Suction Pipe Nozzles* Bearing
Strainer
Rocker Arm
Tappet
Cam Face
Oil Pan
0000042
Figure 4-5-1
Note: Items marked * are not standard equipment on all models.
4-5-2 172663 0BKC2-EN0060

4. ENGINE
4-5-4 Checking Engine Oil Pressure 4-5-5 Oil Pump Components
Perform an engine oil pressure check if there is The oil pump on these model engines is located in
any indication of low oil pressure such as the oil the front gear case and is driven by the same gear
pressure indicator is on or the oil pressure gauge train that drives the camshaft and fuel injection
indicates low oil pressure. pump. You must remove the front gear case cover
to gain access to the oil pump.
1. Disconnect the wire lead from the oil pressure
switch or sending unit (Figure 4-5-2, (1)).
3 7 1 2 6
1
5 4
043933-00X00
1 – Body
Figure 4-5-2 2 – Shaft
3 – Inner rotor
2. Remove the oil pressure switch.
4 – Outer rotor
3. Install a mechanical oil pressure gauge in the 5 – Cover
oil pressure switch port. 6 – Drive gear
4. Start the engine: 7 – Pressure regulator valve
• If the mechanical oil pressure test gauge Figure 4-5-3

indicates good oil pressure, replace the faulty
oil pressure switch or sending unit, or faulty Disassembly of Oil Pump
machine oil pressure gauge in instrument
panel. NOTICE
• If the mechanical oil pressure test gauge If the oil pump must be replaced, replace it as an
indicates low oil pressure, troubleshoot the assembly only. Do not replace individual
lubrication system to locate the cause of the components.
low oil pressure. See Failure Diagnostic List on
page 4-11-5. Repair as necessary.
1. Remove the cooling water fan guard (if
equipped), cooling fan (Figure 4-5-4, (3)),
spacer (Figure 4-5-4, (2)), cooling water pump
V-pulley (Figure 4-5-4, (1)), and V-belt.
4-5-3 172663 0BKC2-EN0060

4. ENGINE
Cleaning and Inspection

Clean the lubricating oil pump, pressure regulator
valve (Figure 4-5-3, (7)), and rotor inserting
2 3 portion. Check the parts for wear or flaw. Replace
the parts with new ones as needed.
NOTICE
• Never overfill the engine with engine oil.
• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.
1
K0000163C
■ Check outer rotor outside clearance

Figure 4-5-4 Inspect the outside diameter clearance of the outer
2. Remove the crank shaft pulley and gear case rotor. To inspect this, insert a feeler gauge between
cover. See Removal of timing gear case cover the outer rotor (Figure 4-5-6, (1)) and the
on page 4-2-28. lubricating oil pump body (Figure 4-5-6, (2)).
3. Remove the lubricating oil pump assembly
mounting bolts. Remove the lubricating oil
pump assembly (Figure 4-5-5, (1)) from the 1
gear case flange (Figure 4-5-5, (2)).
4. You can remove by hand the lubricating oil
pump cover (Figure 4-5-3, (5)) and outer rotor
(Figure 4-5-3, (4)).
Figure 4-5-6
Record the measurement(s) and see "3-2 Engine
Service Standard" section for the service limits.
2
■ Outer rotor to inner rotor tip clearance
Inspect the tip clearance between the outer and
inner rotors. To inspect this, insert a feeler gauge
between the inner rotor tooth tip (Figure 4-5-7, (1))
1 and the outer rotor tooth tip (Figure 4-5-7, (2)),
043934-00X00 and measure the clearance.
Figure 4-5-5
4-5-4 172663 0BKC2-EN0060

4. ENGINE
■ Check rotor shaft clearance

Inspect the rotor shaft clearance. Measure the
outside diameter of the rotor shaft (Figure 4-
5-9, (1)) and the inside diameter of the cover.
1
Determine the clearance by subtracting the outside
diameter of the rotor from the inside diameter of
the cover.
Figure 4-5-7
Figure 4-5-9
Service Standard" section for the service limits. for Record the measurement(s) and see "3-2 Engine
the service limits. Service Standard" section for the service limits. for
the service limits.
■ Check outer rotor side clearance
Inspect the side clearance between the lubricating Reassembly of Oil Pump
oil pump body and the outer rotor. To measure the 1. Apply clean lubricating oil to the lubricating oil
side clearance, use a straight edge and feeler pump body and inner rotor assembly as well as
gauge (as shown in Figure 4-5-8) or a depth to the outer rotor.
micrometer.
2. Insert the outer rotor into the lubricating oil
pump body and inner rotor assembly and
install the cover.
3. Replace the packing with new one.
4. Install the lubricating oil pump assembly to the
gear case by tightening the bolts with the
specified torque.
5. Install the gear case cover. For more
information, See Installation of gear case cover
on page 4-2-50.
6. Install the crank shaft pulley.
7. Install the cooling water pump V-pulley
(Figure 4-5-10, (1)), spacer (Figure 4-
5-10, (2)), cooling water fan (Figure 4-
5-10, (3)), and fan guard (if equipped).
Figure 4-5-8
Service Standard" section for the service limits. for
the service limits.
4-5-5 172663 0BKC2-EN0060

4. ENGINE
2 3
1
K0000163C
Figure 4-5-10
8. Install the V-belt. Adjust the belt to uniform
tensile strength.
4-5-6 172663 0BKC2-EN0060

4. ENGINE
4-6 Starter Motor

page 4-1-1.
4-6-2 Introduction
This section of the Service Manual covers the

servicing of the starter motor. For specific part
detail, see the Yanmar Parts Catalog for the engine
you are working on.
4-6-1 172663 0BKC2-EN0060

4. ENGINE
4-6-3 Starter Motor Specifications
Yanmar Part Number 129242-77010

Mfg. Part Number S114-883
Nominal Output 2.3 HP (1.7 kW)
Weight 7.5 lbs (3.4 kg)
Revolution Direction (As Viewed From Pinion) Clockwise
Engagement System Magnetic Shift
Terminal Voltage / Current 11 V / 90 A or less
No-load
Revolution 2300 rpm (min-1)
Terminal Voltage / Current 8 V / 370 A or less
Loaded
Torque 11.1 ft⋅lbf (15.1 N⋅m) and over
Clutch System Overrunning
Pinion Projection Voltage at 212°F (100°C) 8 V or less
Pinion DP or Module / Number of Teeth DP10/12
4-6-2 172663 0BKC2-EN0060

C30R-3 SVM.book
Engine does not start? NO

Is battery fully charged • Charge or replace battery.
and terminals clean? • Clean terminals.
YES
3 ページ
YES
Inspect wiring up to solenoid switch
Is starter motor solenoid and repair if necessary.
NO • Key switch
switch actuating sound
heard? • Safety relay
• Solenoid switch assembly
NO NO • Electrical connections
２０１８年３月８日
Does engine crank? Is starter motor operating? YES

木曜日
YES
• Adjust / pinion projection length.
• Inspect shift lever for deformation,
NO return spring for fatigue and pinion
4-6-4 Starter Motor Troubleshooting
Pinion and ring gear

meshing normal? for sliding.
YES • Repair meshing between pinion and
ring gear or replace as needed.
YES
午前１１時４４分
Connect M terminal of starter NO • Inspect brush and replace if worn.

Pinion roller clutch or motor directly to battery. • If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.
4-6-3
YES
Solenoid switch assembly If starter motor becomes wet, replace solenoid switch
contact defective. Repair assembly even if function is normal.
4. ENGINE
NO or replace.
(slow revolution) NO
Is revolution normal? Is battery fully charged • Charge or replace battery. If a problem occurs:
and terminals clean? • Clean terminals. Immediately disconnect battery negative terminal
or turn battery cut off switch to OFF position.
172663 0BKC2-EN0060
YES YES
Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES
Does engine turn when YES Repair or replace Repair or replace key switch, starting
starter motor is replaced? starter motor. motor relay or magnetic switch assembly.
Slow Revolution
Inspect condition of engine.

107694-00EN00
4. ENGINE
4-6-5 Starter Motor Components
13
12 14
11
10
9
7
6
5
4
23
3
2
1 15
18
22
21
19
20
17
16 K0000103A
1 – Pinion shaft 13 – Magnetic switch assembly (solenoid)

2 – M4 bolts (3 used) 14 – Cover
3 – Bearing retainer 15 – M6 bolts (2 used)
4 – Pinion clutch assembly 16 – Armature assembly
5 – Return spring 17 – Field coil assembly
6 – Pinion stop 18 – Positive (+) brushes
7 – Retaining ring 19 – Negative (-) brushes
8 – Gear housing 20 – Brush holder assembly
9 – Shift lever 21 – Rear cover
10 – Torsion spring 22 – M5 through bolts (2 used)
11 – Plunger 23 – M4 bolts (2 used)
12 – Dust covers (shims)
Figure 4-6-1
4-6-4 172663 0BKC2-EN0060

4. ENGINE
4-6-6 Starter Motor Disassembly of Starter Motor

1. Loosen the M8 nut from the magnetic switch
WARNING (solenoid) assembly (Figure 4-6-3).
Shock Hazard! Disconnect the wire from the magnetic switch.
• Turn off the battery switch (if
equipped) or disconnect the
• Check the electrical harnesses for cracks,

abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
K0000104
serious injury.
Figure 4-6-3
Note: While starter motor design varies between 2. Remove the two M4 bolts (1, Figure 4-6-4)
models, the basic repair procedures are the securing the rear cover (2, Figure 4-6-4) to the
same. The following procedures are typical brush holder assembly (3, Figure 4-6-4).
and may differ from the starter being
serviced. 7
Removal of Starter Motor
1. Disconnect the battery cables at the battery,
4
negative (-) cable first.
2. Remove the electrical wires from the magnetic
1
switch assembly.
3. Remove the starter mounting bolts
(1, Figure 4-6-2). Remove the starter motor
from the flywheel housing.
1 6 5 3 2 K0000105A
Figure 4-6-4
3. Remove the two M5 through bolts (4, Figure 4-
6-4). Separate the rear cover (2, Figure 4-6-4),
field coil assembly (5, Figure 4-6-4) with the
armature assembly (6, Figure 4-6-4) from the
gear housing (7, Figure 4-6-4).
K0002126
Figure 4-6-2
4-6-5 172663 0BKC2-EN0060

4. ENGINE
4. Pull the brush springs up using a brush spring

puller. On the negative (-) side, bring the brush 1
spring into contact with the side of the brush for
lifting from the commutator surface. On the
positive (+) side, remove the brush from the
brush holder assembly (1, Figure 4-6-5). 2 4
3 K0000108A
Figure 4-6-7
8. Disassemble the dust cover (3, Figure 4-6-8)
and shift the lever (4, Figure 4-6-8) from the
1 gear housing.
K0000106A
1
Figure 4-6-5
5. Remove the brush holder assembly
(1, Figure 4-6-6) from the armature assembly
(3, Figure 4-6-6).
2 K0000109A
1
Figure 4-6-8
9. Remove the three M4 bolts (1, Figure 4-6-9)
securing the bearing retainer assembly
(2, Figure 4-6-9) to the gear housing. Remove
the bearing retainer assembly from the gear
housing.
2 3
K0000107A
Figure 4-6-6 2
6. Pull the armature assembly (3, Figure 4-6-6)

out from the field coil assembly (2, Figure 4-
6-6). 3
7. Remove the two M6 bolts (1, Figure 4-6-7)
retaining the magnetic switch assembly
(2, Figure 4-6-7) to the gear housing. Remove
the magnetic switch assembly, dust cover(s)
1
(3, Figure 4-6-7) and torsion spring K0000110A
(4, Figure 4-6-7) from the gear housing.

Figure 4-6-9
4-6-6 172663 0BKC2-EN0060

4. ENGINE
10. Remove the pinion clutch assembly Cleaning and Inspection

(3, Figure 4-6-9) from the bearing retainer
assembly. ■ Armature
11. Using a flat-blade screwdriver, remove the
Commutator surface inspection
retaining ring (1, Figure 4-6-10) from the shaft
of the pinion. If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth (Figure 4-
6-12).
1
K0000111A
Figure 4-6-10 K0000117
12. Disassemble the pinion stop (3, Figure 4-

Figure 4-6-12
6-11), return spring (4, Figure 4-6-11), pinion
clutch assembly (1, Figure 4-6-11), and pinion Measure commutator outside diameter
shaft (5, Figure 4-6-11). Measure the commutator outside diameter
(Figure 4-6-13). Replace the armature if the
4 measurement is less than the limit.
1
5
2
3
K0000112A
Figure 4-6-11
K0000113
Figure 4-6-13
See Starter Motor Specifications on page 4-6-2 for
the service limit.
4-6-7 172663 0BKC2-EN0060

4. ENGINE
Measure commutator insulation depth Armature coil continuity test

Measure the depth of the insulating material Check for continuity between the commutator
(1, Figure 4-6-14) between commutator segments segments using a multimeter (Figure 4-6-15). The
(2, Figure 4-6-14). If the depth measures less than multimeter should indicate continuity.
the limit, use a hacksaw blade (3, Figure 4-6-14)
to remove the insulating material until the depth is
within the limit.
A normal commutator condition is indicated in
(4, Figure 4-6-14). An abnormal commutator
condition is indicated in (5, Figure 4-6-14).
3 K0000114
Figure 4-6-15
If the multimeter does not indicate continuity,
replace the armature.
1 2 Armature coil insulation test

Check for continuity between a commutator
segment and the shaft or armature using a
multimeter (Figure 4-6-16). The multimeter should
4
not indicate continuity.
5 K0000118
Figure 4-6-14
the service limit.
K0000115
Figure 4-6-16
If the multimeter indicates continuity, replace the
armature.
4-6-8 172663 0BKC2-EN0060

4. ENGINE
Measure armature and commutator run-outs Field coil insulation test

Measure the armature core run-out and the Check for continuity between the field coil terminal
commutator run-out using a dial indicator and the yoke using a multimeter (Figure 4-6-19).
(Figure 4-6-17). Replace the armature if either of The multimeter should not indicate continuity.
the measurements is less than the limit.
If the multimeter indicates continuity, replace the
field coil assembly.
K0000116
Figure 4-6-17
See Starter Motor Specifications on page 4-6-2 for K0000120
the service limit.
Figure 4-6-19
■ Field coil
Measure brush length
Field coil continuity test
Measure the length of the brush (Figure 4-6-20).
Check for continuity between the field coil Replace the brush if the length is less than the
terminals using a multimeter (Figure 4-6-18). The limit.
multimeter should indicate continuity.
replace the field coil assembly.
K0000121
Figure 4-6-20
K0000119
Figure 4-6-18 the service limit.
4-6-9 172663 0BKC2-EN0060

4. ENGINE
■ Magnetic switch Series coil continuity test

If the starter motor becomes wet, replace the Check for continuity between the “S” and “M”
magnetic switch even if the magnetic switch terminals using a multimeter (Figure 4-6-22). The
assembly function is normal. multimeter should indicate continuity.
Shunt coil continuity test If the multimeter does not indicate continuity,
replace the magnetic switch.
Check for continuity between the “S” terminal and
the switch body using a multimeter (Figure 4-
6-21). The multimeter should indicate continuity.
K0000125
Figure 4-6-22
Coil resistance test

K0000124
the service limit.
Figure 4-6-21
4-6-10 172663 0BKC2-EN0060

4. ENGINE
Contact continuity test Slide the pinion clutch assembly on the shaft. It
Depress the plunger at the bottom of the magnetic should slide smoothly on the shaft (Figure 4-6-25).
switch. Check for continuity between the “B” and Rust, too much grease or damage could prevent
“M” terminals using a multimeter (Figure 4-6-23). the pinion clutch from sliding smoothly. If the pinion
The multimeter should indicate continuity. clutch assembly does not slide smoothly, clean the
shaft and pinion clutch assembly or replace the
If the multimeter does not indicate continuity, damaged component.
K0000128
Figure 4-6-25
K0000126
Ball bearing inspection
Figure 4-6-23 Rotate each ball bearing while holding the pinion
clutch assembly (Figure 4-6-26). Replace the ball
■ Pinion clutch assembly bearing if it does not rotate smoothly or has
Pinion clutch assembly inspection excessive play.
Manually rotate the pinion clutch assembly in the
drive direction (Figure 4-6-24). It should rotate
freely in the drive direction and is locked by turning
it in the opposite direction. Replace the pinion
clutch assembly if the results are different.
K0000129
Figure 4-6-26
K0000127
Figure 4-6-24
4-6-11 172663 0BKC2-EN0060

4. ENGINE
Reassembly of Starter Motor

3
1. Apply the appropriate starter bendix grease
(obtain locally) to the pinion shaft. Reassemble
the pinion shaft (5, Figure 4-6-27), pinion 2
clutch assembly (1, Figure 4-6-27), return 1
spring (4, Figure 4-6-27) and pinion stop
(3, Figure 4-6-27). Reinstall the retaining ring
(2, Figure 4-6-27) in the groove in the pinion
shaft. Slide the piston stop over the retaining 5
ring.
4
4
1 K0000268
5
Figure 4-6-28
2
5. Reassemble the magnetic switch assembly to
3 the gear housing. Pry the pinion away from the
K0000112A
gear housing to allow installation of the
Figure 4-6-27 magnetic switch assembly (Figure 4-6-29).
2. Reinstall the pinion clutch assembly into the

bearing retainer assembly.
3. Reinstall the bearing retainer assembly and
pinion assembly to the gear housing. Reinstall
and tighten the three M4 bolts.
4. Apply a small amount of high temperature
lithium grease (obtain locally) to the sliding
portions of the shift lever (1, Figure 4-6-28). K0000131
Reassemble the torsion spring (2, Figure 4-

6-28), shift lever and dust cover(s) Figure 4-6-29
(3, Figure 4-6-28), plunger (4, Figure 4-6-28) 6. Secure the magnetic switch assembly to the
and magnetic switch assembly (5, Figure 4- gear housing using the two M6 bolts.
6-28).
4-6-12 172663 0BKC2-EN0060

4. ENGINE
7. Carefully install the armature assembly 12. Reinstall the two M4 through bolts (Figure 4-
(1, Figure 4-6-30) into the field coil assembly 6-32). Securely tighten the through bolts.
(2, Figure 4-6-30). Reconnect the wire to the magnetic switch
assembly. Tighten the M8 nut. Reinstall the
cover over the connection.
1
2
K0000269
Figure 4-6-30
8. Position the brush springs in brush holders K0000104
(Figure 4-6-31). Reinstall the brushes in the

brush holders. Reversing the brushes will Figure 4-6-32
cause the starter motor to turn backwards.
Check Pinion Projection Length
1. Connect the positive (+) lead from a battery to
the “S” terminal.
2. Connect the negative (-) lead to the “M”
terminal.
3. Lightly pull the pinion away from the gear
housing.
4. Turn the switch ON and measure the pinion
moving distance L in the thrust direction
K0000106A-2 (Figure 4-6-33). Perform this test within 10
seconds. See Starter Motor Specifications on
Figure 4-6-31 page 4-6-2 for the service limit.
9. Carefully install the brush holder assembly to
the armature assembly.
10. Reinstall the field coil assembly with the
armature assembly to the gear housing.
11. Reinstall the rear cover to the brush holder
assembly. Securely tighten the two bolts.
K0000132
Figure 4-6-33
4-6-13 172663 0BKC2-EN0060

4. ENGINE
5. If the measured L dimension is outside the

standard range, adjust the dust covers to
obtain the standard range. Dust covers 3
(1, Figure 4-6-34) are available in 0.020 in.
6 1
(0.5 mm) and 0.031 in. (0.8 mm) thicknesses.
M 8
2
7
1
5
4 K0002127A
Figure 4-6-35
3. Connect a wire lead between the mounting
base of the starter motor (4, Figure 4-6-35)
and the battery negative terminal (5, Figure 4-
K0000133 6-35).
4. Connect a voltmeter (7, Figure 4-6-35) to the
Figure 4-6-34
battery negative (-) terminal (5, Figure 4-6-35)
No-Load Test and the main positive (+) battery terminal
(3, Figure 4-6-35) on the starter motor.
Test the characteristics of the starter motor by
5. Install a switch (6, Figure 4-6-35) in a circuit
performing a no-load test.
between the battery positive (+) terminal
(2, Figure 4-6-35) and the starter magnetic
NOTICE switch (solenoid) terminal (8, Figure 4-6-35)
The starter motor can be damaged if operated on the starter motor.
continuously longer than 10 seconds while 6. Use a suitable tachometer to monitor the rpm
performing the no-load test. of the starter.
7. Turn the switch to the ON position. Monitor the
1. Secure the starting motor in a vise or other rpm, amperage draw and voltage. For test
suitable fixture. specifications., See Starter Motor
Specifications on page 4-6-2.
2. Connect an ammeter (1, Figure 4-6-35) in
series between the battery positive (+) terminal
(2, Figure 4-6-35) and the main positive (+)
terminal (3, Figure 4-6-35) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to
or greater than the amperage draw
specification for the starter motor being
tested.
4-6-14 172663 0BKC2-EN0060

4. ENGINE
Installation of Starter Motor

1. Reinstall the starter motor to the flywheel
housing.
2. Reinstall the starter mounting bolts
(1, Figure 4-6-36). Tighten the bolts to
specification.
K0002126
Figure 4-6-36
3. Reconnect the electrical wires to the magnetic
switch assembly (solenoid). Be sure to place
the cover over the battery positive (+) cable
connection.
4. Reconnect the battery cables at the battery.
4-6-15 172663 0BKC2-EN0060

4. ENGINE
4-7 Alternator

4-7-1 172663 0BKC2-EN0060

4. ENGINE
4-7-2 Introduction
This section of the Service Manual describes the servicing of the alternators. Yanmar Part No. 129423-
77200 alternator is used in this section to show the service procedures for the representative alternator.
For specific part detail, see the Parts Catalog for the engine you are working on.
4-7-3 Alternator Specifications
Yanmar Part Number 129052-77220

Nominal Output (13.5 Volts Heat) 55 A
Weight 6.95 lb (3.15 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 V
Rated Revolution 5000 rpm (min-1)
Operating Range 1070 to 18000 rpm (min-1)
Grounding Characteristics Negative (-) Side of Circuit
Integrated Regulator IC Regulator
Outside Diameter of Pulley 2.72 in. (69.2 mm)
Belt Shape Type A
4-7-2 172663 0BKC2-EN0060

C30R-3 SVM.book
3 ページ
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF Replace the battery indicator.
Does battery indicator and IG terminal at alternator L terminal. Does battery Battery indicator is available from
turn ON? indicator turn on? driven machine manufacturer.
ON ON Inspect rotor assembly and

brushes.
２０１８年３月８日
Start Engine.
Inspect or replace V-belt.

木曜日
Battery indicator ON.

4-7-4 Alternator Troubleshooting
Inspect alternator.
At idle, does battery Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?
Battery indicator
午前１１時４４分
OFF is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
4-7-3
Battery voltage minus
L terminal voltage is Excessive voltage drop between
greater than 0.5 volt. BAT and batt ( + side) terminal.
With engine idling,
4. ENGINE
Does battery indicator Battery indicator

come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500
172663 0BKC2-EN0060
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.
Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?
OFF
Notes: Not abnormal.
1) Use a fully charged battery
2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test
4. ENGINE
4-7-5 Alternator Components
Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.
14
12 13
10 11
8 9
6
5
29
4
3 7 19
2
16 18
1 17
25
15 28
27
26
24
23
22 0000255
21
20
1 – Nut 17 – Insulation Bushing
2 – Pulley 18 – Spring (2 used)
3 – Collar 19 – Brush Holder
4 – Front Frame Housing 20 – Rear Frame Housing
5 – Stator Assembly 21 – Bolt (2 used)
6 – Stud (2 used) 22 – Holder
7 – Front Frame Housing Bearing 23 – IC Regulator Assembly
8 – Bearing Cover 24 – Bolt (2 used)
9 – Bearing Cover Bolt (4 used) 25 – Bolt
10 – Rotor Assembly 26 – Brush (2 used)
11 – Rear Frame Housing Bearing 27 – Bolt
12 – Bearing Cover 28 – Rear Cover
13 – Thrust Washer 29 – Bolt (3 used)
14 – Thrust Washer
15 – Nut (2 used)
16 – Nut
Figure 4-7-1
4-7-4 172663 0BKC2-EN0060

4. ENGINE
4-7-6 Alternator Wiring Diagram
IG 1
IG
B
P L
2
F
IC
L
3
0.5μF
4
E
5 6 107695-00X00
1 – Key Switch 4 – Battery

2 – Charge Lamp (3.4 Watts Max.) 5 – Alternator Assembly
3 – Load 6 – IC Regulator Assembly
Figure 4-7-2
NOTICE NOTICE
Do not short-circuit the charging system between Do not remove the positive (+) battery cable from
alternator terminals IG and L. Damage to the alternator terminal B while the engine is operating.
alternator will result. Damage to the alternator will result.
NOTICE
Do not connect a load between alternator
terminals L and E. Damage to the alternator will
result.
4-7-5 172663 0BKC2-EN0060

4. ENGINE
4-7-7 Alternator Standard Output
Output current
70
Cold
60
Hot
50
temperature at 77 °F (25 °C)
13.5 V, constant ambient
40
30
20
10
0 1 2 3 4 5 6 7 8
Alternator speed (× 10³ min-1)
059574-00EN00
Figure 4-7-3
4-7-6 172663 0BKC2-EN0060

4. ENGINE
4-7-8 Alternator 2- Remove the alternator mounting nut, and

remove the alternator.
WARNING
Shock Hazard!
4
• Turn off the battery switch (if
equipped) or disconnect the 3
1
• Check the electrical harnesses for cracks, 2
071057-00X00
abrasions, and damaged or corroded
connectors. Always keep the connectors and Figure 4-7-4
terminals clean.
• Jack type
serious injury. 1- Loosen the adjuster bolt lock nut
(1, Figure 4-7-5) adjusting the tension and
the belt adjuster mounting bolt (2, Figure 4-
Removal of Alternator 7-5), and loosen the adjuster bolt
(3, Figure 4-7-5) to a certain degree.
CAUTION 2- Loosen the mounting nut (4, Figure 4-7-5)
at the bottom of the alternator. Remove the
Pinch Hazard! tightening bolt (5, Figure 4-7-5) from the
Carefully rotate the alternator alternator, and loosen the V-belt.
toward the cylinder block while Here, do not loose the spacer (6, Figure 4-
loosening the V-belt. Failure to 7-5).
comply may result in minor or
3- Remove the alternator mounting nut
moderate injury.
(4, Figure 4-7-5), and remove the
alternator.
1. Disconnect the electrical wires from the
alternator. 6
• Manual type
1- Loosen the alternator mounting nut
(1, Figure 4-7-4) and belt adjuster
mounting bolt (2, Figure 4-7-4), and
4
remove the V-belt adjuster bolt
(3, Figure 4-7-4) from the belt adjuster to 3
loosen the V-belt.
Here, do not loose the spacer (4, Figure 4- 1
7-4).
5
2 071058-00X00
Figure 4-7-5
4-7-7 172663 0BKC2-EN0060

4. ENGINE
Disassembly of Alternator
3
1. Remove the nut (1, Figure 4-7-6) from the 1
shaft of the rotor assembly. Remove the pulley 4
(2, Figure 4-7-6).
K0000258A
Figure 4-7-8
5. Remove the bolts retaining the holder
2
1 K0000256 (2, Figure 4-7-8) to the rear frame housing.
Remove the holder.
Figure 4-7-6
6. Remove the nut (3, Figure 4-7-8) retaining the
2. Remove the three bolts (1, Figure 4-7-7) insulation bushing (4, Figure 4-7-8). Remove
retaining the rear cover (2, Figure 4-7-7) to the the insulation bushing.
rear frame assembly. 7. Remove the two bolts (1, Figure 4-7-9) and
two nuts (2, Figure 4-7-9) securing the rear
frame housing to the front frame housing.
3 1 2
1
4 2
5
K0000257A
K0000265A
Figure 4-7-7 Figure 4-7-9

3. Remove the brush holder (3, Figure 4-7-7). 8. Using a press, remove the rotor assembly
Remove the brush springs (4, Figure 4-7-7) (1, Figure 4-7-10) from the front frame housing
and brushes (5, Figure 4-7-7). (2, Figure 4-7-10) and rear frame housing
4. Remove the bolt retaining the regulator (1, Figure 4-7-10).
assembly (1, Figure 4-7-8) to the holder
(2, Figure 4-7-8).
4-7-8 172663 0BKC2-EN0060

4. ENGINE
2
3
2
1
K100266A
K0000260A
Figure 4-7-10
9. Remove the stator assembly (1, Figure 4- Figure 4-7-12
7-11) from the front frame housing.
Reassembly of Alternator
4 1. If removed, reinstall the two trust washers
(3, Figure 4-7-13) and bearing cover
(2, Figure 4-7-13) in the rear frame housing.
3 Lubricate the outside diameter of a new
bearing (1, Figure 4-7-13). Press the bearing
into the rear frame housing.
2
3
K0000259A 2
1
Figure 4-7-11
10. If it is necessary to replace the bearing
(2, Figure 4-7-11) in the front frame housing,
remove the four bolts (3, Figure 4-7-11)
securing the plate (4, Figure 4-7-11) to the K0000260A
front frame housing. Remove the plate. Use a

puller to remove the bearing. Discard the Figure 4-7-13
bearing.
11. If it is necessary to replace the bearing
(1, Figure 4-7-12) in the rear frame housing,
use a puller to remove. Discard the bearing.
Remove the bearing cover (2, Figure 4-7-12)
and two thrust washers (3, Figure 4-7-12).
4-7-9 172663 0BKC2-EN0060

4. ENGINE
2. If removed, lubricate the outside diameter of a

new front frame housing bearing. Press the 2
bearing (2, Figure 4-7-14) into the front frame
housing. Reinstall the plate (4, Figure 4-7-14)
to the front housing. Tighten the four bolts
(3, Figure 4-7-14). 1
K0000265A
2
Figure 4-7-16
6. Reinstall the insulation bushing (4, Figure 4-
7-17) and nut (3, Figure 4-7-17).
1
3
1
4
K0000259A
Figure 4-7-14
3. Position the stator assembly (1, Figure 4-7-14)
on the front frame housing studs.
4. Lubricate the shaft of the rotor assembly
(1, Figure 4-7-15). Press the rotor assembly
into the front frame housing (2, Figure 4-7-15) 2
and rear frame housing (3, Figure 4-7-15).
3 K0000258A
Figure 4-7-17
1
7. Reassemble the regulator assembly
2
(1, Figure 4-7-17) to the holder (2, Figure 4-
7-17).
K100266A
Figure 4-7-15
5. Align the front frame housing with the rear
frame housing. Reinstall the two bolts
(1, Figure 4-7-16) and two nuts (2, Figure 4-
7-16).
4-7-10 172663 0BKC2-EN0060

4. ENGINE
8. Reinstall the brush holder (3, Figure 4-7-18), Installation of Alternator

springs (4, Figure 4-7-18) and brushes
(5, Figure 4-7-18). 1. Install the alternator.
9. Reattach the regulator assembly and holder to • Manual type

the rear frame housing. 1- Insert the stud bolt of the gear case to the
alternator, and temporarily tighten the
alternator mounting nut (1, Figure 4-7-20).
2- With the belt adjuster mounting bolt
1 (2, Figure 4-7-20) temporarily tightened,
3
temporarily tighten the V-belt adjuster bolt
(3, Figure 4-7-20) to the alternator.
4 2
5 3
1
K0000257A
2
Figure 4-7-18 071057-00X01
10. Reinstall the rear cover (2, Figure 4-7-18) to Figure 4-7-20
the rear frame housing with three bolts
• Jack type
(1, Figure 4-7-18).
1- Insert the stud bolt of the gear case to the
11. Reassemble the pulley (2, Figure 4-7-19) and
alternator, and temporarily tighten the
nut (1, Figure 4-7-19) to the shaft of the rotor
alternator mounting nut (1, Figure 4-7-21).
assembly. Tighten the nut.
2- With the belt adjuster mounting bolt
(2, Figure 4-7-21) temporarily tightened,
temporarily tighten the belt adjuster
tightening bolt (3, Figure 4-7-21).
2
1 K0000256
Figure 4-7-19
3
2 071058-00X01
Figure 4-7-21
2. Reconnect the electrical wires to the alternator.
Tighten the nuts to 15 - 20 in.-lb (1.7 - 2.3 N·m;
17 - 23 kgf·m).
4-7-11 172663 0BKC2-EN0060
4. ENGINE
3. Reinstall the V-belt. Tighten the V-belt to the

proper tension.
4. Start the engine. Listen for any unusual sounds
from the alternator.
NOTICE
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.
5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating
the engine.
4-7-12 172663 0BKC2-EN0060

4. ENGINE
4-8 Electronic Control System

4-8-1 172663 0BKC2-EN0060

4. ENGINE
4-8-2 System Structure
YANMAR TNV engines come with the following • Engine speed control schemes
systems: Droop control/Isochronous control/Low-idling
speed up/High-idling speed down/Auto
• Common rail system as shown in the Figure 4- deceleration
3-1 on page 4-3-2.
• Starting aid
• Exhaust Gas Recirculation (EGR) system that Auto preheating/After heating
controls the exhaust gas recirculation flow rate
depending on the engine load and speed. • Engine failure detection
• System that controls the Diesel Particulate Filter • CAN communication with the control system of
(DPF) condition (for clogging), and controls the the driven machine
DPF regeneration by controlling the intake
throttle. • Diesel Particulate Filter (DPF) regeneration
control
Figure 4-8-1 illustrates the outline of the electronic
control system. However components and features vary depending
on the driven machine. For details, refer to the
Features of the electronic engine control system operation manual provided by the driven machine
include: manufacturer for these functions.
Fuel feed pump

Supply pump (mechanical) Rail pressure sensor Rail Relief valve
DOC
Outlet temp.
sensor SF
DOC Pressure
Inlet temp difference
sensor sensor Main filter
Intake metering
DOC SF valve
DPF
Intake Exhaust
EGR-Valve
Re-circulation
Intake throttle
valve
Inj.Nozzle
Liner
Piston
Fuel feed pump
EGR (electromagnetic)
Fuel cooler
Crank speed sensor Injector
Pre-filter
ECU
Gear speed sensor
Accelerator sensor
Fuel tank
Flow of intake
Flow of injection fuel Flow of electrical signal
/return fuel
043932-01E00
Figure 4-8-1
4-8-2 172663 0BKC2-EN0060

4. ENGINE
4-8-3 Electronic Engine Speed Control Droop control

The VM series engines for general use are
The content described here refers to a general designed so that the engine speed is reduced by a
engine. For more specific details, see Engine ECU certain percentage from 30 % load to full rated
(engine controller) on page 5-4-1. load. See curves (1) in Figure 4-8-4 below. The
same percentage droop is maintained at any no-
■ Speed control
load speed.
The electronically controlled engines have no
governor lever. For these engines, the position Isochronous control
signal of the throttle lever or accelerator pedal of The CL series consists of isochronous design
the driven machine is converted into an electric engines, the speed of which is kept constant from
signal by the accelerator sensor Figure 4-8-2, no load to full rated load. See curves (2) in
which is then delivered to the fuel injector through Figure 4-8-4 below.
the ECU Figure 4-8-3, allowing the engine speed
to be controlled. Some VM series engines for general use may be
custom-engineered and have the isochronous
capability. Consult the operation manual for the
driven machine for application details of such
engines.
1 2
120 %
110 %
100 %
Torque
Figure 4-8-2
30 %
800 min-1 60 % 100 %

Engine speed
Figure 4-8-4
044590-00X01
■ Other engine speed control
Figure 4-8-3 Low-idling speed up

This feature increases the low-idling speed to
■ Engine speed curves some extent depending on the engine coolant
Figure 4-8-4 shows typical engine speed curves temperature. When the coolant temperature
that outline the relationship between engine speed reaches a predetermined value, this feature
and load. returns the engine speed to the normal low idle
setting, thus reducing the warm-up time.
4-8-3 172663 0BKC2-EN0060

4. ENGINE
High-idling speed down

The high-idling speed is controlled to 1500 min-1
when starting the engine in cold weather
conditions (-15 °C or below). At least 10 seconds
after the engine starts, the engine speed returns to
the normal high idle setting by operating the
accelerator lever. The engine speed is maintained
at 1500 min-1 if the accelerator lever is not
operated, thus preventing the seizures of the
turbocharger. This is a standard feature. However
it depends on the engine model. Refer to the
operation manual provided for your engine model.
Auto deceleration
This feature brings the running engine in low idle
mode automatically when the accelerator pedal is
not operated for a predetermined period of time.
When the pedal is operated, i.e., the accelerator
sensor is activated, the low idle mode is cancelled.
A certain ON/OFF combination of switches (1) - (4)
on the operator’s console Figure 4-8-5 will
implement this optional feature. For details, see the
operation manual for the driven machine.
1 2 3 4
Figure 4-8-5
Others
Other optional features can be provided by
selecting certain ON/OFF combinations of
switches (1) - (4) on the operator’s console
Figure 4-8-5 will implement this optional feature.
For details, see the operation manual for the driven
machine.
4-8-4 172663 0BKC2-EN0060

4. ENGINE
4-8-4 Diesel Particulate Filter (DPF) Because ash is a metallic component, it cannot be
combusted in the DPF for treatment like the PM.
The DPF consists of the Diesel Oxidation Catalyst Therefore, ash is over-accumulated in the SF over a long
(DOC) and the Soot Filter (SF), held by a case that period of time. This increases the pressure loss and has
sends the exhaust gas to the DOC and the SF. adverse effects on the engine. In this case, maintenance
(Figure 4-8-6) must be performed to remove the SF with the
The role of the DPF is to prevent the discharge of PM accumulated ash from the DPF. Yanmar recommends to
by breaking down the hazardous constituents with do this maintenance once every 3,000 operating hours.
the DOC and collecting the PM with the SF. The PM
clogs the SF if left there and the engine performance Be sure to use the specified fuel and lubricating oil so that
decreases, so a means of regeneration is required. the DPF can fulfill its function. For fuel, use diesel fuel
YANMAR engines use a continuous regeneration (ultra-low sulfur) with a sulfur mass of 15 ppm or lower. If
method. While continuing the operation, the DPF you use a fuel other than the specified, performance of
collects the PM and is regenerated at the same time. the catalyst contained in the DOC deteriorates rapidly due
To perform the regeneration, the PM collected in the to sulfur. Because of this, the DPF cannot develop its
SF is combusted with NO2 generated in the DOC regeneration capabilities and PM accumulates easier.
and O2 in the exhaust gas. At the same time, the This leads to increased fuel consumption and a
DOC purifies the exhaust gas elements such as HC deterioration of general engine receptiveness caused by
and CO into H2O and CO2. decreased engine performance and frequent switching to
the regeneration mode.
Apart from the PM, ash also collects in the SF. This
comes mostly from metallic components in the additives For lubricating oil, use low ash oil. If you use any
to the lubricating oil. Part of the lubricating oil is burnt in other than the specified lubricating oil, a large
the high temperature combustion chamber and amount of ash is vented through the exhaust and
exhausted along with the combustion gas. In that case, the DPF will clog within a short period of time. This
metallic components are collected together with the PM in will not only cause the engine output to decrease
the SF. However, because the amount of ash is very little and the fuel costs to increase, but also makes
compared to the PM, it does not clog the SF immediately. earlier maintenance of the SF necessary.
Outline of Diesel Particulate Filter (DPF)
Pressure difference
sensor
Silencer portion
Hold mat (Option parts)
Exh. Gas in Exh. gas out
Exh. gas out

Case, SF
SF(soot filter)
Case, DOC
DOC
(diesel oxidation catalyst) 044869-00EN00
Figure 4-8-6
4-8-5 172663 0BKC2-EN0060

4. ENGINE
■ Overview of Diesel Particulate Filter • White smoke may be discharged from the
(DPF) regeneration control exhaust pipe right after starting a cold engine or
during acceleration.
Electrical components such as the DPF differential
This is due to discharge of water vapor. When
pressure sensor, temperature sensor, and intake
the exhaust temperature increases, the white
throttle are installed in the DPF. If the DPF cannot
smoke disappears. Always perform the DPF
perform continuous regeneration due to low load
regeneration in a well-ventilated and safe
operation, the ECU uses these electrical
location.
components to control assisted DPF regeneration
(DPF regeneration control) automatically to • The exhaust gas is purified through the catalyst
prevent PM from over-accumulating. installed in the DPF, so the smell of the exhaust
gas is different from the exhaust gas of a
■ Self-regeneration conventional diesel engine.
Regeneration without the use of regeneration
*1: After-injection and post-injection
assistance devices (normal)
Both of these are functions to inject fuel with a delay
During the operation at high speed or high load, following the main injection. However, the post-injec-
the exhaust temperature rises and PM is tion is slightly more delayed than the after-injection.
continuously combusted and eliminated. That allows the exhaust temperature to increase to
assist DPF regeneration.
■ Assisted regeneration
CAUTION
Regeneration with the use of assistance devices
(e.g. the intake throttle) • During reset regeneration, post-injection is
used and fuel is burned directly inside the
When the differential pressure in the SF inlet/outlet DPF (burned by chemical reaction inside the
in the DPF rises, the differential pressure sensor DOC). Through this heat, regeneration occurs
installed to the DPF detects the increase. The ECU inside the SF, but the combustion increases
commands the intake throttle to open the throttle the temperature of the exhaust gas to close
according to the detected differential pressure to to 600 °C (1112 °F). Stay away from the
adjust the amount of engine intake air. The ECU exhaust gas. Extremely hot exhaust gas may
also controls the regeneration by performing after- burn you. Be careful that neither people nor
injection to increase the exhaust temperature. At flammable materials are near the exhaust gas
this time, the EGR valve is closed. outlet.
■ Reset regeneration • Post-injection can cause the fuel
consumption to increase by a small amount.
Regeneration with the combined use of assisted
regeneration and post-injection • Through this genuine YANMAR regeneration
method, the dilution of the lubricating oil with
50 hours after the initial operation, and every 100 fuel caused by the post-injection is kept to a
hours of operation thereafter, the assisted minimum, but some dilution is possible for
regeneration and post-injection*1 are automatically low-load operation (low temperature exhaust
used together to control regeneration by increasing gas) of fork lifters or similar machines. Make
the exhaust temperature to burn off and remove sure that you do a daily check of the oil level.
PM.
These automatic regenerations can be performed
during operation. No special operation is required
for the operator. The following conditions may
occur due to the characteristics of the DPF
system, but they are not malfunctions.
• The engine sound may change due to the
adjustment of intake throttle valve and degree of
opening of the EGR valve when starting and
completing the DPF regeneration.
4-8-6 172663 0BKC2-EN0060

4. ENGINE
■ Stationary regeneration • The stationary regeneration is complete after

Although the DPF performs the regeneration approximately 25 to 30 minutes.
control, if the operation conditions with idling at no • If you want to interrupt the stationary
load and low speed/low load operation are regeneration, perform one of the following
frequently repeated, the PM may not be operations.
regenerated. • Turn the interlock switch to “Regeneration
If the ECU determines that performing the Disabled”.
stationary regeneration is required at this time, the
• Raise the accelerator lever above the lowest
DPF regeneration request lamp comes on.
position.
If the DPF regeneration request lamp comes on,
immediately perform the stationary regeneration • Turn off the power switch.
by performing the following operation. If the 5. When the above-mentioned time has elapsed,
operation is continued with the DPF regeneration the engine speed decreases to low idling, the
request lamp being come on, an excessive amount regeneration approval lamp and the exhaust
of PM will accumulate. Abnormal combustion of temperature warning lamp turn off, and the
PM may cause fire and damage to the DPF. stationary regeneration is complete.
Operation procedures of stationary ■ Precautions for stationary regeneration
regeneration
• Do not disconnect SMARTASSIST DIRECT
1. Move to a well-ventilated and safe location.
(SAD) or the computer while performing the
2. Move the accelerator lever to the lowest stationary regeneration. (Check the remaining
position and operate the engine in idling. battery level. Stationary regeneration takes
Note: If the DPF regeneration prohibition approximately 1 hour to complete.)
switch is installed, turn the DPF
• Be sure to check the remaining fuel level to avoid
regeneration prohibition switch to
the engine from running out of fuel. (Stationary
“Regeneration Permitted”.
regeneration requires sufficient fuel that can run
3. Operate the interlock mechanism including the the engine for at least 1 hour.)
parking brake and activate the interlock • Make sure that no other failure other than
function. excessive deposits is observed.
Note: When the ECU verifies that the interlock
mechanism is enabled with the
regeneration interlock switch, the DPF
regeneration approval lamp starts
blinking.
4. Press the DPF regeneration request switch for
3 seconds (standard) or longer to start the
stationary regeneration. (The time required to
start the stationary regeneration can be
changed. Refer to the operation manual for the
detailed operation.)
• When the stationary regeneration starts, the
engine speed increases gradually to high idle
speed. Then the reset regeneration is
performed at that operation condition.
• When the stationary regeneration starts, the
DPF regeneration request lamp turns off, the
DPF regeneration approval lamp switches
from blinking to continuously lit, and the
exhaust temperature warning lamp lights up.
4-8-7 172663 0BKC2-EN0060

4. ENGINE
■ Recovery regeneration (optional)

NOTICE
The DPF can not be regenerated by the reset
regeneration or the stationary regeneration when If DPF is clogged quickly, check the following items.
the excessive PM is accumulated. Therefore, • Please use the specified fuel. Fuel with a high
optional recovery regeneration function is sulfur content can deteriorate the catalyst
available. performance inside the DOC, resulting in
deterioration of DPF regeneration performance
The recovery regeneration requires longer and PM accumulation.
regeneration time and lower temperature than that
of the reset regeneration and the stationary • Please use the specified lubricating oil. If
regeneration. However, the function varies lubricating oil contains a large amount of ash, the
depending on the driven machine. For details, refer ash content is vented through the exhaust,
to the operation manual provided by the driven causing the DPF to clog quickly.
machine manufacturer for these functions. • Soot accumulates easily due to incomplete
combustion as the resistances in the intake/
■ Precautions for recovery regeneration exhaust system increase. Periodically check and
• Do not disconnect SMARTASSIST DIRECT clean the air cleaner, EGR valve, and exhaust
(SAD) or the computer while performing the throttle (if equipped).
recovery regeneration. (Check the remaining • For more information on factors causing black
battery level. Recovery regeneration takes smoke, see Quick Reference Table for
approximately 4 hour to complete.) Troubleshooting on page 4-10-4.
• Be sure to check the remaining fuel level to avoid
the engine from running out of fuel. (Recovery
regeneration requires sufficient fuel that can run
the engine for at least 4 hour.)
• Make sure that no other failure other than
excessive deposits is observed.
4-8-8 172663 0BKC2-EN0060

4. ENGINE
■ DPF service Exh. gas Pressure

temp sensors difference sensor
Refer to the Operating Manual for details about
replacing and cleaning the Diesel Particulate Filter
(DPF). Silencer
Case, DPF
DOC SF
044159-00EN00
Figure 4-8-7
■ Procedures for servicing the Diesel Particulate Filter (DPF)

1. SF cleaning
In order to clean the SF, it is necessary to remove it with the case from the DPF. In principle, the SF
can be removed while the DPF unit is still mounted to the engine, but depending on how the engine is
mounted in the driven machine, it may be easier to first remove the removing the DPF assembly and
then remove the SF. Accordingly, select the procedure taking into account the DPF unit mounting
location and how the engine is mounted.
2. DOC replacement
Replacement of the DOC requires replacement of both the catalyst section and case section as a unit,
therefore removal of the DPF unit is necessary. (In reality, the DOC is not normally replaced on its own
- instead, the whole DPF assembly including SF is usually replaced.)
4-8-9 172663 0BKC2-EN0060

4. ENGINE
4-8-5 How to Remove and Reattach the Diesel Particulate Filter (DPF)
An overview of the Diesel Particulate Filter (DPF) DPF flywheel housing-mounted type
is given in page 4-8-5, however explanations of 1. Removal of the SF side exhaust pressure hose
components in removal, reattachment, and
• Loosen the hose clip (3, Figure 4-8-10) for the
replacement are given in Figure 4-8-8 and
hose (2, Figure 4-8-10) connected to the SF
Figure 4-8-9. side exhaust pressure pipe (1, Figure 4-
Figure 4-8-8 shows the whole DPF unit, and 8-10), and remove from the pipe.
broadly speaking, the DPF unit comprises the DPF
2
assembly and the sensor unit. The sensor unit
3
contains an exhaust temperature sensor and
exhaust differential pressure sensor. 1
Figure 4-8-9 shows the DPF assembly by itself
after the sensor unit has been removed, and this
comprises the DOC, SF, silencer or outlet flange, 4
and stiffener.
071828-00X00
Sensor unit
Exhaust temperature sensor Figure 4-8-10
Exhaust differential pressure sensor
NOTICE
• SF cleaning is also possible while the
exhaust pressure pipe is attached, therefore
it is not necessary to remove the pipe joint
bolts (4, Figure 4-8-10).
DPF complete • When replacing the SF case, remove the
071827-00EN00
pipe joint bolts together with the gasket.
Figure 4-8-8 DPF unit
2. Removal of the sensor bracket
• Loosen the sensor bracket (3, Figure 4-8-11)
Stiffener
M8 flange bolts (2 pcs.) (4, Figure 4-8-11)
that mount the exhaust differential pressure
sensor (1, Figure 4-8-11) and the exhaust
temperature sensor coupler (2, Figure 4-
DOC 8-11), and remove.
• Put the removed sensor bracket on the engine
SF side with the sensor, coupler, hose, harness
Silencer or and other parts connected so that they do not
outlet flange 071829-00EN00 interfere when removing other parts.
1 2 34
Figure 4-8-9 DPF assembly
■ How to remove the soot filter (SF) case

When cleaning the SF, it is possible to remove the
SF case alone from the DPF unit without removing
the DPF unit from the engine. The DPF unit may
be mounted either on top of the flywheel housing
or on top of the exhaust manifold. Some details
may differ, so different procedures are shown
below.
071830-00X00
Figure 4-8-11
4-8-10 172663 0BKC2-EN0060
4. ENGINE
3. Removal of the DPF stay fixing bolts

5
• Remove the silencer (or outlet flange) 4
(1, Figure 4-8-12) side DPF stay
(2, Figure 4-8-12) and the M10 bolts (2 pcs.) 2
(3, Figure 4-8-12) that affix the flywheel
housing. Leave the stiffener (4, Figure 4-
8-12) attached to the DPF stay.
1 1
3
4
5 6
2 2 071832-00X00
1 – Silencer
3 2 – Stiffener A
3 – DPF gasket
057634-00X01 4 – SF case
5 – Stiffener B
Figure 4-8-12 6 – DPF stay
4. Removal of the silencer (or outlet flange) Figure 4-8-14

• Remove the M8 bolts and flange nuts 5. Removal of the SF case
(3, Figure 4-8-13) (8 or 10 of each) that fix the
• Remove the M8 bolts and flange nuts
silencer (or outlet flange) (1, Figure 4-8-13)
(3, Figure 4-8-15) (8 or 10 of each) that fix the
and SF case (2, Figure 4-8-13).
SF case (1, Figure 4-8-15) and DOC case
• Remove the stiffeners (4 pcs.) (4, Figure 4- (2, Figure 4-8-15).
8-13) that hold the mating surface of the
• Remove the stiffeners (4 pcs.) (2 pcs. on each
silencer and SF case flange while DPF stay is
side) (4, Figure 4-8-15) that hold the mating
attached to one of the stiffeners, and remove
surface of the SF case and DOC case flange,
the silencer (or outlet flange).
and remove the SF and SF case as a unit.
For mounting position of the stiffener, see
Mark the stiffeners so that they can be
Figure 4-8-14.
reassembled in the original position.
2 4
3 3
071831-00X00
1 057637-00X01
Figure 4-8-13
Figure 4-8-15
NOTICE This completes the removal of the SF case.
Remove the stiffener making note of its position
and angle.
4-8-11 172663 0BKC2-EN0060

4. ENGINE
DPF exhaust manifold-mounted type

2 1
In principle, the procedure is the same as for the
flywheel housing-mounted type, but with the
exhaust manifold-mounted type, the sensor
bracket has a stiffener between the DOC case and
the SF case.
1. Removal of the SF side exhaust pressure
hose
• Loosen the hose clip for the hose (2, Figure 4-
8-16) connected to the SF side exhaust 057639-00X00
pressure pipe (1, Figure 4-8-16), and remove

from the pipe. Figure 4-8-17
3. Removal of the SF case fixing bolts
2 1 3 7 5 6 4 • Remove the M10 flange bolts (2 pcs.)
(3, Figure 4-8-18) and the M10 flange nut
(1 pc.) (4, Figure 4-8-18) that fix the PDF stay
(2, Figure 4-8-18) and stiffener (1, Figure 4-
8-18) mounted on the bottom of the SF case.
Depending on the model, the configuration
and fixing method of the engine-side stay may
differ.
057638-01X00
Figure 4-8-16
NOTICE 3
• SF cleaning is also possible while the

exhaust pressure pipe is attached, therefore
1
it is not necessary to remove the pipe joint 4
bolts (3, Figure 4-8-16). 2 057640-01X00
• When replacing the SF case, remove the

pipe joint bolts together with the gasket. Figure 4-8-18
4. Removal of the silencer (or outlet flange)
2. Removal of the sensor bracket • Remove the M8 bolts and flange nuts
• Loosen the sensor bracket (1, Figure 4-8-17) (5, Figure 4-8-16) (8 or 10 of each) that fix the
M8 flange bolts (2 pcs.) (2, Figure 4-8-17) silencer (or outlet flange) (4, Figure 4-8-16)
that mount the exhaust differential pressure and SF case (7, Figure 4-8-16).
sensor and the exhaust temperature sensor • Remove the stiffeners (4 pcs.) (2 pcs. on each
coupler, and remove. side) (6, Figure 4-8-14) and the silencer (or
• The removed bracket holds the sensor, outlet flange). Mark the stiffeners so that they
coupler, hose, harness, and other parts so that can be reassembled in the original position.
they do not interfere with the engine when
mounted.
4-8-12 172663 0BKC2-EN0060

4. ENGINE
5. Removal of the SF case 2. Reattachment of the silencer (or outlet

• Remove the M8 bolts and flange nuts flange)
(2, Figure 4-8-19) (8 or 10 of each) that fix the • Install the silencer (or outlet flange), following
SF case (1, Figure 4-8-19) and DOC case the same details as for installation of the SF
(4, Figure 4-8-19). case. Making note of its position and angle,
• Remove the stiffeners (4 pcs.) (2 pcs. on each reattach the stiffener in its original position.
side) (3, Figure 4-8-19) that hold the mating (M8 bolts and flange nuts, 8 or 10 of each)
surface of the SF case and DOC case flange, • Replace the M8 flange bolts and nuts with new
and remove the SF and SF case as a unit. ones.
Mark the stiffeners so that they can be • Replace the gasket with a new one.
reassembled in the original position.
3. Reattachment on the DPF stay
4 3 2 1 • Temporarily fasten the DPF stay (1, Figure 4-
8-20) on the silencer (or outlet flange) side to
the flywheel housing using M10 flange bolts
(2 pcs.) (2, Figure 4-8-20).
• Before fully tightening, slightly loosen the M10
flange bolts (2 pcs.) (3, Figure 4-8-18) that
affix the stiffener (4, Figure 4-8-18) and the
DPF stay, and after fully tightening the DPF
stay and the flywheel housing bolts,
057641-00X00 (2, Figure 4-8-20), fully tighten the stiffener
bolts (3, Figure 4-8-20).
Figure 4-8-19
This completes the removal of the SF case.
4
■ How to reattach the SF case
DPF flywheel housing-mounted type
3
1. Reassembly of the SF case
1
• For reassembly of the SF case after cleaning,
3
reverse the steps for its removal.
Reassemble the SF case onto the DOC. 2
Making note of its position and angle, reattach
the stiffener in its original position. (M8 bolts 057644-00X00
and flange nuts, 8 or 10 of each) Figure 4-8-20

• Replace the M8 flange bolts and nuts with new
ones. 4. Reattachment of the sensor bracket
• Replace the gasket with a new one. • Reattach the sensor bracket that had been
moved to the engine side to the outlet flange
side stiffener (4, Figure 4-8-20). (M8 flange
bolts (2 pcs.))
4-8-13 172663 0BKC2-EN0060

4. ENGINE
5. Reattachment of the SF side exhaust

pressure hose
• Replace the exhaust pressure hose with a new
one. Insert a new hose into the SF exhaust
pressure pipe, and tighten the hose clip. As a
guideline, replace the exhaust pressure hose
every 3000 hours.
• At the same time, replace the DOC side
exhaust pressure hose with a new one. 1
M8 bolt tightening torque 26 ± 5 N·m

DPF exhaust manifold-mounted type

Details of reattachment of the SF and silencer (or
outlet flange) are the same as for the flywheel
housing flywheel housing-mounted type.
Reattachment on the DPF stay is different to with 1
the flywheel housing-mounted type, therefore
follow the procedures below.
1. Reattachment on the DPF stay 2
• After reattachment of the SF case on the DOC,

reattach the silencer (or outlet flange) to the
SF case using the stiffener. At this time, align 057650-01X00
the notches on the bottom of the stiffener

(1, Figure 4-8-21) underneath the silencer Figure 4-8-21
with the stud bolt in the center of the DPF stay
(2, Figure 4-8-21), and reattach the stiffener M8 bolt tightening torque 26 ± 5 N·m
(M8 bolts and flange nuts, 8 or 10 of each). M10 bolt tightening torque 49 ± 5 N·m
Make note of the position and angle of the
stiffeners (4 pcs.).
ones.
• Replace the gasket with a new one.
• Next, affix the stiffener (1, Figure 4-8-21) and
DPF stay (2, Figure 4-8-21). (M10 bolts
(2 pcs.), M10 flange nut (1 pc.))
• Depending on the model, the configuration
and fixing method of the DPF stay may differ.
Repair parts required for reattachment after

SF cleaning or replacement are shown on
page 4-8-20.
4-8-14 172663 0BKC2-EN0060

4. ENGINE
■ How to remove the DPF unit

When replacing the DPF or the DOC alone,
removal of the DPF unit is necessary.
1
(See page 4-8-10 for an explanation of the DPF
unit and DPF assembly)
DOC cannot be removed alone. It is necessary to
4
replace the DOC case since the DOC is installed
as a unit with DOC case.
3
1. Removal of the sensor and coupler wiring 2 057646-00X00
• Remove the exhaust differential pressure Figure 4-8-23

sensor connected to the sensor bracket
(1, Figure 4-8-22) and the wiring from the
NOTICE
engine or driven machine that is connected to
the exhaust temperature sensor couplers Do not lift the sensor or wire harness together
(2 pcs.) (2, Figure 4-8-22). with the DPF. The sensor may break.
3. Removal of the sensor unit

When replacing the DPF assembly, the sensor
unit is reused, therefore remove this from the
DPF unit.
2
• Removal of the exhaust temperature
1 sensor
Loosen the band (1, Figure 4-8-24) that fixes
057667-01X00
the exhaust harness. From two locations on
the exhaust temperature sensor, remove the
Figure 4-8-22 17 mm bolt from one location (2, Figure 4-
8-24) and the 13 mm bolt from the other
2. Removal of the DPF unit (3, Figure 4-8-24). Leave the exhaust
• Remove the 4 M8 flange nuts (1, Figure 4- temperature sensor couplers (2 pcs.)
8-23) on the exhaust manifold flange. (4, Figure 4-8-24) mounted on the sensor
• Remove the M10 flange bolts (2 pcs. each, bracket section.
total 4 pcs.) (2, 3, Figure 4-8-23) that affix
the stays (2 locations) (on the back of the DPF 2 3 1 8 7 4 8
housing), that themselves affixes the DPF.
• Remove the DPF unit together with the
exhaust flange gasket (1 pc.). 5
• Leave the stiffener attached to the DPF stay on

the silencer (or outlet flange).
057647-00X00
Figure 4-8-24
4-8-15 172663 0BKC2-EN0060

4. ENGINE
• Removal of the exhaust pressure pipe 2. Removal of the DPF unit

Remove the M12 pipe joint bolts (2 pcs.) • Remove the fixing bolts (2 pcs.) (2, Figure 4-
(6, Figure 4-8-24) that affix the exhaust 8-26) and flange nut (3, Figure 4-8-26) from
pressure pipe (5, Figure 4-8-24). Leave the the DPF stay (1, Figure 4-8-26) on the
exhaust differential pressure sensor silencer (or outlet flange) side.
(7, Figure 4-8-24) mounted on the sensor
bracket section.
• Removal of the sensor bracket
Loosen the M8 flange bolts (2 pcs.)
(8, Figure 4-8-24) and remove the sensor
bracket. Leave the exhaust differential 2
pressure sensor and the exhaust temperature 4
sensor coupler attached to the sensor bracket.
3
This makes the DPF unit the DPF assembly, and
replacement is possible.
1 057651-01X00
If replacing only the DOC case and leaving the

SF case as is, then remove only the sensor unit Figure 4-8-26
connected to the DOC case, and leave the
• Remove the DPF stay (1, Figure 4-8-27)
sensor bracket fixed to the SF case affixed,
fixing bolts (2 pcs.) (2, 3, Figure 4-8-27) on
together with the sensor coupler. Next, remove
the other side. Stay configuration and
the M8 bolts and flange nuts (8 or 10 of each)
numbers of bolts will differ depending on the
that affix the SF case and DOC case. This
model, but the method for fixing will be largely
enables replacement of the DOC unit.
the same.
DPF exhaust manifold-mounted type • Finally, remove the exhaust manifold flange
As with the flywheel housing-mounted type, if nuts (4 pcs.) (4, Figure 4-8-26), and remove
replacing the DPF assembly or the DOC alone, the DOF unit together with the gasket.
then removal of the DPF unit is necessary.
1. Removal of the sensor and coupler wiring
• Remove the exhaust differential pressure
sensor (2, Figure 4-8-25) connected to the 2
sensor bracket (1, Figure 4-8-25), and the
wiring (4, Figure 4-8-25) from the engine or
driven machine that is connected to the 3
exhaust temperature sensor couplers (2 pcs.) 1
(3, Figure 4-8-25).
1 2
057652-00X00
Figure 4-8-27
4 NOTICE
Do not lift the sensor or wire harness together
3 with the DPF. The sensor may break.
057649-00X00
Figure 4-8-25
4-8-16 172663 0BKC2-EN0060

4. ENGINE
3. Removal of the sensor unit 3. Reattachment of the sensor bracket

When replacing the DPF assembly, the sensor • Reattach the removed sensor bracket to the
unit is reused, therefore remove this from the SF stiffener. (M8 flange bolts (2 pcs.))
DPF unit. The procedure for removal is that
same as for the flywheel housing-mounted type. This completes the DPF unit.
Refer to page 4-8-15. Repair parts required for reinstallation of the
This makes the DPF unit the DPF assembly, and exhaust differential pressure sensor are
replacement is possible. shown on page 4-8-20.
If replacing only the DOC case and leaving the 4. Reattachment of the DPF unit
SF case as is, then remove only the sensor unit
• First, slightly loosen the flange bolts (2 pcs.)
connected to the DOC case, and leave the
(2, Figure 4-8-28) that attach the DPF stay
sensor bracket fixed to the SF case affixed,
(1, Figure 4-8-28) and the stiffener so that
together with the sensor coupler. Next, remove
these have some play.
the M8 bolts and flange nuts (8 or 10 of each)
that affix the SF case and DOC case. This • Replace the exhaust manifold flange gasket
enables replacement of the DOC unit. with a new one, and attach the DPF unit to the
exhaust manifold stud bolt.
■ How to reattach the DPF • Temporarily tighten the DPF assembly central
stay M10 bolts (2 pcs.) (3, Figure 4-8-28).
This procedure shows how to install a new DPF • Seat the exhaust manifold flange (4, Figure 4-
assembly. In principle, the procedure is the reverse 8-28) using M8 flange nuts (4 pcs.), and
of that for removal. First, reattach the removed temporarily tighten.
sensor unit to the DPF assembly. • Fully tighten the central stay M10 bolts
(3, Figure 4-8-28).
1. Reattachment of the exhaust temperature
sensor • Fully tighten the flange nuts (4 pcs.) on the
exhaust manifold flange.
• On two locations on the removed exhaust
temperature sensor, attach the 17 mm bolt in • Fully tighten the M10 flange bolts (2 pcs.)
one location, and the 13 mm bolt in the other. (5, Figure 4-8-28) of the DPF stay on the
flywheel housing side.
Tightening torque 40 ± 5 N·m • Fully tighten the DPF stay M8 flange bolts
(2 pcs.) (2, Figure 4-8-28).
• Tighten the 2 loosened exhaust temperature
sensor harness bands.
2. Reattachment of the exhaust pressure pipe 6
4
• Reattach the removed exhaust pressure pipe
(2 pcs.). At this time, replace the pipe joint bolt,
the gasket, and the hose with new ones. As a 2
guideline, replace the exhaust pressure hose 1
every 3000 hours. 2
• When tightening the pipe joint bolt, apply anti- 5
seize compound to the threaded sections.
3 057653-00X00
M12 pipe joint bolt
29.4 ± 5 N·m
tightening torque Figure 4-8-28
26 ± 5 N·m
M8 bolt tightening torque
(Lock nut: 16 ± 5 N·m)
4-8-17 172663 0BKC2-EN0060

4. ENGINE
5. Driven machine wiring • Temporarily tighten the stiffener (1, Figure 4-

• Connect the exhaust pressure sensor to the 8-30) and the DPF stay (2, Figure 4-8-30) on
sensor bracket and the wiring from the engine the silencer (or outlet flange) side with flange
or driven machine to the exhaust temperature bolts (2 pcs.) (3, Figure 4-8-30) and a flange
sensor couplers (2 pcs.). nut (4, Figure 4-8-30) until it is seated.
• Next, fully tighten the flange nuts on the
This completes reattachment of the DPF unit. exhaust manifold flange (4 pcs.) (5, Figure 4-
If only the DOC case has been replaced, then 8-30), then fully tighten the DPF stay flange
first affix the DOC case and SF case using M8 bolts and flange nuts.
bolts and nuts (8 or 10 of each), and with the
DPF assembly, proceed as above.
• Replace the M8 flange bolts and nuts with new 2
ones. 3
• Replace the gasket with a new one. 5
Cylinder head-mounted type
If the engine is cylinder head-mounted type, stay 1
configuration and fixing method will differ 4 057669-01X00
depending on the engine model. This explains a
typical model. Figure 4-8-30
1. Reattachment of the sensor unit • Next, affix the DPF unit to th DPF stay on the
• Reattach the removed sensor unit (exhaust flywheel housing side. First, slightly loosen the
temperature sensor and exhaust differential fixing bolts (2, Figure 4-8-31) of the DPF stay
pressure sensor), and reattach the bracket to (1, Figure 4-8-31) on the flywheel side in 2
the SF stiffener. Up until this point is the same locations so that these have some play.
as for the flywheel housing-mounted type, so Temporarily tighten the fixing bolts
refer to the details on the previous pages. (4, Figure 4-8-31) that fix the DPF unit and
stay.
Repair parts required for reinstallation of the Next, temporarily tighten the DPF stay fixing
exhaust differential pressure sensor are bolts (2, Figure 4-8-31) until it seats, then fully
shown on page 4-8-20. tighten the DPF and stay fixing bolts
(4, Figure 4-8-31). Lastly, fully tighten the DPF
2. Reattachment of the DPF unit stay fixing bolts (2, Figure 4-8-31).
• Replace the exhaust manifold flange gasket
with a new one, place the DPF unit upon this,
and temporarily tighten the flange nuts (4 pcs.)
(1, Figure 4-8-29).
4
3
1 057645-00X00
Figure 4-8-31
057668-01X00
26 ± 5 N·m
M8 bolt tightening torque
(Lock nut: 16 ± 5 N·m)
Figure 4-8-29
4-8-18 172663 0BKC2-EN0060

4. ENGINE
Note: In principle, it is not necessary to loosen

the fixing bolts (3, Figure 4-8-31) that
affix the DPF stay to the engine,
however adjust according to conditions.
3. Driven machine wiring
Connect the exhaust differential pressure
sensor to the sensor bracket and the wiring from
the engine or driven machine to the exhaust
temperature sensor couplers (2 pcs.).
This completes reattachment of the DPF unit.
If only the DOC case has been replaced, then
first affix the DOC case and SF case using M8
bolts and nuts (8 or 10 of each), and with the
DPF assembly, proceed as above.
ones.
• Replace the gasket with a new one.
4-8-19 172663 0BKC2-EN0060

4. ENGINE
4-8-6 SF and DPF Maintenance Kit
The required individual parts are available for SF cleaning and replacement, and for maintenance when
replacing the DPF assembly and the DOC, however the kit as below is also available. There are two types
- for the DPF housing, and for the differential pressure sensor hose, therefore select in accordance with
the engine model and the DPF installation location.
Engine model name
Kit name Part name Part code DPF installation location 4TNV88C
Remarks FW side Exh. M side
129930-13201 80 × 80 1 –
Gasket
Exhaust 128300-13230 102 × 102 – 1
gage flange 26306-080002 M8 4
Flange nut
26306-100002 M10 – 4
DOC-SF
bolt 129A00-16610 M8 × 28 16 16
maintenance kit
DPF Flange nut 26306-080002 M8 16 16
Stiffener 129A00-16600 – 2 2
DPF Gasket
129E00-16600 – – –
Kit code 129A00-16900
129A00-17600 L = 170 – –
Hose CMP 129C00-17600 L = 200 1 –
(ø13.5) 129A00-17610 L = 90 – 1
129C01-17610 L = 105 – –
Differential
pressure sensor Hose CMP 129A00-17650 L = 130 1 –
hose kit (ø9.8) 129A00-17670 L = 90 – 1
Pipe joint bolt 129A00-13350 – 2 2
Gasket 129A00-17311 – 4 4
Kit code 129C00-17900 129C01-17900
The required individual clamps are available when replacing the wire harnesses and other parts. However
the kit as below is also available.
Kit name Kit code Part name Part code Qty

Band clip 129A00-91200 25
Band 129C00-91200 3
Harness clamp Band 29621-200000 4
129A00-91000
service kit Band 29621-100000 3
Connector crop 129A00-91430 5
Boots 129A00-91450 3
4-8-20 172663 0BKC2-EN0060

4. ENGINE
4-8-7 Troubleshooting of Electronic Control System
The electronically controlled engine with built-in

common rail system is equipped with a engine
1
failure lamp. The following section describes how
to detect faults on those engines. Operator’s console
A Engine failure B
Fault Detection Capability Preheat
On the electronically controlled engine, the ECU or
Oil pressure
performs various kinds of self-diagnosis based on
Regeneration Exhaust gas
the information from the sensor for electronic Engine coolant request temperature
temperature
control and various types of preset engine fault
detection sensors. According to the status of each Charge
sensor, you can set the operations during a fault
(optional). When such a fault is detected, the ECU 061969-00EN00
indicates occurrence of failure.

Figure 4-8-32
ECU turns on the engine failure lamp, and the
indicator indicates that the fault is detected. Note: This figure is for reference only. The gauges
located on the operator's console may vary
The engine failure lamp comes on for
depending on the machine. Refer to the
approximately 2 seconds when the key switch is
operation manual provided by the driven
turned on, then goes off. With this lamp, you can
machine manufacturer for details.
check whether the power is supplied to ECU.
The engine failure lamp is located on the panel as
shown in (1, Figure 4-8-32).
Figure 4-8-33 exemplifies flashing patterns of the
engine failure lamp.
NOTICE The engine failure lamp comes on for
Shut down the engine if the engine failure lamp approximately 2 seconds when the switch is turned
comes on. Continuing running the engine with the on, and goes off while the engine is running. If a
engine failure lamp being on may result in a fault occurs in ECU, this indicator lamp will come
serious malfunction of or damage to the engine, on 3 seconds after the indicator lamp goes off, and
and will void the engine warranty. the lamp continuously stays on. If a fault occurs
while the engine is running, the engine failure lamp
comes on at the time of fault occurrence.
(Normal operation)
Power up
2s
On
Off
(When faults occur)

Power up
2s 3s On
On
Off 054321-00EN00
Figure 4-8-33
4-8-21 172663 0BKC2-EN0060

4. ENGINE
Fail-safe
Engine kept running
Fault • Limp-home for as long as possible
• Engine shutdown
Operator’s console
ECU
Engine failure lamp turns on
USB
CAN
Connector Interface
Engine box
SA-D
Output to other ECU(s) 071789-00EN00
Figure 4-8-34
NOTICE
If the engine failure lamp comes on, stop the engine immediately and contact your local YANMAR dealer.
As shown in Figure 4-8-34, SMARTASSIST DIRECT (SA-D), Yanmar genuine diagnosis tool, is required
to connect to your engine for fault diagnosis.
SA-D allows reviewing detailed fault information, historical fault/alarm logs and freeze frame data. In
addition, you can monitor the engine status and perform the fault diagnosis by using SMARTASSIST
DIRECT. Events in the fault/alarm logs can be time stamped.
4-8-22 172663 0BKC2-EN0060

4. ENGINE
SMARTASSIST DIRECT (SA-D) NOTICE

When the ECU or injectors are replaced, you need
• Do not plug or unplug the ECU for a period of at
to rewrite the individual data inside the ECU.
least 60 seconds after power to the unit has been
A special treatment is also necessary when turned on or off.
replacing DPF or sensors that affects the • Do not touch connector pins of the ECU with
electronic control system. bare hands. Doing so may result in corrosion of
the connector pins and/or damage to the internal
A connector is provided at an end of the harness of
circuits of the ECU due to static electricity.
the driven machine so that the YANMAR genuine
SMMARTASSIST DIRECT (SA-D) can be loaded • Do not force a measuring probe into the female
with data from the ECU. See Figure 4-8-35 and coupler. Doing so may cause contact failure of
Figure 4-8-36. the connector pins, resulting in malfunction of the
ECU.
Contact your authorized YANMAR dealer or
• Take care to prevent water from entering the
distributor that can handle SA-D to repair or
couplers when plugging or unplugging the
replace the electronic control parts.
corrosion, resulting in malfunction of the ECU.
WARNING
• Avoid plugging/unplugging the connector more
• Never use the ECU for purposes that are not than approx. 10 times.
intended by YANMAR; such as using Frequent plugging/unplugging of the connector
unauthorized ECU, writing unauthorized data may cause contact failure of the connector pins,
to ECU, leaving it broken, or removing sensors resulting in malfunction of the ECU.
and actuators. Doing so could result in the
• Do not use the ECU that has ever suffered drop
violation of emission control regulations and
impact.
will void the product warranty.
• Do not disassemble the ECU terminal.
• Be sure to use the ECU in conjunction with
the engines whose models or serial numbers
are specified by YANMAR.
■ About SA-D use
Other ECU/engine combinations than
specified will void the engine warranty. SA-D is a diagnosis tool that automatically
transmits the following information to the YANMAR
• When replacing the fuel injector, you need to data server (SMARTASSIST CORE (SA-C)) from
rewrite the fuel injection quantity adjustment the ECU equipped in your driven machine via the
data in the ECU. When replacing the ECU, Internet.
you need to export data from the existing
ECU to the new ECU. In order to operate as • Injector, exhaust gas post-treatment equipment,
above, you need to connect the YANMAR parts replacement information for controllers that
genuine SA-D. Be sure to contact your are necessary for exhaust gas warranty claims.
authorized YANMAR dealer. ECU that does
not have the proper fuel injection quantity • Accumulated operation information required for
adjustment data written, or ECU that does not the reuse of exhaust gas post-treatment
have the data transferred correctly will void equipment.
the engine warranty. • Operation history of an engine including fault
• You will also need to connect to SA-D for history, operation time, engine speed, and load
replacing other CR related products, so be ratio.
sure to contact your authorized YANMAR
All the obtained data will be used for the following
dealer.
purposes.
• Improper use or misuse of the ECU may
result in death or serious injury due to an • To prevent improper service in the market
abrupt and unexpected increase in engine • To provide more accurate and prompt service
speed.
4-8-23 172663 0BKC2-EN0060

4. ENGINE
• To improve product quality through YANMAR

Research and Development
SMARTASSIST DIRECT
(YANMAR genuine)
Windows
PC
USB
CAN
Communication
adaptor
ISO 15765-4
Figure 4-8-35
DEUTSCH
DTM06-06S-E007
Batt.12V NC
CANH NC
CANL GND
Mating connector (SMARTASSIST-DIRECT side)

DEUTSCH
DTM04-06P-E003
Figure 4-8-36
4-8-24 172663 0BKC2-EN0060

4. ENGINE
4-8-8 Replacement of Components
If any part for the electronic control system must be repaired or replaced as a result of periodic
maintenance or the failure diagnosis conducted using the SMARTASSIST DIRECT, do not attempt to
repair the individual device of the electronic control system. Refer to the separate TROUBLESHOOTING
manual, and replace the parts or entire assembly.
■ Processing the DPF regeneration after the parts replacement

The following parts are used for the calculation of the accumulated PM amount. Therefore, when there is
a fault in these parts, the accumulated PM amount may be miscalculated. Be sure to perform the DPF
regeneration in order to eliminate the calculation error of the accumulated PM amount after replacing
parts.
• Injector • Rail CMP or rail pressure sensor

• Supply pump • DOC
• EGR valve • Intake throttle
• ECU • EGR gas temperature sensor
• EGR pressure sensor • DPF inlet temperature sensor
• DPF differential pressure sensor • Intake manifold temperature sensor
• DPF inside temperature sensor • Fuel temperature sensor
• Exhaust manifold temperature sensor • Crankshaft rotation sensor
• Cooling water temperature sensor • Exhaust throttle
1. Start and warm-up the engine until the cooling water temperature is 60 °C or higher, then let it idle.
2. Without optional recovery regeneration function equipped, when the ECU determines that the PM
sediment amount is 10 g/l or more, the stationary regeneration request is displayed. Perform the
stationary regeneration. For details on regeneration operation, see Operation procedures of stationary
regeneration on page 4-8-7.
3. If the stationary regeneration request lamp does not come on (sediment is 10 g/l or less), connect
SMARTASSIST DIRECT (SA-D) and perform stationary regeneration. For operation procedures for
stationary regeneration using SA-D, refer to the SMARTASSIST-DIRECT operating manual, 6.5.9
supplementary materials “Active Control”.
4. With optional recovery regeneration function equipped, when the ECU determines that the PM
sediment amount is 12 g/l or more, the recovery regeneration request is displayed. Perform recovery
regeneration. For details on regeneration operation, see Operation procedures of stationary
regeneration on page 4-8-7.
5. If sediment is 12 g/l or less, then go to the stationary regeneration determination flow.
4-8-25 172663 0BKC2-EN0060

4. ENGINE
Procedure to eliminate calculation errors of the accumulated PM amounts when using method C
Warm-up operation
(Cooling water temperature > 60 °C) Step 1
Option setting
Accumulated PM amount Recovery regeneration

g/l or more
12 g/L
Step 4
Step 5
Accumulated PM amount Stationary regeneration

g/l or more
10 g/L
Step 2
Step 3
Stationary regeneration using SA-D
END
054081-00EN02
Figure 4-8-37
Calculation of PM sediment amount in DPF

ECU calculate the PM sediment amount that is accumulated in soot filter (SF) by following 2 methods:
• Method C calculates the difference between the estimated PM sediment amount that is discharged from
the engine and the estimated PM sediment amount that is burned inside the SF.
• Method P calculates the PM sediment amount accumulated in the SF from the pressure difference
between the inlet and outlet of the SF.
ECU uses the PM sediment amount whichever is greater for regeneration control.
■ Processing after the ECU replacement (when it is impossible to inherit from the old ECU)
When the history data could not be inherited from the old ECU at the time of replacing the ECU, the data
for the accumulated Ash amount is reset, accordingly estimate the PM sediment amount from the
accumulated Ash using method P, and determine if SF cleaning is necessary.
Procedures for when the history data could not be inherited are shown below.
1. After ECU replacement, the procedure for burning PM by using DPF regeneration (stationary
regeneration or stationary regeneration using SA-D, or recovery regeneration when optional recovery
regeneration function equipped) is the same as in the previous chapter.
2. If PM sediment is 10 g/l or more, and stationary regeneration is being performed, then after regeneration
has completed, connect SMARTASSIST DIRECT (SA-D) so that this can be used to confirm the PM
sediment concentration (P method). If the PM sediment is 10 g/l or less, and the SA-D connected and
stationary regeneration performed, then proceed to the next step while leaving this connected.
3. Operate the engine at high idling for 10 minutes or more until the situation has stabilized.
4. After operation has completed, check the ash sediment amount using SA-D. On the SA-D menu
screen, select “Diagnosis Test” and then pulse/analog input and output, and confirm the “DPF PM
sediment concentration (P method)” data. For operation procedures refer to the SMARTASSIST-
DIRECT operating manual, 6.5.10 supplementary materials “Pulse/Analog Input and Output”.
5. When the PM sediment amount (P method) exceeds 5 g/l, clean the soot filter (SF).
4-8-26 172663 0BKC2-EN0060

4. ENGINE
Procedure to eliminate calculation errors of the accumulated PM amounts when using method C,
and to confirm ash sediment amount
Same as DPF regeneration processing after parts replacement Step 1
Warm-up operation
(Cooling water temperature > 60 °C) Option setting
Accumulated PM amount Recovery regeneration

g/l or more
12 g/L
Accumulated PM amount Stationary regeneration

g/l or more
10 g/L
Stationary regeneration using SA-D
Operate the engine at high idling

Step 3 for 10 minutes or more SA-D connection
Check the PM sediment concentration Step 2

Step 4 (P method) using SA-D
PM sediment concentration Clean the SF

g/l or more
5 g/L
Step 5
END
054082-00EN02
Figure 4-8-38
4-8-27 172663 0BKC2-EN0060

4. ENGINE
■ Required processing at the CR-related

parts replacement
NOTICE
• Do not plug or unplug the ECU for a period of at
SA-D operation least 60 seconds after power to the unit has been
Replacement Bosch turned on or off.
parts Processing DPF
ECU rewrite • Do not touch connector pins of the ECU with
regeneration
bare hands. Doing so may result in corrosion of
ECU  *2 the connector pins and/or damage to the internal
Injector   circuits of the ECU due to static electricity.
DPF   • Do not force a measuring probe into the female
SF   coupler. Doing so may cause contact failure of
DOC   the connector pins, resulting in malfunction of the
Rail   ECU.
Supply pump –  • Take care to prevent water from entering the
Other* 1 –  couplers when plugging or unplugging the
*1: EGR valve, intake throttle, DPF differential pressure corrosion, resulting in malfunction of the ECU.
sensor, DPF inlet temperature sensor, DPF inside • Avoid plugging/unplugging the connector more
temperature sensor, EGR pressure sensor, intake manifold than approx. 10 times.
temperature sensor, EGR gas temperature sensor,
exhaust manifold temperature sensor, crankshaft speed
Frequent plugging/unplugging of the connector
sensor, fuel temperature sensor, cooling water may cause contact failure of the connector pins,
temperature sensor. resulting in malfunction of the ECU.
*2: When the history data could not be inherited from the old • Do not use the ECU that has ever suffered drop
ECU, processing the DPF regeneration is required. impact.
Furthermore, it is required to clean the SF when the
accumulated amount by method P after the DPF
regeneration exceeds 5 g/L.
4-8-28 172663 0BKC2-EN0060

4. ENGINE
4-8-9 Installation Position of Sensors
Do not unnecessarily touch the sensor coupler portion with your bare hands.
The sensor may be damaged due to static electricity.
Injector
DPF inlet exhaust temperature
sensor Exhaust temperature sensor
DPF inside exhaust temperature
sensor EGR valve
DPF differential pressure sensor EGR pressure sensor

sensor
Intake air throttles
Crank rotation sensor

Cam speed sensor
New air temperature sensor
EGR temperature sensor Pump discharge control
valve
Intake temperature sensor
Fuel temperature sensor
Rail pressure sensor 044896-00EN01
Figure 4-8-39
Crank Rotation Sensor
Vout A Vout B
037282-00X00
Figure 4-8-40
Part No. 129A00-21710

Sensor installation tightening torque 8 ± 2 N·m
4-8-29 172663 0BKC2-EN0060

4. ENGINE
Cam Speed Sensor
Vout
Vin GND
037283-00X00
Figure 4-8-41
Part No. 129A00-14710

Sensor installation tightening torque 8 ± 0.5 N·m
New Air Temperature Sensor
Vout GND
037253-00X00
Figure 4-8-42
Part No. 129A00-12711

Sensor installation With turbocharger 7.0 ± 1.4 N·m
tightening torque Without turbocharger 3.5 ± 0.5 N·m
4-8-30 172663 0BKC2-EN0060

4. ENGINE
EGR Temperature Sensor
GND Vin 044575-00X00
Figure 4-8-43
Part No. 129A00-13752

Intake Temperature Sensor
GND Vin 044574-00X00
Figure 4-8-44
Part No. 129A00-12721

4-8-31 172663 0BKC2-EN0060

4. ENGINE
Fuel Temperature Sensor (equipped on supply pump)
MPROP
Fuel temperature sensor
037312-00E00
Figure 4-8-45
Part No. 129A00-51200

Cooling Water Temperature Sensor
Vout
M12x1.5 GND
037249-00X00
Figure 4-8-46
Part No. 129927-44900

4-8-32 172663 0BKC2-EN0060

4. ENGINE
Diesel Particulate Filter (DPF) Inside/Inlet, Exhaust Temperature Sensor
GND Vout
037254-00X00
Figure 4-8-47
Exhaust temperature DPF inside exhaust DPF inlet exhaust

sensor temperature sensor temperature sensor
Part No. 129A00-13770 (Main) 129C00-13950 (Main) 129C00-13940 (Main)
Sensor installation tightening torque 25 - 40 N·m 25 - 40 N·m 25 - 40 N·m
Safety precaution Do not lift the DPF by holding the sensor part.
Note: The parts numbers for the sensors are different depending on the engine model.
Refer to the parts catalog for the correct parts number when replacing.
Rail Pressure Sensor
GND Vout Vin
037318-00X00
Figure 4-8-48
Part No. 129A00-57100

4-8-33 172663 0BKC2-EN0060

4. ENGINE
EGR Pressure Sensor
PS-X429
**** **
Vin Vout (Intake side)
GND Vout (Exhaust side)
BLANK BLANK
Intake side 40° 40° 40°

ALLOWABLE 40° ALLOWABLE
MOUNTING ANGULAR MOUNTING ANGULAR
Exhaust side
037257-00E00
Figure 4-8-49
Part No. 129978-12700

4-8-34 172663 0BKC2-EN0060

4. ENGINE
Diesel Particulate Filter (DPF) Differential Pressure Sensor
PS-X434
**** ** Vin Vout (High pressure side)
GND Vout (Differential pressure side)
BLANK Vout (Low pressure side)
40° 40° ALLOWABLE

High pressure side MOUNTING ANGULAR
40° ALLOWABLE
40° MOUNTING ANGULAR
Low pressure side
037255-00E00
Figure 4-8-50
Part No. 129978-17700

If you install a pipe to the DPF differential pressure
sensor, do not install it as shown in the below figure. If
water collects, the pressure cannot be detected.
Good Bad
Diff. press. sensor Diff. press. sensor
Safety precaution
Pipe
Water collects
037256-00E00
Differential pressure sensor pipe installation (example)
4-8-35 172663 0BKC2-EN0060

4. ENGINE
EGR Valve
CAN-L GND
CAN-H Vin
037280-00X00
Figure 4-8-51
4TNV88C
Part No. 129C00-13901
4-8-36 172663 0BKC2-EN0060

4. ENGINE
Intake Air Throttles
M- Vout1
Motor terminal
M+ Vin
Sensor terminal
Vout2
GND 037319-00E00
Figure 4-8-52
Part No. 129A00-12900

Sensor installation tightening torque 9.0 ± 1.8 N·m
Be sure to read the precautions before handling the
Safety precaution
intake throttle.
4-8-37 172663 0BKC2-EN0060

4. ENGINE
4-9 Electric Wiring
4-9-1 Electric Wiring Precautions
Failure to follow these precautions may result in

the failure of an electrical component and the loss NOTICE
of warranty coverage on that item as well as Removing the battery cables or the battery while
related items. Make sure that all users read and the engine is operating may cause damage to the
understand these precautions. current limiter depending on the electrical
equipment being used. This situation could cause
NOTICE loss of control of output voltage. The continuous
high voltage of 23 - 24 V (for 5000 min-1 (rpm)
Do not reverse the positive (+) and negative (-) dynamo) will damage the current limiter and other
ends of the battery cable. The alternator diode and electrical equipment.
stator coil will be damaged.
NOTICE
NOTICE
Reversing the battery cable connections at the
When the battery indicator goes out, it should not battery or on the engine will destroy the SCR diode
come on again. The battery indicator only comes in the current limiter. This will cause the charging
on during operation if the alternator fails. However, system to malfunction and may cause damage to
if an LED is used in the battery indicator, the LED the electrical harnesses.
will shine faintly during normal operation.
NOTICE
Make sure that the combined total resistance of
the battery cable in both directions between the
starter motor and the battery is within the value
indicated in the Battery Cable Resistance chart in
the Electric Wiring Section of this manual. The
starter motor will malfunction and fail if the
resistance is higher than the specified value.
4-9-1 172663 0BKC2-EN0060

4. ENGINE
4-10 Failure Diagnosis
4-10-1 Special Service Tools
13 -0.1
0
16mmx18/1inch
(Whitworth screw thread)
13
ø13
25
82
18
For measuring compression pressure
(5)
Compression
YANMAR Part No.129978-92950
gauge
(141)
(1)
(ø16)
68
ø17
R0
.2
17
0
ø7.2 -0.1
043931-00E00
4-10-1 172663 0BKC2-EN0060

4. ENGINE
4-10-2 Troubleshooting by Measuring Compression Pressure
Decrease in compression pressure is one of the 10. Connect the diagnosis tool, SMARTASSIST-
major causes of increased blow-by gas (results in DIRECT (SA-D) with the engine key switch in
contamination and increased consumption of “ON” position, and cut the fuel injection to all
lubricating oil) and starting problems. The cylinders using “Active Control” function.
compression pressure is affected by the following For details, see P91 on SMARTASSIST-
factors: DIRECT operation manual.
• Size of clearance between the piston and 11. Install the specified gauge adapter along with a
cylinder gasket (129978-11871) at the cylinder to be
• Size of clearance of intake/exhaust valve measured. Fix with a retainer.
seats
• Gas leakage from nozzle gasket or cylinder 1 2
head gasket
The pressure will decrease due to increased parts
wear. Pressure decrease reduces the durability of
the engine.
Pressure decrease may also be caused by
damage to cylinders and pistons. This can occur
due to dust entering and wearing the piston rings
caused by contamination of the air cleaner
043938-00X03
element. Measure the compression pressure to
determine the condition of the engine. Figure 4-10-1
Compression Pressure Inspection 12. Attach a compression gauge to the adapter.
Procedures 13. Crank the engine until the compression gauge
reading is stabilized, and measure the
1. Warm up the engine.
compression pressure. (Figure 4-10-2)
2. Stop the engine and close the valves of the fuel
system.
3. Remove injector harnesses (couplers)
(1, Figure 4-10-1) from all cylinders.
4. Remove the fuel return hose (2, Figure 4-10-1)
from the injectors. (See Reassembly of injector
on page 3-7.)
5. Remove the high-pressure fuel injection lines
(injector to common rail) as an assembly.
6. Loosen the retainer mounting bolts that fix the
injector, and remove the retainer. 050405-00X00
7. Remove the injector and injector seat (gasket).

Figure 4-10-2
When removing the injectors, mark the cylinder
No. 14. After checking the compression pressure, turn
8. Connect all injectors and rail with a high- off the SMARTASSIST-DIRECT active control,
pressure pipe in the direction that will not affect communication, and engine key switch.
the inspection work. 15. Remove the compression gauge, specified
9. Attach the injector harnesses (couplers) to the adapter, and injector gasket.
injectors.
4-10-2 172663 0BKC2-EN0060

4. ENGINE
Attaching the Injector 3. Install the fuel return hose and injector
harnesses (couplers). For details, see
1. Remove the injector from the injector and the Reassembly of injector on page 4-3-7.
high-pressure fuel pipe set next to the engine,
and insert to the correct cylinder. Replace the 4. Open valves of fuel system.
injector gasket to new. 5. Start the engine and check for fuel leaks.
2. Remove the high-pressure fuel pipe from the
rail, replace it to new, and connect the rail and
injector.
■ Standard compression pressure (reference value)

Compression pressure at 250 min-1 Deviation between
Engine model
Standard Limit cylinders
3.14 - 3.34 MPa 2.45 - 2.65 MPa 0.2 - 0.3 MPa
4TNV88C
(32 - 34 kgf/cm2) (25 - 27 kgf/cm2) (2 - 3 kgf/cm2)
■ Engine speed and compression pressure (use for reference)
4.0
3.5
Compression pressure (MPa)
3.0
2.5
2.0
150 200 250 300 350 400 450
Engine speed (min-1) 050977-00EN02
Figure 4-10-3
4-10-3 172663 0BKC2-EN0060

4. ENGINE
4-10-3 Measured Value and Troubleshooting
When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective action

Clogged element Clean the element.
1 Air cleaner element Broken element
Replace the element.
Defect at element seal portion
2 Valve clearance Excessive or no clearance Adjust the valve clearance.
3 Valve timing Incorrect valve clearance Adjust the valve clearance.
Replace the gasket.
4 Cylinder head gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake/exhaust valve Sticking valve Replace the intake/exhaust valve.
5 Gas leak due to worn valve seat or
Valve seat Lap the valve seat.
foreign matter trapped in valve
Piston
6 Piston ring Gas leak due to scratching or wear Perform honing and use an oversized part.
Cylinder
4-10-4 Quick Reference Table for Troubleshooting
The following table summarizes the general trouble symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service
life.
For details of troubleshooting on electronic control (ECU), refer to the SA-D section in Tier 4
Troubleshooting Manual.
4-10-4 172663 0BKC2-EN0060

4. ENGINE
Failure Diagnostic List
Engine stall Insufficient Cooling

Symptoms and conditions of failures Defective start after start Defective rotation control engine output Noise/vibration Lubricant water Intake Exhaust Fuel Electrics/electronics
Starter not Starter Exhaust
Speed change by accelerator not available (constant speed)

Without load At work Exhaust color At work
rotate rotates fume
ECU indicator lamp not on just after key-on (2 seconds)

ECU indicator lamp on just after key-on (2 seconds)
Fuel mixed with water (oil-water separator lamp on)

Engine not start (stall after serial combustion)
Engine not start (not even initial combustion)
Prescribed ECU control function not operate

ECU indicator lamp not on just after key-on
Oil pressure too low (oil pressure lamp on)
Fuse meltdown, disconnection (repeated)

Noise other than combustion from engine
Overheated (water temperature lamp on)
Battery charge defect (charge lamp on)

Knocking noise at combustion too high
Specified speed setting not available
Pressure down (air cleaner lamp on)

Action Referenced page number
Fuel filter contaminated too early

Lubricant consumption too much
Return to low speed not smooth
Engine starts later then ever
ECU indicator lamp flashing

Fuel consumption too much
Lubricant mixed with water
Water temperature too low

Combustion noise uneven
Lubricant diluted with fuel
Exhaust temperature up
Engine vibration too big
White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Black
Much
None
Little
Cause
Intake/exhaust valve clearance      

Valve clearance adjustment See Measuring and Adjusting Valve
incorrect Clearance on page 4-2-24
Valve seat facing See Valve face and valve seat on page 4-
Compression failure at valve seat         
2-18.
Correction or replacement of intake/ See Removal of Intake/exhaust Valves
Intake/exhaust valve seizure           
exhaust valve on page 4-2-14.
Gasket replacement See Removal of Cylinder Head on
Cylinder head gasket blow-out   
page 4-2-13.
Piston ring sticking or breakage             Piston ring replacement See Removal of pistons on page 4-2-32.
Horning work and usage of over-sized See Honing and Boring on page 4-2-42.
Wear of piston ring, piston or cylinder       
parts
Repair or replacement See Installation of crankshaft on page 4-
Seizure of crank pin metal or bearing parts       
Engine system
2-46.
Closed gap position fault of piston ring     Correction of closed gap position See Removal of pistons on page 4-2-32.
Reverse assembling of piston ring     Correction of assembling See Removal of pistons on page 4-2-32.
Wear of crank pin metal and journal      
Measurement and replacement See Installation of crankshaft on page 4-
metal 2-46.
Tightening at specified torque See "3-7-2 Engine Tightening Torque"
Connecting rod bolt loose   
Foreign material entered into    
Disassembling and repair See Disassembly of Engine on page 4-
combustion chamber 2-27.
Gear mesh adjustment See Checking timing gear backlash on
Gear backlash too big 
page 4-2-28.
Wear of intake/exhaust valve guide    Measurement and replacement See Valve stem bend on page 4-2-17.
Open/close timing failure of intake/      
Valve clearance adjustment See Measuring and Adjusting Valve
exhaust valve Clearance on page 4-2-24.
Engine vibration isolating support    
Repair or replacement of faulty parts
loose, damage
Thermostat replacement See Engine Coolant Pump on page 4-
Radiator super cooled   
4-4.
Cooling water system
Thermostat replacement See Engine Coolant Pump on page 4-4-4

Insufficient radiator cooling   
or check for fan belt loose
Water leak inspection of cooling water See Engine Coolant Pump on page 4-4-4
Insufficient cooling water quantity   
system
Repair or replacement See Engine Coolant Pump on page 4-
Water jacket cracks   
4-4.
Fan belt elongation    Adjustment of belt tension
Inspection or replacement See Engine Coolant Pump on page 4-
Thermostat fault    
4-4.
4-10-5 172663 0BKC2-EN0060

4. ENGINE


rotate rotates fume









White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Black
Much
None
Little
Cause
Incorrect lubricant       Usage of correct lubricant

Repair See Disassembly of Oil Pump on page 4-
Lubricant system leakage  
5-3.
Lubricant system
Insufficient discharge rate of trochoid 

Inspection and repair See Disassembly of Oil Pump on page 4-
pump 5-3.
Lubricant filter clogged   Cleaning or replacement
Cleaning, adjustment or replacement See Disassembly of Oil Pump on page 4-
Regulator valve fault 
5-3.
Insufficient lubricant quantity   Replenishment of correct lubricant
Excess filling into crankcase    Engine oil check
Incorrect fuel         Usage of correct fuel
Water entered into fuel system          Drainage of fuel filter
Fuel filter clogged      Cleaning or replacement
Air entered into fuel system       Bleeding
Fuel system
Fuel pipe clogged, cracked    Cleaning or replacement

Insufficient fuel feeding to fuel supply     
Check of fuel tank cock, fuel filter, fuel
pump pipe, fuel feed pump
Valve in priming pump pinched dust See Fuel System Diagram on page 4-3-4.
Priming not available 
(disassembled cleaning)
Strainer at feed pump inlet clogged    Cleaning of strainer
Check of fuel tank and cap, as well as
Sealing defect of fuel tank   installation of
genuine parts
Air filter clogged         Cleaning of air filter
Intake
Engine operation at high temperature     

Consideration of matching output
or high land reduction with load
Exhaust pipe clogged       Cleaning of exhaust pipe
4-10-6 172663 0BKC2-EN0060

4. ENGINE


rotate rotates fume









White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Black
Much
None
Little
Cause
Inspection and replacement of fuse

Fuse meltdown, disconnection     
Repair or replacement of harness
Starter fault   Repair or replacement of starter See Starter Motor on page 4-6-1.
Alternator fault   Repair or replacement of alternator See Alternator on page 4-7-1.
Wiring disconnection        
disconnection
Wiring short-circuit (insulator broken), Inspection, repair or replacement of
electric power load of added device too   harnesses
big Review of added devices
Battery voltage descent   - Inspection and charging of battery

Key switch fault, disconnection   
Key switch replacement
Instantaneous interruption of key  
Key switch replacement
switch
Failure, disconnection, short-circuit of 
starter relay Replacement of starter relay
Electric system
Main relay fault Repair or replacement of harness For harness inspection method,
(Error other than contact sticking that   Replacement of main relay see Failure Diagnosis on page 4-10-1.
ECU can’t detect)
Actuator relay fault   
Replacement of actuator relay
(Error of contact that ECU can’t detect)
The start assist relay may be faulty.    
Replacement of start assist relay
(Error of contact that ECU can’t detect)
Accelerator sensor signal error    
Repair or replacement of accelerator Monitor the accelerator sensor by the
(Error at which level ECU can’t detect) sensor diagnosis tool.
Water temperature sensor signal error     
Replacement of water temperature Monitor the cooling water temperature by
(Error at which level ECU can’t detect) sensor the diagnosis tool.
Speed sensor signal error Cleaning or replacement of speed sensor Monitor the engine rotational speed by
(Cause of noise etc. that ECU can’t       Repair or replacement of fuel supply the diagnosis tool.
detect) pump
Rack position sensor signal error      

Repair or replacement of fuel supply Monitor the rack position sensor signal by
(Level that ECU can’t detect) pump the diagnosis tool.
Operation defect of rack actuator      
Repair or replacement of fuel supply Check the movement of rack actuator by
(Level that ECU can’t detect) pump the diagnosis tool.
Replace the lamp.
ECU failure lamp disconnected 
Repair or replace the harness.
ECU faulty (ECU self diagnosis failure)      Replace the ECU.
4-10-7 172663 0BKC2-EN0060

Engine stop or operation limits
by ECU failure diagnosis function
Cause
valve motor
accelerator sensor
Engine over speed

temperature sensor
Speed sensor signal error
CAN communication error

Disconnection/short-circuit of
ECU control function operating
Malfunction by ECU self-diagnosis

Disconnection/short-circuit of EGR
Disconnection/short-circuit of water
Symptoms and conditions of failures

rotate


Starter not

Defective start

Starter
rotates

None


4-10-8
Little
fume
Exhaust
after start
Much
Engine stall
4. ENGINE






Poor acceleration
172663 0BKC2-EN0060
Without load
Hunting
Hunting
Defective rotation control
At work
Normal



White
Insufficient
Black
Exhaust color
engine output

Noise/vibration

Lubricant

water

Cooling

Pressure up
Intake
White exhaust color
Black exhaust color

At work
Blow-by too much

Exhaust
Fuel











Electrics/electronics
pump
sensor
Not failure
ECU Replacement
ECU Replacement
Action
Implement regular usage
Replacement of EGR valve

Check speed sensor signal.

Replacement of water temperature
Replacement of accelerator sensor
Check operating machine’s driving.

Repair or replacement of fuel supply
starter restraint by a diagnosis tool.
Referenced page number
Check the causes of engine stop or

CHAPTER 5
ELECTRIC SYSTEM
5-1 Electric Equipment of Machine ........................................................... 5-1-1

5-1-1 Parts Layout of Electrical Equipment ......................................... 5-1-1
5-1-2 LCD Monitor and Alarm Systems............................................. 5-1-10
5-2 Circuit Description of Engine Start and Stop ...................................... 5-2-1
5-3 vCircuit Description of Engine Start and Stop..................................... 5-3-1
5-4 Engine ECU (engine controller) .......................................................... 5-4-1
5-4-1 Engine ECU ............................................................................... 5-4-1
5-4-2 Circuit Description of Auto Deceleration Mode .......................... 5-4-3
5-4-3 Circuit Description of Eco Mode................................................. 5-4-4
5-4-4 Control Functions....................................................................... 5-4-5
5-5 Error Code .......................................................................................... 5-5-1
5. ELECTRIC SYSTEM
5. Electric System
5-1 Electric Equipment of Machine
5-1-1 Parts Layout of Electrical Equipment
1) Main harness
1/2
A-11
A-17 A-23
A-16
A-15 A-22
A-13 A-14
A-21
A-20
A-29 A-19
A-18
A-12
A-27
A-24
A-25
A-38
A-35
A-62
A-39 A-6
A-4 A-63
Connect to
engine harness
J I H G A-7
Connect to
A-28
front harness
A A-58 A-66 A-64
Connect to
seat harness
E F
A-61
A-26 A-8
A-10
A-65 A-9
108440-00EN00
5-1-1 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
Ref. No. Part Ref. No. Part

A-4 Feed pump A-23 Buzzer
A-6 Diode (starter restraint) (Wiring color: Y/R, Y/B, L/B) A-24 Fuel gauge
A-7 Resister (starter restraint) A-25 Hydraulic oil temperature sensor
A-8 Travel pilot oil pressure switch A-26 Resister (travel alarm)
A-9 Single solenoid valve A-27 Diode (prevent reverse) (Wiring color: L/W, B)
A-10 Triple solenoid valve A-28 Resister (speed signal)
A-11 Engine control dial A-29 Diode (speed signal) (Wiring color: Sb, L/W, Lq)
A-12 Starter switch A-35 Engine oil pressure switch
A-13 Diode (head light) (Wiring color: Y/B, W/R, Lq) A-38 Glow plug
A-14 Light switch A-39 Starter
A-15 Auto deceleration switch A-58 Generator
A-16 ECO mode switch A-61 Resister (travel alarm)
A-17 Parking switch A-62 Diode (accelerator VCC)
(Wiring color: W, W/L, L/W)
A-18 Beacon lamp switch (option) A-63 Diode (accelerator GND)) (Wiring color: L/W, L, L/R)
A-19 Travel alarm switch (option) A-64 Diode (accelerator signal)
(Wiring color: O/W, O/L, Br)
A-20 Rear working lamp switch (option) A-65 Accelerator sensor (front)
A-21 DPF manual regeneration switch A-66 Accelerator sensor (rear)
A-22 LCD monitor
Each reference number (e.g., A-1) corresponds to the numbers described in Section "2-8 Wiring Diagram" and
"APPENDIX Wiring Diagram".
5-1-2 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
2/2
A-68 A-73 A-72 A-74 A-75

A-48
A-47 Forward A/D-1 Vessel A/D-2 Parking-1
A-53
A-52 A-46 Backward Safety Travel Parking-2 Parking-3
A-51 A-45
A-57 A-44 A-69 A-71 A-70 A-76 A-77
A-50
A-56 A-43 A-81 A-80 A-83
A-49
A-55 A-42 EGR
ACC-3 ACC-2
A-54 A-41
Starter Glow Valve
Engine Relay Relay Inter
ACC-1
A-40 Control Lock
A-79 A-82 A-86 A-85 A-84
(Relay, fuse box and battery cut switch removed)

A-32
A-67
A-30
A-78
A-33
A-5
A-60
A-34
A-37
A-36 A-31
A-59
View from A
108441-00EN00
5-1-3 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM

A-5 Diode (A/D resistant) (Wiring color: P, L/Y, Br) A-56 Slow blow fuse (Starter)
A-30 Diode (surge ACC1) (Wiring color: B, R/G) A-57 Slow blow fuse (Glow)
A-31 Diode (engine oil) (Wiring color: P, G/W) A-59 Battery
A-32 Resister (charge, oil, DPF lock) A-60 Battery cut off switch
A-33 Diode (charge, DPF lock) Wiring color: W/L, Gr/R, A-67 Engine ECU
P)
A-34 Diode (eco, A/D) (Wiring color: O, Gr, Br) A-68 Relay (forward) [No:CM1-R-12V]
A-36 Resister (eco, A/D) A-69 Relay (rearward) [No:CM1-R-12V]
A-37 Resister (A/D restraint) A-70 Relay (accelerator) [No:CM1-R-12V]
A-40 Fuse (power outlet) A-71 Relay (safety) [No:CM1-R-12V]
A-41 Fuse (alarm and travel) A-72 Relay (wagon) [No:CM1-R-12V]
A-42 Fuse (vessel) A-73 Relay (A/D 1: wagon) [No:CM1-R-12V]
A-43 Fuse (option-1) A-74 Relay (A/D 2: parking) [No:CM1-R-12V]
A-44 Fuse (lamp) A-75 Relay (parking 1: signal) [No:CM1-R-12V]
A-45 Fuse (controller-2) A-76 Relay (parking 2: release) [No:CM1-R-12V]
A-46 Fuse (LCD monitor -1) A-77 Relay (parking 3: lock) [No:CM1-R-12V]
A-47 Fuse (controller -1) A-78 Relay (travel dual speed) [No:CA1-DC12V-N]
A-48 Fuse (parking) A-79 Relay (ACC 1) [No:CM1-R-12V]
A-49 Fuse (LCD monitor-2) A-80 Relay (ACC 2) [No:CM1-R-12V]
A-50 Fuse (key switch) A-81 Relay (ACC 3) [No:CM1-R-12V]
A-51 Fuse (immobilizer) A-82 Relay (engine control) [No:CM1-R-12V]
A-52 Fuse (EGR valve) A-83 Relay (EGR valve) [No:CM1-R-12V]
A-53 Fuse (engine) A-84 Relay (inter lock) [No:CM1-R-12V]
A-54 Slow blow fuse (Main) A-85 Relay (glow) [No:CB1aH-12V]
A-55 Slow blow fuse (Charge) A-86 Relay (starter) [No:CB1aH-12V]
5-1-4 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
2) Seat harness
B-14
Three-side flaps wagon type Swing wagon type
B-13
B-8
B-9 B-1
B-1
Connect to
main harness
E F
B-5 B-12
B-7
B-11
B-10 B-6
B-2
B-4
B-3
108439-01EN00
5-1-5 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM

B-1 Seat direction switch (rearward) B-8 Wagon control lever (Swing wagon type)
B-2 Seat direction switch (forward) B-9 Wagon control lever (Three-side flaps wagon type)
B-3 Seat switch (backward) B-10 Power outlet
B-4 Seat switch (forward) B-11 Connector (SMARTASSIST-Direct)
B-5 Selector valve B-12 Connector (LCD monitor data)
B-6 Engine stop switch B-13 Resister (engine stop, DPF)
B-7 Travel lever B-14 Diode (engine stop, DPF) (Wiring color: B/R, O/B, L)
5-1-6 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
3) Front harness
Connect to
C-1 main harness A
C-3
C-2 104701-00EN00

C-1 Horn C-3 Head light (Right)
C-2 Head light (Left)
5-1-7 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
4) Engine
A-2 A-3
E-15
E-7 A-1
E-1
E-2
E-3 E-18
E-4
E-11
E-13
E-14
E-9
E-16 E-10
E-12
E-6
Connect to
main harness
G H I
E-17 Connect to
main harness
J E-8
E-5
074046-00EN01
5-1-8 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM

A-1 DPF differential pressure sensor E-9 Crank speed sensor
A-2 DPF intermediate temperature sensor E-10 Cam speed sensor
A-3 DPF inlet temperature sensor E-11 EGR pressure sensor
E-1 Injector #4 E-12 Intake temperature sensor
E-2 Injector #1 E-13 Coolant temperature sensor
E-3 Injector #2 E-14 Intake throttle
E-4 Injector #3 E-15 Intake manifold temperature sensor
E-5 Supply pump E-16 EGR gas temperature sensor
E-6 Rail pressure sensor E-17 Resistor
E-7 Exhaust manifold temperature sensor E-18 EGR valve
E-8 Fuel temperature sensor
5-1-9 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
5-1-2 LCD Monitor and Alarm Systems
For safer machine operation, the operator needs to have a clear understanding of the machine's condition. However,
it is difficult for the operator to keep an eye on every aspect of the machine he/she is operating.
Therefore, gauges and alarms are installed to warn the operator of any trouble of the machine at the early stage.
Note:
The monitors do not give a full assurance of the machine's condition. The indications shown on them should be used
as a guide for daily check and periodic maintenance according to the operation and maintenance manual.
1) Part Name
LED lamps
Caution lamp
Information lamp
High beam lamp
Warning lamp
Hydraulic oil temp.
Parking brake lamp
lamp
High speed travel
lamp
Engine oil pressure lamp
Low speed travel lamp Battery charge lamp
Fuel consumption
10.0 ｌ
ｉｔ/ｈ
AM 10:00 LCD screen
Clock
Engine speed
h
Hour meter
1234.5 1500rpm
Fuel meter
Engine water temp.

meter
Function switches
Menu switch
menu F1 F2 F3 F4
F4 switch
F1 switch
F3 switch
F2 switch
072675-00EN01
5-1-10 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
2) Alarm Sensor Function

• When the starter switch is turned to the ON position, relevant LED lamps should come on and the buzzer should
sound for a few seconds, then the lamps should go out and the buzzer should stop.
• All the alarm lamps should remain off while the engine is running.
3) In the event of Machine Failure
In the event of machine failure, icon(s) and error code(s)
corresponding to the failure(s) are displayed on the LCD
screen and the warning and/or caution lamps flash, where
applicable.
For details of error codes, refer to Section 5-5.
00 000110.00
AM
10:00
h STOP
1234.5
menu F1 F2 F3 F4
046905-00X00
4) Sensor Operation
(1) Oil pressure switch (for detecting low engine oil pres-
sure)
When the engine oil pressure falls, the lamp comes on and
the buzzer sounds.
Starter switch Engine start

ON
Lamp
Lamp OFF
Engine oil ON Lamp
Buzzer sounds
pressure ON
Normal
Pressure drop
< 5.69 to 8.53 PSI
(< 0.04 to 0.06 MPa) 041589-01EN00
When this switch detects low engine oil pressure, it causes

the engine oil pressure warning lamp on the LCD monitor to
come on and the buzzer to sound.
• Working pressure: 5.69 to 8.53 PSI (39.2 to 58.8 kPa) PT1/8
• Installation position: Engine block
Terminal 0.945 in (24 mm)

038358-00EN00
5-1-11 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
If the buzzer sounds, the following items must be checked.

• Engine oil degradation
• Oil filter element clogging
• Oil pressure switch malfunction
For details of the inspection procedure, refer to "4-5-4 Checking Engine Oil Pressure"
• Pressure regulator malfunction
• Lube oil pump wear or breakage
(2) Coolant temperature sensor

This sensor displays the temperature of the engine coolant.
If the temperature of the engine coolant rises abnormally during operation of the machine, the water temperature
meter and the warning lamp flash and the error code and icon that indicate an abnormal coolant temperature are
displayed and at the same time the buzzer sounds.
Starter switch
ON
Lamp goes out two seconds later.
Lamp
Engine start Buzzer sounds
ON
Lamp Lamp
Coolant ON OFF
temperature Coolant temperature rise
> 225 to 235 °F
Normal (> 107 to 113 °C)
044688-02EN00
Turned on: Coolant temperature: 225 to 235 °F (107 to 113°C) M12×1.5(fine)

Turned off: Coolant temperature: 212 °F (100°C) or less
Installation position: Coolant pump on engine
(19 mm)
0.75 in.
If the buzzer sounds, checks must be carried out in accordance

with"4-4-6 Engine Coolant Pump" of Chapter 4 “Engine” and 041592-00EN00
Chapter 8 “Troubleshooting.”
(3) Battery charge

When a potential difference occurs between the output voltage of the alternator and the voltage of the battery, the
battery charge lamp comes on and the buzzer sounds, and at the same time, the caution lamp flashes.
Starter switch Engine start Lamp

ON Lamp Buzzer sounds.
ON
OFF
Lamp
Alternator’s Battery
ON
terminal voltage voltage
Normal Potential difference

(Voltage drop) 041593-01EN00
If the buzzer sounds, the following items must be checked.

• Battery degradation or malfunction
• Refer to Chapter 8 "Troubleshooting."
5-1-12 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(4) Fuel meter

When the starter switch is turned to the ON position, the fuel
meter is activated and indicates the fuel level in the fuel tank.
When the fuel level in the tank becomes low, the fuel meter
and the caution lamp flash. 050809-00X00
The remaining fuel level indication can change depending

on the inclination of the machine body, which does not con-
stitute a malfunction.
Fuel gauge unit
Full
126.1±4
3/4
(37.2)
(110°)
(60)
1/2
(143.8)
195±4
1/4
Empty
104626-00X00
Float position Resistance (Ω)

Full 10 +1.0
-0.5
1/2 32±3
Empty 80 +12
+2
(5) Hour meter

When the starter switch is turned to the ON position, the
hour meter is activated.
h
1234.5
046874-00X00
5-1-13 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(6) Hydraulic oil temperature sensor

This sensor measures the hydraulic oil temperature in the hydraulic oil tank.
M12×1.5 (fine)
Hydraulic oil tank
19 mm
104625-00EN00
(7) Accelerator sensor

Knob
The engine of this machine is equipped with an electronic
control governor that uses an accelerator sensor, instead of
a governor lever used by a mechanical governor, to set a
Nut
target engine speed. The engine speed is determined by
Washer
the voltage the ECU reads from the accelerator sensor.
The accelerator sensor is connected to the knob and
changes the voltage by sensing the position of the knob.
O-ring
Water proof ring
Accelerator volume 106040-00EN00
Accelerator pedal
Accelerator sensor
106041-00EN00
5-1-14 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(1) Accelerator volume (Engine control dial)
3 2 1
0.5RY 0.5Y 0.5BY

031938-00E
Parts No. 172A69-12100
(2) Accelerator sensor
B C 107692-00X00
Terminal Wire
A GND GND-A
B OUTPUT APS
C INPUT AVCC
Rated voltage DC 5 V ± 0.01 V

Part number 129A22-77800
Entire resistance (sensor resistance) 5 ± 1.5 kΩ
5-1-15 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(3) Accelerator Sensor Input
[1] The accelerator volume, for example, is explained below.

The ECU calculates a target engine speed as a control
standard based on the input voltage from the accelerator High idle
Target speed
sensor. (Note that the actual engine speed is not always 3.0
identical to the target engine speed because it is deter-
mined based on the relationship between the maximum
Low idle
engine torque and load torque.)
0.7
The accelerator sensor input voltage is converted into rota-
tional speed and as shown in the figure below, it is preset 0.2 4.6
so that the input voltage is converted into low idle speed at 0 5.0
Input voltage [V]
a voltage of 0.7V and into high idle speed at a voltage of
Sensor error Sensor error
3.0V.
If the input voltage from the accelerator sensor becomes Figure: Accelerator Sensor Input
029809-00E
0.2V or less or 4.6V or more, the ECU detects an accelera-
tor sensor failure.
[2] The ECU has a detection error in the electrical circuit and a hysteresis characteristic provided by software in
regard to the input voltage from the accelerator sensor, and the sum of these values is ±0.125V.
Therefore, when the accelerator sensor is used within a preset voltage range between 0.7V and 3.0V, the accel-
erator sensor input voltage must be within the range shown in the figure below.
High idle
Target speed
Low idle
0.2 0.7 3.0 4.6

5.0
Sensor input voltage [V]
Sensor error Sensor error
Low voltage side: 0.325V to 0.575V High voltage side: 3.125V to 4.475V
Figure: Accelerator Sensor Accuracy Requirements 029810-00E
5-1-16 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
5-2 Circuit Description of Engine Start and Stop
1. Engine Start
Starter switch is in "OFF" position. Starter switch 1A is always supplied with electric current from the battery.
(Battery → Slow blow fuse (Main) 120A → Fuse (Key switch) 5A → Starter switch
1A)
Engine ECU is supplied with electric Engine ECU K1, K3 and K5 are also always supplied with electric current from battery.
current. (Battery → Slow blow fuse (Main) 120A → Fuse (Engine) 20A → Engine ECU K1,
K3, K5)
Turn starter switch to "ON" position. Starter switch terminal BATT connects to BR1.
ACC-1 relay is actuated and terminals Starter switch (BATT → BR1) → Power relay (ACC-1)C
D and E are connected.
Electric current flows to Engine ECU Battery → Slow blow fuse (Main) 120A → Power relay (ACC-1) (E → D) → Fuse
K88, and Engine ECU perform the ini- (Controller-1 ACC) 5A → Engine ECU K88B
tial operation of common rail system
before engine startup.
Glow relay is activated by engine ECU Engine ECU K70 → Glow relay C
and glow is activated to heat the
engine. Heating time varies depending Battery → Slow blow fuse (Glow) 60A → Glow relay (A → D) → Glow plug
on coolant temperature.
Turn Starter switch to "START" position. Starter switch terminals BATT, BR1 and C1 are connected.
Electric current flows from Engine Engine ECU K73 → Starter relay (C → B) → Engine ECU K28
ECU K73 to Engine ECU K28 through
Starter relay, and Starter relay is actu-
ated. Terminals A and D of Starter
relay are connected.
Electric current is supplied from bat- Battery → Slow blow fuse (Starter) 60A → Starter relay (A → D) → Starter motor S
tery to Starter motor S through Starter Starter motor B is always supplied with electric current from battery.
relay, to rotate the starter motor. The magnetic switch of the starter motor is actuated, causing the pinion gear to
jump out.
At the same time, the crankshaft of the engine is rotated to start the engine.
2. Engine Stop
Turn Starter switch to "OFF" position.
Engine ECU performs the engine stop

control to stop the engine.
5-2-1 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
Starter switch diagram

POSITION B BR1 BR2 C2 C1
OFF
1
2
Starter switch
BATT
3
F02B R/G AVSS 0.5 f

K70 W/G AVSS 0.5 f
K35 Y/R AVSS 0.5 f

K73 L/G AVSS 0.5 f
K28 B/L AVSS 0.5 f
BR1 BR2 C1 C2
F04A R AVSS 2 f
F04B R AVSS 2 f
F04 R AVSS 2 f
1A 2A 2B 2C 2D
S10 W/G AVSSX 0.5 f

V01 W/R AVSSX 0.5 f
F01 R AVSSX 0.5 f
K70 K88B K28 K73 K35 K70 Graw plug relay K1 K3 K5
K88 Key SW
K28 Starter relay
K73 12V output
K35 Key SW
K01 ECUVB
K03 ECUVB
K05 ECUVB
Engine ECU
A50 K94 K32 K92 K66 K50 K41 K40 K15
K35 Y/R AVSS 0.5 f

K73 L/G AVSS 0.5 f
K28 B/L AVSS 0.5 f
K70 W/G AVSS 0.5 f
V01 W/R AVSSX 0.5 f

Z01 L/W AVSS 0.5 f
M04 O/L AVSS 0.5 f
G10H B AVSS 0.75 f
V01 W/R AVSSX 0.5 f
F02C R/G AVSS 0.5 f
K70 W/G AVSS 0.5 f
M04 O/L AVSS 0.5 f
Z01 L/W AVSS 0.5 f

K35 Y/R AVSS 0.5 f
AVSS 0.5 f
AVSS 0.5 f
R06 R/L AVSS 0.5 f

G10K B AVSS 0.5 f
B10C R/W AVS 2

AVX 3
B30 R/B AVS 3

AVS 3
B11 R/L AVS 2

E01 W AVX 3
R/W
L/G
R/L
B/L
S01
B40
K73
K28
D A CB D A C B EB D AC E B D A C
+ - + -
Relay Relay Relay Relay

(starter) (glow) (remote) (ACC1)
[No:CB1aH-12V] [No:CB1aH-12V] [No:CM1-R-12V] [No:CM1-R-12V]
Relay box
S01 R/W AVX 3 G10C B
E01 W AVX 3 AVSS 2 f
R06 R/L AVSS 0.5 f
F02C R/G AVSS 0.5 f F02B R/G
AVSS 0.5 f
Battery cut off Switch

B11 R/L AVS 2
G10CB B AVSS 0.5 f
B10B R/W AVS 3

Z01 L/W AVSS 0.5 f
R06 R/L AVSS 0.5 f
F02 R/G AVSS 0.5 f
F01 R AVSSX 0.5 f
2A 1A
B10A R/W AVS 5
S01 R/W AVX 3

F04 R AVSS 2 f
B10 R/W AVS 5
B10 R/W AVS 5

G00 B SEBB 60
G01 B SEBB 60
B11 R/L AVS 2

B30 R/B
B40 R/L
E01 W AVX 3
G10 B AVS 5
AVS 3
AVS 3
B01 R SEBB 60
B00 R AV 5
B00 R AV 5
B00 R
AVS 5
B00A R
2A 1A A
AVS 5
A B
SEBB 60
Earth
B01 R
Battery Earth
controller-1
key switch
A B A B A B
Glow
AVSSX 0.5 f
20A
1A 2A
AB AB A B Diode,
5A
5A
AVSS 0.5 f
plug To A06 of
Starter
engine
S10 W/G
prevent reverse
120A
Fuse,
Fuse,
Fuse,
M04 O/L
B
S
Glow
60A
60A
Main
Remote controller
M
F A G I L D E K J H B C
Slow blow fuse box Fuse box Starter
104627-00EN00
5-2-2 172663 0BKC2-EN0060

Chapter 5-3.fm 1 ページ２０１８年３月８日木曜日午後４時４７分
5. ELECTRIC SYSTEM
5-3 Circuit Description of Engine Start and Stop
1. Brake OFF
The engine starts
Both the right and left lock levers are Relay (safety) C connects to the battery via the cutoff lever R and cutoff lever L.
in release positions (Battery → Slow blow fuse (Main) 120A → Power relay (ACC-1) (E → D) → Fuse
(parking) 15A → Cutoff lever R (A → B)→ Cutoff lever L (A → B)→ Relay (safety))
The operator seat is held in Forward Parking switch B connects to battery via relay (forward) and relay (backward).
[Reverse] position (Battery → Slow blow fuse (Main) 120A → Relay (ACC-1) (E → D) → Fuse (park-
ing) 15A → Relay (backward) (E → B[D])→ Relay (forward) (D[B] → E) → Relay
(safety) (E → D) → Parking switches)
*When the operator seat is held in backward position, active terminals change to the
ones in [ ] for some relays.
When “OFF” position of the parking The triple solenoid valve connects to relay (safety) D.
brake switch is pressed, the triple *When the parking brake switch “OFF” is pressed.
solenoid valve is supplied with power (Relay (safety) D → Parking switch (B → A) → Relay (parking-3 lock) (E → B) →
from the battery to release the parking Triple solenoid valve)
brake. *When the parking brake switch lamp goes off and the parking brake switch returns
*The switch automatically returns to to the neutral position.
the neutral position. (Relay (safety) D → Relay (parking-2 off) (E → D) → Triple solenoid valve)
2. Brake ON
Move the lock lever to lock position When all four of these operations are done, the parking brake works because power
supply to the triple solenoid valve stops.
Set the operator seat in turning condition
Press “ON” position of the parking brake switch
Stop the engine
5-3-1 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
Cut off Cut off Seat direction Seat direction

switch (right) switch (left) switch (rearward) switch (forward)
A B A B B D A C B D A C
AVSS 0.75 f
AVSS 0.75 f
AVSS 0.75 f
AVSS 0.75 f
AVSS 0.75 f
AVSS 0.75 f
AVSS 0.75 f
F06B W/B
F06A W/B
F06 W/B
M21 Y/B
M11 R/L
M20 Lg
M10 G
Starter Parking
Triple solenoid valve switch switch
AVSS 0.75 f
BATT
F06 W/B
SOL1
SOL2
SOL3
3
ON
OFF
+ - + - + - BR1 BR2 C1 C2
1B 1A 2B 2A 3B 3A 1A 2A 2B 2C 2D F B C A H G
W/B AVSSX 0.75 f
V01 W/R AVSSX 0.5 f

T03E R/W AVSS 0.5 f
T01 W/R AVSSX 0.5 f

G10BB B AVSS 0.5 f
T03 R/W AVSS 0.5 f
G10B B AVSS 0.75 f
M26 O AVSSX 0.5 f

Y/B AVSS 0.5 f
F01 R AVSSX 0.5 f
T02 P AVSSX 0.5 f

R/L AVSS 0.5 f
Lg AVSS 0.5 f
F06B
M20
M21
M11
M21 Y/B AVSS 0.5 f

M20 Lg AVSS 0.5 f
M26 O AVSSX 0.5 f
T01 W/R
AVSSX 0.5 f
Relay box T02 P
AVSSX 0.5 f
Relay Relay Relay Relay Relay T03 R/W
(forward) (rearward) (safety) (parking 2: release) (parking 3: lock) AVSS 0.5 f
M11 R/L
[No:CM1-R-12V] [No:CM1-R-12V] [No:CM1-R-12V] [No:CM1-R-12V] [No:CM1-R-12V] AVSS 0.5 f
- + - + - + - + - +
E B D A C E B D A C E B D A C E B D A C E B D A C
M25 R/W AVSS 0.75 f
M25 R/W AVSS 0.75 f
W/R AVSSX 0.5 f

T01 W/R AVSSX 0.5 f
M23A Br AVSS 0.75 f
R/W AVSS 0.5 f

G10H B AVSS 0.75 f
R/L AVSS 0.5 f

T03 R/W AVSS 0.5 f
M21 Y/B AVSS 0.5 f
M11 R/L AVSS 0.5 f

M23 Br AVSS 0.75 f
O AVSSX 0.5 f
M26A O AVSS 0.5 f
M26 O AVSSX 0.5 f

M24 G AVSS 0.75 f
P AVSSX 0.5 f
T02A P AVSS 0.5 f
T02 P AVSSX 0.5 f

M20 Lg AVSS 0.5 f
M26
M11
T01
T02
T03
M20 Lg
AVSS 0.5 f
F06 W/B
AVSSX 1.25 f
M21 Y/B V01 W/R AVSSX 0.5 f
AVSS 0.5 f
Z01 L/W AVSS 0.5 f
AVSSX 0.5 f
G10A B AVSS 2 f
AVSS 0.5 f
V01 W/R
Z01 L/W
B10C R/W AVS 2

B10B R/W AVS 3
B11 R/L AVS 2
E B D A C
- +
Relay box G10H B
AVSS 0.75 f
Relay (ACC1) [No:CM1-R-12V] G10C B
AVSS 2 f
B11 R/L AVS 2
B10B R/W AVS 3
G10CB B AVSS 0.5 f
Z01 L/W AVSS 0.5 f
Battery cut off switch

B11 R/L AVS 2
AVSSX 1.25 f
2A 1A
AVSSX 0.5 f
G10 B AVS 5
G10 B AVS 5
B10A R/W
B10 R/W
SEBB 60
SEBB 60
F06 W/B
G00 B
G01 B
AVS 5
F01 R
AVS 5
B00 R AV 5 B00 R AVS 5
A 2A 1A
A B A B A B A B
(key switch)
(parking)
120A
15A
Earth
Main
5A
Battery
Earth Earth
Fuse
Fuse
Diode
Slow blow (prevent reverse)
Fuse box Fuse box
104995-00EN00
5-3-2 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
5-4 Engine ECU (engine controller)
5-4-1 Engine ECU
Ventilation filter
Engine ECU
104624-00EN00
(1) Circuit Symbols

The figure below shows the pin numbers of the engine ECU. In the electrical wiring diagram, a circuit symbol is indi-
cated as by those pin numbers with an additional letter “A” or “K”.
Engaging side
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 05 06 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
03 04
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 01 02 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
60 pin (A connector) 94 pin (K connector) 037224-00E00
Circuit symbols are indicated as by those pin numbers with an additional letter “A” or “K”.
Pin numbers of the engine ECU connector
(2) ECU specifications

Item Specifications
Rated voltage DC 12 V
Regulation Operating ambient temperature -40°F to 174°F (-40°C to 79°C)
Storage ambient temperature -40°F to 221°F (-40°C to 105°C)
Operating voltage range DC 9.0 V to 32.0 V
Basic Performance
Minimum operating voltage DC 6.0V Min.
5-4-1 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(3) Minimum operating voltage

The minimum operating voltage of the engine ECU is 6.0 V DC. If the engine ECU power supply voltage reaches
below 6.0 V, the engine ECU stops its operation. Once the power supply voltage is regained, the engine ECU is
restarted from the initial condition.
For example, in case of humping and injector energization in the compression process in cranking during low tem-
perature starting, engine start is disabled if the power voltage of engine ECU becomes 6.0 V or below even for a
moment. Be sure to check the battery voltage and engine ECU power voltage.
32.0V
ECU supply voltage（VB）
9.0V
more than 6.0V
NG
cranking running
031319-00E01
Engine ECU power supply voltage conditions at engine start
5-4-2 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
5-4-2 Circuit Description of Auto Deceleration Mode
The figure below shows the connection diagram for auto deceleration mode.
Batt.12V
VB
Engine ECU APP-IP6
APP-IP4
Relay Relay Deceleration

(A/D 1: wagon) (A/D 2: parking) permission
switch
GND (permitted when on)
Connection diagram for auto deceleration 050802-00EN01
The figure below shows the operation timing for auto deceleration mode.
Engine start
Deceleration permission ON
APP-IP6 OFF Less than 4s
Relay operation ON
APP-IP4 OFF
4s later Low idling 4s later Low idling 4s later Low idling
Operation speed speed speed
039580-00E01
Operation timing for auto deceleration mode

Only when the deceleration permission switch is ON (APP-IP6=ON) the automatic deceleration control mode can
activate.When the wagon lock release switch is not pressed for more than 4 seconds while the parking brake works,
the automatic deceleration control mode starts to work and the engine runs in low idling speed.
While the automatic deceleration control mode works, the engine runs in low idling speed independent of input volt-
age to acceleration sensor (or input voltage through CAN communication).
5-4-3 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
5-4-3 Circuit Description of Eco Mode
Electronic control governor has a feature which reduce the high idling speed when the APP-IP5 terminal is GND
connected.
The speed for high idling limitation can be switched by the condition of eco mode switch as shown in this figure.
Batt.12V
VB
Engine
ECU
APP-IP5
Eco mode
switch
GND
Eco mode switch

Limit speed
SW APP-IP5 (E5)
OFF Speed command from the accelerator
ON 2500 [min-1]
Eco mode function

050804-00EN02
5-4-4 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
5-4-4 Control Functions
(1) Structure of the Control Functions

The system overview of the electronic control system for engines conform to Tier 4 is shown in the figure below.
The engine controller (engine ECU) software can be roughly divided into functions as shown below.
1. Driver : The portion that connects the hardware with the software
2. Diagnosis function : The failure diagnosis portion for the engine or other control devices
3. Communication function : The communication portion with a checker or other ECUs
4. Engine control function : The fuel injection control and EGR control by the common rail system
(CRS)
5. Application function : The driven machine application functions such as the engine speed
instruction (acceleration), starter control, starting aid function (glow
plug), and interface portion with the device (CAN communication,
switches, and lamps)
6. DPF system control function : The PM detection and DPF regeneration control (intake air throttle
control, multi-stage injection) portions
Accelerator
Signal
OFF ON Starter
START CAN-Bus (1)
Key Glow plug

· Injector
Switch, light · High pressure pump
· Rail pressure
· Crankshaft,
camshaft speed
E-ECU · Fuel oil temperature
1. Driver CRS · Boost pressure
2. Diagnosis function
3. Communication function · EGR valve
4. Engine control function · EGR pressure
5. Application function · Intake/EGR gas/
6. DPF system control function
Exhaust gas temperature
EGR
· Intake throttle
SA-D TV
· Differential pressure
· Exhaust gas temperature
CAN-Bus (2) DPF
·J1939 (Implement)
·ISO15765 (SA-D) 044513-01EN00
System overview of electronic control system for engines conform to Tier 4
5-4-5 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(2) Engine Control Overview

1) Self-hold function of the engine ECU power supply
• Recording the history data
The engine ECU records the history of engine operations such as the failure history or operating hours on the
internal EEPROM. In order to avoid losing these history data, the engine ECU holds the power supply by itself
until the recording to the EEPROM is complete even when the key switch is turned OFF accidentally.
• EGR valve closing operation
The engine ECU moves the EGR valve to the fully closed condition when the engine is stopped so that the starting
sequence begins with the valve fully closed. Therefore, the engine ECU holds the power supply by itself until the
stop action of the EGR valve is complete when the key switch is turned OFF.
2) Starting control
The basic startup sequence of an engine is shown in the figure on the right. START
1. Engine ECU initial operation (Starter switch ON)
The engine ECU conducts the initial operation just after the starter switch input
is turned to ON. The engine ECU initial operation includes the learning
process of the EGR pressure sensor and DPF differential pressure sensor and 1 Engine ECU initial operation
the readout of the history data recorded in the EEPROM inside the engine
ECU without startup of the engine. It is necessary to restrain the starter
2 On glow control
operation by the starter motor relay and inhibit startup of the engine during the
engine ECU initial operation.
2. On-glow control
Is the key in the
The energizing time to the glow plug relay is controlled according to the start position?
(Starter input ON)
coolant temperature. This will illuminate the preheat lamp. When the on-glow
control is finished, the engine will wait until the starter switch is turned to the
START position.
3. Starting control 3 Start control
If the starter switch is turned to the START position (the starter input terminal is
ON), cranking starts and the engine speed is detected, the starting control is
initiated. Engine start?
4. Speed control
If the engine speed reaches equal to or greater than 600 min-1 (which varies
depending on the engine model), the controller transitions from the start 4 Speed control
control to the speed control. The injection volume is controlled through the 044515-00EN02
speed control so that the engine speed is kept at the speed instructed by the
Basic startup sequence
accelerator. The engine stops when the engine speed reaches 0 min-1, or the
starter switch is turned to OFF.
5-4-6 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(3) Regulation
There is a short delay before the engine speed is stabilized by the specified regulation in a certain situation, such as
when the engine load or speed has changed instantly.
The following engine regulation settings are available:
1. Isochronous
The speed is constant (regulation = 0 %) regardless of the load.
2. Virtual droop (the torque curve of the base engine)
Regulation with approximately 120 min-1 (which varies depending on the engine model) is performed regardless
of the speed.
The speed is maintained to reach a load factor of around 30 % so that the idle (no-load) speed does not change
even if the horsepower loss is somewhat changed after installation to a driven machine.
(2) Virtual droop

(1) Isochronous
120%
110%
100%
Mechanical governor droop

Torque
30%
Virtual droop high idle

Isochronous high idle
Low-idling speed 65 ~ 70% 100%

Engine speed 060902-00EN01
(Example) Conceptual figure of the standard torque curve
5-4-7 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(4) Isochronous Control at Low Idle Speed

The engine can be configured so that the engine speed will not decrease lower than the low-idling speed even while
the virtual droop is active.
Isochronous
at low idling speed Virtual droop
100%
Torque
Low idling speed High idling speed

Engine speed 060903-00EN00
Isochronous control at low idle speed

1) EGR control
The common rail engine provides NOx reduction by installing an electronic control EGR valve.
The engine ECU calculates the EGR valve opening based on the engine speed, engine load factor, intake air tem-
perature/EGR temperature/exhaust gas temperature, and EGR downstream/upstream pressures (intake air pres-
sure/exhaust air pressure) and adjusts the exhaust gas recirculation volume by controlling the EGR valve.
The EGR valve is active under normal warm conditions, however, it is designed not to open when the coolant tem-
perature is 60 °C or lower in order to prevent sulfuric acid corrosion of the engine under cold conditions due to con-
centration of exhaust gas components.
5-4-8 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(5) Electronic Acceleration

1) Acceleration input
Engine ECU calculates the target engine speed based on the input voltage from the acceleration sensor or the input
value from the CAN communication. (Because the actual engine speed is determined by the relationship between
the engine maximum torque and the load torque, it does not necessarily match the target engine speed.)
(6) Starting Aid Control
1) On-glow control (preheat)
When the starter switch is set to the ON position, the system automatically energizes the glow plug relay and keeps
it energized for a particular amount of time depending on the coolant temperature. The engine can configured the
system to turn ON the preheat light while the relay is being energized.
The preheat control status (preheat underway/stopping) is output via CAN communication.
The preheat time for on-glow control is configured as shown in the figure below.
35
30
Preheating time [s]
20
10
1s
0
-30 -20 -10 0 10 20 30 40 50
Coolant temperature [°C]
037812-01E00
On-glow control preheat time

2) Glow plug protection function
To protect the glow plug and glow plug relay, the relay is kept not to energize for a specified time after it is deener-
gized until it is reenergized. However, the state of the lamp depends on the state of ON/OFF control regardless of
the relay. The control status of glow plug is output via the CAN communication.
5-4-9 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(7) Starter Motor Restraint Control

On the YANMAR electronic control system for engines conform to Tier 4, the learning process for the EGR pressure
sensor and the DPF differential pressure sensor and readout of the history data recorded in the EEPROM inside the
engine ECU are performed as the engine ECU initial operation after the starter switch is turned to ON. Therefore, the
starter motor restraint control is performed by connecting the starter relay to the engine ECU as shown in the figure
below in order to prevent the engine from being started during the engine ECU initial operation. (“Starter motor
restraint” means restraining the starter motor from rotating.)
VB
CAN (Y_EC)
Engine stop 1 SW Starter permission 1 SW
NO (Option: NC) NO (Option: NC) START SW
ECU IGN SW
APP-IP9
ON
SHUDNSW Starter OFF START
Relay
Key SW
STR-RLY
B
Permission 1 Logic setup GND S Battery
SW Starting
NO (standard) NC (Option)
motor
OFF (Open) Restraint Permission
ON (Close) Permission Restraint NO: Normally Open
NC: Normally Close
037235-00EN04
(8) Engine Stop Function

Beside an overload and lack of fuel, the causal factors of engine stop (hereinafter referred to as “engine stop factor”)
include the following.
(1) Method by starter switch
(2) Method by external switch
(3) Control fault detection
(1) Method by starter switch

When the starter switch is turned to OFF, engine ECU performs engine stop control to stop the engine.
(2) Method by external switch (SHUDNSW terminal)

Connect an engine stop switch to the SHUDNSW terminal and turn ON the engine stop switch.
(3) Fault detected by the engine ECU

The engine may stop due to a fault detected by the engine ECU.
5-4-10 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(9) Engine Fault Detection

The engine ECU can be connected with various engine fault detection sensors as shown in the figure below, in addi-
tion to electronic control sensors. Fault handling actions performed depending on the status of each sensor are con-
figured, and the engine ECU outputs the status of each sensor through the CAN communication.
The figure below shows standard circuit as an example. For details of circuit connections on each model, refer to
wiring diagram.
Batt.12V Power supply 12 V Power supply 12 V
VB Resistance
or lamp Air cleaner Prefilter
Light (option) (option)
WSSW
ACLSW
ECU CHGSW
LOPSW
Oil pressure Charge

SW (option) Light Light
(option)
GND
037246-00EN07
5-4-11 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(10)CAN Communication Function

The engine ECU is complete with a single CAN communication port that can be used for either communications with
SMARTASSIST-Direct (SA-D) or communications with another controller (inter-ECU communications).
Through inter-ECU communications, the engine ECU can receive various control commands such as target speed
instructions from the ECU of the driven machine. In addition, the engine ECU sends control state information such
as the actual engine speed as well as information commands such as error codes to the ECU of the driven machine.
CAN Bus
Other Controllers
ISO 11898 Ver2.0B
•Error code
•Control Status
•Operation Command
SAE
J1939
Service Tool
(SMARTASSIST-Direct)
Microsoft Windows
PC
ISO15765
&
Monitor ISO14229
• Control status
• Data logging
Diagnostics
• Error code
• Diagnostics test
• Historical data
System Configuration E-ECU

• Compensation data 250/500kbps
ID:29bit
044543-00EN03
CAN communication overview
5-4-12 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
(11)Diesel Particulate Filter (DPF) System Control

1) Overview
YANMAR’s DPF system continuously burns particulate matter that accumulates on the SF (soot filter). This is called
DPF regeneration.
Electrical equipment such as the DPF differential pressure sensor, temperature sensors and intake throttle are
installed to the DPF system. If the DPF can not continue to regenerate while operating at low load, the engine ECU
automatically assist the DPF regeneration (DPF regeneration assistance) using the electrical equipment and avoid-
ing accumulation of particulate matter.
The table below shows the outline of DPF regeneration assistance. YANMAR uses an original DPF regeneration
method that combines regeneration by the regeneration assistance devices (intake air amount control by the intake
throttle and extension of the injection timing by the common rail) and regeneration by the common rail multi-step
injection (post-injection by the common rail).
Outline of DPF regeneration control
Terminology Control content Explanation Remarks

Self regeneration Regeneration without regenera- In a high speed and high load opera- These regenerations can be per-
tion assist unit (normal) tion, the exhaust temperature rises formed during operation. No
and PM are burnt and removed con- operator intervention is needed.
tinuously.
Assist regeneration Regeneration with regenera- In a low speed and low load opera-
tion assist unit. tion, the exhaust temperature is too
Reset regeneration Regeneration with assist regen- low for continuous regeneration.
eration and post injection Therefore engine ECU automatically
performs the regeneration controls
shown on the left to increase the
exhaust temperature and burn/
remove PM.
Stationary (manual) Regeneration with more effec- In a low speed/low load operation When the DPF regeneration icon
regeneration tive reset regeneration and continuing long time, the assisted is displayed, the operator should
automatic control to engine regeneration/reset regeneration may move the driven machine to a
speed suitable for DPF regener- not be enabled because the exhaust safe place without any flammable
ation temperature does not rise sufficiently. matters nearby to perform the
If the PM deposit amount reaches a stationary (manual) regeneration.
certain level in this situation, the DPF For details of operation, refer to
regeneration request icon is dis- Operation manual.
played and the caution lamp flashes. Do not perform any working oper-
At that time, the operator can start the ation because a special control
stationary (manual) regeneration to dedicated for DPF regeneration
burn/remove PM by operating the takes place.
DPF regeneration switch.
5-4-13 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
The figures below show a conceptual figure and the state transitions of DPF regeneration control in YANMAR DPF
system.
Too high
Stationary regeneration
(manual)
12g/l
Accumulated PM amount
Self- Assist regeneration Reset regeneration

High
regeneration (automatic) (automatic)

8g/l
Moderate
Stationary regeneration
Low
permission
50hr 100hr
Engine operating hours 044544-00EN00
Conceptual figure of DPF regeneration control in YANMAR DPF system
PM amount does not decrease

during a regular time.
100hr
More than a threshold

100hr of PM amount
Reset Passive Assist
More than a regular time
More than a or less than a threshold
regular time of PM amount
Man. SW is pressed More than a regular time and

for specified time after less than a threshold of PM amount
50 minutes have passed
Stationary
Stationary
regeneration request
(Manual regeneration)
(Manual regeneration)
More than a threshold Press Man.SW for 3 seconds in
of PM amount following conditions:
1. Lock lever: locked
2. RPM: low idle
3. Engine warmed up
More than a regular time or More than PM amount threshold or more

more than a threshold of PM amount than PM amount threshold after 30 minutes have passed
When ash level is too high
Ash BackUp BackUp Limited output SA-D Recovery

Ash level Cleaning Mode Mode · Limited torque
too high Required (Ash Hi) (Soot Hi) · Limited RPM
044545-01EN00
Transition of DPF regeneration control in standard DPF system
5-4-14 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
1) DPF regeneration and operator interface

The YANMAR DPF system offers DPF regeneration and operator interfaces including lamps for DPF alarm display
and switches for DPF regeneration control operation as shown in the figure below. Beside these contact input/output
terminals, it also offers CAN communication interfaces.
Batt.12V Batt.12V
Panel display Switch
VB
Regeneration request
Exhaust temperature
Red engine stop
Amber Warning
Regeneration
Regeneration
Regeneration
Regeneration
prohibition
prohibition
(option)
(option)
Buzzer
Failure
approval
request
FAIL-LMP
REOP3
REOP4
DPF-M3
DPF-M1
ECU DPF-M4
REGSW
DPF-M2
REGMSW
REOP2
CAN
GND
044546-00EN01
Example of wiring diagram used for DPF regeneration & operator interface
Specifications of switches
Name Specification
DPF regeneration Used for starting manual stationary regeneration.
request switch
DPF regeneration inhibit • Used for inhibiting manual reset generation.
switch (option) • Used for interrupting reset/stationary regeneration.
Interlock switch Because engine-ECU changes the target engine speed automatically in stationary regeneration, it is
necessary to inform engine-ECU that the interlock mechanism such as the parking brake, neutral is
enabled (drive force interrupted). This switch is used.
5-4-15 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
The table below shows operator interface displays and operations.

[1] Self regeneration (normal operation) and assist regeneration operating
LCD monitor DPF regeneration switch with lamp
10.0 ｌｉｔ/ｈ
AM 10:00
ｈ
1234.5 1500rpm
073995-00EN01
Description
• When 50 hours have passed since the last reset/stationary regeneration, DPF transfers to the state [2] described below.
[2] Self regeneration (normal operation) and assist regeneration operating (Elapsed time since last reset: 50 hours or more)
10.0 ｌｉｔ/ｈ
AM 10:00
ｈ
1234.5 1500rpm
073995-00EN01
Description
• When 100 hours have passed since the last reset regeneration, reset regeneration is started automatically (transfer to [3]
described below).
• When 50 hours have passed since the last reset regeneration, stationary regeneration execution is permitted.
• At that time, setting the interlock switch to lock position and holding the DPF regeneration switch to “ON” state for 10 sec-
onds or more causes DPF to transfer to the stationary regeneration standby state ([4] described later). For the operation
method after the stationary regeneration standby state, refer to [4] described later.
5-4-16 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
[3] Reset regeneration operating (Elapsed time since last reset: 100 hours)
10.0ｌｉｔ/ｈ
AM 10:00
ｈ
1234.5
060898-00EN01
Description
• The reset regeneration is completed in approximately 25 to 30 minutes. (After the reset regeneration completion, DPF
transfers to [1] described before.)
• As in [2] described before, setting the interlock switch to lock position and holding the DPF regeneration switch to “ON”
state for 10 seconds or more causes DPF to transfer to the stationary regeneration standby state ([4] described later).
[4] Stationary regeneration standby
00 003719.16
AM 10:00
ｈ
1234.5
060899-00EN02
Description
• An operator intervention ([2], [3] above) (hereinafter referred to as “Allow state”) or detection of certain PM deposit
amount or more (hereinafter referred to as “Emergency state”) causes DPF to transfer to the stationary regeneration
standby.
• When the transition is made from the above “Allow” condition to the stationary regeneration standby, only the DPF regen-
eration request icon is displayed on LCD monitor. When PM accumulation transits in the above emergency condition, the
regeneration icon and alarm lamp go on and the error code "00 003719.16" is displayed.
• Make sure to refer to operation manual and confirm the operation procedures and precautions for the DPF stationary
(manual) regeneration before starting stationary regeneration (transfer to [5] described later).
• If a certain length of time elapses and/or the PM deposit amount reaches to or above a certain level, DPF automatically
transfers to the backup mode ([6] described later).
5-4-17 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
[5] Stationary regeneration operating
10.0ｌｉｔ/ｈ
AM 10:00
ｈ
1234.5
060898-00EN01
Description
• The stationary regeneration is completed in approximately 25 to 30 minutes. (After the stationary regeneration comple-
tion, DPF transfers to [1] described before.)
• If the stationary regeneration has started in the Allow state, setting the interlock switch to unlock position interrupts the
stationary regeneration and DPF transfers to the state [2] described before.
• If the stationary regeneration has started in the Emergency state, any of the following operations interrupts the stationary
re-generation and DPF transfers to the stationary regeneration standby state ([4] described before).
• When the interlock switch is set to unlock position
• Command an accelerator position equal to or more than the minimum position
• Turn starter switch to OFF
[6] Backup mode
00 003719.00
AM 10:00
ｈ
1234.5
060900-00EN01
Description
• In the backup mode, the engine is operated with speed limit and max. injection amount limit.
• In the backup mode, error code for the relevant factor as listed below is displayed along with the specified error code: "00
003719.00".
1. If PM deposit amount (C method) is equal to or larger than a certain amount, error code: "00 522573.00"
2. If PM deposit amount (P method) is equal to or larger than a certain amount, error code: "00 522574.00"
3. If PM deposit amount is equal to or larger than a certain amount even after stationary regeneration has been executed for
a specified time, error code: "00 522575.07"
4. If a certain length of time elapses in stationary regeneration standby state, error code: "00 522577.11"
• To cancel the backup mode, it's necessary to use SMARTASSIST-Direct (SA-D).
5-4-18 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
5-5 Error Code
The LCD monitor and the controllers including the engine ECU are connected via CAN.
If the LCD monitor or any of the controllers detects an abnormality, an error code corresponding to the abnormality is
displayed on the LCD monitor. For detailed description of error codes, refer to the error code list.
Connecting SMARTASSIST-Direct (SA-D), a controller failure diagnosis tool, to the controllers allows checking of
detailed failure information and history for the engine ECU as well as implementation of status monitoring and diag-
nostic tests.
For detailed information and operation of SA-D, refer to the SMARTASSIST-Direct operation manual and the engine
troubleshooting manual.
Note:
Information on the LCD monitor cannot be checked by SA-D.
Engine ECU
CAN
LCD monitor
SMARTASSIST-Direct
Indicate error code Coupler Interface box
Windows PC
073999-00EN00
5-5-1 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
1) SA-D Connection Procedure

(1) Remove the terminal cover from the SA-D coupler to connect the interface box cable to the SA-D coupler as
shown below.
(2) Turn the starter switch to the ON position and start the SA-D software.
• For details of the SA-D software operation method, refer to the SMARTASSIST-Direct operation manual.
• When the starter switch is in the OFF position, SA-D cannot communicate with the controllers.
(3) To remove SA-D, first turn the starter switch to the OFF position, then disconnect the SA-D coupling cable from
the coupler and connect the coupler to the original coupler under the seat. Then, close the seat mount cover.
Coupling cable
Coupler
Cover
USB
Windows PC Interface box

SMARTASSIST-Direct 104623-00EN00
5-5-2 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
Error Code List
Error code Classification Error description Detection condition Causes Corrective measures
Check the connector, wire harness, intake throttle position sensor

1. Improper connector engagement, 2. Faulty wire harness,
Intake throttle position sensor malfunction: High The sensor voltage is higher than 4.8 V when the and engine ECU. Turn the starter switch to the "OFF" position and
00 000051.03 Caution 3. Intake throttle position sensor failure, 4. Engine ECU internal cir-
voltage engine is not cranking. then to the "ON" position to check if the error code is displayed
cuit failure
again.
Check the connector, wire harness, intake throttle position sensor
Intake throttle position sensor malfunction: Low The sensor voltage is lower than 0.2 V when the and engine ECU. Turn the starter switch to the "OFF" position and
00 000051.04 Caution 3. Intake throttle position sensor failure, 4. Engine ECU internal cir-
cuit failure
again.
1. Improper connector engagement, 2. Faulty wire harness, Check the connector, wire harness, accelerator sensor and engine
00 000029.03 Caution Accelerator sensor malfunction: High voltage The sensor voltage is higher than 4.0 V. 3. Accelerator sensor (pedal) failure, 4. Engine ECU internal circuit ECU. Turn the starter switch to the "OFF" position and then to the
failure "ON" position to check if the error code is displayed again.
1. Improper connector engagement, 2. Faulty wire harness (Sensor Check the connector, wire harness, accelerator sensor and engine
00 000029.04 Caution Accelerator sensor malfunction: Low voltage The sensor voltage is lower than 0.2 V. 5V disconnection or short to ground), 3. Accelerator sensor (pedal) ECU. Turn the starter switch to the "OFF" position and then to the
failure, 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
1. Improper connector engagement, 2. Faulty wire harness, Check the connector, wire harness, accelerator sensor and engine
00 000091.03 Caution Accelerator sensor malfunction: High voltage The sensor voltage is higher than 4.6 V. 3.Accelerator sensor (pedal) failure, 4. Engine ECU internal circuit ECU. Turn the starter switch to the "OFF" position and then to the
failure "ON" position to check if the error code is displayed again.
1. Improper connector engagement, 2. Faulty wire harness (Sensor Check the connector, wire harness, accelerator sensor and engine
00 000091.04 Caution Accelerator sensor malfunction: Low voltage The sensor voltage is lower than 0.2 V. 5V disconnection or short to ground), 3. Accelerator sensor (pedal) ECU. Turn the starter switch to the "OFF" position and then to the
failure, 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
1. Low engine oil pressure, 2. Engine lubrication system failure,
After the engine starts, the engine oil pressure switch Check the amount of engine oil, engine lubrication system, wire har-
3. Faulty wire harness (Engine oil pressure switch wire short to
stays on for a specific period of time at an engine ness, engine oil pressure switch and engine ECU. Turn the starter
00 000100.01 Warning Low engine oil pressure alarm ground), 4. Engine oil pressure switch failure (Short to ground on a
speed of 600 min-1 or more and at a battery voltage of switch to the "OFF" position and then to the "ON" position to check
wire inside the engine oil pressure switch), 5. Engine ECU internal
9V or more. if the error code is displayed again.
circuit failure
1. Improper connector engagement, 2. Faulty wire harness (Engine
Before the engine starts with the starter switch in the oil pressure switch wire disconnection or short to power), 3. Engine Check the connector, wire harness, engine oil pressure switch and
00 000100.04 Warning Engine oil pressure switch disconnection "ON" position, the engine oil pressure switch stays off oil pressure switch failure (Wire disconnection or short to power on engine ECU. Turn the starter switch to the "OFF" position and then
for one second at a battery voltage of 9 V or more. a wire inside the engine oil pressure switch), 4. Engine ECU internal to the "ON" position to check if the error code is displayed again.
circuit failure
1. Improper connector engagement, 2. Faulty wire harness (Sensor
Check the connector, wire harness, EGR pressure sensor and
EGR low pressure-side sensor malfunction: The sensor voltage is higher than 4.8 V when the signal wire short to ground), 3. EGR pressure sensor failure
00 000102.03 Warning engine ECU. Turn the starter switch to the "OFF" position and then
High voltage engine is not cranking. (Improper sensor output due to short to ground on a wire inside the
to the "ON" position to check if the error code is displayed again.
EGR pressure sensor), 4. Engine ECU internal circuit failure
EGR low pressure-side sensor malfunction: The sensor voltage is lower than 0.2 V when the 1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
Low voltage engine is not cranking. pressure sensor failure, 4. Engine ECU internal circuit failure
The final offset value for the intake manifold pressure Check the connector, wire harness, EGR pressure sensor and
EGR low pressure-side sensor malfunction: 1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
00 000102.13 Warning is lower than the threshold value or higher than the engine ECU. Turn the starter switch to the "OFF" position and then
Abnormal learning value pressure sensor failure, 4. Engine ECU internal circuit failure
threshold value. to the "ON" position to check if the error code is displayed again.
Check the connector, wire harness, intake manifold temperature
Intake manifold temperature sensor malfunc- The sensor voltage is higher than 4.8 V when the sensor and engine ECU. Turn the starter switch to the "OFF" posi-
00 000105.03 Warning 3. Intake manifold temperature sensor failure, 4. Engine ECU inter-
tion: High voltage engine is not cranking. tion and then to the "ON" position to check if the error code is dis-
nal circuit failure
played again.
Check the connector, wire harness, intake manifold temperature
Intake manifold temperature sensor malfunc- The sensor voltage is lower than 0.2 V when the sensor and engine ECU. Turn the starter switch to the "OFF" posi-
00 000105.04 Warning 3. Intake manifold temperature sensor failure, 4. Engine ECU inter-
tion: Low voltage engine is not cranking. tion and then to the "ON" position to check if the error code is dis-
nal circuit failure
played again.
5-5-3 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
Check the atmospheric pressure sensor and engine ECU. Turn the
Atmospheric pressure sensor malfunction: High The sensor voltage is higher than 4.8 V when the 1. Failure of atmospheric pressure sensor inside engine ECU,
00 000108.03 Caution starter switch to the "OFF" position and then to the "ON" position to
voltage engine is not cranking. 2. Engine ECU internal circuit failure
check if the error code is displayed again.
Check the atmospheric pressure sensor and engine ECU. Turn the
Atmospheric pressure sensor malfunction: Low The sensor voltage is lower than 0.2 V when the 1. Failure of atmospheric pressure sensor inside engine ECU,
voltage engine is not cranking. 2. Engine ECU internal circuit failure
1. Failure of atmospheric pressure sensor inside engine ECU,
The final offset values for both the intake manifold 2. Engine ECU internal circuit failure, 3. Abnormal characteristics of Check the atmospheric pressure sensor and engine ECU. Turn the
Abnormal atmospheric pressure sensor charac-
00 000108.10 Caution pressure and the exhaust manifold pressure remain at both EGR high pressure-side and low pressure-side sensors, starter switch to the "OFF" position and then to the "ON" position to
teristics
5 kPa or higher for 600 ms. 4. Obstruction due to foreign matter in the sensor area or frozen check if the error code is displayed again.
sensor
Check the amount of engine coolant, engine cooling system and
1. Engine overheating, 2. Insufficient engine coolant, 3. Engine
Abnormally-high coolant temperature (Over- 60 seconds after the engine starts, the coolant tem- coolant temperature sensor system. Turn the starter switch to the
00 000110.00 Warning cooling system failure, 4. Coolant temperature sensor system fail-
heating) perature remains at 110°C or higher for 20 seconds. "OFF" position and then to the "ON" position to check if the error
ure
code is displayed again.
ground wire disconnection or short to power, sensor signal wire dis- Check the connector, wire harness, coolant temperature sensor and
Coolant temperature sensor malfunction: High The sensor voltage is higher than 4.8 V when the
00 000110.03 Warning connection or short to power), 3. Coolant temperature sensor failure engine ECU. Turn the starter switch to the "OFF" position and then
voltage engine is not cranking.
(Improper sensor output due to wire disconnection inside the cool- to the "ON" position to check if the error code is displayed again.
ant temperature sensor), 4. Engine ECU internal circuit failure
Check the connector, wire harness, coolant temperature sensor and
Coolant temperature sensor malfunction: Low The sensor voltage is lower than 0.2 V when the signal wire short to ground), 3. Coolant temperature sensor failure
voltage engine is not cranking. (Improper sensor output due to short to ground on a wire inside the
coolant temperature sensor), 4. Engine ECU internal circuit failure
1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump and rail pressure sensor. Turn
The rail pressure remains at 170 MPa or higher for a
00 000157.00 Warning Abnormally high rail pressure failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system the starter switch to the "OFF" position and then to the "ON" posi-
specified period of time (5 seconds).
failure (Air intrusion, fuel shortage) tion to check if the error code is displayed again.
Check the connector, wire harness, rail pressure sensor and engine
The sensor voltage is higher than 4.75 V when the 1. Improper connector engagement, 2. Faulty wire harness, 3. Rail
00 000157.03 Warning Rail pressure sensor malfunction: High voltage ECU. Turn the starter switch to the "OFF" position and then to the
engine not cranking. pressure sensor failure, 4. Engine ECU internal circuit failure
"ON" position to check if the error code is displayed again.
Check the connector, wire harness, rail pressure sensor and engine
The sensor voltage is lower than 0.24 V when the 1. Improper connector engagement, 2. Faulty wire harness, 3. Rail
00 000157.04 Warning Rail pressure sensor malfunction: Low voltage ECU. Turn the starter switch to the "OFF" position and then to the
engine not cranking. pressure sensor failure, 4. Engine ECU internal circuit failure
The actual rail pressure is higher than the target value 1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump and rail pressure sensor. Turn
Abnormal rail pressure deviation: Excessively
00 000157.15 Warning and the pressure difference remains at 20 MPa or failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system the starter switch to the "OFF" position and then to the "ON" posi-
high rail pressure
higher for a specific period of time (5 seconds). failure (Air intrusion, fuel shortage) tion to check if the error code is displayed again.
1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system and supply pump. Turn the starter switch to
00 000157.16 Warning Common rail pressure limiting valve (PLV) open The common rail pressure limiting valve (PLV) is open. failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system the "OFF" position and then to the "ON" position to check if the error
failure (Air intrusion, fuel shortage) code is displayed again.
The actual rail pressure is lower than the target value 1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump and rail pressure sensor. Turn
Abnormal rail pressure deviation: Too low rail
00 000157.18 Warning and the pressure difference remains at 20 MPa or failure, 3. SCV stuck open, 4. SCV stuck closed, 5. SCV intermittent the starter switch to the "OFF" position and then to the "ON" posi-
pressure
higher for a specific period of time (3 seconds). fault, 6. Fuel system failure (Air intrusion, fuel shortage) tion to check if the error code is displayed again.
1. Abnormal battery charging, 2. Alternator failure, 3. Faulty wire Check the alternator, connector, wire harness, battery charge
After the engine start, the engine speed is higher than
harness (Battery charge switch wire short to ground), 4. Battery switch and engine ECU. Turn the starter switch to the "OFF" posi-
00 000167.01 Caution Battery charge alarm 600 min-1 and the battery charge switch stays on for 10
charge switch failure (Short to ground on a wire inside the battery tion and then to the "ON" position to check if the error code is dis-
seconds or more.
charge switch), 5. Engine ECU internal circuit failure played again.
5-5-4 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
1. Improper connector engagement, 2. Faulty wire harness (Battery

Before the engine starts with the starter switch in the charge switch wire disconnection or short to power), 3. Battery Check the connector, wire harness, battery charge switch and
00 000167.05 Caution Battery charge switch disconnection "ON" position, the battery charge switch stays off for charge switch failure (Wire disconnection or short to power on a engine ECU. Turn the starter switch to the "OFF" position and then
one second. wire inside the battery charge switch), 4. Engine ECU internal circuit to the "ON" position to check if the error code is displayed again.
failure
ground wire disconnection or short to power, sensor signal wire dis- Check the connector, wire harness, intake (new air) sensor and
Intake (new air) temperature sensor malfunc- The sensor voltage is higher than 4.85 V when the
00 000172.03 Caution connection or short to power), 3. Temperature sensor failure engine ECU. Turn the starter switch to the "OFF" position and then
tion: High voltage engine is not cranking.
(Improper sensor output due to wire disconnection inside the tem- to the "ON" position to check if the error code is displayed again.
perature sensor), 4. Engine ECU internal circuit failure
Check the connector, wire harness, intake (new air) sensor and
Intake (new air) temperature sensor malfunc- The sensor voltage is lower than 0.15 V when the signal wire short to ground), 3. Temperature sensor failure
00 000172.04 Caution engine ECU. Turn the starter switch to the "OFF" position and then
tion: Low voltage engine is not cranking. (Improper sensor output due to short to ground on a wire inside the
temperature sensor), 4. Engine ECU internal circuit failure
Check the connector, wire harness, exhaust manifold temperature
Exhaust manifold temperature sensor malfunc- The sensor voltage is higher than 4.8 V when the sensor and engine ECU. Turn the starter switch to the "OFF" posi-
00 000173.03 Caution 3. Exhaust manifold temperature sensor failure, 4. Engine ECU
tion: High voltage engine is not cranking. tion and then to the "ON" position to check if the error code is dis-
internal circuit failure
played again.
Check the connector, wire harness, exhaust manifold temperature
Exhaust manifold temperature sensor malfunc- The sensor voltage is lower than 0.2 V when the sensor and engine ECU. Turn the starter switch to the "OFF" posi-
00 000173.04 Caution 3. Exhaust manifold temperature sensor failure, 4. Engine ECU
played again.
Check the fuel temperature sensor system, fuel tank and fuel
After the engine starts, the fuel temperature remains at 1. Low level of fuel in the fuel tank, 2. Inability to cool due to clogged
00 000174.00 Warning Abnormally high fuel temperature cooler. Turn the starter switch to the "OFF" position and then to the
90ºC or higher for a specific period of time. fuel cooler, 3. Fuel temperature sensor system failure
ground wire disconnection or short to power, sensor signal wire dis- Check the connector, wire harness, fuel temperature sensor and
Fuel temperature sensor malfunction: High volt- The sensor voltage is higher than 4.8 V when the
00 000174.03 Warning connection or short to power), 3. Fuel temperature sensor failure engine ECU. Turn the starter switch to the "OFF" position and then
age engine is not cranking.
(Improper sensor output due to wire disconnection inside the fuel to the "ON" position to check if the error code is displayed again.
temperature sensor), 4. Engine ECU internal circuit failure
Check the connector, wire harness, fuel temperature sensor and
Fuel temperature sensor malfunction: Low volt- The sensor voltage is lower than 0.2 V when the signal wire short to ground), 3. Fuel temperature sensor failure
age engine is not cranking. (Improper sensor output due to short to ground on a wire inside the
fuel temperature sensor), 4. Engine ECU internal circuit failure
1. Crank speed sensor malfunction (Temporary failure caused by
Check the crank speed sensor, cam speed sensor, injector and
external factors such as radio waves), 2. Cam speed sensor mal-
00 000190.00 Warning Overspeed The engine speed exceeds the threshold value. engine ECU. Turn the starter switch to the "OFF" position and then
function (Temporary failure caused by external factors such as radio
waves), 3. Engine ECU internal circuit failure, 4. Injector failure
When the engine is not cranking, with the starter
Check the connector, wire harness, machine controller and engine
CAN communication failure: Abnormal received switch in the "ON" position and at a battery voltage of 1. CAN communication error of the machine controller, 2. Engine
00 000237.13 Caution ECU. Turn the starter switch to the "OFF" position and then to the
VI data 10 V or higher, the received VI data does not match the ECU internal circuit failure
existing VI data on the engine ECU.
When the engine is not cranking, with the starter
1. CAN communication error of the machine controller, 2. Improper Check the connector, wire harness, machine controller and engine
CAN communication failure: VI data reception switch in the "ON" position and at a battery voltage of
00 000237.31 Caution connector engagement, 3. Wire harness disconnection or short cir- ECU. Turn the starter switch to the "OFF" position and then to the
timeout 10 V or higher, no response is received to three VIN
cuit, 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
requests.
5-5-5 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
Check the connector, wire harness, EGR gas temperature sensor

1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
EGR gas temperature sensor malfunction: High The sensor voltage is higher than 4.8 V when the and engine ECU. Turn the starter switch to the "OFF" position and
00 000412.03 Caution gas temperature sensor failure, 4. Engine ECU internal circuit fail-
ure
again.
Check the connector, wire harness, EGR gas temperature sensor
1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
EGR gas temperature sensor malfunction: Low The sensor voltage is lower than 0.2 V when the and engine ECU. Turn the starter switch to the "OFF" position and
00 000412.04 Caution gas temperature sensor failure, 4. Engine ECU internal circuit fail-
ure
again.
Check the engine ECU. Turn the starter switch to the "OFF" position
Engine ECU malfunction: EEPROM memory When switching between the EEPROM pages (sec-
00 000630.12 Caution 1. Engine ECU internal circuit failure and then to the "ON" position to check if the error code is displayed
clearance error tors), the page is not cleared.
again.
1. Improper connector engagement, 2. Faulty wire harness (SCV
Check the connector, wire harness, SCV (MPROP) and engine
High-pressure pump drive circuit malfunction: A short to VB condition continues for a specific period positive output short to power, SCV negative output short to power),
00 000633.03 Warning ECU. Turn the starter switch to the "OFF" position and then to the
High-side short to VB of time (300 ms). 3. SCV failure due to coil short circuit, 4. Engine ECU internal circuit
failure
1. Improper connector engagement, 2. Faulty wire harness (SCV Check the connector, wire harness, SCV (MPROP) and engine
High-pressure pump drive circuit malfunction: An open condition is detected in the high-pressure
00 000633.05 Warning (MPROP) disconnection), 3. SCV (MPROP) failure due to wire dis- ECU. Turn the starter switch to the "OFF" position and then to the
Open circuit pump drive circuit.
connection, 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
High-pressure pump drive circuit malfunction: A shot to ground condition is detected in the high-pres-
00 000633.06 Warning (MPROP) high-side short to power), 3. SCV(MPROP) failure due to ECU. Turn the starter switch to the "OFF" position and then to the
High-side short to ground sure pump drive circuit.
short to power, 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
1. Improper connector engagement, 2. Faulty wire harness (Short in Check the connector, wire harness, engine ECU and injector. Turn
A low-side short to +B is detected in the injector drive
00 000651.03 Caution Cylinder No. 4 injector malfunction: Short circuit the injector drive circuit), 3. Engine ECU internal circuit failure, the starter switch to the "OFF" position and then to the "ON" posi-
circuit.
4. Short in the injector internal circuit tion to check if the error code is displayed again.
1. Improper connector engagement, 2. Faulty wire harness (Injector Check the connector, wire harness, engine ECU and injector. Turn
Cylinder No. 4 injector malfunction: Open circuit High-side or low-side open is detected in the injector
00 000651.05 Caution drive circuit open), 3. Engine ECU internal circuit failure, 4. Injector the starter switch to the "OFF" position and then to the "ON" posi-
(Inherent to injector) drive circuit.
internal circuit open tion to check if the error code is displayed again.
Cylinder No. 4 injector malfunction: Coil short High-side and low-side short circuits are detected on
00 000651.06 Caution the injector drive circuit), 3. Engine ECU internal circuit failure, the starter switch to the "OFF" position and then to the "ON" posi-
circuit the Injector coil.
circuit.
circuit.
Cylinder No.2 injector malfunction: Coil short High-side and low-side short circuits are detected on
5-5-6 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
circuit.
Cylinder No.1 injector malfunction: Open circuit High-side or low-side open is detected in the injector
EGR high pressure-side sensor malfunction: The sensor voltage is higher than 4.8 V when the 1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
High voltage engine is not cranking. pressure sensor failure, 4. Engine ECU internal circuit failure
EGR high pressure-side sensor malfunction: The sensor voltage is lower than 0.2 V when the 1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
Low voltage engine is not cranking. pressure sensor failure, 4. Engine ECU internal circuit failure
The final offset value for the exhaust manifold pressure Check the connector, wire harness, EGR pressure sensor and
EGR high pressure-side sensor malfunction: 1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
00 001209.13 Warning is lower than the threshold value or higher than the engine ECU. Turn the starter switch to the "OFF" position and then
Abnormal learning value pressure sensor failure, 4. Engine ECU internal circuit failure
threshold value. to the "ON" position to check if the error code is displayed again.
1. Improper connector engagement, 2. Faulty wire harness (Short to
After the starter switch is turned to the "OFF" position, Check the connector, wire harness, main relay and engine ECU.
ground on the main relay coil side downstream wire), 3. Main relay
00 001485.02 Caution Main relay malfunction: Early opening engine ECU power is shut down before EEPROM writ- Turn the starter switch to the "OFF" position and then to the "ON"
contact failure (Main relay contact stuck), 4. Engine ECU internal
ing process. position to check if the error code is displayed again.
circuit failure
1. Improper connector engagement, 2. Faulty wire harness (Short to
Check the connector, wire harness, main relay and engine ECU.
The main relay does not open even when 150 ms have ground on the main relay coil side downstream wire), 3. Main relay
00 001485.07 Caution Main relay malfunction: Contact stuck Turn the starter switch to the "OFF" position and then to the "ON"
passed since engine ECU was shut off. contact failure (Main relay contact stuck), 4. Engine ECU internal
position to check if the error code is displayed again.
circuit failure
Check the battery and EGR valve. Turn the starter switch to the
The voltage supplied to the EGR valve remains higher
00 002791.00 Caution EGR overvoltage 1. Overcharged battery, 2. EGR valve internal circuit failure "OFF" position and then to the "ON" position to check if the error
than 18V for 5 seconds.
Check the wire harness, battery and EGR valve. Turn the starter
The voltage supplied to the EGR valve remains lower 1. Deteriorated battery, 2. EGR valve short to power, 3. EGR valve
00 002791.01 Caution EGR undervoltage switch to the "OFF" position and then to the "ON" position to check
than 8V for 13 seconds. internal circuit failure
if the error code is displayed again.
Check the EGR valve. Turn the starter switch to the "OFF" position
The motor drive overload condition continues for a
00 002791.07 Caution Abnormal EGR feedback 1. EGR valve internal circuit failure and then to the "ON" position to check if the error code is displayed
specific period of time.
again.
Disruption of the signal transmitted from the engine 1. Improper connector engagement, 2. Faulty wire harness, 3. EGR
00 002791.09 Caution Abnormal engine ECU data on EGR and then to the "ON" position to check if the error code is displayed
ECU to ERG is detected. valve internal circuit failure
again.
00 002791.12 Caution Open circuit between EGR motor and coil Open circuit to the motor is detected. 1. DC motor failure of the EGR valve and then to the "ON" position to check if the error code is displayed
again.
1. Improper connector engagement, 2. Faulty wire harness (Injector
bank 1 high-side short to power, injector bank 1 high-side short to Check the connector, wire harness, injector and engine ECU. Turn
Injector drive circuit malfunction: Bank 1 short High-side and low-side shorts to ground or high-side
00 002797.06 Caution ground, injector bank 1 low-side short to power, injector bank 1 low- the starter switch to the "OFF" position and then to the "ON" posi-
circuit short to +B are detected in the injector drive circuit.
side short to ground), 3. Injector failure due to short to power, tion to check if the error code is displayed again.
4. Engine ECU internal circuit failure
5-5-7 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
1. Improper connector engagement, 2. Faulty wire harness (Injector

bank 2 high-side short to power, injector bank 2 high-side short to Check the connector, wire harness, injector and engine ECU. Turn
Injector drive circuit malfunction: Bank 2 short High-side and low-side shorts to ground or high-side
00 002798.06 Caution ground, injector bank 2 low-side short to power, injector bank 2 low- the starter switch to the "OFF" position and then to the "ON" posi-
circuit short to +B are detected in the injector drive circuit.
side short to ground), 3. Injector failure due to short to power, tion to check if the error code is displayed again.
4. Engine ECU internal circuit failure
1. Improper connector engagement, 2. Faulty wire harness (High-
Check the connector, wire harness, intake throttle and engine ECU.
Intake throttle drive circuit malfunction: H bridge side short to power in the intake throttle drive circuit), 3. Intake throt-
00 002950.03 Caution Output terminal 1 of the drive circuit is shorted to VB. Turn the starter switch to the "OFF" position and then to the "ON"
output 1 short to power tle failure due to short to power, 4. Engine ECU internal circuit fail-
ure
Intake throttle drive circuit malfunction: H bridge Output terminal 1 of the drive circuit is shorted to side short to ground in the intake throttle drive circuit), 3. Intake
00 002950.04 Caution Turn the starter switch to the "OFF" position and then to the "ON"
output 1 short to ground ground. throttle failure due to short to ground, 4. Engine ECU internal circuit
failure
Intake throttle drive circuit malfunction: No load side open in the intake throttle drive circuit, low-side open in the
00 002950.05 Caution No load (open) is detected in the drive circuit. Turn the starter switch to the "OFF" position and then to the "ON"
in H bridge circuit intake throttle drive circuit), 3. Intake throttle failure due to open cir-
cuit, 4. Engine ECU internal circuit failure
Intake throttle drive circuit malfunction: H bridge The temperature of a component of the drive circuit side short in the intake throttle drive circuit, low-side short in the
circuit overloaded exceeds the threshold value. intake throttle drive circuit), 3. Intake throttle failure due to short cir-
cuit, 4. Engine ECU internal circuit failure
1. Improper connector engagement, 2. Faulty wire harness (Low-
Intake throttle drive circuit malfunction: H bridge side short to power in the intake throttle drive circuit), 3. Intake throt-
00 002951.03 Caution Output terminal 2 of the drive circuit is shorted to VB. Turn the starter switch to the "OFF" position and then to the "ON"
output 2 short to VB power tle failure due to short to power, 4. Engine ECU internal circuit fail-
ure
1. Improper connector engagement, 2. Faulty wire harness (Low-
Intake throttle drive circuit malfunction: H bridge Output terminal 2 of the drive circuit is shorted to side short to ground in the intake throttle drive circuit), 3. Intake
output 2 short to ground ground. throttle failure due to short to ground, 4. Engine ECU internal circuit
failure
1. Improper connector engagement, 2. Faulty wire harness, 3. DPF
Check the connector, wire harness, DPF inlet temperature sensor,
inlet temperature sensor system failure, 4. Engine ECU internal cir-
DPF inlet temperature sensor: Abnormally high The DPF inlet temperature remains at 700 ºC or higher engine ECU, injector and exhaust piping. Turn the starter switch to
00 003242.00 Caution cuit failure, 5. Combustion gas blow-by (Piping damage in the pas-
temperature for a specific period of time (15 seconds). the "OFF" position and then to the "ON" position to check if the error
sage to DOC), 6. Defective injector (Decrease in injection quantity,
incorrect injection timing)
Check the connector, wire harness, DPF inlet temperature sensor
ground wire disconnection or short to power, sensor signal wire dis-
DPF inlet temperature sensor malfunction: High The sensor voltage is higher than 4.8 V when the and engine ECU. Turn the starter switch to the "OFF" position and
00 003242.03 Warning connection or short to power), 3. DPF inlet temperature sensor fail-
ure (Improper sensor output due to wire disconnection inside the
again.
DPF inlet temperature sensor), 4. Engine ECU internal circuit failure
1. Improper connector engagement, 2. Faulty wire harness (Sensor Check the connector, wire harness, DPF inlet temperature sensor
DPF inlet temperature sensor malfunction: Low The sensor voltage is lower than 0.2 V when the signal wire short to ground), 3. DPF inlet temperature sensor failure and engine ECU. Turn the starter switch to the "OFF" position and
00 003242.04 Warning
voltage engine is not cranking. (Improper sensor output due to short to ground on a wire inside the then to the "ON" position to check if the error code is displayed
DPF inlet temperature sensor), 4. Engine ECU internal circuit failure again.
1. Improper connector engagement, 2. Faulty wire harness, 3. DPF Check the connector, wire harness, DPF intermediate temperature
During regeneration, the DPF intermediate tempera-
DPF intermediate temperature sensor: Abnor- intermediate temperature sensor system failure, 4. Engine ECU sensor, engine ECU and injector. Turn the starter switch to the
00 003250.00 Warning ture remains at 700 ºC or higher for a specific period of
mally high temperature (Post injection failure) internal circuit failure, 5. Defective injector (Increase in injection "OFF" position and then to the "ON" position to check if the error
time (30 seconds).
quantity, incorrect injection timing) code is displayed again.
5-5-8 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM

intermediate temperature sensor system failure, 4. Engine ECU
Check the connector, wire harness, DPF intermediate temperature
internal circuit failure, 5. DOC deterioration due to external factors
DPF intermediate temperature sensor: Abnor- The DPF regeneration failure timer reaches a specific sensor system, engine ECU, injector, DOC and piping. Turn the
00 003250.01 Caution such as sulfur poisoning (Increase in activation temperature),
mally low temperature value (1200 seconds). starter switch to the "OFF" position and then to the "ON" position to
6. Combustion gas blow-by (Catalytic damage, piping damage in
the passage to DOC), 7. Defective injector (Decrease in injection
quantity, incorrect injection timing)
ground wire disconnection or short to power, sensor signal wire dis- Check the connector, wire harness, DPF intermediate temperature
DPF intermediate temperature sensor malfunc- The sensor voltage is higher than 4.8 V when the connection or short to power), 3. DPF intermediate temperature sensor and engine ECU. Turn the starter switch to the "OFF" posi-
00 003250.03 Warning
tion: High voltage engine is not cranking. sensor failure (Improper sensor output due to wire disconnection tion and then to the "ON" position to check if the error code is dis-
inside the DPF intermediate temperature sensor), 4. Engine ECU played again.
Check the connector, wire harness, DPF intermediate temperature
signal wire short to ground), 3. DPF intermediate temperature sen-
DPF intermediate temperature sensor malfunc- The sensor voltage is lower than 0.2 V when the sensor and engine ECU. Turn the starter switch to the "OFF" posi-
00 003250.04 Warning sor failure (Improper sensor output due to short to ground on a wire
inside the DPF intermediate temperature sensor), 4. Engine ECU
played again.
Check the connector, wire harness, DPF differential pressure sen-
After the engine starts, the DPF differential pressure 1. Improper connector engagement, 2. Faulty wire harness, 3. DPF
DPF differential pressure sensor: Abnormally sor and engine ECU. Turn the starter switch to the "OFF" position
00 003251.00 Warning remains at 50 kPa or higher for a specific period of differential pressure sensor failure, 4. Engine ECU internal circuit
high differential pressure and then to the "ON" position to check if the error code is displayed
time (15 seconds). failure
again.
DPF differential pressure sensor malfunction: The sensor voltage is higher than 4.8 V when the sor and engine ECU. Turn the starter switch to the "OFF" position
00 003251.03 Warning differential pressure sensor failure, 4. Engine ECU internal circuit
High voltage engine is not cranking. and then to the "ON" position to check if the error code is displayed
failure
again.
DPF differential pressure sensor malfunction: The sensor voltage is lower than 0.2 V when the sor and engine ECU. Turn the starter switch to the "OFF" position
00 003251.04 Warning differential pressure sensor failure, 4. Engine ECU internal circuit
Low voltage engine is not cranking. and then to the "ON" position to check if the error code is displayed
failure
again.
The final offset value for the DPF differential pressure
DPF differential pressure sensor malfunction: 1. Improper connector engagement, 2. Faulty wire harness, 3. EGR sor and engine ECU. Turn the starter switch to the "OFF" position
00 003251.13 Warning is lower than the threshold value or higher than the
Abnormal learning value pressure sensor failure, 4. Engine ECU internal circuit failure and then to the "ON" position to check if the error code is displayed
threshold value.
again.
Check the connector, wire harness, DPF high pressure-side sensor
DPF high pressure-side sensor malfunction: The sensor voltage is higher than 4.8 V when the and engine ECU. Turn the starter switch to the "OFF" position and
00 003609.03 Warning high pressure-side sensor failure, 4. Engine ECU internal circuit fail-
High voltage engine is not cranking. then to the "ON" position to check if the error code is displayed
ure
again.
Check the connector, wire harness, DPF high pressure side sensor
DPF high pressure-side sensor malfunction: The sensor voltage is lower than 0.2 V when the and engine ECU. Turn the starter switch to the "OFF" position and
00 003609.04 Warning high pressure-side sensor failure, 4. Engine ECU internal circuit fail-
Low voltage engine is not cranking. then to the "ON" position to check if the error code is displayed
ure
again.
1. Engine ECU left in the stationary regeneration standby emer-
gency mode for a specific period of time, 2. Engine ECU internal cir-
Connect the SMARTASSIST-Direct (SA-D) and perform a DPF
cuit failure, 3. DOC deterioration due to external factors such as
The engine ECU has been switched into the backup recovery regeneration. Check the injector, engine ECU, DOC and
00 003719.00 Warning DPF backup mode sulfur poisoning (Increase in activation temperature), 4. Combustion
mode and the DPF is not under recovery regeneration. piping. Turn the starter switch to the "OFF" position and then to the
gas blow-by (Catalytic damage, piping damage in the passage to
DOC), 5. Defective injector (Decrease in injection quantity, incorrect
injection timing)
5-5-9 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
When the recovery regeneration is started, the amount

of PM accumulated in the DPF (according to Method
C) remains larger than the threshold value for a spe- Check the soot filter. Turn the starter switch to the "OFF" position
PM is overaccumulated and the recovery regeneration cannot be
00 003719.07 Warning DPF recovery regeneration prohibition cific period of time or the total amount of time the and then to the "ON" position to check if the error code is displayed
performed.
amount of PM accumulated in the DPF (according to again.
Method P) is larger than the threshold value exceeds a
specified value.
1. DPF intermediate temperature sensor system failure, 2. DOC
Check the DPF intermediate temperature sensor system, injector
The engine ECU determines that the recovery regen- deterioration or DOC breakage due to external factors such as sul-
00 003719.09 Warning DPF recovery regeneration failure and DOC. Turn the starter switch to the "OFF" position and then to
eration has failed. fur poisoning, 3. Defective injector (Decrease in injection quantity,
the "ON" position to check if the error code is displayed again.
1. Inadequate regeneration capability due to low operating load,
2. Reset regeneration with regeneration prohibition switch on con-
The engine ECU is switched into the stationary regen- tinued for a specific period of time, 3. Engine ECU internal circuit Perform a stationary (manual) DPF regeneration. Check the injec-
Stationary DPF regeneration standby (Station- eration mode due to factors other than external switch failure, 4. DOC deterioration due to external factors such as sulfur tor, engine ECU, DOC and piping. Turn the starter switch to the
00 003719.16 Caution
ary regeneration request) and CAN commands when the DPF is not under sta- poisoning (Increase in activation temperature), 5. Combustion gas "OFF" position and then to the "ON" position to check if the error
tionary regeneration. blow-by (Catalytic damage, piping damage in the passage to DOC), code is displayed again.
6. Defective injector (Decrease in injection quantity, incorrect injec-
tion timing)
Replace or clean the soot filter. Check the DPF and engine ECU.
1. Engine ECU internal circuit failure, 2. Increase in actual differen-
00 003720.00 Warning DPF ash cleaning request 2 The ash deposit density is 60 g/L or more. Turn the starter switch to the "OFF" position and then to the "ON"
tial pressure of the soot filter (Ash accumulation)
Replace or clean the soot filter. Check the DPF and engine ECU.
The ash deposit density is greater than or equal to 50 1. Engine ECU internal circuit failure, 2. Increase in actual differen-
00 003720.16 Caution DPF ash cleaning request 1 Turn the starter switch to the "OFF" position and then to the "ON"
g/L and less than 60 g/L. tial pressure of the soot filter (Ash accumulation)
An injector drive IC failure is detected by the engine
00 004257.12 Caution Injector drive IC failure - -
ECU.
When thermistor output stays at less than 0.2V for 3 Check the EGR valve. Turn the starter switch to the "OFF" position
00 522183.01 Caution EGR high-temperature thermistor malfunction seconds or more, thermistor voltage on the high-tem- 1. EGR valve internal circuit failure and then to the "ON" position to check if the error code is displayed
perature side in the control unit is 0.2 V or less. again.
When thermistor output stays at less than 0.2V for 3 Check the EGR valve. Turn the starter switch to the "OFF" position
00 522184.01 Caution EGR low-temperature thermistor malfunction seconds or more, thermistor voltage on the low-tem- 1. EGR valve internal circuit failure and then to the "ON" position to check if the error code is displayed
perature side in the control unit is 0.2 V or less. again.
1. Improper connector engagement, 2. Faulty wire harness (Starting
When no current is supplied to the starting aid relay, Check the connector, wire harness, starting aid relay and engine
aid relay output circuit open, starting aid relay output short to
00 522243.05 Caution Starting aid relay malfunction: Open circuit open circuit is detected by the IC inside the engine ECU. Turn the starter switch to the "OFF" position and then to the
power), 3. starting aid relay failure, 4. Engine ECU internal circuit
ECU. "ON" position to check if the error code is displayed again.
failure
When current is supplied to the starting aid relay, a 1. Improper connector engagement, 2. Faulty wire harness (Starting Check the connector, wire harness, starting aid relay and engine
Starting aid relay malfunction: Short circuit to
00 522243.06 Caution short to ground is detected by the IC inside the engine aid relay output short to ground), 3. Starting aid relay failure, ECU. Turn the starter switch to the "OFF" position and then to the
GND
ECU. 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
Check the connector, wire harness, crank speed sensor, engine
Crank speed sensor malfunction: Abnormal sig- A specific number of abnormal pulses (15 pulses) are ECU and pulser. Turn the starter switch to the "OFF" position and
00 522400.02 Caution 3. Crank speed sensor failure, 4. Engine ECU internal circuit failure,
nal detected. then to the "ON" position to check if the error code is displayed
5. Pulser malfunction or incorrect sensor installation
again.
Check the connector, wire harness, crank speed sensor, engine
No crank signal is input during a specific number of ECU and pulser. Turn the starter switch to the "OFF" position and
00 522400.05 Caution Crank speed sensor malfunction: No signal 3. Crank speed sensor failure, 4. Engine ECU internal circuit failure,
rotations of the cam (2 rotations). then to the "ON" position to check if the error code is displayed
5. Pulser malfunction or incorrect sensor installation
again.
5-5-10 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
An incorrect number of cam pulses or an incorrect cam 1. Improper connector engagement, 2. Faulty wire harness, 3. Cam Check the connector, wire harness, cam speed sensor, engine ECU
Cam speed sensor malfunction: Abnormal sig-
00 522401.02 Caution position is detected during a specific number of rota- speed sensor failure, 4. Engine ECU internal circuit failure, and pulser. Turn the starter switch to the "OFF" position and then to
nal
tions of the crank (2 rotations). 5. Pulser malfunction or incorrect sensor installation the "ON" position to check if the error code is displayed again.
1. Improper connector engagement, 2. Faulty wire harness, 3. Cam Check the connector, wire harness, cam speed sensor, engine ECU
No cam pulse signal is input during a specific number
00 522401.05 Caution Cam speed sensor malfunction: No signal speed sensor failure, 4. Engine ECU internal circuit failure, and pulser. Turn the starter switch to the "OFF" position and then to
of rotations of the crank (2.2 rotations).
5. Pulser malfunction or incorrect sensor installation the "ON" position to check if the error code is displayed again.
A state where the phase difference between the cam 1. Improper connector engagement, 2. Faulty wire harness, 3. Cam Check the connector, wire harness, cam speed sensor, engine ECU
00 522401.07 Caution Abnormal angle offset and crank is larger than 30 degrees or smaller than -20 speed sensor failure, 4. Engine ECU internal circuit failure, and pulser. Turn the starter switch to the "OFF" position and then to
degrees is detected twice. 5. Pulser malfunction or incorrect sensor installation the "ON" position to check if the error code is displayed again.
The high-pressure pump drive circuit remains low-side 1. Improper connector engagement, 2. Faulty wire harness (SCV Check the connector, wire harness, injector and engine ECU. Turn
High-pressure pump drive circuit malfunction:
00 522571.03 Warning shorted to VB for a specific period of time (300 sec- (MPROP) low-side short to power), 3. SCV (MPROP) failure due to the starter switch to the "OFF" position and then to the "ON" posi-
Low-side short to VB
onds). short to power, 4. Engine ECU internal circuit failure tion to check if the error code is displayed again.
High-pressure pump drive circuit malfunction: A short to ground is detected in the high-pressure
00 522571.06 Warning (MPROP) low-side wire short to ground), 3. SCV (MPROP) low-side ECU. Turn the starter switch to the "OFF" position and then to the
Low-side short to ground pump drive circuit.
short to ground, 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
High-pressure pump drive circuit malfunction: 1. Improper connector engagement, 2. Faulty wire harness, 3. SCV
00 522572.06 Warning The drive current is higher than the threshold value. ECU. Turn the starter switch to the "OFF" position and then to the
Overcurrent (MPROP) failure, 4. Engine ECU internal circuit failure
High-pressure pump drive circuit malfunction: 1. Improper connector engagement, 2. Faulty wire harness, 3. SCV
00 522572.11 Warning An overheat state of the drive circuit is detected. ECU. Turn the starter switch to the "OFF" position and then to the
Pump overload (MPROP) failure, 4. Engine ECU internal circuit failure
1. Inadequate regeneration capability due to low operating load,
The engine ECU is switched into the recovery regener- Check the DPF intermediate temperature sensor system. Turn the
2. Regeneration not performed in response to the stationary regen-
00 522573.00 Caution DPF PM overaccumulation (Method C) ation mode due to PM overaccumulation evaluated starter switch to the "OFF" position and then to the "ON" position to
eration request, 3. DPF intermediate temperature sensor system
using Method C. check if the error code is displayed again.
failure
The engine ECU is switched into the recovery regener- 1. Inadequate regeneration capability due to low operating load, Check the DPF differential pressure sensor system. Turn the starter
00 522574.00 Caution DPF PM overaccumulation (Method P) ation mode due to PM overaccumulation evaluated 2. Regeneration not performed in response to the stationary regen- switch to the "OFF" position and then to the "ON" position to check
using Method P. eration request, 3. DPF differential pressure sensor system failure if the error code is displayed again.
1. DPF intermediate temperature sensor system failure, 2. DOC
The engine ECU is switched into the recovery regener- Check the DPF intermediate temperature sensor system, injector
DPF regeneration failure: Stationary regenera- deterioration or DOC breakage due to external factors such as sul-
00 522575.07 Caution ation mode due to failure to complete a stationary and DOC. Turn the starter switch to the "OFF" position and then to
tion failure fur poisoning, 3. Defective injector (Decrease in injection quantity,
regeneration within a specified period of time. the "ON" position to check if the error code is displayed again.
Engine ECU malfunction: EEPROM memory An EEPROM read failure is determined based on the
read error checksum.
again.
1. Improper connector engagement, 2. Faulty wire harness (Regen-
When a stationary regeneration request is sent, a sta- Check the connector, wire harness, LCD monitor, regeneration
eration not performed in response to the stationary regeneration
DPF regeneration failure: Stationary regenera- tionary regeneration is not performed within a specified request switch and engine ECU. Turn the starter switch to the
00 522577.11 Caution request, regeneration request not displayed, defective regeneration
tion not performed period of time and the engine ECU is switched into the "OFF" position and then to the "ON" position to check if the error
request switch), 3. Engine speed remains decreased to low idling
backup mode. code is displayed again.
during regeneration, 4. Engine ECU internal circuit failure
Engine ECU malfunction: EEPROM memory When writing to EEPROM, the engine ECU fails to
writing error write the same data three times.
again.
Overcurrent due to a short circuit between the EGR
00 522579.12 Caution Short circuit between EGR motor and coil 1. DC motor failure of the EGR valve and then to the "ON" position to check if the error code is displayed
motor and coil is detected.
again.
An excessive high or low EGR position sensor signal
00 522580.12 Caution EGR position sensor malfunction 1. EGR valve internal circuit failure and then to the "ON" position to check if the error code is displayed
voltage is detected.
again.
5-5-11 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
An excessively large number of steps between the fully Check the EGR valve. Turn the starter switch to the "OFF" position
00 522581.07 Warning EGR valve stuck open open position and the fully closed position during ini- 1. EGR valve stuck and then to the "ON" position to check if the error code is displayed
tialization is required (45 steps or more). again.
The time taken to complete initialization exceeds the 1. EGR valve internal circuit failure, 2. EGR valve malfunction,
00 522582.07 Warning EGR initialization failure and then to the "ON" position to check if the error code is displayed
specified range. 3. EGR valve stuck
again.
The thermistor voltage on the high-temperature side in
00 522583.01 Caution EGR high-temperature thermistor malfunction 1. EGR valve internal circuit failure and then to the "ON" position to check if the error code is displayed
the control unit is 0.2 V or less.
again.
The thermistor voltage on the low-temperature side in
00 522584.01 Caution EGR low-temperature thermistor malfunction 1. EGR valve internal circuit failure and then to the "ON" position to check if the error code is displayed
the control unit is 0.2 V or less.
again.
Engine ECU internal abnormality: CY146 SPI The communication between the CPU and the H
00 522585.12 Warning 1. Engine ECU internal circuit failure and then to the "ON" position to check if the error code is displayed
communication error bridge control IC is not normally performed.
again.
Engine ECU internal abnormality: Supply 1 The 5V supply voltage to the actuator drive is exces-
overvoltage error sively high.
again.
Engine ECU internal abnormality: Supply 1 The 5V supply voltage to the actuator drive is exces-
undervoltage error sively low.
again.
1. Improper engagement of the sensor connector that uses sensor Check the connector, wire harness and engine ECU. Turn the
Engine ECU internal abnormality: Sensor sup- The 5 V supply voltage to the sensor exceeds the
00 522590.12 Caution power supply 1 (K43 or K44 terminal), 2. Faulty wire harness, starter switch to the "OFF" position and then to the "ON" position to
ply voltage error 1 threshold value.
3. Engine ECU internal circuit failure check if the error code is displayed again.
00 522591.12 Caution power supply 2 (K45 or A08 terminal), 2. Faulty wire harness, starter switch to the "OFF" position and then to the "ON" position to
3. Engine ECU internal circuit failure check if the error code is displayed again.
00 522592.12 Caution power supply 3 (A07 terminal), 2. Faulty wire harness, 3. Engine starter switch to the "OFF" position and then to the "ON" position to
ECU internal circuit failure check if the error code is displayed again.
When the engine is not cranking, at a battery voltage
of 10V or higher, a reception timeout is detected 2 sec- 1. CAN communication error of the machine controller, 2. Improper Check the connector, wire harness, machine controller and engine
CAN communication failure: TSC1 reception
00 522596.09 Caution onds after the starter switch is turned to the "ON" posi- connector engagement, 3. Wire harness disconnection or short cir- ECU. Turn the starter switch to the "OFF" position and then to the
timeout (SA1)
tion, and the reception timeout continues for a specific cuit, 4. Engine ECU internal circuit failure "ON" position to check if the error code is displayed again.
period of time.
CAN communication failure: Y_EC reception
timeout
period of time.
of 10V or higher, a reception timeout is detected 2 sec- 1. Improper connector engagement, 2. Wire harness disconnection Check the engine ECU, connector, wire harness and EGR valve.
EGR CAN communication failure: Reception
00 522610.09 Caution onds after the starter switch is turned to the "ON" posi- or short circuit, 3. Engine ECU internal circuit failure, 4. EGR valve Turn the starter switch to the "OFF" position and then to the "ON"
timeout
tion, and the reception timeout continues for a specific internal circuit failure position to check if the error code is displayed again.
period of time.
5-5-12 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM

Check the engine ECU, connector, wire harness, exhaust throttle
of 10V or higher, a reception timeout is detected 2 sec- 1. Improper connector engagement, 2. Wire harness disconnection
Exhaust throttle CAN communication failure: and EGR valve relay. Turn the starter switch to the "OFF" position
00 522611.09 Caution onds after the starter switch is turned to the "ON" posi- or short circuit, 3. Engine ECU internal circuit failure, 4. Exhaust
Reception timeout and then to the "ON" position to check if the error code is displayed
tion, and the reception timeout continues for a specific throttle internal circuit failure, 5. EGR valve relay failure
again.
period of time.
Check the EGR valve and engine ECU. Turn the starter switch to
The EGR valve position instructed by the engine ECU
00 522617.12 Caution Out of range for EGR target values 1. Engine ECU software malfunction the "OFF" position and then to the "ON" position to check if the error
stays out of range for a specific period of time.
CAN communication failure: EBC1 reception
timeout
period of time.
CAN communication failure: Y_DPFIF recep-
tion timeout
period of time.
1. Improper engagement of the actuator connector that uses 12V
Check the connector, wire harness and engine ECU. Turn the
Engine ECU internal abnormality: Actuator Overcurrent at the UB2 terminal is detected by the IC power supply 1 (UB2: K68 terminal), 2. Faulty wire harness (12V
drive circuit 1 short to ground inside the engine ECU. power supply 1 (UB2: K68 terminal) wire short to ground), 3. Engine
ECU internal circuit failure
The power supply voltage detected by the exhaust
throttle is one of the following: Check the battery and exhaust throttle. Turn the starter switch to the
00 522746.12 Caution Exhaust throttle voltage abnormality • The detected voltage stays at 6V or less for 10 sec- 1.Battery malfunction, 2. Exhaust throttle internal circuit failure "OFF" position and then to the "ON" position to check if the error
onds.
• The detected voltage stays at 16V or more for 1 sec-
ond.
One of the following is occurring in the exhaust throttle:
• The motor drive overload condition continues for a Check the exhaust throttle. Turn the starter switch to the "OFF"
specific period of time. 1.Exhaust throttle DC motor failure, 2. Exhaust throttle internal cir-
00 522747.12 Warning Exhaust throttle motor malfunction position and then to the "ON" position to check if the error code is
• The learning position is outside the normal range. cuit failure, 3. Exhaust throttle stuck
• An overcurrent, overvoltage, disconnection, or short displayed again.
circuit is detected in the motor coil
One of the following is occurring in the exhaust throttle:
• An overvoltage or undervoltage is detected in the sen-
sor supply. Check the exhaust throttle. Turn the starter switch to the "OFF"
00 522748.12 Warning Exhaust throttle sensor malfunction • An overvoltage or undervoltage is detected in the 1. Exhaust throttle internal circuit failure, 2. Exhaust throttle stuck position and then to the "ON" position to check if the error code is
position sensor signal. displayed again.
• A mismatch of the objective divergence and actual
divergence continues for a certain period of time.
Check the exhaust throttle. Turn the starter switch to the "OFF"
00 522749.12 Caution Exhaust throttle MPU malfunction The MPU inside the exhaust throttle is faulty. 1. Exhaust throttle internal circuit failure position and then to the "ON" position to check if the error code is
displayed again.
Check the exhaust throttle. Turn the starter switch to the "OFF"
An overvoltage or undervoltage is detected in the tem-
00 522750.12 Caution Exhaust throttle PCB malfunction 1. Exhaust throttle internal circuit failure position and then to the "ON" position to check if the error code is
perature thermistor inside the exhaust throttle.
displayed again.
One of the following is occurring:
• A startup malfunction is detected in the CAN commu- 1. Improper connector engagement, 2. Faulty wire harness, Check the engine ECU, connector, wire harness, and exhaust throt-
00 522751.19 Caution Exhaust throttle CAN malfunction nication controller of the exhaust throttle. 3. Exhaust throttle internal circuit failure, 4. Engine ECU software tle. Turn the starter switch to the "OFF" position and then to the
• Exhaust throttle reception timeout continues for a spe- malfunction "ON" position to check if the error code is displayed again.
cific period of time.
5-5-13 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM

Engine ECU internal abnormality: Actuator Overcurrent at the UB3 terminal is detected by the IC power supply 2 (UB3: K90 or A50 terminal), 2. Faulty wire harness
drive circuit 2 short to ground inside the engine ECU. (12V power supply 2 (UB3: K90 or A50 terminal) wire short to
ground), 3. Engine ECU internal circuit failure
Check the connector, wire harness, crank speed sensor, cam speed
Crank and cam speed sensor malfunction: No No signal from the crank and cam speed sensors is 1. Simultaneous malfunction of crank speed sensor and cam speed sensor, engine ECU and pulser. Turn the starter switch to the "OFF"
00 523249.05 Warning
signal detected. sensor, 2. Starter system failure position and then to the "ON" position to check if the error code is
displayed again.
Check the connector, wire harness, SCV (MPROP), fuel tempera-
Rail pressure control abnormality: Pump and The rail pressure sensor and high pressure pump drive
1. Rail pressure sensor or wiring fault, 2. SCV or wiring fault, 3. Fuel ture sensor and engine ECU. Turn the starter switch to the "OFF"
00 523460.07 Warning fuel temperature sensor malfunctions during rail circuit (MPROM) are defective or the rail pressure sen-
temperature sensor or wiring fault position and then to the "ON" position to check if the error code is
pressure sensor malfunction sor and fuel temperature sensor are defective.
displayed again.
Connect the SMARTASSIST-Direct (SA-D) and re-enter the injector
Cylinder No. 1 injector malfunction: Improper The injector correction value is not input or consistent 1. Input failure of the injector correction value, 2. Engine ECU inter- correction value. Check the engine ECU. Turn the starter switch to
00 523462.13 Warning
correction value and unable to read from EEPROM. nal circuit failure the "OFF" position and then to the "ON" position to check if the error
00 523463.13 Warning
00 523464.13 Warning
Connect the SAMRTASSIST-Direct (SA-D) and re-enter the injector
00 523465.13 Warning
After the common rail pressure limiting valve opens, 1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump and rail pressure sensor. Turn
Common rail pressure limiting valve (PLV): Mal-
00 523468.09 Warning the rail pressure falls outside the range of 50 to 120 failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system the starter switch to the "OFF" position and then to the "ON" posi-
function
MPa. failure (Air intrusion, fuel shortage) tion to check if the error code is displayed again.
1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump, rail pressure sensor and
Common rail pressure limiting valve (PLV): The number of times the common rail pressure limiting
00 523469.00 Warning failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system engine ECU. Turn the starter switch to the "OFF" position and then
Excessive number of times valve open valve opens exceeds 50.
failure (Air intrusion, fuel shortage) to the "ON" position to check if the error code is displayed again.
While the rail pressure sensor is in normal operation, 1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump, rail pressure sensor and
Common rail pressure control value (PLV):
00 523470.00 Warning the total amount of time the common rail pressure limit- failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system engine ECU. Turn the starter switch to the "OFF" position and then
Excessively-long valve opening time
ing valve is open exceeds 5 hours. failure (Air intrusion, fuel shortage) to the "ON" position to check if the error code is displayed again.
Engine ECU internal abnormality: Actuator Overcurrent at the UB5 terminal is detected by the IC power supply 3 (UB5: K73 terminal), 2. Faulty wire harness (12V
drive circuit 3 short to ground inside the engine ECU. power supply 3 (UB5: K73 terminal) wire short to ground), 3. Engine
Engine ECU internal abnormality: AD converter A pulse error is detected through AD converter diagno-
malfunction 1 sis.
again.
Engine ECU internal abnormality: AD converter A voltage error is detected through AD converter diag-
malfunction 2 nosis.
again.
5-5-14 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
Engine ECU internal abnormality: External An error is detected through mutual diagnosis between
monitor IC and CPU malfunctions 1 the external monitor IC and CPU.
again.
Engine ECU internal abnormality: External A communication error between the external monitor
monitor IC and CPU malfunctions 2 IC and CPU is detected.
again.
During self maintenance of the engine ECU power Check the engine ECU. Turn the starter switch to the "OFF" position
Engine ECU internal abnormality: ROM mal-
00 523477.12 Warning after the starter switch is turned to the "OFF" position, 1. Engine ECU internal circuit failure and then to the "ON" position to check if the error code is displayed
function
the checksum fails in the entire ROM area. again.
During the shutoff path test performed by the external
Engine ECU internal abnormality: Shutoff path monitor IC after the engine ECU power is turned on,
1 failure the external monitor IC detects an error in the
again.
response from the CPU to the external monitor IC.
2 failure the external monitor IC detects an operational error in
again.
the shutoff path test.
3 failure the external monitor IC detects a response time error
again.
in the shutoff path test.
4 failure the external monitor IC detects a communication error
again.
5 failure the external monitor IC detects an undervoltage value
again.
6 failure the external monitor IC detects an external monitor IC
again.
error in the shutoff path test.
7 failure the external monitor IC detects an OS call time out
again.
error in the shutoff path test.
8 failure the external monitor IC detects a positive test error in
again.
9 failure the external monitor IC detects an operating time error
again.
10 failure the external monitor IC detects an overvoltage error in
again.
5-5-15 172663 0BKC2-EN0060

5. ELECTRIC SYSTEM
An error is detected through mural diagnoses of the
00 523488.00 Warning Engine speed recognition error 1. Engine ECU internal circuit failure and then to the "ON" position to check if the error code is displayed
engine speed.
again.
When abnormally-high common rail pressure has
1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump and rail pressure sensor. Turn
Common rail pressure limiting valve (PLV): occurred (the rail pressure remains at 160 MPa or
00 523489.00 Warning failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system the starter switch to the "OFF" position and then to the "ON" posi-
Non-operating higher for 10 seconds or more), the common rail pres-
failure (Air intrusion, fuel shortage) tion to check if the error code is displayed again.
sure limiting valve does not open.
Rail pressure control abnormality: High fuel 1. Rail pressure sensor system failure, 2. SCV drive circuit system Check the fuel system, supply pump and rail pressure sensor. Turn
After the common rail pressure limiting valve opens,
00 523491.00 Warning temperature when common rail pressure limit- failure, 3. SCV stuck open, 4. SCV intermittent fault, 5. Fuel system the starter switch to the "OFF" position and then to the "ON" posi-
the fuel temperature exceeds 80˚C.
ing valve is open failure (Air intrusion, fuel shortage) tion to check if the error code is displayed again.
1. Connection failure of connectors 2. Harness wiring failure (sensor
Check the connectors, harnesses and fuel sensor.
Sensor resistance stays at 1 Ω or less for a specific signal line short circuited to GND or sensor GND line short circuited
28 000096.02 Caution Short circuit of fuel sensor Turn the starter switch to the “OFF” position and then the “ON” posi-
period of time. to power supply) 3. Defective fuel sensor 4. Engine ECU internal
tion. Then check that the error code is displayed again.
circuit failure
1. Connection failure of connectors 2. Harness wiring failure (nearly Check the connectors, harnesses and fuel sensor.
Sensor resistance stays at 300 Ω or more for a specific
28 000096.04 Caution Disconnection of fuel sensor broken wiring of sensor signal line, sensor 5 V line or sensor GND Turn the starter switch to the “OFF” position and then the “ON” posi-
period of time.
line) 3. Defective fuel sensor 4. Engine ECU internal circuit failure tion. Then check that the error code is displayed again.
1. Insufficient amount of engine oil 2. Clogging of engine oil filter
Check the engine oil filter element, engine oil pressure switch and
28 000100.00 Warning Abnormal engine oil pressure Engine oil pressure decrease during engine operation 3. Defective engine oil pressure switch or engine oil pressure
lube oil pump.
decrease
Inspect the engine cooling system.
1. Engine overheating 2. Insufficient amount of engine coolant
Water temperature alarm switch stays on for a specific Check the connectors, harnesses and coolant temperature sensor.
28 000110.00 Warning Abnormal engine coolant temperature: too high 3. Defective engine cooling system 4. Defective coolant tempera-
period of time. Turn the starter switch to the “OFF” position and then to the “ON”
ture sensor system
Check the connectors, harnesses and coolant temperature sensor.
Short circuit of engine coolant temperature sen- Sensor resistance stays at 80 Ω or less for a specific signal line short circuited to GND or sensor GND line short circuited
28 000110.02 Caution Turn the starter switch to the “OFF” position and then to the “ON”
sor period of time. to power supply) 3. Defective coolant temperature sensor 4. Engine
1. Connection failure of connectors 2. Harness wiring failure (nearly
Check the connectors, harnesses and coolant temperature sensor.
Disconnection of engine coolant temperature Sensor resistance stays at 30 KΩ or more for a specific broken wiring of sensor signal line, sensor 5 V line or sensor GND
28 000110.04 Caution Turn the starter switch to the “OFF” position and then to the “ON”
sensor period of time. line) 3. Defective coolant temperature sensor 4. Engine ECU inter-
nal circuit failure
Low battery charge signal detected during engine 1. Connection failure of connectors 2. Disconnection or short circuit
28 000167.00 Caution Low battery charge Check the battery, alternator and harnesses.
operation of harness 3. Defective engine ECU
Check that the connectors, terminals and harnesses for CAN com-
Engine data cannot be obtained due to disconnection of CAN com-
28 000639.12 Warning CAN communication error (Engine ECU) LCD monitor cannot receive data from engine ECU. munication are correctly connected. Also, check the engine ECU for
munication line or defective engine ECU.
blown fuse.
Check the connectors, harnesses and hydraulic oil temperature
Sensor resistance stays at 80 Ω or less for a specific sensor.
28 520777.02 Caution Short circuit of hydraulic oil temperature sensor signal line short circuited to GND or sensor GND line short circuited
period of time. Turn the starter switch to the “OFF” position and then the “ON” posi-
to power supply) 3. Defective hydraulic oil temperature sensor
Check the connectors, harnesses and hydraulic oil temperature
1. Connection failure of connectors 2. Harness wiring failure (nearly
Disconnection of hydraulic oil temperature sen- Sensor resistance stays at 30 KΩ or more for a specific sensor.
28 520777.04 Caution broken wiring of sensor signal line, sensor 5 V line or sensor GND
sor period of time. Turn the starter switch to the “OFF” position and then the “ON” posi-
line) 3. Defective hydraulic oil temperature sensor
5-5-16 172663 0BKC2-EN0060

C30R-3 SVM.book 1 ページ２０１７年９月２２日金曜日午後２時３１分
CHAPTER 6
HYDRAULIC SYSTEM
6-1 Outline ................................................................................................ 6-1-1

6-2 Component Parts ................................................................................ 6-2-1
6-2-1 Arrangement of the main hydraulic equipment .......................... 6-2-1
6-2-2 Oil Flow ...................................................................................... 6-2-2
6-2-3 Description of hydraulic main circuit .......................................... 6-2-4
6-3 Circuit Operation ................................................................................. 6-3-1
6-3-1 Traveling and controlling direction ............................................. 6-3-1
6-3-2 Wagon control............................................................................ 6-3-6
6-4 Hydraulic Pump (HST) ........................................................................ 6-4-1
6-4-1 Main specifications..................................................................... 6-4-1
6-4-2 Operation theory ........................................................................ 6-4-1
6-4-3 Exploded view and Parts comprised.......................................... 6-4-7
6-4-4 Disassembly and Reassembly................................................. 6-4-12
6-5 Travel motor........................................................................................ 6-5-1
6-6 Swing Motor ........................................................................................ 6-6-1
6-7 Control Valve ...................................................................................... 6-7-1
6-8 Pilot Valve ........................................................................................... 6-8-1
6-8-1 Wagon control lever (pilot valve R) ............................................ 6-8-1
6-8-2 Travel lever (pilot valve L)........................................................ 6-8-31
6-9 Proportional solenoid valve................................................................. 6-9-1
6-9-1 Single solenoid valve ................................................................. 6-9-1
6-9-2 Triple solenoid valve .................................................................. 6-9-2
6-10 Triple solenoid valve ....................................................................... 6-10-1
6-11 Hydraulic cylinder ........................................................................... 6-11-1
6-11-1 Sectional View and Parts (Three-side flaps wagon type) ...... 6-11-1
6-11-2 Sectional View and Parts (Swing wagon type) ...................... 6-11-2
6-11-3 Disassembling and assembling ............................................. 6-11-3
6. HYDRAULIC SYSTEM
6. Hydraulic System
6-1 Outline
This machine employs a hydrostatic transmission (HST) system, and configure closed circuits with swash-plate-type
variable displacement piston pumps that are applicable to the forward/reverse circuits of each of the left and right
travel motors. In each closed circuit, operate the pilot oil valve to control the discharging amount from the pump, vari-
ably change the vehicle traveling speed from 0 to maximum. Switching the vehicle’s forward/reverse travel, direc-
tion, and dumping operation are controlled by the pilot oil supplied from the gear pump via each pilot oil valve. Two
linked external gear pumps attached to the HST main pump are used for pilot and charging on the main pump side,
and the pump on the tip part is used as the attachment (dump cylinder) pump.
6-1-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-2 Component Parts
6-2-1 Arrangement of the main hydraulic equipment
■ Three-side flaps wagon type
Hydraulic pump (HST) Selector valve
Wagon control lever Travel lever

(Right pilot valve) (Left pilot valve) Dump cylinder
Triple solenoid valve
Right
Rear
Hydraulic oil tank
Front Left
Single solenoid valve Travel motor Control valve 105243-00EN00
6-2-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
■ Swing wagon type
Hydraulic pump (HST) Dump cylinder

Selector valve
Wagon control lever Travel lever
(Right pilot valve) (Left pilot valve)
Right
Rear
Swing motor
Swivel joint
Hydraulic oil tank
Front
Left
Single solenoid valve Travel motor Control valve 109600-00EN00
6-2-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-2-2 Oil Flow
(1) Pilot oil flow

The hydraulic pump consists of HST pumps (x2) which
are variable displacement piston pumps, a machine (Pilot valve L) (Pilot valve R) Control valve
T
pump (gear pump), and a charge pump.
P P T
The drive shaft of the hydraulic pump is connected to the B1
engine flywheel via rubber coupling, and the HST pump, Dump
A1
machine pump, and charge pump are driven with the 1 Up Down 2 Pb1
same speed of the drive shaft. (1) (2) (3) (4)
Dump cylinder
The two ports: for intake and discharge of HST pump,
6
are switched depending on the direction of the swash 1 2 3 4 Pa1
plate controlled by the servo mechanism. P T
The change of the discharging port of the HST pump
changes the turning direction of the travel motor.
Selector valve
Pump displacemen P1 T1 P2 T2
a1 Pf P3
Travel automatic Working Traveling
(Displacement per one turn )t dual speed switching A Parking brake B1 Cut off B2 Cut off B3
Drain block
P1
cu. in. (cu. cm) / rev R/G
No. Pump C30R-3 T P2

Drain block
1 HST pump 1.34 (22.0) A1 B1 A2 B2 P3 P T A1 A2 A3

2 Charge pump 0.73 (11.9) Accumulator 7
3 Machine pump 0.49 (8.1)
Drain block
(2) Travel motor
8
The travel motor, which is the variable displacement pis- Charge filter
ton motor, is attached to the truck frame. a2 Ps
Travel motor (R)
The built-in reduction gear box lowers the speed and
Pp3 Pp4 Pp6 Pp5
T2 B2 Pp1
drives the crawler via the sprocket.
3
Displacement per one turn of motor (cm3/rev) Hydraulic pump 4 2 4 a1 Pf P3
Speed change C30R-3 PgC

1
Pg1 Pg3 B1 B3
Low speed 2.06 (33.8) P1 P3 P1
R/G
High speed 1.03 (16.9) P2
5 5
(3) Oil Flow Engine P2 P1 P3 P4 S1 S3
T1,T2
1) Hydraulic pump to Travel motor 5 5 7
The two ports of the HST pump are connected to the two P2 Pg4 P4
Pg2 S
ports of the travel motor, and configures a closed circuit.
T1
HST pump
HST pump
The two HST pumps and the left and right travel motors Charge pump Implement pump
8
configures two closed circuits. By switching the dis- a2 Ps
Travel motor (L)
charging ports for the hydraulic oil boosted by HST
pump, the travel motor can be switched between forward Check valve
and rearward travel. When the combination of the dis-
charging ports of the two HST pumps are P1 and P3, or Oil cooler
P2 and P4, the left and right travel motors run in the
same direction to travel forward or back. Combinations Line filter
other than the above makes the travel motors move in Suction filter
opposite directions and the vehicle spins.Oil leaked from
the closed circuit returns to the hydraulic oil tank via port Hydraulic oil tank
T1. The lacking hydraulic oil due to leakage from the 105058-00EN00
closed circuit is refilled from the charge pump to the port
B2 via the charge filter.
6-2-3 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Implement pump (S3)

Implement pump is the gear pump. The hydraulic oil
sucked in via the suction filter of the hydraulic oil tank is
supplied to the control valve for dump cylinder. If the Travel lever Wagon control lever
spool of the control valve is neutral, the oil flown in from P T
(Pilot valve L) (Pilot valve R) Control valve
P T
the port P1 goes through the spool and returns to the
B1
hydraulic oil tank from port T.
Dump
A1
3) Charge pump (S1) (1) (2) (3) (4)

1 Up Down 2 Pb1
The hydraulic oil sucked in from port S is discharged Dump cylinder

from port B1, and is supplied to the two HST pumps via 6
1 2 3 4 Pa1
the charge filter, port B2, and orifice (throttle) 2. Some oil
P T
goes through Pgc and Pp1 and flows into the single
solenoid valve for automatic switching of low/high
speed, and the triple solenoid valve for travel cut-off. P1 T1 P2 T2
Selector valve
When sufficient hydraulic oil is supplied to the HST Travel automatic Working Traveling
a1 Pf P3
closed circuit and charge pressure is enough, the dual speed switching A Parking brake B1 Cut off B2 Cut off B3
Drain block
remaining hydraulic oil returns through the relief valve
P1
R/G
and T2 port. After going through the charge filter, part of T P2

Drain block
the oil flows in via port A1 of the triple solenoid valve for A1 B1 A2 B2 P3 P T A1 A2 A3

releasing the parking brake, and port A2 of the triple Accumulator
solenoid valve for machine (attachment) cut-off, to be
Drain block
used as pressure for releasing the brake of the travel
motor, and also as pilot oil pressure for the machine
(attachment). Charge filter
a2 Ps
Travel motor (R)
Pp3 Pp4 Pp6 Pp5
4) Relief valves T2 B2 Pp1
The two closed circuits of HST are each provided with 3

two relief valves 5, which prevent the pressure inside the Hydraulic pump 4 4
2 a1 Pf P3
closed circuit to go over a specific value. Relief valves 6 PgC

1
Pg1 Pg3 B1 B3
are also provided between the machine pump and the P1 P3 P1
R/G
dump cylinder control valve, which prevent the pressure P2
inside the dump cylinder to go over a specific value. 5 5

Engine P2 P1 P3 P4 S1 S3
T1,T2
5 5
P2 Pg4 P4
Pg2 T1 S
HST pump
HST pump
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

105058-00EN01
6-2-4 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-2-3 Description of hydraulic main circuit
The main circuit of the hydraulics is a system of closed

circuit. The turning direction and speed of the travel
motor depends on the flowing direction of the hydraulic P T
P T
oil in the closed circuit and its flow rate. Oil discharged B1
from the charge pump flows via the travel lever to the
Dump
selector valve, to drive the servo cylinder 4 controlling A1
1 Up Down 2 Pb1
the swash plate of the HST pump. (1) (2) (3) (4)
Dump cylinder
6
(1) Controlling the HST pump flow rate 1 2 3 4 Pa1
Oil discharged from the charge pump (S1) goes through P T
the charge filter, and flows into the hydraulic pump again
from port B2. P1 T1 P2 T2
Selector valve
a1 Pf P3
Part of the oil that went through orifice 2 is supplied to Travel automatic Working Traveling
dual speed switching A Parking brake B1 Cut off B2 Cut off B3
the closed circuit. Another part of the oil goes through Drain block
P1
R/G
pressure reducing valve 1 and flows from the triple sole- T P2
noid valve for travel cut-off to the port P of the travel pilot A1 B1 A2 B2 P3 P T A1 A2 A3
Drain block
Single solenoid valve Triple solenoid valve
valve. Pressure Switch
Accumulator
T1,T2
The pressure reducing valve 1 is a differential pressure

Drain block
valve that controls the opening amount from the differ-
ence in pressures on the forward and rear of the orifice
Charge filter
2. a2 Ps
Travel motor (R)
As the pressure difference is larger, the opening of the Pp3 Pp4
T2 B2 Pp1
Pp6 Pp5
pressure reducing valve 1 widens, and the pressure of 3

the pilot oil supplied to the travel pilot valve increases. Hydraulic pump 4 4
2 a1 Pf P3
On the downstream of the orifice 2, which is the

PgC
Pg1
1 Pg3 B1 B3
upstream of the pressure reducing valve, a relief valve 3 P1 P3 P1
R/G
is provided to keep the pressure flowing into the pres- 5 5 P2
sure reducing valve to a predetermined pressure Engine P2 P1 P3 P4 S1 S3

T1,T2
(2.8MPa). The pilot oil passed through the pressure 5 5

reducing valve is reduced to 1.2 to 2.5 MPa depending P2 Pg4 P4
Pg2 T1 S
HST pump
on the opening amount. The discharging amount of the HST pump
charge pump which is the gear pump increases with the
a2 Ps
rise of engine speed, and the pressure on the upstream Travel motor (L)
side of the orifice increases.

Check valve
Because pressure on the downstream side of the orifice
Oil cooler
2 is kept within the predetermined value with the relief
valve 3, the opening of the pressure reducing valve 1
Line filter
widens with the rise of engine speed, and the pressur-
Suction filter
ized pilot oil is supplied to the travel lever.
Hydraulic oil tank
105058-00EN02
6-2-5 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Controlling the HST pump flow rate (continued)

The oil that has flown from port P to the travel lever
passes through the selector valve and runs the servo
cylinder 4. Travel lever Wagon control lever
When the engine speed rises, the opening of the pres- P T P T
sure reducing valve widens and the pilot pressure B1
increases, which the servo cylinder increases the incli- Dump

A1
nation of the swash plate of the HST pump. (3) (4)

1 Up Down 2 Pb1
(1) (2)
As a result, the discharge amount increases and the Dump cylinder
travel motor speeds up. 6
1 2 3 4 Pa1
Oppositely, if load is applied to the travel motor and the
P T
engine speed is low, because the differential pressure is
smaller and the pilot pressure supplied from the pres-
Selector valve
sure reducing valve is smaller, the driving force of the P1 T1 P2 T2
a1 Pf P3
servo cylinder lowers. Therefore, it decreases the incli- dual speed switching A Parking brake B1 Cut off B2 Cut off B3
Drain block
nation of the swash plate of the HST to lower the load on P1
R/G
the HST pump. T P2

Drain block
As a result, the engine speed recovers. A1 B1 A2 B2 P3
Single solenoid valve
P T
A1 A2 A3
T1,T2
Pressure Switch
Thus, this servo system configured from charge pump, Accumulator
orifice, pressure reducing valve, travel lever, and servo Drain block
cylinder, has a speed sensing function for controlling the
load to the engine by changing the pilot oil pressure for Charge filter
a2 Ps
traveling depending on the change in engine speed. Pp3 Pp4 Pp6 Pp5
Travel motor (R)
On the downstream side of the orifice 2, overload is T2 B2 Pp1
applied to the travel motor and opens the relief valve. 3

Hydraulic pump 4 4
When hydraulic oil of the closed circuit flows in, the pres- PgC
2 a1 Pf P3
sure rises. Pg1

1 Pg3 B1 B3
P1 P3 P1
If it exceeds the predetermined value, the relief valve 3 R/G
5 5 P2
opens, and returns to the hydraulic oil tank via the drain
block. T1,T2
5 5
P2 Pg4 P4
Pg2 T1 S
HST pump
HST pump
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

105058-00EN02
6-2-6 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) Travel motor

The oil path from the charge pump (S1) via the charge
filter passes through the triple solenoid valve for releas-
ing the parking brake, and is connected to the brake Travel lever Wagon control lever
release pilot ports P3 of the left and right travel motors. P T P T
By releasing the lock lever and switching off the parking B1
switch, the triple solenoid valve opens and oil flows out, Dump
A1
releasing the parking brakes of the left and right travel (3) (4)
1 Up Down 2 Pb1
(1) (2)
motors. Dump cylinder
Moreover, the oil path that goes from port B2 to the ori-
1 2 3 4 Pa1
fice (φ3.8) 2 is connected to the automatic low/high
P T
switching pilot port Ps of the left and right travel motors
via the single solenoid valve for automatic switching of
Selector valve
low/high speed from port Pgc of hydraulic pump, which P1 T1 P2 T2
a1 Pf P3
allows switching the traveling speed by operating the dual speed switching A Parking brake B1 Cut off B2 Cut off B3
Drain block
automatic low/high speed switch. P1
R/G
T P2
Drain block
A1 B1 A2 B2 P3 P T A1 A2 A3

Accumulator
Drain block
Charge filter
a2 Ps
Travel motor (R)
Pp3 Pp4 Pp6 Pp5
T2 B2 Pp1
Hydraulic pump
PgC
2 a1 Pf P3
Pg1 Pg3 B1 B3
P1 P3 P1
R/G
P2
T1,T2
P2 Pg4 P4
Pg2 T1 S
HST pump
HST pump
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

105058-00EN03
6-2-7 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-3 Circuit Operation

Travel lever
6-3-1 Traveling and controlling direction (Pilot valve L)
Spool position When seat is
(1) Forward travel (seat facing forward) Travel lever
facing forward
1) Flow of pilot oil (Pilot valve L) Spool (2)

Wagon control lever （2）
By pushing forward the travel lever, spool (2) is pushed Spool (2) (Pilot valve R) Control valve
P T P T
via the push rod, and circuit is switched. （1）（3）
B1
Oil discharged from the charge pump (S1) is filtered
through the charge filter, and is supplied to port P of the Dump A1 （4）
1 Up Down 2 Pb1
travel lever via the pressure reducing valve 1 and the tri- （2）
（1）（3）
（4）
ple solenoid valve for travel cut-off. Dump cylinder

6
The supplied oil goes through the spool (2), into the Shuttle valve 1 1 2 3 4 Pa1
shuttle valve and selector valve of ports 1 and 2, and Shuttle valve 2 P T
flows into ports Pp4 and Pp6 of servo cylinder 4 of the

HST pump. This moves the servo cylinder 4, and con- P1 T1 P2 T2
Selector valve
trols the both swash plates of the two HST pumps. Travel automatic Working Traveling
a1 Pf P3
dual speed switching Ａ Parking brake B1 Cut off B2 Cut off B3

Drain block
P1
2) Oil flow of hydraulic pump R/G

T P2
The moving servo cylinders 4 move the swash plates of A1 B1 A2 B2 P3 ＰＴ A1 A2 A3
Drain block
the HST pumps forward, and pressurized oil is dis- Pressure Switch Single solenoid valve Triple solenoid valve T1,T2
Accumulator
charged from ports P2 and P4 of the HST pumps.
Drain block
Oil flows into the port P1 of travel motor L and port P2 of
travel motor R. Each travel motor is rotated forward,
Charge filter
moving the vehicle forward. a2 Ps
Travel motor (R)
The returning oil from the port P2 of the travel motor L Pp3 Pp4 Pp6 Pp5
T2 B2 Pp1
and the port P1 of the travel motor R are flown into ports 1
P1 and P3 of the HST pumps respectively, and returns 4 4
Hydraulic pump a1 Pf P3
into the HST ports. PgC
Pg1 Pg3 B1 B3
P1 P3 P1
R/G
P2
Engine S1 S3
T1,T2
P2 Pg4 P4
Pg2 T1 S
HST pump
HST pump
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

105058-00EN05
6-3-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) Right turn: Pivot turn

(when seat is facing forward)
1) Flow of pilot oil Travel lever
(Pilot valve L)
By pushing the travel lever to the forward-right direction, Spool position When seat is
facing forward
spools (2) and (3) are pushed via the push rods, and cir- Travel lever
Spool (2)
(Pilot valve L) Wagon control lever
cuits are switched. Oil discharged from the charge pump Spool (3) Control valve
（2）
Spool (2) T
(Pilot valve R)
(S1) is strained through the charge filter, and is supplied
P P T
（1）（3）
to the P port of the travel lever via the pressure reducing
B1
valve 1 and the triple solenoid valve for travel cut-off. Dump A1 Spool (3)
（4）
The supplied oil goes through (2) and (3), into ports 1, 2, （2）
（1）（3）
（4）
1 Up Down 2 Pb1
and 3, passes each shuttle valve and selector valve, and Dump cylinder
6
flows into Ports Pp4, Pp5, and Pp6 of servo cylinder 4 of 1 2 3 4 Pa1
Shuttle valve 1
HST pump. Oil flown into port Pp4 moves the servo cyl- P T
Shuttle valve 2
inder 4, and controls the swash plate of the HST pump
Shuttle valve 3
to the forward direction. Oil flown into ports Pp5 and Pp6
pushes the servo cylinder 4 from both sides. When the Travel automatic
a1 Pf P3
Working Traveling
Selector valve
pushing amount of spools (2) and (3) of the travel lever P1 T1 P2 T2 dual speed switching Ａ Parking brake B1 Cut off B2 Cut off B3
Drain block
P1
are the same, because the pressure of ports Pp5 and R/G
T P2
Pp6 are the same, servo cylinder 4 is kept in neutral, Drain block
ＰＴ A1 A2 A3
and the swash plate of the HST pump stays neutral. Single solenoid valve Triple solenoid valve T1,T2
A1 B1 A2 B2 P3 Accumulator
Pressure Switch Drain block
2) Oil flow of hydraulic pump
The moving servo cylinders 4 move the swash plates of
the HST pumps forward, and pressurized oil is dis- Charge filter
a2 Ps
Travel motor (R)
charged from port P2 of the HST pumps, and flows into Pp3 Pp4 Pp6 Pp5
T2 B2 Pp1
port P1 of the travel motor L, to run the motor in the for-
1
ward traveling direction.
Hydraulic pump 4 4 a1 Pf P3
However, because the swash plate of the HST pump PgC
that connects to the travel motor R is kept neutral, pres- P1

Pg1 Pg3 B1 B3
P3 P1
R/G
surized oil is not discharged, and the travel motor R P2
does not run. Engine S1 S3

T1,T2
As a result, only the travel motor L runs forward, leading
to a pivot turn of the vehicle to the front-right direction. P2 Pg4 P4
The oil returned from port P2 of the travel motor L goes Pg2 T1
HST pump S
HST pump
through port P1 of the HST pump and returns to the HST Charge pump Implement pump
pump. a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

105058-00EN10
6-3-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(3) Right side spin-turn

(when seat is facing forward)
1) Flow of pilot oil Travel lever
By pushing the travel lever to the right, spool (3) is (Pilot valve L)
Spool position
pushed via the push rod, and circuit is switched. Oil dis- Travel lever When seat is
(Pilot valve L) facing forward
charged from the charge pump (S1) is filtered through Wagon control lever （2）
Spool (3) (Pilot valve R) Control valve
the charge filter, and is supplied to port P of the travel P T P T
（1）（3）
lever via the pressure reducing valve 1 and the triple B1
solenoid valve for travel cut-off. The supplied oil goes Dump
A1
（4） Spool (3)
through spool (3), into ports 2 and 3, passes each shut- （2）
（1）（3）
（4）
1 Up Down 2 Pb1
tle valve and selector valve, and flows into ports Pp4 and Dump cylinder
6
Pp5 of servo cylinder 4 of HST pump. The oil flown into 1 2 3 4 Pa1
port Pp4 moves the servo cylinder 4, and controls the Shuttle valve 2 P T
swash plate of the HST pump to the forward direction. Shuttle valve 3
The oil flown into port Pp5 moves the servo cylinder 4,
and controls the swash plate of the HST pump to the Selector valve Travel automatic
a1 Pf P3
P1 T1 P2 T2 Working Traveling
rear direction. dual speed switching Ａ Parking brake B1 Cut off B2 Cut off B3
Drain block
P1
R/G
2) Oil flow of hydraulic pump

T P2
Drain block
ＰＴ A1 A2 A3
The moving servo cylinder 4 controls the swash plate of Single solenoid valve Triple solenoid valve T1,T2
A1 B1 A2 B2 P3
the HST pump, and the oil discharged from the P2 port Accumulator
Pressure Switch
of the HST pump flows into port P1 of the travel motor L, Drain block
to run the motor in the forward traveling direction. The oil

discharged from port P3 of HST pump flows into port P1 Charge filter
a2 Ps
Travel motor (R)
of travel motor R to run the motor in the reverse traveling Pp3 Pp4 Pp6 Pp5
direction. As a result, the travel motor L runs in the for- T2 B2 Pp1
1
ward traveling direction, and due to the travel motor R
Hydraulic pump 4 4
running in the reverse traveling direction, the vehicle
a1 Pf P3
PgC
makes a right spin. The returning oil from the port P2 of Pg1 Pg3 B1 B3
P3 P1
P1
the travel motor L and the port P1 of the travel motor R P2
R/G
are flown into ports P1 and P4 of the HST pumps Engine S1 S3
respectively, and returns into the HST ports. T1,T2
P2 Pg4 P4
Pg2 T1 S
HST pump
HST pump
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

105058-00EN11
6-3-3 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(4) Reverse travel (seat facing rear)

1) Flow of pilot oil
Travel lever
When the seat is turned to face the rear, the limit switch (Pilot valve L)
under the seat switches the selector valve. Travel lever
Spool position When seat is
facing forward
By pushing forward the travel lever, spool (2) is pushed (Pilot valve L)
Wagon control lever Spool (2)
via the push rod, and the circuit is switched. Oil dis- Spool (2) (Pilot valve R) Control valve （2）
P T P T
charged from the charge pump (S1) is filtered through
B1 （1）（3）
the charge filter, and is supplied to port P of the travel
Dump
lever via the pressure reducing valve 1 and the triple A1
（4）
1 Up Down 2 Pb1
solenoid valve for travel cut-off. The oil goes through the （2）
（1）（3）
（4）
Dump cylinder
spool (2), into the shuttle valve of ports 1 and 2, and by 6
passing through the switched selector valve, it flows into Shuttle valve 1 1 2 3 4 Pa1
ports Pp3 and Pp5 of servo cylinder 4 of the HST pump. Shuttle valve 2 P T
This moves the servo cylinder 4, and controls the both

swash plates of the two HST pumps to the rear direction. P1 T1 P2 T2
Selector valve
a１ Pf P3
dual speed switching Ａ Parking brake B1 Cut off B2 Cut off B3
2) Oil flow of hydraulic pump Drain block
P1
The moving servo cylinders 4 move the swash plates of T P2

R/G
the HST pumps rearward, and pressurized oil is dis- A1 B1 A2 B2 P3 ＰＴ A1 A2 A3

Drain block
charged from ports P1 and P3 of the HST pumps, and Pressure Switch Single solenoid valve Triple solenoid valve T1,T2
Accumulator
flows into port P2 of travel motor L and port P1 of travel
Drain block
motor R, to run each travel motor in the rear traveling
direction. Thus, the vehicle moves rearward.
Charge filter
The returning oil from the port P1 of the travel motor L a２ Ps
Travel motor (R)
and the port P2 of the travel motor R are flown into ports Pp3 Pp4 Pp6 Pp5
T2 B2 Pp1
P2 and P4 of the HST pumps respectively, and returns 1
into the HST ports. Hydraulic pump 4 4 a１ Pf P3
PgC
Pg1 Pg3 B1 B3
P1 P3 P1
R/G
P2
Engine S1 S3
T1,T2
P2 Pg4 P4
Pg2 T1 S
HST pump
HST pump
a２ Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank 105058-00EN07
6-3-4 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(5) Automatic switching of low/high speed

(The circuit diagram on the right showing an
example when traveling forward with the seat
facing forward) Travel lever Wagon control lever
1) Flow of pilot oil P T P T
By turning on the automatic low/high speed switch, the B1
spool of the single solenoid valve for automatic switching Dump

A1
of low/high speed is switched. 1 Up Down 2 Pb1
Oil discharged from the charge pump (S1) is filtered (1) (2) (3) (4)
Dump cylinder
through the charge filter, passes through ports B2 and
PgC of the pump, and is supplied to port P of the single 1 2 3 4 Pa1
solenoid valve for automatic switching of low/high P T
speed.
The oil goes through the spool and passes port A, and
Selector valve
then branches into ports Ps of the left and right travel P1 T1 P2 T2
a1 Pf P3
motors, to switch the two-speed spool 8. Travel automatic Working Traveling
2) Speeding up the travel motor Drain block
P1
Switching of the two-speed spool 8 supplies the high T P2

R/G
pressure oil from the HST pump to the swash plate con- A1 B1 A2 B2 P3
Drain block
P T A1 A2 A3
trol piston 7, and the swash plate control piston 7 acti- Pressure Switch Single solenoid valve Triple solenoid valve T1,T2 7
vates to reduce the inclination angle of the swash plate. Accumulator
Here, the piston stroke of the travel motor is shortened Drain block
and the capacity of the travel motor is decreased. There-
8
fore, the speed is slower and the traveling switches to Charge filter
two-speed travel. Because the piston stroke is shorter, a2 Ps
Travel motor (R)
the output torque of the travel motor is smaller, and the Pp3 Pp4 Pp6 Pp5
T2 B2 Pp1
driving force of the two-speed travel is shorter.
1
3) Automatic switching from two-speed operation
Hydraulic pump 4 4 a1 Pf P3
single-speed operation PgC
The oil from the gear pump P3 flows through the paral- P1
Pg1 Pg3 B1 B3
P3 P1
lel-flow divider, blade and swing sections and the parallel R/G
P2
passage to the arm section. Therefore, the machine can
Engine P2 P1
travel with no deviation even when the arm control lever
P3 P4 S1 S3
T1,T2 7
is moved while the machine is traveling. When a high
traveling load is applied (for example, when starting or P2 Pg4 P4
Pg2 T1 S
climbing up a hill), the pressure on the high-pressure HST pump
HST pump
side circuit of the travel motor rises. This pressure
Charge pump Implement pump 8
applies to the two-speed spool 8, and when it over- a2 Ps
Travel motor (L)
comes the pilot oil pressure of the port Ps, the two-
speed spool 8 is returned and the circuit that is con- Check valve
nected to the swash plate control piston 7 is discon-
Oil cooler
nected. The swash plate control piston 7 is returned by a
spring, and the inclination angle of the swash plate
Line filter
increases. Here, the piston stroke of the travel motor is
longer and the capacity of the travel motor is increased. Suction filter
Therefore, the speed is slower and the traveling
Hydraulic oil tank
switches to single-speed travel. Because the piston
stroke is longer, the output torque of the travel motor is 105058-00EN09
larger, and the driving force of traveling is stronger,

which corresponds to the increased traveling load.
6-3-5 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-3-2 Wagon control
■ Three-side flaps wagon type

(1) Wagon “Raise” Travel lever Wagon control lever
1) Flow of pilot oil (Pilot valve L) (Pilot valve R) Control valve
P T P T
By setting the wagon control lever to “Raise Up” posi- B1
tion, oil from the charge pump S1 goes through port B2

Dump
of triple solenoid valve for machine (attachment) cut-off,
A1
1 Up Down 2 Pb1
and passes port 1 of the wagon control lever (pilot valve (1) (2) (3) (4)
Dump cylinder
R) into port Pb1 of control valve, to switch the spool. 6
1 2 3 4 Pa1
2) Oil flow of hydraulic pump P T
Oil from Implement pump S3 goes through spool from

port P of control valve, and passes through port B1 to P1 T1 P2 T2
Selector valve
a1 Pf P3
flow into the bottom side of the dump cylinder to extend Travel automatic Working Traveling
Drain block
the rod and lift the wagon. P1
R/G
Oil returned from rod side of the dump cylinder goes T P2
Drain block
through the port A1 of control valve to the spool into the A1 B1 A2 B2 P3 P T A1 A2 A3
Single solenoid valve Triple solenoid valve T1,T2
port T and line filter, returning to the hydraulic oil tank. Pressure Switch
Accumulator
Drain block
(2) Wagon “Lower”
Charge filter
By setting the wagon control lever to “Lower” position, oil a2 Ps
Travel motor (R)
from the charge pump S1 goes through port B2 of triple
Pp3 Pp4 Pp6 Pp5
T2 B2 Pp1
solenoid valve for machine (attachment) cut-off, and

3
passes through No. 2 of the wagon control lever (pilot Hydraulic pump 4 2 4 a1 Pf P3
PgC
valve R) into port Pa1 of control valve, to switch the 1 Pg3 B1 B3
Pg1
spool. P1 P3 P1
R/G
P2
5 5
Engine
2) Oil flow of hydraulic pump P2 P1 P3 P4 S1 S3
T1,T2
The flow of the oil to the cylinder is the same besides the 5 5
fact that it occurs on the opposite side of the port. P2
Pg2 T1
Pg4
S
P4
HST pump
HST pump
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

105058-00EN04
6-3-6 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
■ Swing wagon type

(1) Wagon “Raise”
By setting the wagon control lever to “Raise Up” posi- Swing motor
Control valve Dump cylinder
tion, oil from the charge pump S1 goes through port B2 Travel lever Wagon control lever
B2
A2
(Pilot valve L) (Pilot valve R) Ｐa2
Swivel joint
of triple solenoid valve for machine (attachment) cut-off, P T P T
Swing
PB DB
and passes port 1 of the wagon control lever (pilot valve Ｐｂ2
D
F F
D
ＢＢ
R) into port Pb1 of control valve, to switch the spool. Ｂ1
ＣＣ
E E
1 3 2 4 Ｐa1 A A
(1) (2) (3) (4) Right Left Up Down A1 G
G
Dump
Dr
2) Oil flow of hydraulic pump Ｐｂ1
Dr
Oil from Implement pump S3 goes through spool from 1 2 3 4
port P of control valve, and passes through port B1, via 6 GB B

Left
ＭＡ
Right
GA
P T
port D of the swivel joint, to flow into the bottom side of
the dump cylinder to extend the rod and lift the wagon. P1 T1 P2 T2
Selector valve
Oil returned from rod side of the dump cylinder goes via a1 Pf P3

port B of the swivel joint, through the port A1 of control dual speed switching Ａ Parking brake B1 Cut off B2 Cut off B3
Drain block
P1
R/G
valve to the spool into the port T and line filter, returning T P2
Drain block
to the hydraulic oil tank. A1 B1 A2 B2 P3 ＰＴ A1 A2 A3

Accumulator
(2) Wagon “Lower” Drain block
By setting the wagon control lever to “Lower” position, oil Charge filter
a2 Ps
from the charge pump S1 goes through port B2 of triple Travel motor (R)
Pp3 Pp4 Pp6 Pp5
solenoid valve for machine (attachment) cut-off, and T2 B2 Pp1
passes through No. 4 of the wagon control lever (pilot 3

Hydraulic pump 4 4
valve R) into port Pa1 of control valve, to switch the ＰgC
2 a1 Pf P3
spool. Pg1 1 Pg3 B1 B3

P1 P3 P1
R/G
P2
5 5
2) Oil flow of hydraulic pump Engine P2 P1 P3 P4 S1 S3
T1,T2
The flow of the oil to the cylinder is the same besides the 5 5 Charge pump
fact that it occurs on the opposite side of the port. P2 P4
Pg4
Pg2 T1 HST pump S Implement pump
HST pump
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

109593-00EN01
6-3-7 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(3) Right Swing

When the wagon control lever is moved to the position of
“Swing to Right”, the oil discharged from the charge Swing motor
pump S1 flows through the port B2 of the triple solenoid Travel lever Wagon control lever
B2
A2
Swivel joint
valve for implement operation cutoff and the port 1 of the P T P T
Swing
PB DB
wagon control valve (RH pilot valve) to the port Pa2 of Ｐｂ2
D
F F
D
ＢＢ
the control valve to move the spool of the wagon swing Ｂ1
ＣＣ
E E
section. (1) (2) (3) (4)
1
Right
3
Left
2
Up
4
Down
Ｐa1
A1
A
G G
A
Dump
Dr Dr
Ｐｂ1
2) Oil flow of hydraulic pump 1 2 3 4
The oil discharged from the implement pump S3 flows 6 GB B

Left
ＭＡ
Right
GA
P T
through the port P of the control valve, the wagon swing
section spool, the port A2 of the control valve and the P1 T1 P2 T2
Selector valve
port C of the swivel joint to the port A of the brake valve a1 Pf P3

to rotate the swing motor. The return oil from the port B dual speed switching Ａ Parking brake B1 Cut off B2 Cut off B3
Drain block
P1
R/G
of the brake valve flows back through the port A of the T P2
Drain block
swivel joint and the port B2 of the control valve to the A1 B1 A2 B2 P3 ＰＴ A1 A2 A3

hydraulic oil tank. Accumulator
Drain block
(4) Left Swing
1) Flow of pilot oil Charge filter
a2 Ps
When the wagon control lever is moved to the position of Travel motor (R)
Pp3 Pp4 Pp6 Pp5
“Swing to Left”, the oil discharged from the charge pump T2 B2 Pp1
S1 flows through the port B2 of the triple solenoid valve 3

Hydraulic pump
4 4
for implement operation cutoff and the port 3 of the ＰgC 2 a1 Pf P3
1
wagon control valve (RH pilot valve) to the port Pb2 of P1
Pg1 Pg3 B1 B3
P3 P1
R/G
the control valve to move the spool of the wagon swing P2
5 5
section. Engine P2 P1 P3 P4 S1 S3
T1,T2
5 5 Charge pump
2) Oil flow of hydraulic pump P2 P4
Pg4
The oil flows in the opposite direction to the oil flow in the HST pump
Right Swing operation with regard to the swing motor.
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

109593-00EN02
6-3-8 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(5) Release and Operation of Swing Motor

Mechanical Brake
1) Release
When the lock lever is pushed forward, the oil from the Swing motor
charge pump S3 flows to the port PB of the swing motor Travel lever Wagon control lever
B2
A2
Swivel joint
and presses the piston (with a spring) of the swing motor P T P T
Swing
PB DB
Ｐｂ2
mechanical brake to release the brake. D
F F
D
ＢＢ
ＣＣ
Ｂ1
E E
2) Operation
1 3 2 4 Ｐa1 A A
(1) (2) (3) (4) Right Left Up Down A1 G
G
Dump
Dr Dr
When the lock lever is pulled backward, the oil from the Ｐｂ1
charge pump S3 does not flow to the swing motor so 1 2 3 4
that the spring force causes the brake to be applied. 6 GB B

Left
ＭＡ
Right
GA
P T
(6) Swing Motor Hydraulic Brake Operation P1 T1 P2 T2

Selector valve
When the swing control lever is released (i.e., returned
a1 Pf P3
Travel automatic Working Traveling Drain block

to the neutral position), the oil flow to the swing motor is dual speed switching Ａ Parking brake B1 Cut off B2 Cut off B3 P1
R/G
blocked and the pressures at the ports A (L) and B (R) of T P2
Drain block
the brake valve become equal and consequently the A1 B1 A2 B2 P3 ＰＴ A1 A2 A3

brake is applied. However, the swing motor continues to Accumulator
rotate in a short time due to its inertia. This causes the Drain block
motor to act like a pump and increases the circuit pres-
sure on the port B2 side. The increased pressure opens Charge filter
a2 Ps
the relief valve in the A (L) circuit to let the oil on the Pp3 Pp4 Pp6 Pp5
Travel motor (R)
lower pressure side escape to the port A2, so that the T2 B2 Pp1
circuit pressure is absorbed and cavitation is prevented 3

Hydraulic pump
4 4 a1 Pf P3
on the port A2 side. ＰgC 2
1
The port M of the swing motor has the drain function and P1
Pg1 Pg3 B1 B3
P3 P1
R/G
a circuit which directly takes in the return oil flowing from P2
5 5
the hydraulic oil tank to prevent negative pressure in the Engine P2 P1 P3 P4 S1 S3
T1,T2
swing motor. 5 5 Charge pump
The relief valve of the hydraulic brake is a shockless P2 P4
Pg4
type which has a piston to absorb the shock caused by HST pump
the brake operation.
a2 Ps
Travel motor (L)
Check valve
Oil cooler
Line filter
Suction filter
Hydraulic oil tank

109593-00EN02
6-3-9 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-4 Hydraulic Pump (HST)
6-4-1 Main specifications
Model PSVH2-28C
Displacement 0 to 0.34 (22.0)[cu.in. (cu.cm)/rev.]
Swash plate angle 0 to ±14.1°
Dry mass Approximate 121.3 (55.0) [lbs. (kg)]
Maximum pressure 4975 (34.3) [PSI (MPa)]
(Set pressure of the relief valve))
Input speed (Rated) 2800 rpm
Pressure in case Less than 14.2 (0.098) [PSI (MPa)]
6-4-2 Operation theory
(1) Pump citcuit

The figure 6-1 shows the rotary group of the swash plate type axial piston pump and nine pistons are installed in its
cylinder block. The shaft directly connects to the crankshaft of engine and the cylinder block synchronizes with rota-
tion of the shaft. (Swash plate does not rotate)
When the shaft center and swash plate are perpendicular to each other as shown in the figure 6-1, volume of cylin-
drical chamber A and that of chamber B in the cylinder block are the same so that the pump neither intakes nor dis-
charges oil, and has no pumping function. When the swash plate is inclined at β degrees, volumes of the cylindrical
chambers A and B change as shown to the figure 1-2. When the shaft rotates to the direction φ, the pump intakes oil
while the piston moves from B to A on the above condition. Accordingly, when intake and discharge pipes are con-
nected to two crescent-shaped ports as shown in the figure 1-3, one pump is constructed. In the figure 6-3, Ps is an
intake port and Pd is a discharge port. As mentioned above, when swash plate angle β is 0°, the pump neither
intakes nor discharges oil. Only when the difference of volumes of the cylindrical chambers A and B in the cylinder
block develops, the pump starts to intake and discharge oil. The more volume difference between chambers A and
B because of larger angle of swash plate, more oil flow in the circuit.
The pump discharge volume is calculated in the following expression.
DPMAX • tan • N in • vp
Q
tan( MAX ) (cm3 / min)
D PMAX : Maximum pump displacement (cm3 / min)

Į : Inclination angle of swash plate (deg)
Į MAX : Maximum inclination angle of swash plate (deg)
N in : Pump input speed (rpm)
Ș vp
: Pump volume efficiency
6-4-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
X
Swash plate A
Shaft
Cylinder block B Pd Ps
Figure 6-1 Figure 6-2

104881-00EN00
D
β X
A
B 104882-00EN00
Figure 6-3
6-4-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) Charge circuit

There is internal oil leak in a pump circuit and the charge circuit replenish for the leak.
The oil discharged from the charge pump flows to pump circuits through the valve assembly
(3) Pump operation
(a) Neutral (Operation levers : Neutral position)
When the servo piston is in neutral, the pump does not work even if the input shaft rotates. Therefore, the pump
does not supply oil to the motors and they do not rotate.
The oil discharged from the charge pump flows to pump circuits through the valve assembly and some part of the
oil flows to inside of a case through the drain passage of the valve assembly and returns to the hydraulic oil tank
after cooling of rotary parts. The remaining oil flows back to the tank through the low pressure relief valve.
The servo spool is in neutral position and the servo piston chambers A and B are led to the drain circuit through
the servo spool so that the servo piston keeps its neutral position owing to the force of neutral return spring.
(b) Forwarding (Inclination angle of swash plate : α side)
With the pump input shaft rotated clockwise viewing from the shaft end of case side, gradually incline the swash
plate from the neutral position to α. According to inclination angle of the swash plate, discharge volume from the
pump increases and the oil flows to the motors to start traveling.
<Servo operation at α of inclination angle of the swash plate>

When the lever is moved to supply pilot oil to the port Pp4, pressure difference between the servo piston cham-
bers a and b develops. At this time, thrust Fp caused by pressure difference becomes larger than spring force Fs
for spring return so that the servo piston moves in lower direction.
Similarly, when the pilot oil is supplied to the port Pp4, pressure difference between the servo piston chambers a'
and b' develops and the servo piston moves in lower direction. The servo piston connects to the swash plate
through the slide metal and the swash plate inclines to α side, the pump discharges oil and supplies oil to the
motors.
The relief valves are usually closed but when motor output shaft detects excessive load and the pressure in the
pump circuit exceeds 34.3 MPa, the relief valve opens and escapes high pressure oil to prevent each component
from damages. In this case, as hydraulic oil energy changes to temperature, the temperatures in pump/motor cir-
cuits rapidly increase. Therefore, try to limit time of the relief valve operation as short as possible (within 30 sec-
ond). The oil passed through the relief valve flows to the low pressure circuits
(C) Reversing (Inclination angle of swash plate : β side)
When the swash plate is inclined to β side, the pump discharges oil as well as forwarding. More inclination angle
of the swash plate, more pump discharge volume, and oil is supplied to the motors to rotate them.
<Servo operation at β of inclination angle of the swash plate.

When the lever is moved to supply pilot oil to the port Pp3, pressure difference between the servo piston cham-
bers a and b develops, and the servo piston moves upward. Similarly, when the pilot oil is supplied to the port
Pp5, pressure difference between the servo piston chambers a' and b' develops and the servo piston moves
upward. The servo piston connects to the swash plate through the slide metal and the swash plate inclines to β
side.
6-4-3 172663 0BKC2-EN0060

C30R-3 SVM.book
4 ページ
High pressure oil circuit

Charge oil circuit
Pilot oil circuit
Gear pump Case pressure
２０１７年９月２２日
Suction (Intake) pressure

SS Valve
金曜日
Strainer Filter
Hydraulic oil tank

Oil cooler
(4) Neutral (Operation levers : Neutral position)
午後２時３１分
P1 P2
Servo piston chamber (a')
Servo piston chamber (a)
6-4-4
N N
Check & Relief valve
Pp4
Pp6
172663 0BKC2-EN0060
6. HYDRAULIC SYSTEM
Pp3 P4 P3
Pp5
Figure 6-4 Neutral (Operation levers : Neutral position)

Servo piston chamber (b') Servo piston chamber (b)
104883-00EN00
C30R-3 SVM.book
5 ページ

Charge oil circuit
Pilot oil circuit
２０１７年９月２２日

SS Valve
金曜日
Strainer Filter
Hydraulic oil tank

Oil cooler
P1 P2
6-4-5
(5) Forwarding (Inclination angle of swash plate : α side)
Į N
Pp4
Pp6
172663 0BKC2-EN0060
6. HYDRAULIC SYSTEM
Pp3 P4 P3
Pp5
N
Į
Figure 6-5 Forwarding (Inclination angle of swash plate : α side)

104884-00EN00
C30R-3 SVM.book
6 ページ

Charge oil circuit
Pilot oil circuit
２０１７年９月２２日

SS Valve
金曜日
Strainer Filter
Hydraulic oil tank

Oil cooler
P1 P2
ȕ
6-4-6
(6) Reversing (Inclination angle of swash plate : β side)
N
Pp4
Pp6
172663 0BKC2-EN0060
6. HYDRAULIC SYSTEM
Pp3 P4 P3
Pp5
N ȕ
Figure 6-6 Reversing (Inclination angle of swash plate : β side)

104885-00EN00
6. HYDRAULIC SYSTEM
6-4-3 Exploded view and Parts comprised
47
46
72
See next page
73
44
29
20
21
43
25
23
25
43
29
44
22
3
5
67 26 27
19
8
30 31 15
7
74
6
10 50
28
48
29
74
4
24 49
66
34
33
38
1
32
12
37 14
11 16
40
17
Front side 105238-00EN00
6-4-7 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
35
36
28
29
32
39
65
2
34
33
38
37 18
24
28 29
49
14
66
13
74
48
74
4
6
7
8
19
5
22
23
21
20
9
50
30
31
15
Rear side See previous page

105239-00EN00
6-4-8 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
77
73
77
53
52
54
51
55
80
56
79
57
62
78 63
61
75
58
76
45
40
40
64
79
1
80
61
58
59
62
58
57
59
56
60
55
51
54
Front side (around servo piston) 105240-00EN00
6-4-9 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
54
55
51
58 59
56
60
57
59
62
61
64
58
45 40
80
79
2
61
62
40
57
76
58
56
78
55
63
54
79
80
52
75
77 53
73
51
77
Rear side (around servo piston) 105241-00EN00
6-4-10 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
No. Description Q'ty No. Description Q'ty No. Description Q'ty

1 Front case ass'y 1 28 Plug 3 55 Spring 4
2 Rear case ass'y 1 29 O-ring 7 56 Spring 4
3 Port block 1 30 Gasket 2 57 Spring seat 4
4 Swash plate 2 31 Pin 4 58 Nut 10
5 Cylinder block 2 32 Socket head screw 4 59 Seal washer 4
6 Piston ass'y 18 33 Cover 2 60 Cap nut 2
7 Retainer plate 2 34 O-ring 2 61 Snap ring 4
8 Retainer holder 2 35 Socket head screw 2 62 Washer 4
9 Valve plate 1 36 Spring seat 2 63 Cover 2
10 Valve plate 1 37 Snap ring 2 64 Cover 2
11 Oil seal case 1 38 Screw 6 65 O-ring 1
12 Shaft 1 39 Gear pump 1 66 Plug 4
13 Shaft 1 40 O-ring 2 67 Plug 1
14 Ball bearing 2 41 Name plate 1 68 Shipping plug 6
15 Needle bearing 3 42 Drive screw 2 69 Shipping plug 1
16 Oil seal 1 43 Spring 4 70 Shipping plug 8
17 Snap ring 1 44 Plug 4 71 Shipping plug 1
18 Snap ring 1 45 Pin 4 72 O-ring 1
19 Pin 3 46 Valve ass’y 1 73 O-ring 4
20 Snap ring 2 47 Socket head screw 4 74 Guide ass'y 4
21 Spring seat 2 48 Slide metal 2 75 Nut 2
22 Washer 2 49 Needle bearing 4 76 Adjuster 2
23 Spring 2 50 Pin 4 77 Back-up ring 4
24 Pin 4 51 Socket head screw 12 78 O-ring 2
25 Valve ass’y 4 52 Servo piston 2 79 Air breather 4
26 Plug 4 53 Rod 2 80 Rubber cap 4
27 O-ring 4 54 Spring seat 4
6-4-11 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-4-4 Disassembly and Reassembly
(1) Precautions for Disassembly and Reassembly

• Since all the parts of the hydraulic pump is processed with precision, disassemble or assemble at dustless clean
area.
• Prepare clean tools and cleaning oil and handle the parts carefully.
• Prepare plugs or covers to prevent all the ports opened from entering of dirt, dust and so on.
• First clean the external surface of the removed assembly to surely remove dirt, dust and so on.
• Drain hydraulic oil in the cases.
• Completely clean all removed parts with cleaning oil and air blow.
• Carefully handle all the parts not to be scarred, damaged or made dirty due to dropping and touching the other
parts.
• Before beginning disassembly, review the drawings of the internal construction and prepare the required parts
according to the purpose and extent of the disassembly.
• Never disassemble or readjust the adjust screws unless required. If they are disassembled or readjusted, it may
cause the set horsepower to be changed and have a negative influence. Put original position marks on them in
prior when disassembling or readjusting the adjust screws is necessary.
• After disassembly, replace the removed seals and O-rings with new ones in principle. As some replacement parts
are available only as subassemblies, see the parts catalog to prepare the necessary subassemblies in advance.
• Handling O-rings
Lubricate the O-rings and the O-ring fitting seats with clean grease or hydraulic oil.
The O-rings may not be damaged in handling or distorted by heat.
Do not permanently deform the O-rings.
Avoid rolling the O-rings when fitting them. A distorted O-ring may not return to its original shape, and therefore,
may cause oil leak.
• Lubricate the oil seals (especially seal lip), O-rings and O-ring fitting seats with clean grease or hydraulic oil before
installation.
• Before beginning reassembly, check the mating surfaces of each section to be sure that there is no cleaning oil or
hydraulic oil on the outer surface of the O-ring grooves. If reassembly is performed without cleaning such oil, it
may be mistaken for oil leak.
• Use a torque wrench to tighten the bolts following the specified torque specification.
• When installing or removing snap rings, take care not to let snap rings jump out. It may result in injury and damage
the other parts.
6-4-12 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) Tools for disassembly and reassembly

Tools Applicable part Form
Elastic hammer Light alloy
Internal snap ring pliers H-2, H-3
External snap ring pliers S-1, S-2
Hexagon bar wrench Width across flats:0.2 in. (6 mm), 0.3 in. (8 mm)
Torque wrench 5.1 to 94.7 ft ･ lbf
(6.9 to 128.4 N?m )
Hexagon bar socket for torque wrench Width across flats:0.2 in. (6 mm), 0.3 in. (8
mm), 0.4 in. (10 mm)
Open end wrench head for torque wrench Width across flats:0.7 in. (22 mm), 0.5 in. (13
mm)
Open end wrench Width across flats:0.3 in. (8 mm)
Socket for torque wrench Width across flats:0.7 in. (22 mm)
Eyebolt M10 2pcs
Thickness gauge Leaf thickness : 0.004 in. (0.3 mm)
6-4-13 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(3) Disassembly
Procedure
• Removal of gear pump 39 and valve ass'y
(1) Loosen two socket head screws 35 to remove washer 36.
35
36
104898-00X00
(2) Remove gear pump 39 and O-ring 65.
39
65
104899-00X00
(3) Loosen four socket head screws 47.
47
104900-00X00
6-4-14 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(4) Remove Valve ass'y 46 and O-rings 72, 73 from port block
3.
46
72
73
104901-00X00
• Separation of front case 1 and rear case 2 from port block

3. 64 51 63
(5) Loosen twelve socket head screws 51 of servo cover 63,

64.
104902-00X00
(6) Slightly loosen four socket head screws 32 of rear case 2.
Note :
Do not completely loosen socket head screws 32 to remove
them.
2 32 104903-00X00
(7) Loosen four socket head screws 32 of front case 1.

1 32
104904-00X00
6-4-15 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(8) Screw two eye bolts into tap bores for gear pump holding
screws of rear case 2.
Note :
Securely tighten eyebolts not to come off when pump assem-
bly is lifted.
Eyebolt 2 104905-00EN00
(9) Slowly lift up rear case 2 and port block 3 with hoist..
Hoist hooks
Note :
• When pump assembly is lifted up, take care not to drop
valve plate 10 unless it was removed from port block 3
• Be careful not to lift up cylinder block 5 together. Three pins
19 may come off and further disassembly may not be possi-
2
ble.
104906-00EN00
(10) Remove gasket 30 and two pins 31.
31
30
104907-00X00
6-4-16 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(11) Lower rear case 2 and port block 3 lifting by hoist upside
down as shown to the right.
2
104908-00X00
(12) Completely loosen four socket head screws 32 which

hold rear case 2 to port block 3 and are slightly loosened
at Step 6.
32
104909-00X00
(13) Slowly raise port block 3 to remove from rear case 2.
Note :
• After port block is raised until pins 31 are pulled out and cyl-
inder block 5 is separated from port block 3, raise port block 3
3 more to separate it from rear case 2.
• Be careful not to lift up cylinder block 5 together. Three pins
19 may come off and further disassembly may not be possi-
ble.
104910-00X00
6-4-17 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(14) Remove gasket 30 and two pins 31 from rear case 2.
31 30
104911-00X00
• Disassembly of front case 1
(15)Remove valve plate 10 and cylinder block ass'y from front Cylinder block
case 1. ass'y
Note :
• Take care not to lose three pins 19. 10
• Piston ass'y 6 may adhere to swash plate 4. Remove cylin-
der block ass'y after removing piston Ass'y from swash 1
plate 4 one by one.
• Refer to Figure 6-16 on page 6-4-43 for details of cylinder
block ass'y 6.
104912-00EN00
(16) Remove snap ring 17 from front case 1
Note :
Remove snap ring 17 with holding swash plate 4 by hand in
order not to drop it. 1
17
104913-00X00
6-4-18 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(17) Lightly drive end of shaft 12 with plastic hammer to
remove shaft 12 from front case 1.
Plastic
hammer
12 104914-00EN00
(18) Remove swash plate 4 from front case 1.

4
Note :
Take care not to lose slide metal 48.
1
104915-00X00
(19) Remove two needle bearings 49 and two pins 24 from

front case 1. 49
Note :
• Be careful not to lose needles of two needle bearings 49.
• If it is hard to remove two pins 24, needle pliers or some-
thing like that is available but take care not to deform them.
If they deform, two pins 24 cannot be installed into bores of
two bearing 49 holders and pump may be seriously dam-
aged.
1
104916-00X00
6-4-19 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(20) Loosen three socket head screws 51.
51
104917-00X00
(21) Remove cover ass'y 63 and O-ring 40.
63
40
104918-00X00
(22) Loosen three socket head screws 51.
51
104919-00X00
6-4-20 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(23) Remove servo piston ass'y 52 with cover 64.
64 52
104920-00X00
(24) Lastly, remove two pins 45 and O-ring 40 from front case
1.
Repeat Steps 15 to 24 with rear case 2 to disassemble it.
45
40
104921-00X00
• Disassembly of servo piston Ass'y
(25) Loosen cap nut 60 and nut 58 to remove two seal wash-
ers 59 from servo piston ass'y 52. 60 59 58 52
104932-00X00
(26) Take off cover 64 from rod 53.
64 53
104933-00X00
6-4-21 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(27) Loosen two outside nuts 58 and then screw in inside nut
58 until washer 62 smoothly moves.
58（Outside）
58（Inside） 104934-00EN00
(28) Remove snap ring 61 and washer 62 from one side.
61 62
104935-00X00
(29) Loosen inside nut 58 to take off spring seat 57, springs
55, 56 and spring seat 54 from rod 53.
58 57 56 55
54 53 104936-00X00
(30) Screw in inside nut 58 of the other side until washer 62

smoothly moves and remove snap ring 61 and washer
62.
61 62
58 104937-00X00
6-4-22 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(31) Loosen inside nut 58 to take off spring seat 57, springs
55, 56 and spring seat 54 from rod 53.
58 57 56 54
55 53 104938-00X00
(32) Remove rod 53 from servo piston 52.
52 53
104939-00X00
• Disassembly of port block 3
(33) Loosen four plugs on both sides of port block 3 to

remove four springs 43 and valve assemblies 25.
44 43 25
104940-00X00
6-4-23 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Reassembly
Procedure
• Reassembly of servo piston ass'y 52.
(1) Install O-ring 73 and two back-up rings 77 on rod 53. 77 77 53
Note :
Install back-up rings 77 so as to sandwich O-ring 73.
73 104944-00X00
(2) Install rod 53 into servo piston 52.
Note :
• Coat grease on O-ring 73 and inside surface of servo piston
52 bore not to damage O-ring 73 during installation of rod
53.
• Make sure two back-up rings 77 are securely installed on
rod 53 before installation. Inappropriate installation of them
may cause back-up rings 77 to be damaged and may dis-
able a carrier.
52 53
104945-00X00
(3) Install spring seat 54, springs 55, 56, spring seat 57, nut
58 and washer 62 in order onto one side of rod 53.
62 58 56 54
57 55 53 104946-00X00
(4) Screw in nut 58 until snap ring groove of servo piston 52

appears.
58
104947-00X00
6-4-24 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(5) Install snap ring 61.
61
104948-00X00
(6) Install spring seat 54, springs 55, 56, spring seat 57, nut
58 and washer 62 in order onto the other side of rod b.
62 58 55 54
57 56 53 104949-00X00
(7) Screw in nut 58 until snap ring groove of servo piston 52

appears.
58
104950-00X00
(8) Install snap ring 61.
61
104951-00X00
6-4-25 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(9) Loosen inside nut 58 once to adjust rod 53 position with-
out play, and then tighten outside nuts 58 of both ends to
specified torque.
58（Outside）
Note :
Make sure each clearance between washer 62 and snap ring
61, spring seat 57 and nut 58 is less than 0.004 in (0.1 mm)
with thickness gauge.
Tightening torque: 13.0 ft·lbf (17.7 N·m)

58（Inside） 104934-00EN00
(10) Install cover 64 onto rod 53 and temporarily assemble

seal washer 59, nut 58 and cap nut 60.
Note : 60 58 64
Adjust projection of rod 53 tip from bearing surface of cover
64 to 0.528 in (13.4 mm).
(13.4 mm)
0.528 in
64 59 53 104953-00X00
53
104997-00EN00
Similarly, assemble servo piston ass'y on the other side.

After completion of two servo piston assemblies, neutral
adjustment is required.
• Reassembly of front case 1 and rear case 2.

Reassembly procedures of front case 1 and rear case 2 are
almost same so that reassembly procedures of front case 1 is 1
given as a representative of them. For unique information with
reassembly procedures of B, both are given in the same step.
(11) Install two pins 45, O-ring 40 and servo piston ass'y to
Servo piston
front case 1. ass'y 40
45 104954-00EN00
6-4-26 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(12) Temporarily tighten three socket head screws 51 to make
clearance between front case 1 and cover 64 0.2 to 0.4
in (5 to 10 mm).
64
51
104955-00JA00
(13) Install two needle bearings 49 and two pins 14 in front

case 1.
49
104956-00X00
(14) Put slide metal 48 on swash plate ass'y 4.

4 48
Note :
Refer to figure 6-11 on page 6-4-41 for details of swash plate
ass'y 4 and figure 6-10 on page 6-4-40 for press-fit method of
two guide assemblies b.
74 104957-00X00
6-4-27 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(15) Install swash plate ass'y 4 into front case 1.
4
Note:
• When swash plate ass'y 4 is installed, guide ass'y 74 should
enter groove of bearing 49 holder and bore of front case 1, 1
plus, slide metal 48 should fit into groove of servo piston 52
at the same time.
• Rock swash plate 4 after its installation to check movement
of servo piston 52. If it does not move smoothly, do reas-
sembly all over again because fitting of swash plate 4 and
needle bearing 49 may be inappropriate.
104958-00X00
(16) Install O-ring 40 and cover ass'y 63 onto front case 1.
Note: 1
• Install cover 63 so as for breather 79 to position as shown
to the right. Take care that breather 79 position of front case
1 and that of rear case 2 are different.
• Refer to figure 6-15 on page 6-4-42 for details of cover ass'y
63.
79
40
63
104959-00X00
(17) Tighten six socket head screws 51 to specified torque to

install covers 63, 64 of both ends of servo piston on front
case 1. 1
Tightening torque: 28.9 ft·lbf (39.2 N·m) 51
63
51
64 104960-00X00
6-4-28 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(18) Install front shaft ass'y 12 into front case 1. Install rear
shaft ass'y 13 and snap ring 18 into rear case b. 12
Note:
• Take care that swash plate 4 does not come off when shaft 1
ass'y is installed. Unless swash plate is correctly installed,
needle bearing 49 and guide ass'y 74 comes off from front
case 1 or rear case 2 and can be a cause of breakdown .
• Refer to figure 6-8 on page 6-4-38 for details of front shaft
ass'y 12 and rear shaft ass’y 13, and figure 6-9 on page 6-
4-39 for press fitting method of ball bearing 14.
104961-00X00
(19) Install O-ring 40 on oil seal case 11 and fix it to front case
b with snap ring 17. 17 11
Note: 40
• Refer to figure 6-14 on page 6-4-42 for press fitting method
of oil seal 16.
• This step is for reassembly of front case 1 only.
1
104962-00X00
(20) Install cylinder block ass'y 5 into front case 1.
Note:
• Apply hydraulic oil on sliding surface of swash plate 4
1
before installation of cylinder block ass'y 5.
• Be careful that three pins 19 do not come off. After installa-
tion, make sure if three pins bare not found inside of front
case 1.
• Refer to figure 6-16 on page 6-4-43 for details of cylinder
block ass'y 5.
104963-00X00
6-4-29 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
• Reinstallation of port block
31
(21) Install two pins 31 on rear case 2.
2
104973-00X00
(22) Slightly coat grease on gasket 30 and install it on rear

case 2. 30
104974-00X00
(23) Install valve plates 9, 10 on port block ass'y b. Tip of notch Tip of notch
Drain bores for valve ass'y
Note: Metal plug
• Align grooves of valve plates 9, 10 to pins 50.to install them. 3
• Slightly coat grease on mating surfaces of valve plates 9,
10 not to come off.
• Notch tip of valve plate 10 on front side directs counter-
clockwise and that of valve plate 9 on rear side directs
clockwise. Install both valve plates facing its ocherous sur-
face to outside.
• Install port block 3 facing its metal plug side to front case 1
and its drain bores (for valve plate) side to rear case 2.
Rear side Front side

9 10
50 104975-00EN00
6-4-30 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(24) Install port block 3 on rear case 2 with aligning two pins
31 of rear case 2 and pin bores of port block 3.
3
Note:
• Coat hydraulic oil enough on sliding surface of cylinder
block 5 before installation.
• Reconfirm if valve ass'y drain bores og port block 3 face to
2
rear case 2 before installation.
104976-00X00
(25) Temporarily tighten four socket head screws 32.
32
104977-00X00
(26) Screw two eye bolts into tap bores for gear pump holding
screws of rear case 2.
Note:
Securely tighten eyebolts not to come off when pump assem-
bly is lifted.
Eye bolt
104978-00EN00
6-4-31 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(27) Slowly lift up and lower rear case 2 and port block 3 with
hoist aligning two pins 31 of front case 1 and bores of
port block 3 to install them on front case 1. Hook
Note:
• When hoisting, take care not to damage valve plate 10 in
front case 1 and gasket surface of port block 3.
• Be careful not to drop valve plate 10 from front case 1.
• Coat hydraulic oil enough on sliding surface of cylinder
block 5 before installation.
• When front shaft 12 and rear shaft 13 do not fit each other,
turn input spline gear of front shaft 12 to engage gears of
both shafts.
104979-00EN00
(28) Tighten eight socket head screws 32 to specified torque.
32 104980-00X00
(29) Install four valve assemblies 25 and four springs 43 to

port block 3.
25
3
43 104981-00X00
6-4-32 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(30) Tighten four plugs 44 to specified torque.
44
Tightening torque: 78.1 to 95.4 ft·lbf (106.0 to 129.4 N·m)
Notes:
Refer to figure 6-13 on page 6-4-42 for details of port block
ass'y 3.
104982-00X00
• Installation of gear pump 39

65
(31) Install O-ring 65 on rear case 2.
104983-00X00
(32) Engage shaft of gear pump 39 with rear shaft 13 to rein-

stall gear pump 39 to rear case 2.
Suction port 39
Notes:
Install gear pump 39 facing its suction port to side of cover 64.
13
64 104984-00EN00
6-4-33 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(33) Install two washers 36 and tighten two socket head
screws 35 to specified torque.

35
Notes:
Sharp edge surface of washer 36 contacts pump flange sur-
face. 36
104985-00X00
• Reassembly of valve ass'y 46
(34) Install two O-rings 72, 73 on port block 3 72 73
104986-00X00
(35) Install valve ass'y 46 onto port block 3.
Notes: 3 46
Align drain holes of valve ass'y 46 and those of port block 3 to
reassemble them.
104987-00X00
(36) Tighten four socket head screws 47 to specified torque.

47
Notes:
• Make sure if shaft 12 can smoothly turn after completion of
reassembly.
• Fill front and rear cases with hydraulic oil without fail before
test run. The pump runs without enough hydraulic oil in both
cases, pistons may be seized and it may cause pump
breakdown.
104988-00X00
6-4-34 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
• Adjustment of neutral
(37) According to the table of adjustment of neutral on page

6-4-43, prepare to measure pressures at the specified
ports.
Notes:
• When swash plate 4 and slide metal 48 are replaced, or
servo piston assembly is disassembled, adjustment of neu-
tral is required.
• Failure to do the adjustment of neutral may result in serious
accident due to carrier creeping.
adjustment of neutral. The pump runs without enough
hydraulic oil in both cases, pistons may be seized and it
may cause pump breakdown.
(38) Remove cap nut 60, two seal washers 59 and nut 58.
60 59 58 104989-00X00
(39) After 2 to 3 minutes of running in at about 1200 rpm,

raise engine speed to around 2800 rpm and turn rod 53
to adjust differential pressure between P1 (P3) and P2
(P4) to within 0.2 MPa.
Notes:
• Do adjustment of neutral without supplying oil to ports Pp3
(Pp4) and Pp5 (Pp6) while pump discharge port is blocked.
• When pressure of P2 (P3) is high, loosen rod 53 and when
pressure of P1 (P4) is high, tighten rod 53.
53 104990-00X00
6-4-35 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(40) After adjustment, install two seal washers 59 and tighten
nut 58 and cap nut 60 to specified torque.

8.0 to 9.4 ft·lbf (10.7 to 12.9 N·m))
104991-00X00
• Adjustment of maximum oil flow
(41) After adjustment of neutral, according to the table of

adjustment of maximum oil flow on page 6-4-43, prepare
to measure oil flow rate at the specified ports.
Notes:
• When cover 63, adjuster 76 or cylinder block assembly 5 is
replaced, adjustment of maximum oil flow is required.
• Failure to do the adjustment of maximum oil flow may result
in serious accident due to carrier deviation.
adjustment of maximum oil flow. The pump runs without
enough hydraulic oil in both cases, pistons may be seized
and it may cause pump breakdown.
(42) Loosen nut 75 and measure oil flow rate of each circuit of
P1 and P4 on the following condition.
Input speed : 2800 rpm
Pilot oil pressure of Pp3 and Pp6 : 362.6 PSI (2.5 MPa),
⊿ P : 1450 PSI (10 MPa)
75
104992-00X00
6-4-36 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(43) Measure oil flow rate of each circuit of P2 and P3 on the
following condition and turn 76 to adjust pressure differ-
ence between P1 (P2) and P2 (P4) to be within 0.6 L/
min.
Input speed : 2800 rpm
Pilot oil pressure of Pp4 and Pp5 : 362.6 PSI (2.5 MPa),
⊿ P : 1450 PSI (10 MPa)
Notes:
When oil flow rate of P2 (P3) is less than that of P1 (P4), turn
adjuster 76 to the left, and turn to the right when oil flow rate of 76
P2 (P3) is more than that of P1 (P4)
104993-00X00
(44) After adjustment, tighten nut 75 to specified torque.
75
104992-00X00
6-4-37 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(4) Replacement criteria for parts subject to wear

Replace parts if wear exceeds the standard values shown in the table below.
Parts Inspection point Standard value / Wear limit (mm)
Piston ass'y a. Play of swaged part of piston and shoe 0.0004 to 0.0059 in. (0.01 to 0.15mm )/ ε
< 0.008 in. (0.2mm)
104941-00X00
b. Clearance between piston and cylinder block bore (D-d) 0.0008 in. (0.02mm) / δ < 0.001 in.
(0.03mm)
104942-00X00
c. Thickness of shoe 0.118 in. (3.0mm) / t > 0.114 in. (2.9mm)
104943-00X00
Roughness of shoe sliding surfaced. 0.18 to 0.35a /< 0.4a

Cylinder block Roughness of mating surface with valve plate 0.4a /< 0.8a
Valve plate Roughness of mating surface with cylinder block 0.2a /< 0.4a
Swash plate Roughness of mating surface with piston ass'y 0.2a /< 0.4a
Note :
If damages are found on sliding surface, remove them by lapping. Lapping depth must be less than 0.0002 in.(0.005
mm) and replace part with new one if damages remain even after lapping.
6-4-38 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(5) Reference information
37 14 13
104998-00X00
Figure 6-7 Rear shaft assembly
12 14 37
104999-00X00
Figure 6-8 Front shaft assembly
6-4-39 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Press
13 12
Use the cylindrical jig with cross hatching

to press fit the bearing 14
Press the shaft to
contact the bearing 14
with its flange
14
60
60
ø27 ø27
ø37 ø37 105000-00EN00
Figure 6-9 Shaft bearing press fitting method
6-4-40 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
35
23.8
Use the jigs shown to the left to press fit
the guide assembly 74 to the swash plate 4
13
10
(Surface hardness is recommended
to be more than HRC 43)
2.9
ø16.3 ø14.2
ø21.5 ø16
ø25 30°
105001-00EN00
Press
74
105002-00EN00
Press
74
105003-00EN00
Figure 6-10 Guide assembly press fitting method
6-4-41 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
74
The guide assembly 74 can be installed

in either direction.
105004-00EN00
Figure 6-11 Swash plate assembly
25 25
29 29
43 43
44 44
70 70
27 26 26 27 105005-00X01
Figure 6-12 Port block assembly
6-4-42 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3 Note 1
Press fit two needle bearings 15 facing its carved stamp
3 3
to outside and projecting its tip to 3 mm from the port
15 15 block 3.
Note 2
3 3
Press fit the pin 50 projecting its tip to 3 mm from the
50 50 port block b.
Grooved part Grooved part
105006-00EN00
50 Pin grooved part
3 Grooved part
105007-00EN00
Figure 6-13 Parts to be press fitted to the port block 3 and its method
Note 3
11
Press fit the oil seal 16 to 2 mm of depth from the end
face of oil seal case 11.
16
0.08 in.
(2 mm)
105008-00EN00
Figure 6-14 Oil seal press fitting method

(11.2 mm)
Note 4
0.4 in.
Install the cover assembly 63 after temporarily assem-

75
80 ble the adjuster 76 projecting 0.4 in (11.2 mm) from the
79 bearing surface. The adjustment of maximum oil flow
described in page 6-4-35 is required after installation of
63 the cover assembly 63.
76
78
105009-00EN00
Figure 6-15 Cover assembly
6-4-43 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
• Component parts of the cylinder block assembly

7 No. Part Q'ty
8 5 Cylinder block 7
19 6 Piston ass’y 9
22 7 Retainer plate 1
6 8 Retainer holder 1
23
19 Pin 3
5
20 Snap ring 1
21
20 21 Washer 1
105010-00X00
22 Spring seat 1
23 Spring 1
Figure 6-16 Cylinder block assembly
Pp1 B2 T2
Pp5 Pp6 Pp4 Pp3
PgC
Pg3 Pg1
B3 B1
P3 P1
P4 P2
S Pg4 T1 Pg2
105011-00X00
Figure 6-17 Hydraulic schematic of pump and combination of each port piping at measuring
(6) Measuring points

Adjustment of maximum oil flow
Adjustment of neutral
Ports Oil flow check of P1, P4 Oil flow check of P2, P3
Piping Measurement Piping Measurement Piping Measurement
P1 Block Pressure - Oil flow Tank -
P2 Block Pressure Tank - - Oil flow
P3 Block Pressure Tank - - Oil flow
P4 Block Pressure - Oil flow Tank -
T1 Drain - Drain - Drain -
S Tank - Tank - Tank -
B1 Port B2 - Port B2 - Port B2 -
B3 Drain - Drain - Drain -
Pp1 Block - Block - Block -
B2 Port B1 - Port B1 - Port B1 -
T2 Drain - Drain - Drain -
Pp3 Drain - 362.6 PSI (2.5 MPa) - Drain -
Pp4 Drain - Drain - 362.6 PSI (2.5 MPa) -
Pp5 Drain - Drain - 362.6 PSI (2.5 MPa) -
Pp6 Drain - 362.6 PSI (2.5 MPa) - Drain -
6-4-44 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(7) Troubleshooting
When the pump assembly fails, it should be replaced with new one, in principle. For emergency or temporary rem-
edy, typical troubles, possible causes and measures are listed below:
Trouble Cause Measure
Motor does not rotate Charge pump is failed Measure charge pressure and replace pump
even when the opera- assembly as required
tion lever is moved
Set pressure of the low pressure relief valve Measure pressure of low pressure circuit and
decreases replace parts related
Set pressure of the high pressure relief valve Replace parts related
decreases
Charge oil flow decreases Replace parts related
Air sucked in pump Check suction piping of charge pump and oil
level in tank (Purge air after measurement)
Pump malfunction due to inner parts breakdown After flushing hudraulic oil circuits, replace pump
or failure of input shaft or coupling assembly (Repair coupling)
Carrier does not stop Check valve malfunction (clogging, etc.) Disasssemble, clean and reassemble check
even valve
when operation rever
Failure of valve seat of check valve or high pres- Replace parts.
is returned to neutrel
sure relief valve
position
Servo piston malfunction Replace parts.
Wear of connection parts of servo regulator and Replace parts
slide metal
Swash plate inclines due to out of neutral position Do adjustment of neutral
on servo piston
Carrier deviates Maximum oil flow of P1(P2) and P4 (P3) is differ- Do adjustment of maximum oil flow
ent
Motor speed is low Oil flow in circuit is inadequate due to clogging of Clean or replace filuter and strainer
filter or strainer
Air sucked in pump Check suction piping of charge pump and oil
level in tank (Purge air after measurement)
Servo piston malfunction Replace parts.
Discharge volume of charge pump is inadequate Low temp.: Warm up
due to unusual temperature of oil High temp. : Stop engine and restart after a while
Pump develops Air sucked in pump Check suction piping of charge pump and oil
unusual noise level in tank (Purge air after measurement)
Oil flow in circuit is inadequate due to clogging of Clean or replace filuter and strainer
filter or strainer
Discharge volume of charge pump is inadequate Low temp.: Warm up
due to unusual temperature of oil High temp. : Stop engine and restart after a while
Pump malfunction due to inner parts breakdown After flushing hudraulic oil circuits, replace pump
or failure of input shaft or coupling assembly (Repair coupling)
Oil leak Damage of oil seal, O-ring or gasket Replace related parts (Take care not to damage
seal lip and shaft while oil seal is installed on
shaft. If pressure of pump case is high, remedy
for drain piping failure is required)
6-4-45 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-5 Travel motor
1. Structure
The main component devices of the travel motor are integrated. These include the swash plate axial piston motor,
flushing valve, parking brake, 2-speed switching mechanism, and reduction gear box.
The swash plate type axial piston motor has 9 pistons and a 2-speed (slow and fast) switching mechanism.
The reduction gear reduces the output revolutions of the piston motor through the planetary double-reduction mech-
anism and increases the output torque to transmit it to the sprocket.
Swash plate type piston motor
Flushing valve Reduction gear
Parking brake
2-speed switching mechanism
Structure of Traveling motor

109679-00EN00
6-5-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2. Theory of Operation
1) Motor
When the travel control valve is switched to "Travel", the hydraulic oil flows through the counter balance valve to the
port A of the valve plate.
When the pressure at the port A rises, the hydraulic oil flows into the bores corresponding to the port A in the cylin-
der barrel.
When the hydraulic oil flows into the bores, the pistons are pressed against the sliding surface of the swash plate,
and the shoes fitted on the pistons slide on the sliding surface of the swash plate towards the circumference. That
motion of more than one piston on the high pressure side is converted into the rotational motion of the cylinder bar-
rel.
The output shaft splined to this cylinder barrel also starts to rotate together with the rotation of the cylinder barrel.
When the pistons move to the low pressure side, the pistons are pushed into the bores and discharge hydraulic oil
from them. The hydraulic oil discharged from the cylinder barrel flows through the port B of the valve plate to the
return passage.
When the travel control valve is switched to the opposite side, the pressure at the port B becomes high and the pres-
sure at the port A becomes low, so that the rotation of the output shaft is reversed.
Swash plate
Output shaft
Piston assembly
Cylinder barrel
Valve plate
Port A
Port B
051692-00EN00
6-5-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Operating principle of flushing valve

(1) Neutral
This flushing valve acts to gently stop the piston motor, and prevents external loads from causing the motor to oper-
ate in excess of a predetermined speed (over-running).
When the control valve is moved to the neutral position, the hydraulic oil flow to the ports P1 and P2 is blocked. This
causes the pressures in the chambers R and L to fall to nearly zero, and the spool is returned to the neutral position
by the force of the springs on both sides. When the spool is returned to the neutral position, the ports M1 and M2 of
the piston motor are blocked by the plunger and the check valve, and the motor is stopped rotating.
Valve ass'y (50) (Flushing valve)

Orifice or Low pressure relief valve
oil circuit 1
hydraulic
Orifice (40)
P2 P1
Spring (37)
Spool (31)
Structure of Flushing valve 109680-00JA00
(2) Flushing
Hydraulic oil discharged by the hydraulic pump flows into the flushing valve P1 port. The hydraulic oil then passes
through the orifice and acts on the end face of the spool, moving the spool against the spring on the opposite side
with a force proportional to the pressure of the oil.
Once a certain pressure is reached, the spool moves, and the oil flows to the low-pressure relief valve on the P2 port
side. At this time, the hydraulic oil on the P2 port side passes through the outer notch of the spool, and flows to the
orifice and low-pressure relief valve.
Valve ass'y (50) (Flushing valve)

Orifice or Low pressure relief valve
oil circuit 1
hydraulic
Orifice (40)
P2 P1
Spring (37)
Spool (31)
Operating drawing of Flushing valve 109680-00EN01
6-5-3 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) 2-Speed Switching Mechanism

(1) 1st Speed (Low Speed)
The swash plate has three surfaces a, b and c, as shown in the figure, and is installed on the flange holder with two
steel balls so that it can move. When the control valve is in the low speed position, since the spool is located in the
position as shown in the left figure by the force of the spring and oil passage is connected to the port T via Pi 1 and
Pi 2, the low pressure of the return passage only works on the swash plate control piston. In this condition, the
swash plate control piston does not push up the swash plate. Accordingly, the surface a at the rear of the swash
plate is pressed against the vertical surface by the thrust force of the motor and the force of the spring with the steel
balls as the inclination axis. The inclination angle of the swash plate is "α" as shown in the figure.
M1 M2
P1 (Driving pressure)
Pi1 Pi2
P2 (Driving pressure)
Spring
Spool
Į
Surface c ȕ
Valve plate Surface b
Piston assembly
Steel ball Steel ball
L1
Ȉ)+)S1
Low Low
L0
pressure pressure
)3+)6
Spring
Port B (Low pressure) Spring Surface a
Swash plate Swash plate control piston
Port A (High pressure) 051696-00EN00
6-5-4 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) 2nd Speed (High Speed)

When the control valve is switched to the high speed position, the pressure oil from the pump is led to the end face
of the spool and the spool is shifted to the position as shown in the left figure. This causes the ports M1 and M2 to
open and the hydraulic oil from the port A (high pressure) in the valve plate of the motor is supplied to the swash
plate control piston though the valve port M1. This pressure oil pushes up the swash plate control piston, which over-
comes the motor thrust force and the spring force, and the surface a of the swash plate is detached from the vertical
surface to cause the surface b to be contacted with the vertical surface tightly. When the surface b contacts with the
vertical surface, the inclination angle of the surface c, which is the sliding surface of the swash plate, is reduced to
"β". Accordingly, the stroke of the piston is reduced to lower the motor displacement. The motor with smaller dis-
placement rotates faster (high speed).
When the motor revolves in reverse, the same action as the above occurs, except that the high and low pressure
ports are reversed.
When the engine is stopped, since no pumps work, no pressure oil is supplied to the end face of the spool and the
spool returns to the 1st speed position by the spring force. Accordingly, no force is applied to the swash plate control
piston to press the swash plate, and the swash plate maintains its 1st low inclination angle "α" through the spring
force. Thus, the low speed condition is always maintained at starting.
0 0
3 'ULYLQJSUHVVXUH
3L 3L
3 'ULYLQJSUHVVXUH
6SULQJ
6SULQJ
6XUIDFHF ȕ
9DOYHSODWH 3LVWRQDVVHPEO\ 6XUIDFHE
6WHHOEDOO
/
Ȉ))V
Lo
/RZSUHVVXUH +LJK
SUHVVXUH
)V)V
3RUW% /RZSUHVVXUH 6SULQJ 6XUIDFHD 6SULQJ
3RUW$ +LJKSUHVVXUH 6ZDVKSODWH 6ZDVKSODWHFRQWUROSLVWRQ 051697-00EN00
6-5-5 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4) Auto Tow Speed Change Mechanism

Auto two speed control mechanism consists of two spools and spring. This valve automatically changes motor dis-
placement in accordance with the difference between the pilot oil pressure and the motor inlet pressure. This valve
works while the pilot port “Ps” is pressurized.
(1) At high motor inlet pressure
The swash plate and 2-speed spool positions when the motor displacement is maximum (traveling in low speed) are
shown below.
When the motor inlet pressure increases more than the pilot pressure that controls the motor displacement, the 2-
speed spool moves to the left to switch the motor displacement to low speed.
Motor pressure : Pout
Motor inlet pressure
Motor pressure : Pin
chamber area
Pilot Pressure chamber area : Ap
Ps : Pilot pressure
Low Speed Position
Automatic Two speed (Motor pressure is high) 109682-00EN00
6-5-6 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) At low motor inlet pressure

The swash plate and 2-speed spool positions when the motor displacement is minimum (traveling in high speed) are
shown below.
The pilot oil flows through the oil passage A to the pilot pressure chamber in the left end of the 2-speed spool and
moves the spool to the right. Conversely, the motor inlet oil flows through the oil passage B to the motor inlet pres-
sure chamber and moves the spool to the left.
When the motor inlet pressure that develops the force to move the spool to the left is less than the pilot oil pressure
for moving the spool to the right, the spool keeps its position as shown below and the traveling speed stays in the
high speed.
Motor pressure : Pout
Motor inlet pressure
Oil passage B
Motor pressure : Pin chamber area
Pilot Pressure chamber area : Ap
Ps : Pilot pressure
Oil passage A
High Speed Position To chamber of two speed piston
Automatic Two speed (Motor pressure is low) 109681-00EN00
6-5-7 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5) Parking Brake
Brake piston chamber

Collar
Brake piston
Friction plate
Disk
Cylinder block
Spline
Spring
Parking brake mechanism 109683-00EN00
The parking brake is a negative brake that consists of a disc (friction plate) as a rotating part, a brake piston and a
spring.
The cylinder block and disc are connected via the spline and friction materials are attached to both side surfaces of
the disc. Friction force is generated on the disc between the flange holder and brake piston due to the spring force to
limit the force to rotate the motor, thereby providing a parking brake function.
When pressurized oil is led into the motor, spool 31-1 starts moving and the parking brake release port is opened. In
addition, when spool 31-1 starts moving, the spool of the anti-cavitation valve also starts moving simultaneously, as
shown in the figure above, and the pressurized oil is led into the parking brake release port.
When the pressurized oil is led into the brake piston chamber, thrust force F corresponding to the pressure receiving
area of the brake piston is generated and the generated thrust force F exceeds the spring force f and moves the
brake piston. The disc freely rotates between the flange holder and brake piston and deactivates the parking brake
function.
When the parking brake release port is connected to the hydraulic oil tank again, the pressurized oil in the brake pis-
ton chamber is led into the hydraulic oil tank and the parking brake is applied by the spring.
6-5-8 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6) Reduction Gear
The reduction gear comprises a planetary double-reduction mechanism.
4 3
Z2 2
Z4
Z1
1
Z5
Z6 Z3
6 5 7
Structure 051698-00EN00
The drive gear 1 engages with the 1st-stage planetary gear 2 and the 2nd-stage sun gear 4 engages with the 2nd-
stage planetary gear 5. The 2nd-stage planetary carrier 6 is fastened to the machine body. The planetary gears 2
and 5 engage with the ring gear (housing) 7.
The driving force from the piston motor is transmitted to the drive gear 1 and reduced by the gears. The reduced
driving force is then transmitted to the ring gear 7 though the planetary gear 5 of the 2nd-stage planetary carrier 6
fastened to the machine body. (Driving force is also transmitted from the 1st-stage planetary gear 2.) The input and
output revolutions are opposite to each other.
6-5-9 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3. Exploded View and Parts Comprised
38 39 45-1 45-2
37 56
36 43 48
58 31
11 44 44
10 59 61
9 42
8 41-2 36 37 62
7 41-1 39
12
13
14
15
2 44
5 40 38
6 46
3 47 45-1
4
19 64 45-2
20 26
49
29
27
25
28
21
57
17
24
22
34
35
18
33
18 63
50-3
50-4
50-5
50-2 50-1
15
17
16
20
19 19
18 20
22 1
23
30 2
25
7
26
3
24
4
29 5
27
6
31
8
12
11
10
9
14 13 109696-00X00
6-5-10 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
No. Part Q'ty No. Part Q'ty

1 Reduction gear ASSY 1 21 Spring 8
1-1 Flange holder 1 22 O-ring 1
1-2 Floating seal 2 24 O-ring 1
1-3 Angular bearing 1 25 Valve plate 1
1-4 Ring nut 1 26 Pin 1
1-5 Plug 2 27 Ball bearing 1
1-6 Housing 1 28 O-ring 1
1-7 Steel ball 99 29 O-ring 4
1-8 Plug 2 30 Base plate 1
1-9 Planetary gear B 4 31 Plunger sub ASSY 1
1-10 Needle bearing 4 33 Friction plate 1
1-11 Inner race 4 34 Collar 1
1-12 Thrust washer 4 35 O-ring 1
1-13 Thrust plate 1 36 Spring seat 2
1-14 Screw 4 37 Spring 2
1-15 Sun gear 1 38 Cap 2
1-16 Thrust washer 3 39 O-ring 2
1-17 Holder 1 40 Orifice 2
1-18 Planetary gear A 3 41 pool sub ass'y 1
1-19 Needle bearing 3 41-1 Spool A 1
1-20 Inner race 3 41-2 Spool C 1
1-22 Drive gear 1 42 Spring 2
1-23 Thrust washer (t=1.8, 2.3, 2.8) 1 43 Plug 2
1-24 Cover 1 44 O-ring 4
1-25 O-ring 1 45 Plug 3
1-26 Wire 1 46 Plug 1
1-27 Plug 1 47 Orifice 4
1-29 O-ring 3 48 Hexagon socket head bolt 6
1-30 Bolt 3 49 Pin 4
1-31 Plug 2 50 Valve ASSY 1
2 Shaft 1 50-1 Valve body 1
3 Roller bearing 1 50-2 Orifice 1
4 Oil seal 1 50-3 Plug 2
5 Swash plate 1 50-4 O-ring 2
6 Steel ball 2 50-5 Orifice 1
7 Cylinder block 1 53 Shipping plug 2
8 Collar 1 54 Shipping plug 1
9 Spring 1 55 Plug 1
10 Washer 1 56 Orifice 1
11 Snap ring 1 57 O-ring 8
12 Pin 3 58 Plug 1
13 Retainer holder 1 59 Plug 1
14 Retainer plate 1 60 Shipping plug 1
15 Piston ASSY 9 61 O-ring 1
17 Brake piston 1 62 O-ring 4
18 Disc plate 2 63 Hexagon socket head bolt 1
19 Piston 2 64 Orifice 4
20 Spring 2
6-5-11 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4. Special Tools
Unit: mm
S-2: Eye bolt S-5: Housing disassembly jig
21 (16)
MAX.ø22 surface diameter)

4 12
(Effective seat
2.5
±0.05
ø41
45° 50°
ø14.2
ø2
5
ø20
ø288
ø288
ø201
C
1
G(PF)3/8 Divided 060826-00EN00

Weld
Eye bolt
JIS B 1168 M10 051600-00EN00
S-6: Ring nut tightening jig
Weld ø12.7 +0.3

+0.1
ø180
ø176
4-16
90
10
107 9 051602-00EN01
S-8: Roller bearing disassembly jig S-10: Angular bearing press-fitting jig
7
10°
100
ø31±0.1
ø200
ø218
ø230
ø176
ø190
ø196
ø36
051603-00X02
10 10
10
35 40
060827-00X01
6-5-12 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Unit: mm
S-9: Floating seal assembly jig
9 ±0.2
5
15°±1 15°±1
±0.1
ø219.8 ±0.1
ø230.5 ±0.1
ø219.8 ±0.1
-0.2
-0.2
±0.1
0
0
ø231.5
ø231.5
ø219.8
ø240
ø204
ø226
ø216
9.8
10 ±0.5 3 10 ±0.5 17
060828-00X00
S-11: Flange holder press-fitting jig

9
ø220
051606-00X01
S-12: Oil seal press-fitting jig
110
12 ±0.1 12
11 ±0.1
2
30°
ø23.8 -0.2
0
ø44
ø30
ø52
ø18
051607-00X01
6-5-13 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Unit: mm
S-13: Roller bearing press-fitting jig S-15: Snap ring assembly jig
ø60
ø52 +0.1
+0.05 50
ø30 10
0
ø3
5
7
ø26
35
051609-00X00
051608-00X01
S-16: Roller bearing press-fitting jig
20
ø40
ø35
051610-00X01
Special tool name

S-1: Eye bolt PF3/8
S-2: Round rod φ20×1000mm
S-3: Wire disassembly jig
S-4: Piano wire φ0.2×700mm
S-5: Housing disassembly jig
S-6: Ring nut tightening jig
S-7: Round rod φ10×150mm
S-8: Roller bearing disassembly jig
S-9: Floating seal assembly jig
S-10: Angular bearing press-fitting jig
S-11: Flange holder press-fitting jig
S-12: Oil seal press-fitting jig
S-15: Snap ring assembly jig
6-5-14 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5. Disassembly and Reassembly

1) Precautions for Disassembly and Reassembly
(1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform disassem-
bly and reassembly in a clean area that is free from dust.
(2) Prepare clean tools and cleaning oil and handle the parts carefully.
(3) First clean the external surfaces of the removed assemblies.
(4) Before beginning disassembly, review the drawings of the internal construction and prepare the required parts
(5) After disassembly, replace the removed seals and O-rings with new ones in principle. As some replacement
parts are available only as subassemblies, see the parts catalog to prepare the necessary subassemblies in
advance.
(6) Handling O-rings
[1] Lubricate the O-rings and the O-ring fitting seats with clean grease or hydraulic oil.
[2] The O-rings may not be damaged in handling or distorted by heat.
[3] Do not permanently deform the O-rings.
[4] Avoid rolling the O-rings when fitting them.A distorted O-ring may not return to its original shape, and therefore,
may cause oil leak.
(7) Before beginning reassembly, check the mating surface of each section to be sure that there is no cleaning oil or
hydraulic oil on the surface of the outer side from the O-ring groove. If reassembly is performed without cleaning
such oil, it may be mistaken for oil leak.Tools for disassembly and reassembly.
2) Tool for Disassembly and Reassembly
No. Tool Size Applicable part
1 Torque wrench (6) Plug 50-2, Orifice 40, 47, 50-5, 56, 64
(preset type)
2 (10) Plug 1-8, 45
3 (kgf·cm) (50) Hexagon socket head bolt 63, Bolt 1-30, Plug 1-5, 1-27, 1-31, 50-3,
Screw 1-14
4 (100) Plug 43, 46, 58
5 (300) Ring nut 1-4, Cap 38, Hexagon socket head bolt 48
6 Hexagon bit for torque wrench 2.5 Orifice 40, 47, 56, 64
(Width across flats)
7 3.18 Plug 45
8 (mm) 3 Orifice 50-2, 50-5
9 5 Plug 1-8, Screw 1-14
10 6 Hexagon socket head bolt 63, Plug 50-3
11 8 Plug, 1-5, 1-27, 1-31, 43, 58
12 10 Hexagon socket head bolt 48
13 Socket for torque wrench 22 Plug 46
(Width across flats)
14 31, 76 Plug 50-2
(mm)
15 36 Cap 38
16 Screwdriver Floating seal 1-2, Wire 1-26, Base plate 30, Oil seal 4
17 Hammer Angular bearing 1-3, Plug 1-5, Oil seal 4, Steel ball 1-7, Shaft 2, Pin 26
18 Plastic hammer Base plate 30, Cover 1-24
19 Pliers Wire 1-26
20 Snap ring pliers Snap ring 11
21 Punch Plug 1-5, Pin 26
6-5-15 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Disassembly
Procedure
(1) Remove plugs 1-27 and 1-31, and drain the gear oil.
Tools:
• Torque wrench 1
• Hexagon bit 7 for above
1-31 1-27
109698-00X00
(2) Hold the motor in a vice.

Remove socket head bolts 63 and valve ASSY 50.
63
Tools:
• Torque wrench 1
109699-00X00
(3) If there is no abnormality in the valve ASSY, it need not be

disassembled.
50-2
When disassembling it, hold valve body 50-1 in a vice.
Remove plug 50-3, and then remove orifice plug 50-2 and 50-3
the orifice 50-5.
Tools:
• Torque wrench 2 Other side
50-5
109700-00EN00
6-5-16 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(4) Remove caps 38.
Tools:
38
• Torque wrench 3
109701-00X00
(5) Remove springs 37 and spring seats 36.
37 36
109702-00X00
(6) Remove the spool 31 while slowly rotating it. Be careful to

not scratch or dent the spool when removing it.
31
109703-00X00
6-5-17 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(7) Remove plugs 46 and 58 (connector).
Tools:
• Torque wrench 2
• Socket 12 for above
CAUTION
Be careful that spool C does not fall out from spool A when
loosening and removing plugs 46 and 58. To prevent spool C
from being scratched, check that spool C is inserted into spool
A, and then tighten the plugs.
46 58 109704-00X00
(8) Remove spring seat 59, spring 42, spool A 41-1, and
spool C 41-2. Take care not to give any damage such as
dents and scratches to the outside surface of the spool.
42 59
41-1
41-2
109705-00X00
(9) Remove hexagon socket head bolts 48.
Tools:
• Torque wrench 3
48
Note:
Because base plate 30 is raised by the reaction force of
springs 62 for the parking brake, loosen hexagon socket head
bolts 48 evenly to make it easy to execute the subsequent
works.
109706-00X00
(10) Remove base plate 30, taking care not to pull out cylin-
der block 7. When the base plate is hard to remove,
knock it out with a plastic hammer. If it is still hard to
remove, pry it up lightly with a screwdriver. 30
Tools:
• Plastic hammer 14
• Screwdriver 12
109707-00X00
6-5-18 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(11) Remove pin 49, valve plate 25 and O-rings 28 and 29.
29
28
25
49
109708-00X00
(12) Remove springs 21and 57.
Then remove brake piston 17. 34

To remove the brake piston, blow compressed air into the
17
parking brake release port in flange holder 1-1.
21
Note:
Cover the entire brake piston with a cloth or the like before
removal because the brake piston may suddenly jump out and
oil may also splash out.
57
109709-00X00
(13) Remove cylinder block 7, pins 12, retainer holder 13,

retainer plate 14, piston ASSYS 15 and disc 61.
Take care not to damage the sliding surface of the cylin-
der block. 18•33
14•15 13
12 7 109710-00X00
(14) Remove snap ring 11.

Then remove washer 8, spring 9 and spring seat 10.
8
Tool:
• Snap ring pliers 16 9
10
11
CAUTION
Be careful not to get your fingers caught because the internal
spring may suddenly jump out when removing the snap ring.
109711-00X00
6-5-19 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(15) Remove swash plate 5, steel balls 6, pistons 19 and
springs 20.
20
19
6
5
109712-00X00
(16) Remove wire 1-26. To remove wire 1-26, insert the round
bar S-3 into the hole on the side of the housing, and the
use a screwdriver to push out the wire in the direction of 1-26
the arrow in the drawing to the right. Then use some pli-
ers to remove the wire. Be careful to not damage the
groove when removing the wire 1-26. Cover the wire with
a waste cloth when working to stop it from suddenly fly-
ing out.
Tools:
• Torque wrenches 1, 2
• Eye bolts S-1
• Round bar S-3
109713-00X00
• Screwdriver 12
• Pliers 15
(17) Put hooks through the eye bolts and remove the cover,
or remove it using the round bar.
Tools:
• Eye bolts S-2 1-24
• Round bar S-3
109714-00X00
6-5-20 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(18) Loosen bolt 1-30.
Tools:
• Eye bolts S-1 1-30
• Round bar S-1
Note:
Screw 1-14 is installed using Loctite. Therefore, it is easier to
remove after heating up by using a heat gun or the like.
109715-00X00
(19) Remove sun gear 1-15, holder 1-17, planetary gears A

1-18, needle bearings 1-19, inner races 1-20, thrust
washers 1-16, drive gear 1-22 and thrust plate 1-23. 1-15 1-17
1-22
1-23
1-16
1-20
1-19
1-18 109716-00X00
(20) Remove screws 1-14 and thrust plate 1-13.
Tools:
• Torque wrench 1 1-14
1-13
Note:
Screws 1-14 may be hard to remove due to Loctite applied
when installed. Warm the screw part up by a heat gun or the
like, and the screws can be removed easily.
109717-00X00
6-5-21 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(21) Remove planetary gears B 1-9, needle bearings 1-10,
inner races 1-11 and thrust washers 1-12.
Take care not to damage the gear tooth surfaces and the
rolling surface of the collars.
1-12
1-11
1-10
1-9
109718-00X00
(22) Remove the other plug 1-8.
Tools:
• Torque wrench 1
109719-00X00
(23) Take out steel balls 1-7 through the screw hole for plug
1-8. Degrease the inside of the hole (with thinner or
white gasoline), and take out the steel balls by blowing
air into the screw hole.
Insert a piano wire through the screw hole to check that
all the steel balls have been taken out.
Tools:
• Hammer 13
• Piano wire S-4
Note: 1-7
When the steel balls are hard to take out, lightly tap around
109720-00X00
the outside surface of housing 1-6 with a hammer.
(24) Fit a metal plate or the jig between flange holder 1-1 and
housing 1-6, and then tighten three bolts evenly from the
hosing side to remove the housing.
1-6
Bolt size: M14 x 2.0
Tools:
• Torque wrench 2
• Metal plate or housing disassembly jig S-5
109721-00X00
6-5-22 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(25) Remove plugs 1-5.
Tools: 1-5
• Torque wrench 1
• Hexagon bit 7 or 8 for above
109722-00X00
(26) Remove ring nut 1-4.
Tools:
• Torque wrench 3
• Ring nut tightening jig S-6
CAUTION 1- 4
If a vice is used, clamp the flange portion.
109723-00X00
(27) Put one end of a round bar in steel ball groove1-7 in

angular bearing 1-3 and tap the other end of the round
bar lightly with a hammer to remove the angular bearing.
Tools:
• Hammer 13
• Round bar S-7
Note:
Turning the flange holder little by little, tap steel ball groove 1-
7 in the angular bearing at several points to remove the angu-
lar bearing. 1- 3
Tapping only at one point may cause difficulty in removing the 109724-00X00
angular bearing.
(28) Remove floating seal 1-2 and angular bearing 1-3.

1-2
1-3
051729-00X00
6-5-23 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(29) Remove the other floating seal using two screwdrivers.
Tools:
• Screwdrivers 12
1- 2
CAUTION
Be careful not to damage the sliding surface of floating seal 1-
2 when removing it.
109726-00X00
(30) Remove shaft 2 and roller bearing (inner) 3. Remove the

roller bearing (outer) 3 from the flange holder 1-1.
2 •3 (inner)
3 (outer) 109727-00EN00
(31) Remove oil seal 4.
Tools:
• Screwdriver 12 4
• Hammer 13
CAUTION
Do not reuse removed oil seal 4.
109728-00X00
(32) Remove the roller bearing (inner race) 3 from the shaft 2.
Tool:
• Ball bearing disassembly jig S-8
3 (Roller bearing
inner race)
109729-00EN00
6-5-24 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4) Reassembly
Procedure
(1) Apply a small amount of low-viscosity oil to floating seal 1-
2 and install it into the groove in flange holder 1-1. 1-1
Tool:
• Floating seal assembly jig S-9
1-2
109730-00X00
(2) Press fit angular bearing 1-3 into housing 1-6.
Tool:
• Angular bearing press fitting jig S-10 1-3
1-6
109731-00X00
(3) Apply a small amount of low-viscosity oil to the other float-

ing seal and install it into housing 1-6.
Tool:
• Floating seal assembly jig S-9
1-2
109732-00X00
(4) Wipe the sliding surfaces of floating seals 1-2 with a clean
cloth or the like and apply gear oil to their sliding surfaces.
Install flange holder 1-1 to housing 1-6. 1-1
Tool:
• Flange holder press fitting jig S-11
CAUTION
If foreign materials are caught between the sliding surfaces of
floating seals 1-2, it may cause oil leaks.
109733-00X00
6-5-25 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(5) Tighten angular bearing 1-3 with ring nut 1-4.
Tools:
• Torque wrench 3
• Ring nut tightening jig S-6
Tightening torque: 1- 4
166.4 to 180.8 ft·lbf (225.5 to 245.0 N·m)
CAUTION
Do not reuse the removed ring nut. Replace it with a new one.
109734-00X00
(6) Tighten plugs 1-5.

Do not wrap the plugs with seal tape.
1- 5
Tools:
• Torque wrench 1
109735-00X00
(7) After tightening plugs 1-5, swage each plug at two points
to prevent the plug from loosening.
Tools:
• Hammer 13
• Punch 17
109736-00X00
(8) Install the required number of steel balls 1-7.
Note: 1- 7
When the steel balls are hard to install, lightly tap around the
outside surface of housing 1-6 with a plastic hammer while
installing them.
109737-00X00
6-5-26 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(9) Wrap plug 1-8 with seal tape and tighten it.
Tools:
• Torque wrench 1
CAUTION
If plug is protruding from the housing 1-6, tighten it until the
plug head becomes lower than the outside surface of the
housing.
109719-00X00
(10) Install planetary gears B 1-9, needle bearings 1-10, inner

races 1-11 and thrust washers 1-12.
1-12
1-11
1-10
1-9
109718-00X00
(11) Put thrust plate 1-13 on the trunnions of the flange holder
and fasten it with screws 1-14 on which Loctite #262 has
been applied.
When applying Loctite #262 to the screws, degrease 1-14
them adequately and use a hardening accelerator.
1-13
Tools
• Torque wrench 1
109717-00X00
(12) Assemble the sun gear 1-15, inner race 1-20, holder 1-
17, planetary gear A 1-18, needle bearing 1-19, and
drive gear 1-22. 1-15 1-17
1-22
1-23
1-16
1-20
1-19
1-18 109716-00X00
6-5-27 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(13) Apply Loctite to bolt 1-30 and then insert it.
1-30
109715-00X00
(14) Apply grease to O-ring 1-25 and install it to cover 1-24.

Then install the cover to housing 1-6 with the notch in
cover 1-24 aligned with the screw hole for plug 1-8. 1- 24 •1-25
Tools: Plug hole
Side hole
109738-00EN00
(15) Inset the wire 1-26 into the groove on the inside of the
housing.
1- 26
Tools:
109739-00X00
6-5-28 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(16) The use round bar S-3 or a flat-head screwdriver to gen-
tly tap the wire securely into the groove.
109740-00X00
(17) Press fit oil seal 4 into the flange holder.
Tool:
• Oil seal press fitting jig S-12
Note:
4
Apply a small amount of low-viscosity oil to the outside sur-
face of the oil seal when it is hard to press fit. Be careful not to
apply oil too much.
CAUTION
Do not reuse the removed oil seal. Replace it with a new one.
109741-00X00
(18) As in the figure to the right, press fit the inner race of the
roller bearing 3 into shaft 2, with the flanged part of the
inner race facing upwards.
Tool:
• Roller bearing press fitting jig S-13
2
CAUTION 3 (Roller bearing
inner rade)
Make sure you install the inner race of roller bearing 3 in the
correct direction.
109742-00EN00
6-5-29 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(19) Press fit the outer race of the roller bearing 3 into the
flange holder 1-1. Then, install shaft 2 and the inner race
to the flange holder.
2 •3 3 (Roller bearing
Tool: (Shaft and Roller
inner race)
• Roller bearing press fitting jig S-14 bearing inner race)
CAUTION
Make sure that you install the inner race and outer race (to the
shaft and flange holder respectively) in the same direction as
they were installed prior to disassembly.
109743-00EN00
(20) Install steel balls 6, springs 20, piston assembly 19 and

swash plate 5 into flange holder 1-1.
Before installation, apply grease to springs 20 and install
them to piston assembly 19. Also, apply hydraulic oil to 20
the sliding surface of the swash plate and the piston 19
assembly in advance.
6
5
109712-00X00
(21) Install spring seat 8, spring 9, washer 10 and snap ring

11 into cylinder block 7.
Tools:
• Snap ring pliers 16
• Snap ring press fitting jig S-15
11
10
9 8
7
109744-00X00
(22) Apply grease to pins 12 and install them into three holes
in the cylinder block.
12
109745-00X00
6-5-30 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(23) Install retainer holder 13, retainer plate 14 and piston
ASSYS 15.
Apply hydraulic oil to the 9 holes in the cylinder block. 14•15
Assemble the disc 18 and friction plate 33.
13
Note: 18
For easier installation, align the spline teeth of cylinder block 7
33
with those of retainer holder 13 before installation.
18
109746-00X00
(24) Lay down the motor and install the cylinder block sub
assembly using the shaft splines as a guide.
Apply grease to the reverse side of the swash plate so
that swash plate 5 cannot easily come off.
109747-00X00
(25) Depress the cylinder block by hand to check that the

spring works.
Apply hydraulic oil to the sliding portion of the cylinder
block.
CAUTION
Make sure that there are no foreign substances in the area
enclosed by a circle on the cylinder block shown in the figure
at the right.
If there any foreign substances, wipe them with a clean cloth.
109748-00X00
(26) Assemble the brake piston 17, and O-rings 22 and 24.
Apply a small amount of grease to the O-rings before
installation.
Assemble the collar 34 together with O-ring 35, and 17•22•24
install them to the brake piston 17.
When assembling, use a hand press to apply load to the
entire brake piston and press-fit it.
34•35
109749-00X00
6-5-31 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
Note:
lign the base plate and the pin position and them assemble.
If you do not have a hand press, use a plastic hammer and
uniformly strike the brake piston 17 to install it.
Tool:
• Hammer 18
109750-00X00
(27) Press fit ball bearing 27 into base plate 30.
Tool:
• Ball bearing press fitting jig S-16
27
109751-00X00
(28) Install pin 26 and swage it at one point on its outer side.
Tools:
• Hammer 13
• Punch 17
26
109752-00X00
6-5-32 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(29) Apply grease to the reverse side of valve plate 25 and
install it onto base plate 30.
Install pins 49 to the pin holes in the base plate.
49
25
109753-00X00
(30) Install the springs 21 and 57, the O-rings 28 and 29, and
the base plate 30.
30
21•57
28
29
109754-00X00
(31) Tighten hexagon socket head bolts 48.
Tools:
• Torque wrench 2
48
109706-00X00
(32) Tighten plugs 43 and 46 with O-ring 44.
48
109706-00X00
6-5-33 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(33) Install spring 42, spool A 41-1, spool C 41-2, and the
spring seat 59.
Install the plunger sub ASSY while turning it taking care
so that it is not caught. 42 59
Apply hydraulic oil to plunger sub ASSY 31 before instal-
lation.
CAUTION
Check that spool C 41-2 is inserted into spool A 41-1, and
then assemble to base plate 30.
41-1
41-2
109705-00X00
(34) Tighten the plug 58 to which O-ring 44 is installed.
Tools:
• Torque wrench 2
Tightening torque: 11.0 to 13.2ft·lbf (49.0 to 583.8 N·m)
CAUTION
If the plug 46 becomes loose during removal of the piping, do
not re-install the plug 46. Remove plug 58 and spill assembly
41, and reassemble from procedure No. 32.If it is not assem- 58
bled according to the procedure, the inner spool may be dam- 109757-00X00
aged, and the 2-speed switching mechanism will not work

correctly.
(35) Install the spool assembly 31 to the base plate. Rotate

the spool while installing so that it does not become
stuck. Apply hydraulic oil to the spool assembly 31
before installing.
31
109703-00X00
(36) Install the springs 37 and the spring seats 36.
37 36
109702-00X00
6-5-34 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(37) Install the cap 38 to which O-ring 39 is installed.
Apply a small amount of grease to the O-ring. 38
Tools:
• Torque wrench 5
Tightening torque: 52.8 to 55.1 ft·lbf(235 to 245 N·m)
109701-00X00
(38) Tighten the plug 43 to which O-ring 44 is installed, and

then install the shipping plug 53.
109758-00X00
(39) Use a vice to fix the valve body 50-1 in place. Tighten the
plug 50-3, the orifice plug 50-2, and the orifice 50-5.
Tools:
• Torque wrench 1, 3
• Hexagon bit 8 and 10 for above
Tightening torque: Orifice plug 50-2

0.6 to 0.8 ft·lbf(2.45 to 3.43 N·m)
051780-00X00
(40) Install the O-rings 61 and 62 to the base plate 30.

61
62
109759-00X0
6-5-35 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(41) Place the valve assembly 50 onto the base plate 30, and
fix in place with the socket bolts 63.
Tools:
• Torque wrench 3
Tightening torque: Orifice plug 50-2

0.6 to 0.8 ft·lbf(2.45 to 3.43 N·m)
051780-00X00
Pour specified quantity of gear oil through one of the

screw holes for plug 1-27. Then tighten plugs 1-27 and 1-
31 with O-ring 1-8. 1-27
1-28
Q'ty: 0.95 Qts (900 cc)
Tools:
• Torque wrench 3
109760-00X00
(42) Completion of reassembly.
109761-00X00
6-5-36 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6. How to use the free-wheel function

1) Disassembling the reduction gear box (free-wheeling)
Procedure
(1) Remove the plugs 31 (x2) and 27, and drain the lubricat-
ing oil. Using a flat-head screwdriver, move the tip of the ø3
wire 26 to a position approximately 5 mm from the edge of 31
the hole on the side of the housing 6 (and covering the
hole). D
5
26 6
CAUTION
To prevent deformation when removing the plug, clean away
any mud etc. clogged in the hexagonal hole, and ensure that
the bit is inserted all the way in. If the hexagonal hole
becomes deformed, it may become unusable during assem- 27
bly.
View from D
109685-00EN00
(2) Insert the pin into the hole on the side of the housing 6,
and push the wire 26 out of the housing groove. Insert a
Pin
flat-head screwdriver into the gap between the cover 24
and the wire 26. Run the screwdriver along the groove to
remove the wire b. 6 6
CAUTION
26 Screw
When removing the wire 26, cover the wire with a waste cloth driver
to stop it from suddenly flying out and causing injury. Be care-
ful to not scratch the housing groove or cover 24 when using 24 26
the screwdriver.
Dents or scratches may cause damage to the reduction gear 24
box.
109686-00EN00
(3) Insert the threaded part of a slide hammer until it reaches

the bottom of the tap hole in the drive gear 22.
24
CAUTION
Before starting work, move the vehicle to level ground and M5×1.0（Pull out tap）
make sure that it will not move unexpectedly, as once the
drive gear 22 is removed, the motor becomes free.
23 Slide hammer
22
109687-00EN00
6-5-37 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(4) Use the slide hammer to remove the first stage of the
reduction gear box, and the sun gear 15.
15
CAUTION
When disassembling using a slide hammer, there is a risk that 24
the O-ring attached to cover 24 may break, the thrust plate 23
and cover 24 may suffer heavy impact, and scratches/dents
may occur. This may lead to breakage of the reduction gear
box when reassembling.
Therefore, take due care when removing. Be careful to not 22
drop the first stage of the reduction gear box when removing. First stage of the
It is heavy and may cause injury. After removing the reduction reduction gear box
gear box, use an oil pan etc. to collect any remaining lubricat- 109688-00EN00
ing oil. Make sure to install the cover 24 to prevent mud etc.
from entering when the vehicle is moving.
6-5-38 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Assembling the reduction gear box (free wheel recovery)

Procedure
(1) Secure the holder 17 in a vice, and then remove the bolt
30 and thrust plate 23. Remove the drive hear 22, plane-
tary gear 18, inner race 20, needle bearing 19, and thrust 16 18
washer 16. Clean all of the removed parts. 30
17
Note:
22 20
To enable smooth reassembly.
19
Note:
Disassemble the holder parts in advance to enable smooth
reassembly.
See sections (18) and (19) for the disassembly procedure 23
CAUTION 109689-00X00
Clean away any sludge or dirt that has adhered to each of the
parts.?Failure to do so will result in damage to the reduction
gear box.
Make sure that none of the parts are dented/scratched during
disassembly. If a part is dented/scratched, replace it with a
new one.
(2) Clean inside the housing 6, and then install the sun gear
15 and holder 17.
CAUTION 6
Before installing, check that there is no foreign matter inside
the reduction gear box. It can cause damage to the reduction 17
gear box.
15
109690-00X00
(3) Install the thrust washer 16, planetary gear 18, inner race
20, and needle bearing 19 (3 locations). 16
Install the drive gear 22, and then fix the thrust plate 23 in 19 Draped surface 23
place by tightening the flange bolt 30. 20 Draped surface 16
30
CAUTION
Ensure to install the thrust plate 23 and thrust washer 16 in 18
the correct direction.
23
22
109691-00EN00
6-5-39 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(4) Check that there is no rust or mud adhered to the inser-
tion points of the housing cover. If you find any rust or D
mud, remove it.
Remove any mud or foreign matter from the φ3 hole of the 26 6 22
housing 6.
24
CAUTION
Rust and mud can damage the O-rings when inserting the
cover. This can result in oil leakage.
6
Screw driver
View from D
109693-00EN00
(5) Supply lubricating oil to the reduction gear box, and then
tighten the plugs 31 (x2) and b.
Q'ty: 0.95 Qts (900 cc)

31
Tools:
• Torque wrench
• Hexagon bit
27
CAUTION
Replace the O-rings of plugs 27 and 31 with new ones. Re- 109694-00X00
using covers and O-rings can result in oil leakage.
6-5-40 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
7. Servicing Standards
Clean all disassembled parts with cleaning oil and dry them with compressed air. Then, inspect them based on the
criteria shown below and take necessary corrective actions such as replacement or repair.
Criteria
No. Part Inspection Item [Recommended value for Measures
replacement]
Floating seal 1-2 Sliding surface No excessive flaws, wear or Replace.
1
seizure
Angular bearing 1-3 Rolling surface No excessive flaws, wear or Replace.
2
flaking in ball or race
Housing 1-6 Gear tooth surface No excessive flaws, wear or Replace.
flaking on tooth surface.
3 [More than 10 % pitting in the
engaged area of a tooth sur-
face]
Planetary gears A 1-18 Gear tooth surface Same as No. 3. Replace.
and B 1-9
4
Rolling surface of nee- No excessive flaws, wear or
dle bearing flaking on rolling surface
Needle bearings 1-10, Needle bearing surface No excessive flaws, wear or Replace.
5
1-19 flaking
Inner races 1-11, 1-20 Needle bearing surface No excessive flaws, wear or Replace.
6
flaking
Thrust washers 1-12, 1- Sliding surface No excessive flaws, wear or Replace.
7
16 seizure
Thrust plates 1-13, 1-23 Sliding surface No excessive flaws, wear or Replace.
8
seizure
9 Sun gears 1-15 Gear tooth surface Same as No. 3. Replace.
Holder 1-17 Sliding surface against No excessive flaws, wear or Replace the planetary gear A
10 planetary gear A seizure and the holder together.
11 Drive gear 1-22 Gear tooth surface Same as No. 3. Replace.

O-rings 1-25, 1-28, 28, Surface condition and No flaws or distortion Rubber seal members deterio-
29, 31-5, 39, 44, 50-5, hardness Not hardened. rate with the lapse of time.
12 50-6, 50-7, 57, 65, 66, Replacement with new seals is
74 recommended every time they
are reassembled.
13 Shaft 2 Oil seal surface No flaws or excessive wear Replace.
14 Ball bearing 3, 27 Same as No. 2. Same as No. 2. Replace.
Oil seal 4 Lip surface and hard- No flaws, distortion or exces- Replace.
15 ness sive wear
Not hardened.
Swash plate 5 Sliding surface against No excessive flaws [over When the sliding surface has
piston ASSY 0.00079 in. (0.02 mm)], wear or been roughened, repair it by
seizure lapping (#1000).
16
Surface roughness 0.4a [0.8a] Replace if the damage is
beyond repair.
6-5-41 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Criteria
No. Part Inspection Item [Recommended value for Measures
replacement]
Cylinder block 7 Clearance between it 0.00079 in. (0.02 mm) Replace the cylinder block and
and piston ASSY [0.00157 in. (0.04 mm)] the piston ASSY together.
Sliding surface against No excessive flaws [over When the sliding surface has
valve plate 0.00079 in. (0.02 mm)], wear or been roughened, repair it by
17
seizure lapping (#1000).
Surface roughness 0.4a [0.8a] Replace the cylinder block and

the piston ASSY together if the
damage is beyond repair.
Spring 9, 20, 37, 42, Breakage or distortion Replace.
18
57, 63
Piston ASSY 15 Clearance between it Same as No. 17. Same as No. 17.
and cylinder block
Sliding surface against Same as No. 16. Same as No. 16.

swash plate and sur- 0.2a [0.8a]
19
face roughness
Play between pistons 0.00591 in. (0.15 mm) Replace.

and shoes [0.0157 in. (0.4 mm)]
Piston ASSY 19 Clearance between it Same as No. 17. Same as No. 17.
and flange holder
20
Sliding surface against Same as No. 16. Same as No. 16.
swash plate and sur-
face roughness.
Valve plate 25 Sliding surface against Same as No. 17. Same as No. 17.
cylinder block
21 Surface roughness 0.2a [0.8a]
Thickness: 0.197 in. (5 0.189 in. (4.8 mm) Replace.

mm)
Base plate 30 Sliding surface against No excessive flaws, wear or Replace the base plate and the
22
spool seizure spool together.
Spool 41 Sliding surface against No. excessive flaws, wear or Replace the base plate and the
23
base plate seizure spool together.
6-5-42 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
8. Troubleshooting
1) Motor
Trouble Causes Measures
1. Motor does not rotate. • Malfunction of equipment other than motor, Check whether the specified volume of hydrau-
reduction gear lic oil is fed to the inlet side of motor.
Then, check and repair the equipment.
• Escape of pressure oil due to excessive wear • Replace any excessively worn parts.
of motor’s sliding parts • Repair any flaw or burr on the surfaces,
clean all the parts and reassemble them.
• Malfunction due to breakage of main part of • Disassemble the motor and replace any bro-
motor. ken parts.
• Clean all the parts and reassemble them,
being careful not to allow foreign substances
to enter.
2. Motor speed is low. • Specified volume of oil is not being supplied Check whether the specified volume of hydrau-
to motor due to failure of hydraulic pump, lic oil is fed to the inlet side of motor.
system relief valve, or other equipment. Then, check and repair the equipment.
• Specified speed is not obtained due to drop After disassembling the motor, check them for
of motor displacement. excessive wear of the sliding parts. Repair or
replace any worn parts.
3. Large fluctuation in • A large volume of high pressure oil leaks and • Disassemble the motor and replace any worn
motor revolutions flows out from drain port due to wear of motor parts.
sliding portion, causing a large drop and fluc-
tuation in motor revolutions.
• Worn bearing. • Clean all the parts and reassemble them,
being careful not to allow foreign substances
to enter.
4. Oil leak • Breakage of oil seals or O-rings • Replace any broken oil seals or O-rings with
new ones. Take care not to damage the oil
seal lip.
• Apply a small amount of grease to O-rings
before installation.
6-5-43 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Flushing valve
1. Oil temperature Defective spool actuation • Remove all the foreign substances, repair
increase any damaged area, clean and reassemble
the parts.
If the damage is serious and oil leak is bad,
replace the part.
• Flushing valve orifice is clogged. • Clean the part with cleaning oil and reinstall
it.
• Spring breakage • Replace the spring.
• Remove all the foreign substances, repair
any damaged area, clean and reassemble
the parts.
3) 2-Speed switching mechanism

1. Machine travels with Spool is not moved.
deviation and travel • Foreign substances caught between spool • Remove all the foreign substances, repair
speed does not change. and valve body any damaged area, clean and reassemble
the parts.
If the damage is serious and oil leak is bad,
replace the part.
• Spring is not installed. • Install the spring in the correct position.
• Spring breakage. • Replace the spring.
Remove all the foreign substances, repair
any damaged area, clean and reassemble
the parts.
Oil leak due to excessive wear of two peed con- Replace the two peed control piston.
trol piston Remove all the foreign substances, repair any
damaged area, clean and reassemble the parts.
Two speed control piston is not installed Install the two speed control piston in the cor-
rect position.
Excessive wear of steel ball Replace the steel ball.
Remove all the foreign substances, repair any
4) Automatic 2-speed control valve

1. The machine does not Plunger is not shifted Remove foreign articles thoroughly. Repair
go straight • Foreign articles are jammed between spool A damaged parts, and reassemble the parts after
and body or between spool A and spool C. cleanup. If deep scratches or more than normal
wear are found on the parts, the parts should be
replaced with new ones.
Plunger is not shifted Install spring in proper position.
• Spring is not installed in place.
Plunger is not shifted Replace spring with new one. Remove foreign
• Spring is broken substances thoroughly, repair damaged parts,
then wash the parts before reassembly.
Oil leaks by unusual wear on 2-speed control Replace 2-speed control piston with new one.
piston Remove foreign articles thoroughly, repair dam-
aged parts, then wash the parts before reas-
sembly.
2-speed control piston is not installed in place Install 2-speed control piston in proper position.
Steel balls are excessively worn. Replace steel balls with new ones. Remove for-
eign articles thoroughly, repair damaged parts,
then wash the parts before reassembly.
6-5-44 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5) Parking brake
1. Insufficient braking force Worn disc Replace the disc.
Deterioration of disc surface or contact failure Repair the surface of the other part by polish-
ing, clean and reassemble the parts.
If the surface is seriously deteriorated, replace
the part.
Spring fatigue Replace the spring.
2. Excessive heat occurs Brake is not released. Replace the broken O-ring.
due to dragging of park- • Oil leak due to O-ring breakage
ing brake Brake is not released. Clean the part with cleaning oil and reinstall it.
• Clogged orifice
6-5-45 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-6 Swing Motor
1. Structure and Functions

The swing motor consists of a swash plate type axial piston motor, a relief valve, a make-up valve, a mechanical
brake, a planetary reduction gear and other parts.
The rotary group of the piston motor consists of a cylinder barrel integrated with a drive shaft and nine pistons
located in the cylinder barrel. The cylinder barrel is supported by bearings at both ends.
The piston is guided by a shoe holder and a barrel holder, which ensures that the piston slides smoothly along the
swash plate.
There are housed a relief valve for relieving excessive pressure (cushion relief) and a make-up valve for preventing
cavitation in the housing.
The mechanical brake, which consists of disc plates and steel plates, is installed between the cylinder barrel and the
housing as a parking brake.
Make-up valve Relief valve
062812-00EN00
Valve plate
Cover
Parking brake
Cylinder barrel
Housing Piston
Planetary
single-reduction
gear
062813-00EN00
6-6-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
1) Hydraulic Motor
Hydraulic oil supplied from the pump through the control valve is fed to the valve plate 5 through the relief valve.
When the hydraulic oil is supplied to the port A, the oil flows into the actuator ports of the cylinder barrel 4 which cor-
respond to the port A, and presses the piston 6. The pressing force the piston receives from the hydraulic oil is con-
verted into rotating force through the swash plate 7 and transmitted to the output shaft 3 splined to the cylinder barrel
4.
The return oil from the actuator ports flows out of the port B of the valve plate 5. In the opposite rotation to the above,
the hydraulic oil flows into from the port B and the return oil flows out of the port A.
Port B
Valve plate
Port A
Piston
Housing Thrust plate Output shaft Cylinder barrel
062814-00EN00
6-6-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Mechanical Brake
The mechanical brake serves to mechanically lock the output shaft of the swing motor while the motor is stopped.
When the brake release pressure is in the OFF state, the brake piston fixed to the housing with a pin is kept pressed
by the spring, against the disc plate splined to the cylinder barrel. Consequently, the frictional force disables the rota-
tion of the cylinder barrel, and therefore, the output shaft of the swing motor is locked. (See Fig. A.)
Pin Brake piston
Disc spring
Housing
Brake
release port
Disc plate Brake cylinder chamber

Cylinder barrel 062815-00EN00
Brake release pressure: OFF Brake release pressure: ON

(Fig. A) (Fig. B)
When the brake release pressure is turned ON, the hydraulic oil is led to the brake release port and the oil pressure
which exceeds the force of the spring moves the brake piston in the arrowed direction in Fig. B. Consequently, the
disc plate is disengaged and the frictional force between them is lost, and therefore, the cylinder barrel can be
rotated. (See Fig. B.)
6-6-3 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Make-Up Valve
(1) Make-up valve has two functions.
Make-up valve prevents cavitation caused by the overrun of the piston motor and the drifting of swing.
Even when the pump stops supplying the oil, the motor still continues to rotate due to the inertia force of the upper-
structure, so that the motor acts like a pump. At that time, the extra oil from the port T is supplied to the main circuit
of the motor through the make-up valve to prevent a vacuum inside the circuit.
(2) When a closed circuit is formed between the control valve and the motor in braking or other states, the extra oil
as much as the drain oil from the motor and the oil leakage from the valve is supplied to the circuit through the make-
up valve to prevent a vacuum inside the circuit and apply the brakes in the same state as for a normal circuit.
Make-up valve
Port B Port M Port A
062816-00EN00
6-6-4 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4) Relief Valves
(1) Working principle of relief valves
The relief valves decides the driving and braking force for swinging. It is installed on each main line for the ports A
and B and comprises a circuit where the oil from the relief valve on one side flows to the low pressure line on the
other side.
Poppet Structure of
relief valve
062817-00EN00
(2) Relief valve operation

Relief valve pressure depends on the balance of the pressure force applied to the differential area of S1 and S2 (S1-
S2) and the spring force.
Screws had been set before shipping. Do not readjust the screws. Readjusting the screws may not only cause their
primary performance to lose, but also damage equipment and result in a serious accident.
S1 S2
Spring
Screw
062818-00EN00
6-6-5 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5) Reduction Gear
The motor shaft 1 is splined to the drive gear 2. The drive gear 2 engages with the planetary gears 3. The planetary
gears 3 engage with the ring gear of reduction gear housing 4. The planetary gears 3 are held by the holder 5. The
holder 5 and pinion shaft 6 are splined with each other.
The driving force of the hydraulic motor is outputted from the motor shaft 1, and then transmitted to the pinion shaft
6 through the drive gear 2, the planetary gears 3 and the holder 5.
062819-00X00
6-6-6 172663 0BKC2-EN0060

C30R-3 SVM.book
34
33
7 ページ
32
31
30
9
29
6 8
7
28
5
２０１７年９月２２日
57
43
金曜日
4 59 42
58
3. Exploded View and Component Parts
3 64 A 41
2 63
62 65
1 61 66
65
60 67
19 68
A 69
17 70
71
72
6-6-7
40 61
16 39 62 73
15 38 63 74
14 37 64
13 36
35 75
76
12 51 77
50
11 49
10 48
52
47
172663 0BKC2-EN0060
6. HYDRAULIC SYSTEM
45
46 56
45
44 55
53 54
062820-00X00
6. HYDRAULIC SYSTEM
No. Part Q'ty No. Part Q'ty

1 Pinion shaft 1 44 Brake piston 1
2 Collar 1 45 Spring seat 2
3 Plate 1 46 Disc spring assembly 1
4 Taper-roller bearing 1 47 O-ring 1
5 Housing 1 48 Valve plate 1
6 Plug 1 49 Pin 1
7 O-ring 1 50 Ball bearing 1
8 Oil seal 1 51 Pin 2
9 Taper-roller bearing 1 52 Cover 1
10 Plate 2 53 O-ring 2
11 Collar 1 54 Plug 2
12 Holder B 1 55 O-ring 2
13 Thrust washer 3 56 Socket head bolt 5
14 Inner race 3 57 Socket head bolt 2
15 Needle bearing 3 58 Plug 1
16 Planetary gear B 3 59 O-ring 1
17 Thrust plate 1 60 Orifice 1
19 Drive gear 1 61 Check valve 2
27 O-ring 1 62 Spring 2
28 Housing 1 63 O-ring 2
29 Ball bearing 1 64 Plug 2
30 Shaft 1 65 Back up ring 2
31 Thrust plate 1 66 O-ring 1
32 Piston 9 67 Poppet sheet 1
33 Retainer plate 1 68 Poppet 1
34 Retainer holder 1 69 Relief housing 1
35 Pin 3 70 Spring seat 1
36 Cylinder barrel 1 71 Spring 1
37 Collar 1 72 O-ring 1
38 Spring 1 73 Plug 1
39 Washer 1 74 O-ring 1
40 Snap ring 1 75 Adjuster 1
41 Disc plate 1 76 Washer 1
42 O-ring 1 77 Nut 1
43 O-ring 1
6-6-8 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4. Disassembly
1) Hydraulic Motor
Procedure
(1) Loosen two socket head bolts 57 to remove hydraulic 57
motor assembly from reduction gear body.
Motor assembly
Reduction gear assembly.
062821-00EN00
(2) Remove valve plate 48 and pin 49. 56 56

Note:
Valve plate 48 could be left on motor side.
56 56
56 062822-00X00
52 48
062823-00X00
(3) Remove valve plate 48 and pin 49.
Note:
Valve plate 48 could be left on motor side. 48 49
062824-00X00
6-6-9 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(4) Remove ball bearing 50 and O-rings 53.
53 50
062825-00X00
(5) Remove plugs 64, springs 62 and check valves 61.
64 62 61 062827-00X00 64
062826-00X00
(6) Loosen plug 73 to remove relief valve assembly.
Notes:
• Do not move adjuster kit 75, or set pressure changes.
• Relief valve assembly should not be disassembled. Relief valve
assembly
75
73
062828-00EN00
(7) Remove pins 51 and O-ring 47 from housing 28.

51 47
28
062829-00X00
6-6-10 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(8) Remove disc spring assembly 46 and spring seats 45,
and then remove parking brake piston 44 using gauge
port of housing 28.
46 45 44
(Plug is installed on gauge port.)
Notes:
• Brake piston can be pulled out by gradual air blow from
gauge port.
• Blow air gradually to prevent break piston from jumping out
suddenly.
062830-00X00
Gauge port
062831-00EN00
(9) Remove cylinder barrel assembly.

Cylinder barrel assembly
062838-00EN00
(10) Remove retainer plate 33 and piston assemblies 32 from 33 32

cylinder barrel assembly.
062839-00X00
6-6-11 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(11) Remove pins 35 and retainer holder 34.
34 35
062840-00X00
(12) Remove snap ring 40 pressing washer 39.

39 40
062841-00X00
(13) Remove washer 39, spring 38 and collar 37.

39 37 38
062842-00X00
(14) Remove disc plate 41 and thrust plate 31.

31 41
062843-00X00
6-6-12 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(15) Tap end of shaft 30 with plastic hammer, and then
remove shaft 30. 30
062844-00X00
(16) Disassemble ball bearing 29 and shaft 30. 29 30

Note:
Replace removed bearing with new one.
062845-00X00
6-6-13 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Reduction Gearbox
Procedure
(17) Remove O-ring 27, drive gear 19, thrust plate 17, plane- 27 12 19 14 17 15 13 16
tary gears 16, needle bearings 15, inner races 14, thrust
washers 13 and holder B 12.
27
19
17
16
15
14
13
12
062846-00X00
062847-00X00
(18) Remove collar 11 and plates 10. 10 11

Note:
When replacing taper-roller bearings 4 and 9 and collar 2,
replace them as housing assembly.
1 2 3 4 5 6 8 9 10 11
7
Housing assembly 062849-00EN00

062848-00X00
(19) Remove pinion shaft 1 (with inner case of taper-roller 1

bearing 4, plate 3, and collar 2).
Note:
Take care not to drop them when removing pinion shaft. When
pinion shaft cannot be pulled out easily, tap it out with plastic
hammer.
1 2 3 4
062851-00X00
062850-00X00
(20) Remove inner race from taper-roller bearing 9.

9
062852-00X00
6-6-14 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(21) Remove oil seal 8.
8
Notes:
• Do not use removed oil seal again.
• Take care not to damage outer races of taper-roller bear-
ings 4 and 9.
062853-00X00
(22) Remove outer races of taper-roller bearings 4 and 9 and 9

plug 6.
4 062854-00X00
6-6-15 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5. Reassembly
1) Hydraulic Motor
Procedure
(1) Install relief valve assembly.
Relief valve
Tightening torque: 108.5 to 123.0 ft•lbf
assembly
(147.0 to 167.0 N•m)
062855-00EN00
(2) Install check valves 61 and springs 62.
62 61 062856-00X00
(3) Install plugs 64 (with O-ring).

(37.3 to 41.2 N•m)
64
062857-00X00
(4) Install collar 37, spring 38 and washer 39 into cylinder

barrel 36. 39 37 38 36
Note:
Be careful with installation direction of collar 37.
Surface with taper
Cylinder barrel 062873-00EN00

062872-00X00
6-6-16 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(5) Install snap ring 40 pressing washer 39.
39 40
062874-00X00
(6) Apply grease to pins 35, and then install them into cylin-
der barrel 36.
34 35
(7) Install retainer holder 34.
36
062875-00X00
(8) Set piston assemblies 32 into retainer plate 33, and install 33
them into cylinder 36. 32
Note:
Apply sufficient grease to sliding parts before installing.
36
062876-00X00
(9) Press-fit ball bearing 29 onto shaft 30. 29 30

Note: Snap ring
Install ball bearing 29 with snap ring set to direction shown in
right figure.
062877-00EN00
6-6-17 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(10) Press-fit shaft 30 and ball bearing 29 onto housing 28.
28 30
29 062878-00X00
(11) Apply grease on rear surface of thrust plate 31.

31
Note:
Thrust plate has direction.
Install the thrust plate with the

taper side toward the motor case
062880-00EN00
062879-00X00
(12) Install cylinder barrel assembly.

Cylinder barrel assembly
Note: 35 41
Take care pins 35 do not come off when installing.
062881-00EN00
(13) Apply grease to O-rings 42 and 43, and install them into
brake piston 44.
44
43
42 062882-00X00
6-6-18 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(14) Install brake piston 44 into housing 28 positioning holes
for pins 51. 46 45 44
Install two spring seats 45 and disc spring assembly 46
in right direction.
45
46
Take care 45
about direction.
062884-00EN00
28 062883-00X00
(15) Apply grease to O-ring 47 and install it onto housing 28.

51 44 47
Notes:
• Conform whether pins 51 can be installed into holes in
brake piston 44 and housing 28. If not, remove brake piston
44 to readjust positions.
• Install pins 51 in cover 52 before assembling.
28 062885-00X00
(16) Apply grease to two O-rings 53 and two pins 51, and
install them into cover 52.
53 50 51
(17) Press-fit ball bearing 50 to cover 52.
52 062886-00X00
(18) Install pin 49 and valve plate 48.
Note:
Apply grease to rear surface of valve plate to prevent it from 48 49
dropping.
062887-00X00
6-6-19 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(19) Install cover 52 assembly into housing 28 positioning
pins 51. 51 52 48
Note:
Take care not to drop pins 51 and valve plate 48.
28 062888-00X00
(20) Tighten five socket head bolts 56 temporarily, and then 56 56

retighten them with torque wrench at specified torque.

(121.6 to 135.0 N•m)
56 56
56 062889-00X00
6-6-20 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Reduction Gearbox
Procedure
(21) Press-fit oil seal 8 into housing 5.
Dimension of oil seal

8
after press-fitting
Note:
Apply grease to installation part and outer surface of oil seal 8
before press-fitting.
• Dimension of oil seal after press-fitting: 0.177 in (4.5 mm)
062890-00EN00
(22) Press-fit outer races of taper-roller bearings 4 and 8, and 9

install plug 6.
4 062891-00X00
(23) Apply grease to inner race of taper-roller bearing 4 (with

plate 3 and collar 2) installed into pinion shaft 1. 1 4
3 2 062892-00X00
(24) Install pinion shaft 1 into housing 5. 1 9

Note:
Apply grease to rip of oil seal 8 before installing pinion shaft 1.
(25) Install inner race of taper-roller bearing 9.

8
5
062893-00X00
6-6-21 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(26) Install collar 11 and plates 10. 10 11
062894-00X00
(27) Install thrust washers 13, inner races 14, needle bear-
ings 15, planetary gears 16, thrust plate 17 and drive 5 27 12 19 14 17 15 13 16
gear 19 into holder B 12.
(28) Apply grease to O-ring 27 and install it into housing 5.

12 13 14 15 16 17 19 27
062896-00X00
Note:
Thrust plate has direction..
Install thrust plate with taper side 062895-00X00
toward planetary gear 16
16
062897-00EN00
(29) Put motor assembly onto reduction gear assembly, and

57
then temporarily tighten two socket head bolts 57 and
retighten them at specified torque.
Motor assembly
(121.6 to 135.0 N•m)
Reduction gear assembly
062898-00EN00
6-6-22 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6. Service Standards
Clean the removed parts with wash oil, dry them with compressed air and repair or replace them, if necessary,
according to the following service standards:
1) Motor
No. Part Service standard
1 Piston 32 assembly • Deep flaws on sliding parts or rough sliding surface.
• Too large clearance between piston and cylinder barrel bore.
• Maximum diameter clearance: 0.00157 in. (0.04 mm).
• Too large looseness in shoe ball part.
• Maximum play (travel limit) 0.0157 in. (0.4 mm).
2 Thrust plate 31 • Deep flaws on sliding parts or rough sliding surface.
Retainer holder 34
Retainer plate 33
Valve plate 48
Brake piston 44
3 Cylinder barrel 36 • Deep flaws on sliding parts and rough sliding surface.
• Excessive wear or damage on engaged surface.
4 Disc 41 • Deep flaws or flaking on disc (friction material).
• Excessive wear or damage on engaged surface.
5 Ball bearing 29, 50 • Flaking or break away on rolling contact surface.
• Dents on rolling contact surface.
• Abnormal rotation of bearing (with noise and no smoothness).
6 Spring 38 • Damage or excessive deformation.
7 O-ring 42, 43, 47, 53, 54, 59, 63 • Flaws causing oil leak or loss of seal characteristic, or permanent set.
2) Reduction Gear
1 Pinion shaft 1 • Excessive flaws, wear or flaking on gear tooth surface.
2 Plate 2 • Excessive flaws or wear.
3 Taper-roller bearing 4, 9 • Excessive flaws, dent or flaking in race parts of roller.
• Rotation with noise and no smoothness.
• When replacing housing 5, do it as housing assembly.
4 Oil seal 8 • Flaws, deformation or excessive wear on lip part.
• Stiffened lip part.
5 Housing 5 • Excessive flaws, wear or flaking on gear tooth surface.
Holder 12, • When replacing housing 5, do it as housing assembly.
Drive gear 19
6 Inner race 14 • Excessive flaws, wear and flaking on rolling contact surface with nee-
dle bearing.
7 Needle bearing 15 • Excessive flaws, wear and flaking on surface of needle bearing.
8 Planetary gear B 16 • Excessive flaws, wear and flaking on surface of gear tooth.
• Excessive flaws, wear and flaking on rolling contact surface with nee-
dle bearing.
9 Thrust plate 17 • Excessive flaws, wear and seizing on sliding surface.
6-6-23 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Valve
1 Spring 62 • Deep damage or large distortion.
2 Plug 64, 73 • Flaws causing oil leak or loss seal characteristic.
Check valve 61 • Permanent set.
O-ring 63, 66, 72, 74
Backup ring 65
4) Others
1 Others plugs, O-rings • Flaws causing oil leak or loss of seal characteristic.
• Permanent set.
6-6-24 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
7. Troubleshooting
1) Motor
1. Motor does not rotate. (1) Malfunction of equipment other than Check whether the specified volume of hydraulic oil
piston motor, valve (built-in motor) is fed to the motor suction side. Then, check and
and reduction gear. repair each part.
(2) Escape of pressure oil due to exces- Replace any excessively worn parts.
sive wear of motor's sliding parts. Repair any flaws or burr on the surfaces, clean all
the parts and reassemble them.
(3) Malfunction due to breakage of Disassemble the motor replace any broken parts.
motor's main parts. Clean all the parts and reassemble them.
(In this case, motor makes an
abnormal sound.)
(4) Malfunction due to breakage of main Disassemble the motor replace any broken parts.
parts of reduction gear. Clean all the parts and reassemble them.
(In this case, reduction gear makes
an abnormal sound.)
(5) Operation of relief valve due to too Check the load and regulate it to the value corre-
much load applied to motor. sponding to the set relief pressure.
2. Motor speed is low. (1) Specified volume of oil is not sup- Check whether the specified volume of hydraulic oil
plied to motor due to failure of is fed to the motor suction side. Then, check and
hydraulic pump, system relief valve, repair each part.
etc.
(2) Specified speed is not obtained due After disassembling the motor, check them for
to drop of motor's displacement. excessive wear of the sliding parts. Repair or
replace any worn parts.
3. Large fluctuation in motor (1) A large volume of high pressure oil After disassembling the motor, check the parts and
revolutions. leaks and flows out of drain port due replace any worn parts.
to wear of motor's sliding parts, Clean all the parts and reassemble them.
causing excessive drop and fluctua-
tion in motor revolutions.
The fluctuation is also caused due to
worn bearing.
4. Oil leak. (1) Breakage of oil seals or O-rings. Replace any broken oil seal and O-ring. Take care
not to damage the lip of the oil seal.
Maximum temperature of safety use of O-ring is
176 °F (80 °C). When hydraulic oil temperature
rises more than 176 °F (80 °C), some measures
are necessary, such as oil cooler into hydraulic cir-
cuit.
(2) Due to the reason of [1-(2)] and [3- Repair motor according to procedure of [1-(2)] and
(1)] oil pressure is applied to inside [3-(1)], and then replace oil seal with new one.
of motor housing, causing oil seal Take care not to damage lip part when oil seal
breakage and oil leak. inserting.
 Oil seal
Capacity to resist pressure
42.7 psi (0.3 MPa)
(Maximum momentary)
Common ≤ 14.2 psi (0.1 MPa)
6-6-25 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4. Oil leak. (3) Due to foreign material inside drain Clean clogged drain pipe. Check drain system to
pipe and long thin pipe, back pres- reduce line resistance. After taking these measures
sure rises, causing oil seal breakage so that oil pressure which is less than 42.7 psi (0.3
and oil leak. MPa) is not applied to oil seal, replace oil seal with
 Oil seal new one.
Capacity to resist pressure Take care not to damage lip part when inserting oil
42.7 psi (0.3 MPa) seal.
(Maximum momentary)
Common ≤ 14.2 psi (0.1MPa)
5. Excessive abnormal (1) Increase in drain amount due to According to 2-(2) and 3-(1), take measures and
sound and fluctuation in decreased motor efficiency. remedies.
rotation and pressure due
(2) Malfunction of make-up valve. According to 1-(3), take measures and remedy.
to cavitation.
(3) Short supply of pressure and oil Check supply pressure and oil amount of make-up
amount to make-up valve. valve, and set specified value if necessary.
6-6-26 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Valve
1. Motor does not rotate, or (1) Malfunction of equipment other than Check whether the specified volume of hydraulic oil
rotate at a low speed. piston motor, valve (built-in motor) is fed to suction side of valve. Then, check and
and reduction gear. repair each part.
(2) Increasing inner leaking due to Replace O-ring and backup ring with new one.
breakage of relief valve, O-ring or
seal.
(3) Defective seat of make-up valve. • Remove all foreign substances, repair any dam-
[1] Foreign substances caught inside. aged area, clean parts and reassemble them.
If damage is serious and too much oil leaks,
replace make-up valve seat.
[2] Rough and damaged sliding surface • Repair sliding surface, or replace check valve
of check valve. with new one.
[3] Broken spring. • Replace spring. Remove all foreign substances,
repair any damaged area, clean parts and reas-
semble them. Replace if seriously damaged and
too much oil leaks.
(4) Defective seat of relief valve. • Remove all the foreign substances, repair any
[1] Foreign substances caught inside. damaged area, clean the parts and reassemble
them.
Replace if the damage is serious and too much
oil leaks.
[2] Broken spring. • Replace relief valve assembly.
(5) Too low cracking pressure of relief

valve.
[1] Permanent set of spring. Replace relief valve assembly.
[2] Clogged poppet orifice. Clean part with wash oil and reinstall it.
2. Motor does not stop or is (1) Defective seat of make up valve. • Remove all foreign substances, repair any dam-
slow to stop. [1] Foreign substances caught inside. aged area, clean parts and reassemble them.
[2] Rough and damaged sliding surface • Repair sliding surface, or replace check valve
of check valve. with new one.
too much oil leaks.
(2) Defective seat of relief valve. • Remove all the foreign substances, repair any
[1] Foreign substances caught inside. damaged area, clean the parts and reassemble
them.
Replace if the damage is serious and too much
oil leaks.
[2] Broken spring. • Replace relief valve assembly.
(3) Too low cracking pressure of relief

valve.
[1] Permanent set of spring. • Replace relief valve assembly.
[2] Clogged poppet orifice. • Clean part with wash oil and reinstall it.
6-6-27 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2. Motor does not stop or is (4) Increasing leaking.

slow to stop. [1] Increasing inner leaking due to • According to 1-(2), and 1-(3), take measures and
breakage of O-ring seal. remedies.
3. Abnormal sound. (1) Defective seat of make up valve. • Remove all foreign substances, repair any dam-
[1] Foreign substances caught inside. aged area, clean parts and reassemble them.
too much oil leaks.
(2) Short supply of pressure and oil Check supply pressure and oil amount of make-up
amount to make up valve. valve, and set specified value if necessary.
(3) Resonance with other relief valves Readjust set pressure of relief valve.
due to change of relief set pressure.
4. Large shock in stopping (1) Malfunction of shock reduction sys- • Remove all the foreign substances, repair any
swinging. tem. damaged area, clean parts and reassemble
[1] Foreign substances caught inside. them.
Replace if damage is serious and too much oil
leaks.
[2] Pressure oil is not supplied to piston • Clean relief assembly to remove foreign sub-
chamber. stances clogged in orifice.
[3] Increasing leaking due to worn slid- • Repair any damage area, or replace with new
ing surface of piston. one.
(2) Increasing relief set pressure. Readjust set pressure of relief valve.
(1) Malfunction of relief valve. • Remove all foreign substances, repair any dam-
[1] Foreign substances caught in sliding aged area, clean parts and reassemble them.
parts. Replace if damage is serious and too much oil
leaks.
6-6-28 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Parking Brake
1. Motor does not rotate. (1) No release pressure is generated, Adjust "PB" pressure to specified pressure.
Parking brake is not or supply pressure is too low (less
released. than specified value). Therefore,
brake piston does not operate.
(2) Valve does not operate due to high Measure motor drain pressure, and check for
motor drain pressure. clogged drain circuit and repair it if necessary.
If amount of motor drain is excessively large, check
motor and repair it if necessary.
(3) Brake piston does not operate. • Replace O-ring with new one.
[1] Pressure oil leak due to abnormal • Check parts and repair flaws.
wear or breakage of O-ring of brake If sliding part is seriously damaged, replace pis-
piston. ton with new one.
[2] Malfunction of piston due to wear • Clean sliding parts to remove foreign sub-
and flows of brake piston sliding stances.
parts.
[3] Malfunction due to foreign sub-
stances caught in piston sliding
parts.
2. Parking brake force is (1) Worn disc. • Replace disc with new one.
low.
(2) Permanent set of spring in piston • Replace spring with new one.
Brake force is not gener-
parts.
ated.
[4] Defective sliding part of brake pis- • Repair sliding. Replace with new one if seriously
ton, or deteriorated friction surface damaged. However, surface of friction material of
of disc. disc cannot be repaired.
[5] Pressure inside cylinder chamber is • Clean filter and orifice, or replace them with new
not relieved due to clogged of orifice ones.
and filter.
3. Parking brake cannot be (1) Brake piston is touching on disc due • Adjust "PB" pressure to specified pressure.
released, creating noise, to low release pressure "PB".
vibration, shock, and
(2) Decrease in pressure inside cylinder • Replace O-ring with new one.
abnormality and generat-
chamber due to excessive wear and
ing heat.
breakage of O-ring in brake piston.
6-6-29 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-7 Control Valve

The control valve is located between the gear pump S3 and the dump cylinder on the hydraulic circuit. The oil that
flows from the gear pump S3 is controlled by each component inside the control valve. Thereby, the direction of
operation and the speed of the cylinder change.
1. The control valve consists of the following valve sections.
Relief valve assembly
Dump cylinder section
Inlet section
Tie rod nut
104783-00EN01
2. Control valve function

(1) Control in neutral position
The oil passes through the neutral passage in the control valve and is discharged from the return port.
(2) Control of the dump cylinder operation

By means of switching of the dump cylinder section spool, hydraulic oil flow, direction and pressure are adjusted to
control the cylinder operation and stop, or change the direction and speed for cylinder operation.
(3) The load check valve prevents the descent of the cylinder during operation.
(4) The relief valve limits circuit pressure.
6-7-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3. Controlling the dump cylinder section

(1) In neutral
The hydraulic oil discharged from the pump passes through the neutral passage and is discharged from the return
port. The hydraulic oil of the cylinder ports (A and B) are blocked.
Port A Port B
Port Pa1 Port Pb1
Neutral passage Tank passage 104784-00EN00
(2) When the pilot oil port Pa1 is pressurized

As shown in the figure below, when the port Pa1 is pressurized to switch the spool, the hydraulic oil flow in the neu-
tral passage is blocked and the load check valve is pushed up to let the hydraulic oil flow to the cylinder port A.
The return hydraulic oil from the cylinder port B flows to the tank passage through the orifice part of the spool and is
discharged from the return port. The same is true when the pilot oil port Pb1 is pressurized.
Port A Port B
Port Pa1 Port Pb1
Neutral passage Tank passage 104785-00EN00
6-7-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
B1
A1
Pb1
Pa1
P T 104887-00X00
Hydraulic schematic symbols
6-7-3 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4. Disassembly
Note:
The following precautions must be taken at the time of disassembly.
Be sure to stop the engine after ensuring that any circuit pressure is not muffled. When the engine is cut off with the
muffled pressure in a circuit, high-pressure oil may spout out or the parts may fly out.
• Clean around the parts to be disassembled and prevent foreign material from entering the valve at the time of dis-
assembly.
• Store the disassembled parts with attach tags that make clear how the parts need to be reassembled.
• Replace the disassembled seals (O-rings, backup rings, and wipers) with new ones.
Note:
The relief valve is, in principle, replaced as part of the assembly. Do not disassemble it unless there is an abnormal-
ity. Refer to “Servicing Procedure for Relief Valve” at the time of disassembly. Mark the assembly position of each
part for reassembly.
Be sure to pull out the spool straight to avoid damage and scratches on it. If damaged or scratched, the spool may
damage the spool bore when it is pulled out or it may be difficult to insert it during reassembly; even inserted, it may
cause malfunction.
Mark the assembly position for each spool. If mis-assembled, the cylinder may malfunction which is very danger-
ous.
1) Disassembly of accessory
Remove the relief valve assembly from the inlet section.
Relief valve assembly
Dump cylinder section
Inlet section
Tie rod nut
104783-00EN01
6-7-4 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Disassembly of spool sections

(1) Disassembly of the dump cylinder section
Loosen the socket head bolt 8 (hexagon size 5 mm) to remove the cap 6. Then, remove the spring seat 3, spring 4.
spring seat 5 and O-ring 7. Remove the cap 8 and O-ring 7 on the opposite side. After that, pull out the spool 2 from
the valve housing 1.
ID seat No O-ring on the mating surface.
No passage on this surface.
Tightening torque : 20.9~23.9 ft•lbf

(28.4~30.4 N•m)
11 10 12 9
ID groove for spool installation
5 4 3
6 8 7
Tightening torque (4 screws) : 5.4~7.2 ft•lbf 1 2

(7.3~10.0 N•m) 104786-00EN00
Note:
Be sure to pull out the spool straight to avoid damage and scratches on it. If damaged or scratched, the spool may
damage the spool bore when it is pulled out or it may be difficult to insert it during reassembly; even inserted, it may
cause malfunction.
Mark the assembly position for each spool. If mis-assembled, the cylinder may malfunction which is very danger-
ous.
6-7-5 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) Disassembly of the inlet section

Loosen the pan head screws 6 to remove the seal plate 5. Then, loosen the pan head screws 6 on the opposite side
to remove the seal plate 5 and pull out the spool 2 from the valve housing 1.
6 5 4 3 2 1 3 4 5 6
104787-00X00
3) Removal of load check valve poppets and plugs

Remove the load check valve poppets and plugs before removing the tie rods and disassembling the valve housing.
The poppets and plugs to be removed are as follows:
Valve sections Parts descriptions
Dump cylinder Plug, Spring, Poppet
Inlet Plug assembly
4) Disassembly of valve housing

Loosen the tie rod nuts (hexagon size 8 mm) shown in the figure on p.6-6-1 to remove the tie rods and disassemble
the valve housings of the dump cylinder section and the inlet section..
Remove the O-ring on the mating surface of the inlet section.
6-7-6 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5. Cleaning
Clean all disassembled parts completely with mineral oil. Blow compressed air to dry them and place each part on
clean paper or cloth for checking.
6. Checking
Perform checks to ensure that there are no burrs, scratches, notches and other defects on all surfaces of each part.
(1) Check that the seal groove surface of the valve housing is smooth and free from dust, dent, and rust.
(2) If there is a dent or crack on the check seat surface of the valve housing, remove it by lapping. It must be per-
formed carefully to avoid any lapping agent from remaining in the valve.
(3) All sliding parts and engagement parts must move lightly. All grooves and passages must be free of foreign
material.
(4) If the springs are damaged or deformed, replace them with new ones.
(5) If the relief valve does not function well, perform checks according to the information on p.6-6-10.
(6) Replace all O-rings.
7. Reassembly
At the time of reassembly, the following care must be taken for the handling of O-rings (or seals):
(1) The O-rings must be free from molding defects and damages caused at the time of handling.
(2) The O-rings and their applied parts must be sufficiently lubricated with grease or hydraulic oil.
(3) The O-rings must not be stretched to the extent that they are permanently deformed.
(4) The O-rings must not be rolled over at the time of installation. Twisted O-rings are difficult to untwist naturally and
may cause oil leaks.
1) Reassembly of valve housing

Install the poppet, spring and plugs in each section as shown below:
Dump cylinder Plug, Spring, Poppet 7
Inlet Plug assembly
Reinstall the O-ring onto the mating surface of the inlet section.
Reinstall the tie rods on the valve housings and tighten the tie rod nuts (hexagon size: 8 mm) to the specified torque.
Tie rod nut tightening torque: 19.5 to 21.7 ft•lbf (26.5 to 29.4 N•m)
6-7-7 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Reassembly of spool sections

(1) Installing the spool to the dump cylinder section
Pinch the spring 4 between the spring seats 3 and 5, install the spool 2 to the valve housing 1 in the same direc-
tion prior to disassembly, install the cap 6 with the O-ring 7 with the socket head bolt 8 (hexagon size 5 mm).
Install the cap 6 on the opposite side in the same way.
Socket head screw tightening torque : 5.4 to 7.2 ft•lbf (7.3 to 10.0 N•m)
(2) Installing the spool to the inlet section

Install the O-ring 3 and washer 4 in the seal groove of the housing 1 and hold the seal plate 5 with tightening the pan
head screws 6 to the specified torque. From the seal groove on the other side, install the spool 2 to the valve hous-
ing 1 in the same direction prior to disassembly according to the ID groove on the spool 2. Install the O-ring 3 and
washer 4 onto the seal groove and hold the seal plate 5 with tightening the pan head screws 6 to the specified
torque.
Pan head screw tightening torque: 1.9 to 2.1 ft•lbf (2.5 to 2.9N•m)
3) Installing the load check valve and other parts

Install the load check valve, spring, and plugs (be sure to install the O-ring) as shown below:
Plug, Spring, Poppet
Dump cylinder Plug (hexagon size:14mm) tightening torque: 21.0 to 22.0 ft?lbf
(28.4 to 30.4 N•m)
Inlet Plug assembly
4) Installing the accessory

Reinstall the relief valve assembly on the inlet section.
Relief valve (hexagon size: 24 mm) tightening torque: 50.9 to 57.5 ft•lbf (69 to 78 N•m)
Tighten the cap 1 not the plug 2. (Refer to the figure on the next page)
Note:
• Insert the spool slowly and straight into the spool bore of the housing. After inserting the spool, slide the spool by
hand. If there is reluctance or rugged movement, a spool operation failure may occur.
• After the assembly is finished, recheck the forgotten parts for assembly. If correct tightening is failed, oil leaks may
result from the loosened parts. The instructions for tightening torque are wet values (the conditions in which
hydraulic oil is adhered).
6-7-8 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
8. Servicing Procedure for Relief Valve

1) Disassembly and reassembly
The relief valve is, in principle, replaced with the assembly. Do not disassemble it unless there is abnormality.
2) Main relief valve
9 5 8 12
3 4 13 1 10 11 6 2 7
038261-00X01
(1) Disassembly
Remove the plug 2, sleeve 3, main poppet 4, and spring 9. Loosen the adjuster kit 7 to remove the pilot poppet 6
and spring 8. Do not disassemble the pilot seat 5, because it has caulking at the plug tip.
Note:
Line up all parts removed on a clean place.
(2) Cleaning and inspection

Clean all parts completely with mineral oil. Blow compressed air to dry them and then check each part.
• The seat surface of each poppet and plug must be free from any defects and have an even contact surface.
• The main poppet 4 and sleeve 3 must slide lightly and smoothly.
• The outer circumference of main poppet and the inner circumference of sleeve must be free of scratches.
• The spring 8 must be free from breakage, deformation, and wear.
• The cut holes in the main poppet 4 and pilot seat 5 must not be filled with foreign material.
• The O-rings and backup rings must be replaced with new ones.
If a minor damage is found during the above checks, remove it by lapping. If an abnormal part is found, replace the
relief valve assembly with a new one.
6-7-9 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(3) Reassembly
[1] Install main poppet 4 and spring 9 into the sleeve 3 and
Item Description
put the sleeve 3 over the pilot seat 5 with he O-ring 10
1 Cap
and the back-up ring 11.
2 Plug
[2] Install the O-rings 13 and 12 onto the cap 1 and the plug 3 Sleeve
2 respectively. 4 Poppet
[3] Install the pilot poppet 6 and spring 8 into the plug 2 and 5 Piston
temporarily assemble the adjuster kit b with an O-ring to 6 Pilot poppet
install them on the cap 1. 7 Spring
8 Spring
Plug 2 (hexagon size: 24 mm) tightening torque : 9 Adjuster kit
36.2 to 39.7 ft•lbf (49 to 54 N•m) 10 O-ring
11 Back-up ring
[4] Tighten the cap 1 to the specified torque to install the 12 O-ring
relief valve on the housing. 13 Back-up ring
14 O-ring
Cap 1 (hexagon size: 24 mm) tightening torque : 15 O-ring
50.9 to 57.5 ft•lbf (69 to 78 N•m)
[5] Adjust the set pressure in accordance with the instruction on the following page.
Do not reuse the O-rings and back-up ring but replace them with new ones.
6-7-10 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Set pressure adjustment

(1) Structure
Locknut
Adjust screw
068841-00EN00
(2) Set pressure adjustment procedures

Install a correctly adjusted pressure gauge in the inlet circuit (on the pump port side) and adjust the pressure as fol-
lows:
[1] Loosen the locknut.
[2] Run the engine at rated speed. (To ensure the speed is sufficient not to stall the engine when the set pressure
load is applied to the hydraulic oil pump.)
[3] Move the spool of the dump cylinder section to its stroke end and read the pressure gauge.
[4] Turn the adjuster screw clockwise until the specified set pressure is obtained.
(Reference data: pressure increment per turn of adjuster screw)
Pressure increment per turn 2567 psi (17.7 MPa)
[5] After confirmation of the specified set pressure, hold the adjuster screw to tighten the locknut to the specified
torque.
Locknut tightening torque : 20.3 to 23.1 ft•lbf (27 to 32 N•m)
[6] Raise the circuit pressure again to reconfirm if it is correct set pressure.
4) Installation
Pay the following attention when installing the control valve:
• Take care to give the control valve no stress by the pipings.
• Tighten all the installation screws evenly and thoroughly.
• The valve must note that seals might be damaged by the excessive heat and the spatter when the welding work is
done soon in the vicinity.
• Do not remove the cover or plug of each port until the time of piping for the going into it prevention of dust or for-
eign material.
• It is confirmed that pressure is gradually raised after it is confirmed that the valve array is normal, and the hydraulic
fluid is clean (a low idol operates the working machine the inching), and there is no external leakage.
5) Test running
• It is confirmed that pressure is gradually raised after it is confirmed that the valve array is normal, and the hydraulic
fluid is clean (a low idol operates the working machine the inching), and there is no external leakage.
• Do not raise the relief valve more than the specified set pressure.
• Work really after warming up enough.
Especially, note the following respects to prevent the spool stick by the thermal shock when the temperature of the
hydraulic oil and that of the valve are low for start.
• At warming up, do not continuously operate the relief valve suddenly but operate it so that the hydraulic oil in the
dump cylinder circuit may circulate and raise each part uniformly.
• Do not do inching operation suddenly at the low temperature because it may cause partial generation of heat
caused by each part orifices.
6-7-11 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
9. Troubleshooting
1) All-over control valve assembly
Symptoms Possible causes Remedies
1. Spool does not stroke (1) Oil temperature is abnormally high Remove oil flow resistance in pipings
(2) Oil contamination Renew oil and flush all circuits in the system
(3) Over torque of piping connectors Check for torque
(4) Valve housing is warped due to Loosen valve holding screws to check for
improper installation improper installation
(5) System pressure is too high Measure pressures of port P and cylinder
ports
(6) Spool bends Renew section assembly.
(7) Return spring is damaged Renew damaged parts
(8) Spring or cap is out of position Loosen cap and retighten it after realignment
(9) Temperature distribution in valve is not Warm up entire system circuit
uniform
(10)Dust clogs in valve Flush valve to remove dust
(11)Inadequate pilot oil pressure Inspect pilot oil valve and relief set pressure
of pilot oil circuit
2. Load cannot be retained (1) Oil leak from cylinder Check for cylinder seals
(2) Internal oil leak through clearance Check for damage on spool surface
between spool and housing
3. In beginning of lever movement (1) Load check valve incompletely blocks Disassemble and flush check valve
to dump a vessel, it lowers circuit due to dust or foreign material
against operator's will (2) Check valve poppet or valve seat sur- Renew poppet or lap poppet and valve seat
face is damaged surface
6-7-12 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2) Relief valve
1. Pressure does not raise at all (1) Oil escapes because main poppet, Renew relief valve assembly
sleeve or pilot poppet sticks, otherwise
valve seat incompletely blocks circuit
due to dust or foreign material
2. Relief set pressure is unstable (1) Pilot poppet seat surface is damaged
(2) Piston or main poppet sticks
3. Relief set pressure is out of (1) Seat surface is worn due to dust or for-
specification eign material
(2) Locknut and adjuster screw are loos- Reset pressure and retighten locknut to
ened specified torque
4. Oil leak (1) Relief valve seat surface is damaged Renew relief valve assembly
(2) Related parts stick due to dust or for-
eign material
(3) O-ring is damaged Renew adjuster or related O-ring
3) All-over hydraulic system

1. System malfunctions or does (1) Pump damage Inspect system set pressure or renew pump
not work at all assembly
(2) Relief valve malfunction Renew relief valve assembly
(3) Cylinder malfunction Repair or renew cylinder
(4) Pump load pressure is excessive Inspect system set pressure
(5) Valve housing cracks Renew valve assembly
(6) Spool does not fully stroke Inspect spool movement
(7) Oil level in the oil tank is too low Replenish hydraulic oil
(8) Filter clogging Clean or renew filter
(9) Oil passage in piping is restricted Inspect pipings
6-7-13 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-8 Pilot Valve
6-8-1 Wagon control lever (pilot valve R)
(1) Three-side flaps wagon type

1. Outline
This valve is a remote control valve with a pressure reducing system. It consists of two pressure-reducing valves to
regulate the secondary side pressure and control system for the valves. The secondary side pressure is controlled
by the blade lever movement and it is proportional to the lever stroke.
P T
T
T
1 2
P
Hydraulic schematic symbol
P
1 2
1 2
015185-00E
Primary side pressure Maximum 1000 PSI (6.9 MPa)

Secondary side pressure 0 to 420 PSI <Maximum control pressure> (0 to 2.9 MPa)
Back pressure limit 42 PSI (0.29 MPa)
Rated oil flow 2.64 GPM (10 L/m)
6-8-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2. Operation Theory
Hydraulic schematic example of a typical use of the valve is shown below to explain the operation theory.
5
6
3
1 2
2
4
1 Control pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot oil pump 4 Main control valve 6 Hydraulic cylinder
Hydraulic circuit schematic 015186-00E
1) Control Lever in Neutral

Spool 11 is pushed up by spring 7 via spring seat 10 and kept in
16 4
the neutral position shown to the right. Accordingly, spool 11
connects the secondary side ports 1 and 2 to the return circuit
port T only so that the secondary side pressure is the same as
that of the return circuit port T.
10
8
2) Control Lever Operated 7 T
When the control lever is operated to move cam 4 in the direc- 15
tion of an arrow, push rod 16 of the port 1 side is pushed down 9 P
and spool 11 is moved downward via spring seat 10, spring 8,

11
shim 15 and washer 9. The port P connects to the port 1 and oil 1 2 015187-00X
discharged by the pilot oil pump flows to the port 1 to develop

pressure in the circuit.
When the lever is moved to raise the oil pressure in the port 1
circuit till the designed force of spring 8, the pressure spool 11
receives and the spring force balance, consequently keep the
pressure in the port 1 circuit constant.
Spool of the port 2 side holds its neutral condition and pilot oil
from main control valve returns to reservoir through the return
circuit port T.
6-8-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3. Cross Section Drawing and Component Parts
1 2
3 6
A 4 5
16
18
12
19
20
17
10
8 T
7
15
P
9
14
13
1 2
11 A
Cross section A-A
21 015188-00E
No Description Q’ty No Description Q’ty

1 Rubber boot 1 12 Allen head cap screw 2
2 Allen head screw 1 13 O-ring 1
3 Steel ball 2 14 Plug 1
4 Cam 1 15 Shim 2
5 Bushing 2 16 Push rod 2
6 Cam shaft 1 17 O-ring 2
7 Spring (Return) 2 18 Gasket 2
8 Spring (Secondary side pressure regulating) 2 19 Plug 2
9 Washer 2 20 Cover 1
10 Spring seat 2 21 Casing 1
11 Spool 2
6-8-3 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4. Special Tool
Jig to remove bushing
Center holes less than Ф2 mm (Unit: mm)
for milling cutters are allowable.
10
8
30
20 2
30
015189-00E
6-8-4 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM

1) Precautions
(1) Since the parts of this equipment are generally precision-made for tight clearances, be sure to perform disas-
sembly and reassembly in a clean place that is free from dust.
(2) Prepare clean tools and treated oil.
(3) First, clean the external surface of the removed valve body.
(4) Before beginning disassembly, review the drawings of the internal structure and prepare the required parts
(5) In principle, replace the removed O-rings with new ones.
(6) Handling of O-rings
[1] Lubricate the O-rings and the O-ring fitting seats with clean grease or hydraulic oil.
[2] The O-rings may not be damaged in handing or distorted by heat
[3] Do not extend any O-rings with such great force as to permanently deform them.
[4] O-ring should be installed to the plug with a jig.
2) Tools
Tool Q'ty Size Remarks

Allen key 1 6
Hammer 1 -
Bushing removing jig 1 - Refer to 4. Special Tool
Screwdriver 1 -
• Kerosene • Grease • Vapor phase corrosion inhibitor
Others
• Loctite 241 • Round bar (O.D.:0.28 in.(7 mm) or less)
6-8-5 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Disassembly
Procedure
(1) Plug each port and clean the valve by kerosene.
(2) Fix the valve on a vise with using buffing plates.

1
(3) Pull up rubber boot 1 to remove it from cover 20.
20
015190-00X
(4) Loosen allen head screw 2.
Note : 2
Much torque is required to loosen it because screw lock agent
is applied on its thread.
015191-00X
(5) Punch out cam shaft 6 by using a round bar and hammer.
Round bar 6
015192-00E
(6) Remove cam 4.
Notes :
• Cam 4 and steel ball 3 are inseparable.
• Put marks on cam 4 and cover 20 to reassemble them as
20
they were. 4
3
015193-00X
6-8-6 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(7) Remove two allen head cap screws 12.
12 12
015194-00X
(8) Remove cover 20.
Notes : 20
• Put marks on casing 21 and cover 20 to reassemble them
as they were.
• When removing, take care of push rod 16 and plug 19 for
popping out by spring 7 (plug 19 may remain in casing 21
but it must be temporary due to friction of O-ring 17).
16
21
015196-00X
19
17
015195-00X
(9) Remove plug 19 with push rod 16, gasket 18 and O-ring
17.
Note :
Put marks on plug 19 and casing 16
16
21 to reassemble them as they
were. 19
18
17
19
17
015197-00X 015198-00X
6-8-7 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(10) Remove pressure reducing valve assembly and spring 7
from casing 21.
Note : Pressure reducing valve assembly

Do not mix up two assemblies to reinstall them as they were.
21
015199-00E
015200-00X
(11) Put cover 20 on a flat surface and lightly strike bushing 5

by using a special tool and hammer to remove it.
Special tool
5 20
015201-00E
(12) If disassembling of pressure reducing valve assembly is

required, press spring seat 10 to bow spring 8, laterally
displace spring seat 10 and remove it from spool 11
through larger opening of it. 10
Notes :
• Be careful not to damage spool surface.
• Do not press down spring seat 10 more than 0.16 in.(4
mm).
• Always keep pressure reducing valve as assembly.
015202-00X
6-8-8 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(13) Separate spool 11, spring 8, shim 15 and washer 9.
8
Notes :
• Always keep pressure reducing valve as assembly.
• Washer 9 is used for presetting of spring 8. Its thickness dif-
fers assembly by assembly and some may have no washer
9.
9,15
11
015203-00X
(14) Remove push rod 16 from plug 19.
19
16
015204-00X
(15) Remove gasket 18 from plug 19.
Notes :
• Use appropriate tool to remove gasket 18. 18
• Take care not to damage inner surface of plug 19.
19
015205-00X
(16) Remove O-ring 17 from plug 19.
17
015206-00X
6-8-9 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4) Reassembly
Procedure
(1) Install washer 9, shim 15 and spring 8 on spool 11 in
order. 8
Note :
Washer 9 is used for presetting of spring 8. Its thickness dif-
fers assembly by assembly and some may have no washer 9.
9,15
11
10
015207-00X
(2) Install spring seat on spool 11 through larger opening of it,

press spring seat to bow spring and laterally displace
spring seat to fix it on spool 11.
10
Notes :
• Be careful not to damage spool surface.
• Do not press down spring seat 10 more than 0.16 in.(4
mm).
015202-00X
(3) Fix casing 21 on a vise with using buffing plates and

install spring 7 on casing 21.
Note :
Reinstall the part to the original position before disassembling.
7
21
015209-00X
6-8-10 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(4) Install pressure reducing valve sub-assembled at the
steps (1) and (2) in casing 21.
Notes :
• Reinstall the part to the original position before disassem-
bling. 21
• When installing pressure reducing valve, be careful not to
excessively press the bottom of spool 11 to sharp edge of
casing 21.
Take care not to damage the

valve by sharp edge of casing.
015211-00X
015210-00E
(5) Install O-ring 17 on plug 19.
17
015212-00X
(6) Install gasket 18 on plug 19.
Notes :
• Take care of installation direction of gasket 18.
18
• Coat grease on gasket 18 before installing.
Gasket 19
015213-00E 015214-00X
6-8-11 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(7) Install push rod 16 on plug 19.
Notes :
• Coat hydraulic oil on push rod 16 before installing.
• Do not strongly press push rod 16 or lip of gasket 18 may
be damaged.
16 19
015215-00X
(8) Install push rod sub-assembled at the steps (5), (6) and
(7) in casing 21.
21
015216-00X
(9) Put cover 20 on a flat surface and lightly strike bushing 5

by using a special tool and hammer to fit it.
Note :
Be careful for the end of bushing 5 not to project from the Special tool
inside of cover 20.
5 20
015201-00E
(10) Put cover 20 on casing 21.

20
Note :
Reinstall the part to the original position before disassembling.
21
015217-00X
6-8-12 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(11) Tighten two allen head cap screws 12 to 6.42 to 6.56 ft•lb
(8.7 to 8.9 N•m).
12 12
015218-00X
(12) Install cam 4 on cover 20.
Note :
Reinstall the part to the original position before disassembling. 4
20
015219-00X
(13) Install cam shaft 6 with pressing cam 4 down.
Note :
Coat grease on cam shaft 6 before installing it. 6
015220-00X
(14) Apply Loctite 241 or equivalent of it on allen head screw

2.
015221-00X
6-8-13 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(15) Tighten allen head screw 2 to 4.4 to 5.8 ft•lb (5.9 to 7.9
N•m).
015222-00X
(16) Move cam 4 to coat grease on the top of push rod 16.
Note : 4
Use soft spatula or something so as for surfaces of push rod
16 and plug 14 not to damage.
16
015223-00X
(17) Put rubber boot 1 over cam 4 and then fit its bottom end
into a groove of cover 20.
1
Notes :
• Spray anti-rusting oil on all parts in rubber boot 1 before
installing it. 4
• Securely fit rubber boot 1 into a groove of cover 20, or its
dust and waterproof performances go down.
20
015224-00X
20
015225-00X
6-8-14 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5) Servicing Instruction
All parts disassembled should be rinsed by cleaning oil. According to the criteria below, repair or replace with a new
one as required.
Notes :
• It is preferable that seals like a gasket and O-ring are to be replaced with new ones every time once removed but
can be reused unless it has damage.
• Single service parts supply of spool 11 or casing 21 is disapproved because both parts fitting is controlled at the
factory.
No. Symptoms Criteria Corrections

1 Low secondary side • Low primary side pressure • Obtain proper primary side pressure
pressure • Spring 8 broken or weakened • Replace spring 8
• Excessive clearance between spool 11 and • Replace complete assembly
casing 21
• Too much play in control lever movement • Replace lever
2 Unstable secondary side • Sticky friction part • Repair
pressure • Return line pressure fluctuation • Direct return to reservoir
• Air in the circuit • Purge air
3 High secondary side • High return line pressure • Direct return to reservoir
pressure • Sticky friction part • Repair
6-8-15 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
(2) Swing wagon type

1. Overview
The pilot valve serves to operate the spools of the control valve by outputting pilot pressure corresponding to the
stroke of the control lever from the corresponding output port.
• Structure • Specifications
Primary pressure Maximum pressure:
1001 PSI (6.9MPa)
Secondary pressure Maximum control pressure:
12 0 to 638 PSI (0 to 4.4 MPa)
Allowable Maximum: 44 PSI (0.3 MPa)
5
back pressure
6
Rated flow 15.8 Qts./min (15 L/min)
4
Operating angle ±19, ±25
(For independent operation)
Mass 3.5 lbs. (1.6 kg)
• Parts
No. Part No. Part
1 Casing 7 Spring seat
Spring
2 Plate 8
2 (Secondary pressure)
3
3 Plug 9 Spring (Return)
7
4 Joint 10 Spool
8
5 Disc 11 Washer 2
11 9 Adjusting nut
6 Push rod 12
10 (Lever connection)
A 104868-00X00
• Port layout
P T
3 2
P
1 3 2 4
051482-00X00
Hydraulic symbols
T P: Port P (from pilot pump)
T: Port T (to tank)
1: Port 1
4 1 2: Port 2
3: Port 3
View from side A 051481-00EN00
4: Port 4
6-8-16 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
2. Structure
The pilot valve consists of casing 1 with vertical holes and 12
pressure reducing valve assemblies installed therein. The
pressure reducing valve assembly comprises spool 10, 4
spring (secondary pressure) 8, spring (return) 9, spring seat
7 and washer 2 11. Spring (secondary pressure) 8 has been 5
set so that the specified secondary pressure [73 to 145 PSI
6
(0.5 to 1 MPa)] is achieved. Spool 10 is pressed against
2 7
push rod 6 by spring (return) 9. When the control lever is
tilted, push rod 6 is pushed down and in turn spring seat 7 is
moved down; accordingly, the setting of spring (secondary
3
pressure) 8 is changed. Casing 1 has six ports: port P (inlet 8
1
port), port T (outlet port) and four output ports 1, 2, 3 and 4 9
from which secondary pressure is delivered. 11
10
A 051480-00X00
3. Function
The function of spool 10 is to switch between an oil passage
through which the pilot pressure fed to port P from the
hydraulic pump is led into output ports (1, 2, 3 and/or 4) and
an oil passage through which the pilot pressure at output
port(s) is led into port T. Spring (secondary pressure) 8 acts
on this spool 10 to determine the output pressure. Push rod
6 is slidably installed in plug 3 to change the amount that
spring (secondary pressure) 8 is compressed. Spring
(return) 9 acts on casing 1 and spring seat 7 to return push
rod 6 to the point of zero displacement, regardless of the
output pressure, thereby ensuring that spool 10 returns to
the neutral position. In addition, it serves as a reaction
spring to give an operation feeling to the operator so that an
appropriate operating force is applied.
6-8-17 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
1) When the control lever is in neutral
The force of spring (secondary pressure) 8 that determines
the output pressure of the pilot valve does not act on spool
10. Therefore, spool 10 is pushed up by spring (return) 9
and output ports 2 and 4 and port T are connected. Thus,
the output pressure is equal to the pressure in the hydraulic
oil tank.
7
8 T
9
P
10
Ports 2 and 4
051483-00EN00
2) When the control lever is tilted

When the control lever is tilted and push rod 6 is pushed
down, spring seat 7 and spool 10 is moved down. There-
fore, port P and output ports 2 and 4 are connected and the 6
oil fed from the pilot pump flows into output ports 2 and 4,
thus generating pressure.
7
T
10
Ports 2 and 4
051484-00EN00
3) When the control lever is held in a tilted position

When the pressures at output ports 2 and 4 have risen to
the value equivalent to the force of spring (secondary pres-
sure) 8 that has been set by tilting the control lever, the oil
pressure and the force of spring (secondary pressure) 8
come into balance. If the pressures at output ports 2 and 4
exceed the set pressure, the oil passage between output
ports 2 and 4 and port P is blocked and that between output 8
T
ports 2 and 4 and port T is opened. If the pressures at out-
put ports 2 and 4 become lower than the set pressure, the Port T
P
oil passage between output ports 2 and 4 and port P is Port P
opened and that between output ports 2 and 4 and port T is
blocked. In this way, the secondary pressure is maintained
at a constant value. Ports 2 and 4
051485-00EN00
6-8-18 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5. Cross-sectional View and Component Parts
14
12
13
15
5
6
4
2
7
11
Pressure reducing
valve assembly
10 9
3
051486-00EN00
No. Part No. Part

1 Casing 9 Washer 2
2 Plate 10 Spring (Return)
3 Spool 11 Spring (Secondary pressure)
4 Plug 12 Joint
5 Push rod 13 Disc
6 Seal 14 Adjusting nut
7 O-ring 15 Rubber boot
8 Spring seat
6-8-19 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6. Special Jig
Unit: mm
• Jig body • Bush (Quantity: 2)
R13
15.5 ±0.1 6.5 ±0.1
0.5×15°
1 Material:
5
R4
0.
R
ĭ SCM415N Carburizing .5
5.
C
8
ĭ and hardening
12.5
9.5
23.5 (Width
across flats) 2 Material: S45C
C
0.
5
11.6 ±0.1
13
ĭ
Detailed view of bush
Material: SCM415N Carburizing and hardening
051488-00EN00
Surface Heat Treatment

Method Gas carburizing and hardening

54
50

Surface hardness HRC 56 to 60

Effective case hardness Hmv 550 or higher
25
Effective case depth 0.5 to 0.8 mm

Hardened area Whole surface
ĭ +0.2
0
ĭ +ROH+ +0.013

0
6KDIWQ +0.028
+0.015
ĭ
Bush
Cross-section A-A
ĭ +0.2
0
Detailed view of jig body

A A
Components 1 and 2 to be press-fit together 051487-00EN00
Joint with jig installed thereon

051489-00EN00
6-8-20 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM

• Since the parts of hydraulic equipment are precision-made for tight clearances, be sure to perform disassembly
and reassembly in a clean area that is free from dust.
• Prepare clean tools and cleaning oil and handle them carefully.
• First clean the external surfaces of removed assemblies.
• Before beginning disassembly, review the drawings of the internal construction and prepare necessary parts
• As a general rule, replace the seals and O-rings removed during disassembly with new ones. As some replace-
ment parts are available only as subassemblies, see the parts catalog to prepare necessary subassemblies in
advance.
• Lubricate O-rings and O-ring seats with clean grease or hydraulic oil.
• O-rings may not be damaged in handling or distorted by heat.
• Do not permanently deform the O-rings.
• Avoid rolling O-rings when fitting them.
A distorted O-ring may not return to its original shape, and therefore, may cause oil leaks.
• Before beginning reassembly, make sure that there is no cleaning oil or hydraulic oil on the outer side surface of
the O-ring groove in the mating face of each part. If reassembly is performed without removing such oil, it may be
mistaken for oil leaks during operation.
2) Tools required for Disassembly and Reassembly
Tool Quantity Nominal Size Remarks

1 22
Wrench
1 32
Small flathead screwdriver 1 -
See the drawing of
Special jig 1 -
the special jig.
• White kerosene • Oilstone
Others • Heat-resistance grease • Vapor-phase corrosion inhibitor
• Sandpaper (#1000 and #2000)
6-8-21 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Disassembly
Procedure
(1) Clean the pilot valve using white kerosene.
(2) Hold the pilot valve in a vice using a copper plate (or a
lead plate).
(3) Remove rubber boot 15.
Notes:
Put a plug in each port.
Be careful not to damage rubber boot 15.
15
051490-00X00
(4) Put a wrench on adjusting nut 14 and disc 13 respectively,

and loosen and remove them.
14
13
051491-00X00
(5) Using a jig, loosen joint 12 by turning it counterclockwise.
Note:
If return spring 10 is strong, plate 2, plugs 4 and push rods 5 12
will be pushed up when joint 12 is loosened. Be careful when jig
removing joint 12 because they may jump out.
051492-00EN00
(6) Remove plate 2.
051493-00X00
6-8-22 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(7) If return spring 10 is weak, plugs 4 will be left in casing 1
due to the sliding resistance of the O-ring. In such cases,
use a flathead screwdriver to pull out plugs 4.
Notes:
• Place the tip of the flathead screwdriver in the groove on the
outside surface of the plug and pull out plug 4, being careful
not to damage it due to uneven loading.
• Be careful when removing plug 4 because it may jump out
due to return spring 10.
4
1 051494-00X00
(8) Remove push rods 5, plugs 4, pressure reducing valve

assemblies and return springs 10 from casing 1.
Note:
5
Be sure to record the parts to be installed in the individual
holes in the casing. 4 Pressure reducing
valve assembly
10
1
051495-00EN00
(9) To disassemble the pressure reducing valve, while com-

pressing spring 11 with spring seat 8, move spring seat 8
to the side and remove it from spool 3 through the larger
hole. 8
Notes:
• Be careful not to damage the surface of spool 3.
• Do not depress spring seat 8 more than 0.24 in. (6 mm).
• Store all the removed parts together until they are reassem-
bled into an assembly.
11 3
051496-00X00
(10) Separate spool 3, spring seat 8, spring 11 and washer 2

9 from each other
3 8
9 11
051497-00X00
6-8-23 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
5 4
051498-00X00
(12) Remove O-ring 7 and seal 6 from plug 4.
Note:
Use a small flathead screwdriver or a similar tool to remove
seal 6.
7 4 6 4
051499-00X00
(13) Cleaning of each part removed

1) Clean parts with white kerosene in a container (Rough
cleaning).
2) Put parts in another container with white kerosene and
clean them well to the inside while turning the parts
slowly (Finish cleaning). Wipe off white kerosene
adhered to each part with a clean cloth.
Note:
• Cleaning dirty parts in kerosene may damage parts.
Soak parts in kerosene until dirt and dirty oil becomes loose
enough.
• Contaminated white kerosene may damage parts. Always
use clean white kerosene.
• Do not dry parts with compressed air blow. A part may be
damaged and rusted by dirt and moisture in air.
6-8-24 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(14) Rust prevention
Coat anti-rust agent on each part removed.
Note:
Rust is generated when a part is left with cleaning it and such
a part may not show enough functions after reassembling.
6-8-25 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4) Reassembly
Procedure
(1) Install washer 2 9, spring 11 and spring seat 8 in this order
onto spool 3.
3 8
9 11
051497-00X00
(2) Depress spring seat 8 and, while compressing spring 11,

move spring seat 8 to the side to pass spool 3 through the
larger hole in it and install it on spool 3.
8
Note:
Do not depress spring seat 8 more than 0.24 in. (6 mm).
11
051500-00X00
(3) Install return springs 10 into holes in casing 1.

1
(4) Install pressure reducing valve assemblies into holes in
casing 1.
Note:
Be sure to install them in the same holes in casing 1 they
were removed from.
Pressure reducing 10
valve assembly
051501-00EN00
(5) Install O-ring 7 onto plug 4.
051502-00X00
6-8-26 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(6) Install seal 6 into plug 4.
Note:
Install seal 6 with its lip facing the direction as shown in the
figure below. 4
Plug
Seal
7 6
051504-00EN00
051503-00X00
(7) Install push rod 5 into plug 4.
Note:
Apply hydraulic oil to the surface of push rod 5.
4 5
Apply
Push rod hydraulic oil.
051506-00EN00
051505-00X00
(8) Install plug assemblies into holes in casing 1.
• If return spring 10 is weak, the plug assembly will stay in

place due to the sliding resistance of O-ring 7.
• If return spring 10 is strong, use plate 2 to simultaneously
install four plug assemblies into the holes in casing 1 and
temporarily secure them with joint 12.
1
Plug assembly
051507-00EN00
(9) Install plate 2 and joint 12.
Notes:
• Be careful not to damage the holes in casing 1 by the con-
tact of spool 3 during installation. 12
• Be careful of the plug assemblies and plate 2 because they
may jump out.
051508-00X00
6-8-27 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(10) Using a jig, tighten joint 12 to casing 1 to the specified
torque.
Tightening torque:
32.6 to 36.9 ft•lbf (44.2 to 50.0 N•m)
Adhesive: Loctite 262
Jig
1
051509-00EN00
(11) Install disc 13 onto joint 12.
Notes:
12
• Screw disc 13 onto joint 12 to the point it uniformly contacts
four push rods 5.
• Screwing disc 13 too much may generate secondary pres-
sure even when the control lever is in neutral, resulting in
malfunctions of the machine. To avoid this, be careful not to
screw disc 13 beyond the specified point.
13
051510-00X00
(12) Install adjusting nut 14, put a wrench on disc 13 to hold it

and tighten adjusting nut 14 to the specified torque.
Tightening torque:
47.0 to 54.2 ft•lbf (63.7 to 73.5 N•m) 14
Note:
Make sure that disc 13 is not moved during the tightening of
the nut.
13
051511-00X00
(13) Apply grease to the rotating portion of joint 12 and the

top of push rod 5.
12
5
051512-00X00
6-8-28 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(14) Install rubber boot 15.
Note:
15
051513-00X00
6-8-29 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Notes:
As a general rule, seals such as O-rings should be replaced each time the pilot valve is disassembled.
Because casing 1 and spool 3 are fitted to each other, the spool alone may not be replaced.
No. Inspection Item Criteria Remarks

The pilot valve assembly must be replaced if the Conditions:
quantity of oil leakage exceeds: Primary pressure:
1 Quantity of oil leakage
In neutral: 61 in3 /min (1000 cc/min); or 426 PSI (2.94 MPa)
During operation: 122 in3 /min (2000 L/min) Oil viscosity: 23 mm2/s
The pilot valve assembly must be replaced if the The quantity of oil leakage caused due to the
amount of wear of the sliding portion is 0.00039 worn spool as stated on the left is estimated
2 Spool
in. (10 μm) or more compared to the non-sliding to be almost equivalent to the leakage quan-
portion. tity stated above.
3 Push rod Push rod 5 must be replaced if the amount of wear of its top exceeds 0.039 in. (1 mm).
Disc 13 or joint 12 must be replaced if a play of If the play has been created due to loosened
4 Play in operating part
0.079 in. (2 mm) or more is created in the part. parts, adjustments must be made.
The pilot valve assembly must be replaced if a
problem such as abnormal sounds, hunting or
5 Operational stability primary pressure drop has occurred and the
problem cannot be solved even by implementing
the corrective measures described below.
9. Troubleshooting
No. Trouble Causes Measures

Secondary pressure • Insufficient primary pressure • Obtain adequate primary pressure.
does not rise. • Spring 11 breakage or fatigue • Replace the spring.
• Excessively large clearance between spool 3 • Replace the pilot valve assembly.
1
and casing 1
• Play in operating part • Disassemble and reassemble the pilot
valve, and replace the operating part.
Unstable secondary • Sliding part is caught by other parts • Make repairs so that the sliding part is not
pressure caught by any other parts.
• Fluctuations in pressure in return passage • Connect the return passage directly to the
2
hydraulic oil tank.
• Air in hydraulic circuit • Move the control lever several times to
release the air from the hydraulic circuit.
Too high secondary • Too high pressure in return passage • Connect the return passage directly to the
pressure hydraulic oil tank.
3
• Sliding part is caught by other parts • Make repairs so that the sliding part is not
caught by any other parts.
6-8-30 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-8-2 Travel lever (pilot valve L)
1. Overview
The pilot valve serves to operate the spools of the control valve by outputting pilot pressure corresponding to the
stroke of the control lever from the corresponding output port.
• Structure • Specifications
Primary pressure Maximum pressure:
1001 PSI (6.9MPa)
Secondary pressure Maximum control pressure:
0 to 638 PSI (0 to 4.4 MPa)
12
Allowable Maximum: 44 PSI (0.3 MPa)
4 back pressure
5 6 Rated flow 15.8 Qts./min (15 L/min)
Operating angle ±19, ±25
2 (For independent operation)
Mass 3.5 lbs. (1.6 kg)
3
7 • Parts
No. Part No. Part
1 Casing 9 Spring (Return)
8 2 Plate 10 Spool
9 Secondary pressure
3 Plug 11
adjusting shim
11
Adjusting nut
10 4 Joint 12
(Lever connection)
1 5 Disc 13 Port plate
14 6 Push rod 14 Plate
15 7 Spring seat 15 Seat
16 15 Spring
8 16 Steel ball
(Secondary pressure)
13
A 104869-00X00
•Port layout
1 P T
T
4
Front of
(1) (2) (3) (4)
operator's seat
1 2 3 4
104871-00X00
Hydraulic symbols
2 P: Port P (from pilot pump)
3 P T: Port T (to tank)
View from arrow A
1: Port 1
104870-00EN00
2: Port 2
3: Port 3
4: Port 4
6-8-31 172663 0BKC2-EN0060
6. HYDRAULIC SYSTEM
2. Structure
The pilot valve consists of casing 1 with vertical holes and 12
pressure reducing valve assemblies installed therein. The 4
pressure reducing valve assembly comprises spool 10, 5 6
spring (secondary pressure) 8, spring (return) 9, spring seat
2
7 and washer 2 11. Spring (secondary pressure) 8 has been
set so that the specified secondary pressure [73 to 145 PSI 3
(0.5 to 1 MPa)] is achieved. Spool 10 is pressed against 7
push rod 6 by spring (return) 9. When the control lever is
tilted, push rod 6 is pushed down and in turn spring seat 7 is
8
moved down; accordingly, the setting of spring (secondary
9
pressure) 8 is changed. Casing 1 has six ports: port P (inlet
port), port T (outlet port) and four output ports 1, 2, 3 and 4 11
from which secondary pressure is delivered. 10
1
14
15
16 15
13
A 104869-00X02
3. Function
The function of spool 10 is to switch between an oil passage
through which the pilot pressure fed to port P from the
hydraulic pump is led into output ports (1, 2, 3 and/or 4) and
an oil passage through which the pilot pressure at output
port(s) is led into port T. Spring (secondary pressure) 8 acts
on this spool 10 to determine the output pressure. Push rod
6 is slidably installed in plug 3 to change the amount that
spring (secondary pressure) 8 is compressed. Spring
(return) 9 acts on casing 1 and spring seat 7 to return push
rod 6 to the point of zero displacement, regardless of the
output pressure, thereby ensuring that spool 10 returns to
the neutral position. In addition, it serves as a reaction
spring to give an operation feeling to the operator so that an
appropriate operating force is applied.
6-8-32 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
1) When the control lever is in neutral
The force of spring (secondary pressure) 8 that determines
the output pressure of the pilot valve does not act on spool
10. Therefore, spool 10 is pushed up by spring (return) 9
and output ports 2 and 4 and port T are connected. Thus,
the output pressure is equal to the pressure in the hydraulic
oil tank.
7
8 T
9
P
10
Ports 2 and 4 109033-00EN00
2) When the control lever is tilted

When the control lever is tilted and push rod 6 is pushed
down, spring seat 7 and spool 10 is moved down. There-
fore, port P and output ports 2 and 4 are connected and the
oil fed from the pilot pump flows into output ports 2 and 4,
thus generating pressure.
6
7
T
10
Ports 2 and 4
109034-00EN00
3) When the control lever is held in a tilted position

When the pressures at output ports 2 and 4 have risen to
the value equivalent to the force of spring (secondary pres-
sure) 8 that has been set by tilting the control lever, the oil
pressure and the force of spring (secondary pressure) 8
come into balance. If the pressures at output ports 2 and 4
exceed the set pressure, the oil passage between output
ports 2 and 4 and port P is blocked and that between output 8
T
ports 2 and 4 and port T is opened. If the pressures at out-
Port T
put ports 2 and 4 become lower than the set pressure, the P
oil passage between output ports 2 and 4 and port P is Port P
opened and that between output ports 2 and 4 and port T is
blocked. In this way, the secondary pressure is maintained
at a constant value. Ports 2 and 4
109035-00EN00
6-8-33 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4) LH Pilot valve with the shuttle valve

When the control lever is in the neutral position, pressure at
the port of secondary pressure is the same as that at the
tank port, and pressure at the port of shuttle valve output
and that at the tank port are the same.When the control
lever is moved from the neutral position, the secondary
pressure increases and pins up the steel ball 16 against the
other secondary pressure port to close it. The pressure of
the shuttle valve output port is the same as that at the sec-
ondary pressure port selected as high pressure port so that
higher secondary pressure is selected and discharged from
outlet port of the shuttle valve.
6-8-34 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5. Cross-sectional View and Component Parts
14
12 15
13
5
6
2
4
8
11
7
10
9
3
22
1
21
17
24
21
23
18
18
19
16 20
104869-00X01
No. Part No. Part

1 Casing 13 Disc
2 Plate 14 Adjusting nut
3 Spool 15 Rubber boot
4 Plug 16 Port plate
5 Push rod 17 Plate
6 Seal 18 Seat
7 O-ring 19 Steel ball
8 Spring seat 20 Hexagon socket head screw
9 Washer 2 21 O-ring
10 Spring (Return) 22 Bush
11 Spring (Secondary pressure) 23 Hexagon socket head screw
12 Joint 24 Plug
6-8-35 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6. Special Jig
Unit: mm
• Jig body • Bush (Quantity: 2)
R13
15.5 ±0.1 6.5 ±0.1
0.5×15°
1 Material:
5
R4
0.
R
ĭ SCM415N Carburizing .5
5.
C
ĭ and hardening 8
12.5
9.5
23.5 (Width
across flats) 2 Material: S45C
C
0.
5
11.6 ±0.1
13
ĭ
Detailed view of bush
Material: SCM415N Carburizing and hardening
051488-00EN00
Surface Heat Treatment

Method Gas carburizing and hardening

54
50

Surface hardness HRC 56 to 60

Effective case hardness Hmv 550 or higher
25
Effective case depth 0.5 to 0.8 mm

Hardened area Whole surface
ĭ +0.2
0
ĭ +ROH+ +0.013

0
6KDIWQ +0.028
+0.015
ĭ
Bush
Cross-section A-A
ĭ +0.2
0
Detailed view of jig body

A A
Components 1 and 2 to be press-fit together 051487-00EN00
Joint with jig installed thereon

051489-00EN00
6-8-36 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM

• Since the parts of hydraulic equipment are precision-made for tight clearances, be sure to perform disassem-
bly and reassembly in a clean area that is free from dust.
• Prepare clean tools and cleaning oil and handle them carefully.
• First clean the external surfaces of removed assemblies.
• Before beginning disassembly, review the drawings of the internal construction and prepare necessary parts
• As a general rule, replace the seals and O-rings removed during disassembly with new ones. As some
replacement parts are available only as subassemblies, see the parts catalog to prepare necessary subassem-
blies in advance.
• Lubricate O-rings and O-ring seats with clean grease or hydraulic oil.
• O-rings may not be damaged in handling or distorted by heat.
• Do not permanently deform the O-rings.
• Avoid rolling O-rings when fitting them.
A distorted O-ring may not return to its original shape, and therefore, may cause oil leaks.
• Before beginning reassembly, make sure that there is no cleaning oil or hydraulic oil on the outer side surface
of the O-ring groove in the mating face of each part. If reassembly is performed without removing such oil, it
may be mistaken for oil leaks during operation.
2) Tools required for Disassembly and Reassembly
Tool Quantity Nominal Size Remarks

1 22
Wrench
1 32
Small flathead screwdriver 1 -
See the drawing of
Special jig 1 -
the special jig.
• White kerosene• Oilstone
Others • Heat-resistance grease• Vapor-phase corrosion inhibitor
• Sandpaper (#1000 and #2000)
6-8-37 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
3) Disassembly
Procedure
(1) Clean the pilot valve using white kerosene.
(2) Hold the pilot valve in a vice using a copper plate (or a
lead plate).
(3) Remove rubber boot 15.
Notes:
Put a plug in each port.
15
051490-00X00
(4) Put a wrench on adjusting nut 14 and disc 13 respectively,

and loosen and remove them.
14
13
051491-00X00
(5) Using a jig, loosen joint 12 by turning it counterclockwise.
Note:
If return spring 10 is strong, plate 2, plugs 4 and push rods 5 12
will be pushed up when joint 12 is loosened. Be careful when jig
removing joint 12 because they may jump out.
051492-00EN00
(6) Remove plate 2.
051493-00X00
6-8-38 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(7) If return spring 10 is weak, plugs 4 will be left in casing 1
due to the sliding resistance of the O-ring. In such cases,
use a flathead screwdriver to pull out plugs 4.
Notes:
• Place the tip of the flathead screwdriver in the groove on the
outside surface of the plug and pull out plug 4, being careful
not to damage it due to uneven loading.
• Be careful when removing plug 4 because it may jump out
due to return spring 10.
4
1 051494-00X00
(8) Remove push rods 5, plugs 4, pressure reducing valve

assemblies and return springs 10 from casing 1.
Note:
5
Be sure to record the parts to be installed in the individual
holes in the casing. 4 Pressure reducing
valve assembly
10
1
051495-00EN00
(9) To disassemble the pressure reducing valve, while com-

pressing spring 11 with spring seat 8, move spring seat 8
to the side and remove it from spool 3 through the larger
hole. 8
Notes:
• Be careful not to damage the surface of spool 3.
• Do not depress spring seat 8 more than 0.24 in. (6 mm).
• Store all the removed parts together until they are reassem-
bled into an assembly.
11 3
051496-00X00
(10) Separate spool 3, spring seat 8, spring 11 and washer 2

9 from each other
3 8
9 11
051497-00X00
6-8-39 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
5 4
051498-00X00
(12) Remove O-ring 7 and seal 6 from plug 4.
Note:
Use a small flathead screwdriver or a similar tool to remove
seal 6.
7 4 6 4
051499-00X00
(13) Cleaning of each part removed

1) Clean parts with white kerosene in a container (Rough
cleaning).
2) Put parts in another container with white kerosene and
clean them well to the inside while turning the parts
slowly (Finish cleaning). Wipe off white kerosene
adhered to each part with a clean cloth.
Note:
• Cleaning dirty parts in kerosene may damage parts. Soak
parts in kerosene until dirt and dirty oil becomes loose
enough.
• Contaminated white kerosene may damage parts. Always
use clean white kerosene.
• Do not dry parts with compressed air blow. A part may be
damaged and rusted by dirt and moisture in air.
6-8-40 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(14) Rust prevention
Note:
Rust is generated when a part is left with cleaning it and such
a part may not show enough functions after reassembling.
6-8-41 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
4) Part of shuttle valve (For LH pilot valve only)
Procedure
(1) Hold casing 1 with vice and impingement plate, and
loosen hexagon socket head screws 20 with hexagon bar
wrench.
Notes:
Plug each port and take care not to damage rubber boot 15.
20
104872-00X00
(2) Remove port plate 16 from plate 17.
16
17
104873-00X00
(3) Remove O-ring 21 from plate 17.
21
17
104874-00X00
(4) Loosen hexagon socket head screws 23 with hexagon bar

wrench.
23
104875-00X00
6-8-42 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(5) Remove plate 17, O-ring 21 and bush 22 from casing 1.
•
17
1
21
22
104876-00X00
(6) Hold port plate 16 with vice and loosen plugs 24 with
hexagon bar wrench to remove it from port plate 16.
24
16
104877-00X00
(7) Pull out seat 18 from port 16.
Notes:
Be careful not to damage steel ball contact surface of seat 18.
18
16
104878-00X00
(8) With magnet, take out steel ball 19 from port plate 16.
Magnet
19
16
104879-00EN00
6-8-43 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
5) Reassembly
Procedure
(1) Install washer 2 9, spring 11 and spring seat 8 in this order
onto spool 3.
3 8
9 11
051497-00X00
(2) Depress spring seat 8 and, while compressing spring 11,

move spring seat 8 to the side to pass spool 3 through the
larger hole in it and install it on spool 3.
8
Note:
Do not depress spring seat 8 more than 0.24 in. (6 mm).
11
051500-00X00
(3) Install return springs 10 into holes in casing 1.

1
(4) Install pressure reducing valve assemblies into holes in
casing 1.
Note:
Be sure to install them in the same holes in casing 1 they
were removed from.
Pressure reducing 10
valve assembly
051501-00EN00
(5) Install O-ring 7 onto plug 4.
051502-00X00
6-8-44 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(6) Install seal 6 into plug 4.
Note:
Install seal 6 with its lip facing the direction as shown in the
figure below. 4
Plug
Seal
7 6
051504-00EN00
051503-00X00
(7) Install push rod 5 into plug 4.
Note:
Apply hydraulic oil to the surface of push rod 5.
4 5
Apply
Push rod hydraulic oil.
051506-00EN00
051505-00X00
(8) Install plug assemblies into holes in casing 1.
• If return spring 10 is weak, the plug assembly will stay in

place due to the sliding resistance of O-ring 7.
• If return spring 10 is strong, use plate 2 to simultaneously
install four plug assemblies into the holes in casing 1 and
temporarily secure them with joint 12.
1
Plug assembly
051507-00EN00
(9) Install plate 2 and joint 12.
Notes:
• Be careful not to damage the holes in casing 1 by the con-
tact of spool 3 during installation. 12
• Be careful of the plug assemblies and plate 2 because they
may jump out.
051508-00X00
6-8-45 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(10) Using a jig, tighten joint 12 to casing 1 to the specified
torque.
Tightening torque:
32.6 to 36.9 ft•lbf (44.2 to 50.0 N•m)
Jig
1
051509-00EN00
(11) Install disc 13 onto joint 12.
Notes:
12
• Screw disc 13 onto joint 12 to the point it uniformly contacts
four push rods 5.
• Screwing disc 13 too much may generate secondary pres-
sure even when the control lever is in neutral, resulting in
malfunctions of the machine. To avoid this, be careful not to
screw disc 13 beyond the specified point.
13
051510-00X00
(12) Install adjusting nut 14, put a wrench on disc 13 to hold it

and tighten adjusting nut 14 to the specified torque.
Tightening torque:
47.0 to 54.2 ft•lbf (63.7 to 73.5 N•m) 14
Note:
Make sure that disc 13 is not moved during the tightening of
the nut.
13
051511-00X00
(13) Apply grease to the rotating portion of joint 12 and the

top of push rod 5.
12
5
051512-00X00
6-8-46 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(14) Install rubber boot 15.
Note:
15
051513-00X00
6-8-47 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6) Part of shuttle valve (For LH pilot valve only)
Procedure
(1) Hold port plate 16 with vice and impingement plate, and
install steel ball 19 into port plate 16.
19
16
104879-00X00
(2) Install seat 18 into port plate 16
Note:
Be careful not to damage steel ball contact surface of seat 18.
18
16
104878-00X00
(3) Install plug 24.
24
104877-00X01
(4) Tighten hexagon socket head screws 23 to specified

torque to install plate 17 on casing 1.
Tightening torque: 14.1 to 16.3 ft•lbf (19.1 to 22.1 N•m)
17
23
1
104875-00X01
6-8-48 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Procedure
(5) Install O-ring 21 on plate 17 and tighten hexagon socket
head screws 20 with seal washers to specified tightening
torque to install port plate 16 on plate 17.
Tightening torque: 14.1 to 16.3 ft•lbf (19.1 to 22.1 N•m)

17
Note:
Whenever hexagon socket head screws 20 are removed and 23
reinstalled, replace seal washers with new ones without fail. 1
104875-00X01
20
104880-00X00
6-8-49 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
Notes:
As a general rule, seals such as O-rings should be replaced each time the pilot valve is disassembled.
Because casing 1 and spool 3 are fitted to each other, the spool alone may not be replaced.
No. Inspection Item Criteria Remarks

The pilot valve assembly must be replaced if the Conditions:
quantity of oil leakage exceeds: Primary pressure:
1 Quantity of oil leakage
In neutral: 61 in3 /min (1000 cc/min); or 426 PSI (2.94 MPa)
During operation: 122 in3 /min (2000 cc/min) Oil viscosity: 23 mm2/s
The pilot valve assembly must be replaced if the The quantity of oil leakage caused due to the
amount of wear of the sliding portion is 0.00039 worn spool as stated on the left is estimated
2 Spool
in. (10 μm) or more compared to the non-sliding to be almost equivalent to the leakage quan-
portion. tity stated above.
3 Push rod Push rod 5 must be replaced if the amount of wear of its top exceeds 0.039 in. (1 mm).
Disc 13 or joint 12 must be replaced if a play of If the play has been created due to loosened
4 Play in operating part
0.079 in. (2 mm) or more is created in the part. parts, adjustments must be made.
The pilot valve assembly must be replaced if a
problem such as abnormal sounds, hunting or
5 Operational stability primary pressure drop has occurred and the
problem cannot be solved even by implementing
the corrective measures described below.
9. Troubleshooting
No. Trouble Causes Measures

Secondary pressure • Insufficient primary pressure • Obtain adequate primary pressure.
does not rise. • Spring 11 breakage or fatigue • Replace the spring.
• Excessively large clearance between spool 3 • Replace the pilot valve assembly.
1
and casing 1
• Play in operating part • Disassemble and reassemble the pilot
valve, and replace the operating part.
Unstable secondary • Sliding part is caught by other parts • Make repairs so that the sliding part is not
pressure caught by any other parts.
• Fluctuations in pressure in return passage • Connect the return passage directly to the
2
hydraulic oil tank.
• Air in hydraulic circuit • Move the control lever several times to
release the air from the hydraulic circuit.
Too high secondary • Too high pressure in return passage • Connect the return passage directly to the
pressure hydraulic oil tank.
3
• Sliding part is caught by other parts • Make repairs so that the sliding part is not
caught by any other parts.
Notes:
Typical troubles, possible causes and measures are shown in the table above but other measures than those in the
table may be required because of other troubles and causes than those in the table.
6-8-50 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-9 Proportional solenoid valve
6-9-1 Single solenoid valve
1) Overview
This valve consist of body 1 and electronic switching valve 2.
2) Main Components
P T
P T
2 1
1 Body
2 Proportional solenoid valve
A
105372-00EN00
1. Specifications
Maximum allowable working pressure 566 PSI (3.9 MPa)

Allowable back pressure 142 psi (0.98 MPa) or less
Maximum flow (per spool) 2.6 GPM (10 L/min)
Amount of leakage (per spool) 2.1 cu.in./min (35 cc) or less
Waterproof property JIS C 0920 IP66 or equivalent
Earthquake resistance JIS D 1601 Type-3 Class-B
Hydraulic oil ISO VG46 or equivalent
Oil operating temperature range -4 to 194°F (-20 to 90°C)
Maximum allowable contamination NAS Class 9 or lower
Electrical specifications
Econoseal J series,
Connector type
Tyco Electronics Cooperation
Solenoid valve CSC-D12G-Y
Rated voltage DC 12V
Allowable voltage range 0.82 A
Continuous rating voltage 14.6Ω
6-9-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-9-2 Triple solenoid valve
1) Overview
2) Main Components
B1 B2 B3
A1 A2 A3
A3 A2 A1
1
T
B1 B2 B3
1 Body
105370-00EN00
1. Specifications
Maximum allowable working pressure 711PSI (4.9 MPa)

Allowable back pressure 72.5 psi (0.5 MPa) or less
Econoseal J series,
Connector type
Solenoid valve CSC-D12G-C
6-9-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-10 Triple solenoid valve
1) Overview
2) Main Components
B1 B2 B3
A1 A2 A3
A3 A2 A1
1
T
B1 B2 B3
1 Body
105370-00EN00
1. Specifications
Maximum allowable working pressure 435 PSI (3.0 MPa)

Econoseal J series,
Connector type
Solenoid valve KDRDE5K-31/30E30-110
6-10-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-11 Hydraulic cylinder
6-11-1 Sectional View and Parts (Three-side flaps wagon type)
1 2 3 4 5 6 7 8 9 10
104760-00X00
No. Part Qty Remarks

1 U nut 1
2 Packing 1
3 Piston 1
4 Tube 1
5 Packing 1
6 O-ring 1
7 Back-up ring 1
8 Cylinder head 1
9 Dust seal 1
10 Rod 1
6-11-1 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-11-2 Sectional View and Parts (Swing wagon type)
4 1 2 3 5 6 7 8 9 10
109601-00X00
No. Part Qty Remarks

1 U nut 1
2 Packing 1
3 Piston 1
4 Tube 1
5 Packing 1
6 O-ring 1
7 O-ring 1
8 Lock nut 1
9 Dust seal 1
10 Rod 1
6-11-2 172663 0BKC2-EN0060

6. HYDRAULIC SYSTEM
6-11-3 Disassembling and assembling
Disassembling and assembling the cylinder part

1) Disassembly
Procedure
(1) Lift the wagon and attach the wagon supporting stopper.
(2) Detach the attaching pins on the rod side.
(3) Start the engine, and shorten the piston rod.
(4) Remove the hose.
(5) Remove the pins on the bottom side.
(6) Remove the PWL bearing 7 from the piston 6, hold the
two parts on the PGU packing 8, and remove the pro-
truded part of the packing with your other hand.
(7) Remove the backup ring 5 and O-ring 4 from the cylinder
head.
Note:
When removing the ISI packing 2 and DKB dust seal 3
from the cylinder head 1, be careful not to scratch the
attaching part.
2) Reassembly
Apply the predetermined tightening torques for the bolts and nuts and follow the opposite procedure of disassembly.
6-11-3 172663 0BKC2-EN0060

CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Engine and Electric Equipment ................................. 7-1-1 7-4-2 Removing and Reinstalling the control valve
7-1-1 Removal and Reinstallation of Engine ............. 7-1-1 (Three-side flaps wagon type).......................... 7-4-7
7-1-2 Removal and Reinstallation of 7-4-3 Removing and Reinstalling the control valve
Diesel Particulate Filter (DPF) ...................... 7-1-12 (Swing wagon type)........................................ 7-4-10
7-1-3 Removal and Reinstallation of 7-4-4 Removal and Reinstallation of Pilot Valves .... 7-4-13
Starter Motor .................................................. 7-1-18 7-4-5 Removing and installing the solenoid valve
7-1-4 Removing and reinstalling the fan belt ........... 7-1-20 (single/triple)................................................... 7-4-19
7-1-5 Removal and Reinstallation of Radiator and 7-4-6 Removing and Reinstalling the
Hydraulic Oil Cooler ....................................... 7-1-22 selector valve. ................................................ 7-4-23
7-1-6 Removing and installing the fuel cooler.......... 7-1-27 7-4-7 Removing and installing the line filter ............. 7-4-26
7-1-7 Removing and installing the fuel tank............. 7-1-29 7-4-8 Removing and installing the charge filter ....... 7-4-28
7-1-8 Removing and installing the LCD monitor ...... 7-1-33 7-4-9 Removing and Reinstalling the accumulator .. 7-4-31
7-1-9 Removal and Reinstallation of Engine ECU... 7-1-34 7-4-10 Removing and Reinstalling the dump cylinder
7-2 Undercarriage ........................................................... 7-2-1 (Three-side flaps wagon type)........................ 7-4-33
7-2-1 Removal and Reinstallation of Crawler ............ 7-2-1 7-4-11 Removing and Reinstalling the dump cylinder
7-2-2 Removal and Reinstallation of Travel Motor .... 7-2-8 (Swing wagon type)........................................ 7-4-35
7-2-3 Disassembly and Reassembly of 7-4-12 Removing and Reinstalling the
Idler and Grease Adjuster .............................. 7-2-11 hydraulic oil tank ............................................ 7-4-37
7-2-4 Disassembly and Reassembly of 7-4-13 Disassembly and Reassembly of
Carrier Roller.................................................. 7-2-18 wagon swing motor ........................................ 7-4-40
7-2-5 Disassembly and Reassembly of 7-4-14 Removal and Reinstallation of Swivel Joint.. 7-4-42
Track Roller.................................................... 7-2-22 7-4-15 Disassembly and Reassembly of
7-2-6 Installation of Floating Seal ............................ 7-2-31 swing bearing ................................................. 7-4-45
7-3 Controls ..................................................................... 7-3-1 7-4-16 Piping Layout................................................ 7-4-51
7-3-1 Travel lever, wagon control lever, and 7-5 Wagon ....................................................................... 7-5-1
lock lever components ..................................... 7-3-1 7-5-1 Wagon components
7-3-2 Accelerator pedal components......................... 7-3-5 (Three-side flaps wagon type).......................... 7-5-1
7-3-3 Adjustment of Boom Swing Pedal .................... 7-3-6 7-5-2 Wagon components (Swing wagon type) ......... 7-5-6
7-4 Hydraulic equipment ................................................. 7-4-1 7-5-3 Removing and installing the canopy................. 7-5-8
7-4-1 Removing and Reinstalling the
hydraulic pump................................................. 7-4-1
7. ADJUSTMENT AND REPAIR
7. Adjustment and Repair
7-1 Engine and Electric Equipment
7-1-1 Removal and Reinstallation of Engine
1) Removal
Procedure
(1) Raise the wagon, and fix it in place using the wagon sup-
port stopper 1.
078684-00X02
(2) Remove the floor mat 2.

2
104283-00X00
7-1-1 172663 0BKC2-EN0060

Procedure
(3) Remove the front cover.
(4) Remove the bolts, and then remove the canopy by using
lifting equipment.
(Refer to Section "7-5-2 Removing and installing the can-
opy" for the removal procedure.)
Bolt 10.9 12x45

Apply locking agent: ThreeBond 1324
Bolt 10.9 12x35

104284-00X00
(5) Place a container under the drain plug 3 to collect the

coolant.
(6) Remove the drain plug 3 of the 2-way cock, drain the
coolant.
Quantity: 6.0 Qts. (5.7 L)
Note:
Remove the radiator cap when draining the coolant.
3
104285-00X00
(7) Remove the magnetic plug 4 from the hydraulic oil tank,
and drain the hydraulic oil. Or, replace the oil filler port cap 5
5 with a compression vacuum cap, and then bleed the air.
Type : Hydraulic oil ISO VG46

Quantity : 29.6 Gals (28 L)
Note:
If draining the hydraulic oil, remove the oil filler port cap 5
when draining.
Magnetic plug 4
4 104286-00X00
7-1-2 172663 0BKC2-EN0060

Procedure
(8) Remove the battery clamp 6 and battery clamp rod 7, and
then turn off the battery cut-off switch. Remove battery
cut-off cable A 8, battery cut-off cable B 9, and the battery
6
positive cable 10, and then remove the battery 11.
7 10
Nuts
Tightening torque: 5.2 to 5.9 ft·lbf (7 to 8 N·m)
8
Top M8 U-nut
Tightening torque: 3.6 to 4.4 ft·lbf (4.9 to 5.88 N·m) 9
11
Bottom M8 U-nut
104287-00X00
(9) Remove the monitor cover 12, and then disconnect the
main harness 13 from each electrical device.
13
13
13
12
104288-00X00
7-1-3 172663 0BKC2-EN0060

Procedure
(10) Remove bonnet A 15, bonnet B 14, the bonnet duct 17,
and bonnet L 16. 17
14
16
15 104289-00X00
(11) Remove intake hose A 18, intake hose B 19, and the
hose 20 from the air cleaner 21, and then remove the air
cleaner itself. 18
21
Air cleaner hose hose clips

20
19
104290-00X00
7-1-4 172663 0BKC2-EN0060

Procedure
(12) Remove the DPF cover A 22 and DPF cover B 23.
22
23
104291-00X00
(13) Remove the oil filler bracket 24 and main harness 13,
and then remove the bonnet base 25. 25
Hose clamps
24
Note:
Use needle nose pliers to remove the main harness clamps.
13
104292-00X00
7-1-5 172663 0BKC2-EN0060

Procedure
(14) Open the fuel drain valve located at the front right side of
the track frame. Drain the fuel.
104293-00X00
(15) Remove the bolt 27 which fixes the sub-tank 26, and
then remove the sub-tank.
(16) Remove the fuel tank.

26
(Refer to Section "7-1-7 Removing and installing the fuel
tank" for the removal procedure.)
27
104297-00X00
(17) Remove main harness 13 and engine earth 28 from the 13

engine.
28
13 104294-00X00
7-1-6 172663 0BKC2-EN0060

Procedure
(18)Remove the fuel hose 30 and hose 31 from the fuel pre-
filter 29.
29
30
31
104295-00X00
(19) Remove the bolt 33 from the electrical device stay 32.
Next, remove the main harness 13 mounted on the oil fil-
ter side, and then shift the electrical device stay.
Note: 32
Use needle nose pliers to remove the main harness clamps
13.
33
13
104296-00X00
(20) Remove the oil cooler hoses 34 and 35, and the fuel
cooler hose 36.
Note:
Use needle nose pliers to remove the main harness clamps
13.
Hose clips (25)

36
35
36
104298-00X00
7-1-7 172663 0BKC2-EN0060

Procedure
(21) Remove radiator hoses A 37 and B 38.
Note:
Remove the radiator hoses on the engine side.
Coolant hose Hose clips

39

38
(22) Remove the radiator bracket 39.
37
104299-00X00
(23) Remove the fan guard 40 from the radiator shroud.
40
104300-00X00
7-1-8 172663 0BKC2-EN0060

Procedure
(24) Lift up the radiator 41 and oil cooler 42 and remove from 42
the track frame. 41
104301-00X00
(25) Remove the exhaust cover top 43 and bottom 44, as well
43
as the pump cover 45 and cross member 46.
45
46
44
104302-00X00
7-1-9 172663 0BKC2-EN0060

Procedure
(26) Remove the exhaust pipe clamp bolt 48, and then
remove the exhaust pipe 47. 48
Exhaust pipe clip 47

104303-00X00
(27) Remove the hydraulic hoses (x16) from the hydraulic

pump 49. b
49 d e
a. Hose P1 j. Hose P2
b. Hose P3 k. Hose Pp4
c. Hose T1 l. Hose Pp3
d. Hose B1 m. Hose PgC
g
e. Hose B3 n. Hose B2
a m
f. Hose S o. Hose T2 c
g. Hose Pp6 p. Hose Pp1 n k
h. Hose Pp5 q. Hose clip l j i h
i. Hose P4 o p q
f
Hose clip q
Tightening torque: 2.9 to 3.6 ft·lbf (3.9 to 4.9 N·m) 104304-00X00
(28) Remove the hydraulic pump bolts 50 (x2), and then

remove the hydraulic pump 49.
(Refer to Section "7-4-1 Removing and installing the
hydraulic pump" for the removal procedure.)
Note:
• When removing the hydraulic pump, attach a rope and use
lifting equipment. M10 lifting eye
• When lifting the hydraulic pump, make sure that the rope
does not come into contact with the piping or solenoid.
M14 bolt 50
50
49 104305-00EN00
7-1-10 172663 0BKC2-EN0060

Procedure
(29) Remove the M16 bolts 51 (x2), and M14 bolts 52 (x2). 52
(30) Using lifting equipment, and while paying close attention

to the wire harness mounted on the frame, slowly lift and
remove the engine.
Note:
Don’t forget to remove the engine earth cord.
M14 bolt 52 51
Tightening torque: 137.2 to 151.9 ft·llbf (186 to 206
Nvm)
M16 bolt 51
Tightening torque: 151.8 to 173.5 ft·llbf (205.8 to 235.2 N·lm)
104306-00X00
2) Reinstallation
Reinstall the engine in the reverse order to the removal procedure.
7-1-11 172663 0BKC2-EN0060

7-1-2 Removal and Reinstallation of Diesel Particulate Filter (DPF)
(1) Removal and Reinstallation of soot filter
1) Removal
Procedure
port stopper 1.
078684-00X02
(2) Open bonnet A 2, and remove the top 3 and bottom 4

bonnet covers. 2
104307-00X00
(3) Remove intake hose A 5, intake hose B 6, and the hose b

from the air cleaner b, and then remove the air cleaner
itself. 5
8

Tightening torque: 1.8 to 2.5 ft·llbf (2.5 to 3.4 N·lm)
7
104308-00X00
7-1-12 172663 0BKC2-EN0060

Procedure
(4) Remove DPF covers A 9 and B 10.
10
104309-00X00
(5) Remove the exhaust pipe clamp bolt 12, and then remove
the exhaust pipe 11. 12

Tightening torque: 14.0 to 15.5 ft·llbf (19 to 21 N·lm)
104310-00X00
7-1-13 172663 0BKC2-EN0060

Procedure
(6) Remove the mounting bolts 13 (x8) and nuts 14 (x8), and
then remove the DPF stiffener 15, DPF silencer 16, and
gasket 17.
13
Note:
Before removing, mark the stiffener to ensure that it is re-
installed in its original position.
17
16 15
14
104311-00X00
(7) Remove pressure sensor hoses 18.
18
104312-00X00
(8) Remove the mounting bolts 19 (x8) and nuts 14 (x8), and
then remove the DPF stiffener 21, DPF soot filter 22, and 12
gasket 23.
11
Note:
Before removing, mark the stiffener to ensure that it is re-
installed in its original position.
104310-00X00
7-1-14 172663 0BKC2-EN0060

2) Reinstallation
Reinstall the DPF in the reverse order of the removal procedure.
Note:
Each time the DPF assembly, soot filter of DOC has been replaced, the corresponding data stored on the engine
ECU needs to be rewritten using SMARTASSIST-Direct.
7-1-15 172663 0BKC2-EN0060

(2) Removal and Reinstallation of Radiator and Oil Cooler

1) Removal
Procedure
(1) Disconnect main harness 24 from the couplers of the tem-
perature sensor and pressure sensor.
24
104314-00X00
(2) Remove the main harness 24 from the harness stay rear
25, and then remove the harness stay rear from the track
frame.
Note:
Use needle nose pliers to remove the main harness clamps.
25
24
104315-00X00
7-1-16 172663 0BKC2-EN0060

Procedure
(3) Remove the nuts 26 (x4), and then remove the DOC 27
from the engine.
26
Note: 27
Of the four nuts, three are removed from the bonnet side, and
one from the seat side.
104316-00X00
2) Reinstallation
Reinstall the DPF in the reverse order of the removal procedure.
Note:
• Each time the DPF assembly, soot filter or DOC has been replaced, the corresponding data stored on the engine
ECU needs to be rewritten using SMARTASSIST-Direct.
• Refer to this "Removal and reinstallation of DOC (diesel oxidation catalyst)" for the removal procedures of the DPF
assembly in its entirety.
7-1-17 172663 0BKC2-EN0060

7-1-3 Removal and Reinstallation of Starter Motor

1) Removal
Procedure
(1) Open bonnet A 1, and disconnect battery cut-off cable A
b. Or, turn the battery cut-off switch OFF. 1
Nut
Tightening torque: 5.2 to 5.9 ft·llbf (7 to 8 N·lm)
104317-00X00
(2) Remove the top 3 and bottom 4 bonnet covers.
104318-00X00
(3) Remove the positive cord 6 from the starter motor 5.

5
Nut
6
104319-00X00
7-1-18 172663 0BKC2-EN0060

Procedure
(4) Remove the bolts 7 (x2) from the starter motor 5, and then
remove the starter motor.
5 7
104320-00X00
2) Reinstallation
Reinstall the starter motor in the reverse order of the removal procedure.
7-1-19 172663 0BKC2-EN0060

7-1-4 Removing and reinstalling the fan belt
1) Removal
Procedure
(1) Open bonnet A 1, and remove the top bonnet cover 2.
1
104321-00X00
(2) Remove the fan guard 3.
3
104322-00X00
(3) Remove the bolt from the fuel filter bracket, and shift the
4
filter to the wagon side.
Note:
Do not remove the hoses which are connected to the fuel
104323-00X00
7-1-20 172663 0BKC2-EN0060

Procedure
(4) Loosen the generator adjuster bolt 5, then release the
tension from the fan belt 6 and remove the fan belt.
104324-00X00
2) Reinstallation
Reinstall the fan belt in the reverse order of the removal procedure.
Item Fan belt Compressor driving belt

Pressing force lbf. (N) 22.05 lbf. (98.1 N) 22.05 lbf. (98.1 N)
0.39 to 0.60 in. 0.31 to 0.35 in.
Slack in. (mm)
(10 to 15 mm) (8 to 9 mm)
Fan belt size
Fan belt Law edge A42
080042-00X05
7-1-21 172663 0BKC2-EN0060

7-1-5 Removal and Reinstallation of Radiator and Hydraulic Oil Cooler
1) Removal
Procedure
port stopper 1.
078684-00X02
(2) Remove the floor mat 2.

2
104283-00X00
(3) Remove the front cover.
(4) Remove the bolts, and then remove the canopy by using
lifting equipment.
(Refer to Section "7-5-2 Removing and reinstalling the
canopy" for the removal procedure.)
Bolt 10.9 12x45

Bolt 10.9 12x35

104284-00X00
7-1-22 172663 0BKC2-EN0060

Procedure
(5) Place a container for receiving cooling water under drain
plug 3.
(6) Remove drain plug 3 from the two-way cock for cooling
water and allow the cooling water to drain from the radia-
tor.
Q'ty 6.0 Qts. (5.7 L)
Note:
Remove the radiator cap when draining the coolant.
3
104285-00X00
and drain the hydraulic oil. 5
Or, replace the oil filler port cap 5 with a compression vac-
uum cap, and then bleed the air.
Type Hydraulic oil ISO VG46

Q'ty 15.8 Gals (60 L)
Note:
If draining the hydraulic oil, remove the oil filler plug 5 when
draining.
Magnetic plug 4
Tightening torque: 79.6 to 88.0 ft·lbf (107.9 to 119.3 N·m(
4 104286-00X00
(8) Remove the monitor cover 6, and then disconnect the

main harness 7 from each electrical device.
7
7
104325-00X00
7-1-23 172663 0BKC2-EN0060

Procedure
(9) Remove bonnet A 8, bonnet B 9, and the bonnet duct 10.
8
10
9 104326-00X00
(10)Remove the bolt 12 which fixes the sub-tank 11, and then
remove the sub-tank.
11
12
104327-00X00
(11)Remove the oil cooler hoses 13 and 14, and the fuel
cooler hose 15.
Note:
Make sure that you do not mix up oil cooler hoses and fuel
cooler hose when re-installing.
Hose clips (25)

13
15
14
15
104328-00X00
7-1-24 172663 0BKC2-EN0060

Procedure
(12)Remove radiator hoses A 16 and B 17.
Note:
Remove the radiator hoses on the engine side.

18

17
16
104329-00X00
(13)Lift up the radiator 19 and oil cooler 20 and remove from

the track frame. 19
20
104330-00X00
7-1-25 172663 0BKC2-EN0060

Procedure
(14)Remove the bolts/spring washers 22 (x2), and bolts/plain
22
washers/spring washers 23 (x3) fixing the radiator duct 21
in place, and then remove the radiator duct. 21
Hose clips (25)

24
23
104331-00X00
2) Reinstallation
Reinstall the radiator and the oil cooler in the reverse order of the removal procedure.
7-1-26 172663 0BKC2-EN0060

7-1-6 Removing and installing the fuel cooler
1) Removal
Procedure

Q'ty 15.3 Gals (58 L)
104332-00X00
(2) Remove the bonnet guard 1.
104333-00X00
(3) Remove the hoses 3 from the fuel cooler 2.
Note:
Make sure that you do not mix up fuel cooler hoses when re-
installing.
2
104334-00X00
7-1-27 172663 0BKC2-EN0060

Procedure
(4) Remove bolts 4 (x2), and bolt 5 (x1), and then remove the
fuel cooler b.
4 104335-00X00
2) Reinstallation
Reinstall the fuel cooler in the reverse order of the removal procedure.
7-1-28 172663 0BKC2-EN0060

7-1-7 Removing and installing the fuel tank
1) Removal
Procedure
(1) Open bonnet A 1, and remove bonnet B 2.
1
M10 bolts (spring washer)
2
104336-00X00

Q'ty 15.3 Gals (58 L)
104332-00X00
7-1-29 172663 0BKC2-EN0060

Procedure
(3) Remove the bolt 4 which fixes the fuel drain valve 3, and
then remove the fuel drain valve.
Fuel drain valve 3

Wrap sealing tape around R3/8 part
4 104337-00X00
(4) Remove hose 5, and FO hoses 6 and 7 from the fuel tank.
6
7 104338-00X00
(5) Remove the bolt 9 which fixes the sub-tank 8, and then
remove the sub-tank.
104297-00X01
7-1-30 172663 0BKC2-EN0060

Procedure
(6) Disconnect the fuel gauge 10 and main harness 11.
10
11
104339-00X00
(7) Remove the nut 13 and flange nut 14 that fix the fuel
clamp to the fuel tank. Then, remove the fuel clamp.
M10 flange nut A 14

M10 flange nut B 14

Note:
After installing flange nut A (internal), install flange nut B
(external) and lock in place.
13
14
12
14 104340-00X00
7-1-31 172663 0BKC2-EN0060

Procedure
(8) Remove the fuel tank.
104341-00X00
2) Reinstallation
Reinstall the fuel tank in the reverse order of the removal procedure.
7-1-32 172663 0BKC2-EN0060

7-1-8 Removing and installing the LCD monitor
1) Removal
Procedure
(1) Remove the accelerator knob 1 and binding head screws
1
2 (x9), then remove the monitor cover b.
Note:
3
When removing the monitor cover, disconnect the switches
and main harness.
M10 binding head screws 2

104342-00X00
(2) Remove the bolts 5 (x4) which fix the monitor 4, and then
remove the monitor. 4
5
M5 bolt 5
(3) Disconnect the monitor 4 and main harness 6.

6
104343-00X00
2) Reinstallation
Reinstall the LCD monitor in the reverse order of the removal procedure.
7-1-33 172663 0BKC2-EN0060

7-1-9 Removal and Reinstallation of Engine ECU
1) Removal
Procedure
(1) Remove the battery cover, and then remove the bolt 2 that
fixes the relay stay 1 in place. Next, remove the relay stay.
2
Note:
Remove the relay stay together with the attached relay box.
104344-00X00
(2) Remove the bolt 4 which fixes the engine ECU b, and
then remove the ECU.
104345-00X00
(3) Turn the lock button 6 of the coupler 5 in the direction of

the arrows as shown in the figure to the right.
6
104346-00X00
7-1-34 172663 0BKC2-EN0060

Procedure
(4) Disconnect the main harness coupler 5 from the engine
ECU 3.
3
104347-00X00
2) Reinstallation
Reinstall the engine ECU in the reverse order of the removal procedure.
Note:
• Install the engine ECU on the engine of the same engine model name and engine serial number as indicated on
the engine ECU.
• Do not connect or disconnect the connector to or from the engine ECU for at least 20 seconds after the power is
turned on or off.
• Do not touch any connector pins of the engine ECU with bare hands. Doing so might cause corrosion of the con-
nector pins or static electricity, resulting in damage to the electronic circuit in the engine ECU.
• Do not forcibly insert any devices such as the test probes of test equipment into female couplers (of the harness
side). Doing so may cause contact failure of connector pins, resulting in malfunction.
• Take care not to let water into the couplers when connecting or disconnecting connectors. Water can cause corro-
sion of connector pins, resulting in malfunction.
• Do not connect or disconnect the connector to or from the engine ECU more than 10 times. Doing so may cause
contact failure of connector pins, resulting in malfunction.
• Take care not to drop the engine ECU. If it is dropped, do not use it.
7-1-35 172663 0BKC2-EN0060

7-2 Undercarriage
7-2-1 Removal and Reinstallation of Crawler
1) Removal
Procedure
port stopper 1.
078684-00X02
(2) Use a crane to lift the track frame on the side of carrier
on which you want to remove the crawler. Lift until there
is a gap between the track rollers and crawler.
(3) Place a block under the track frame to support it.
Block 104348-00EN00
7-2-1 172663 0BKC2-EN0060

Procedure
(4) Remove the frame cover 2, and loosen the nipple valve 3.
Note:
Do not loosen the nipple valve more than one turn. High pres-
sure grease is enclosed inside, which may cause the valve to
fly out and cause injury. Furthermore, do not position any part
of your body in front of the valve when loosening.
104349-00X00
(5) Push the idler inwards towards the middle of the carrier.
Note:
4
If the idler does not move, there is another way to push the
idler inward by lifting the middle of the upper part of the
crawler with a belt (or the like).
Belt
Crawler
104350-00EN00
7-2-2 172663 0BKC2-EN0060

Procedure
(6) Remove bolt 5 (x2), and remove the carrier roller 6 from
the track frame. 5
104351-00X00
(7) Remove the bolts 8 (x10) from the sprocket 7, and

remove the crawler 9 together with the sprocket 7.
Note:
Use a bar, etc. when removing the crawler.
7
9 8
104352-00X00
7-2-3 172663 0BKC2-EN0060

2) Reinstallation
Procedure
(1) Attach the sprocket 7 to the travel motor by using the bolts
8 (x10).
M14 bolt 8
8 104353-00X00
(2) Engage the sprocket with the crawler 9.
(3) Push the bottom of the crawler 9 towards the middle of

the carrier so that the core metal of the crawler 9 and the
idlercore metal are adjacent to each other.
Note:
To make work easier, place wooden blocks under the crawler
to take up the slack.
sprocket
Block 104354-00EN00
7-2-4 172663 0BKC2-EN0060

Procedure
(4) Insert a crowbar into the hole in the center of the rubber
crawler from outside and put the tip of the crowbar on the
side of the idler facing the machine body. Press the crow-
bar toward the center of the machine and insert another
crowbar between the core metal of the rubber crawler and
the idler. Then, while raising the rubber crawler with the
crowbars, move the rubber crawler toward the idler and Crowbar
place the protruding portion of the core metal on the cen-
ter of the idler. Repeat this until the entire rubber crawler
is placed securely on the track frame.
104355-00EN00
(5) Attach the carrier roller 6 to the track frame using bolts 5
(x2). 5
104351-00X00
7-2-5 172663 0BKC2-EN0060

3) Crawler tension adjustment

Procedure
(1) After checking that the O-ring 10 of the nipple valve is not
damaged, tighten the nipple valve 3.
Nipple valve 3
Tightening torque: 36.1 to 40.0 ft·lbf (49 to 54.2 N·m)
Note:
(The O-ring should be replaced with a new one when the
valve is reassembled.)
(2) Supply grease from the nipple valve 3.
10
3 104356-00X00
(3) Put the vehicle on a flat place and slack the upper part of
Carrier roller Idler
the crawler. Put the weight [about 132 lbs (60 kg)] on the A
crawler in the middle between the idler and the carrier
roller to slack the crawler a little. [B=0.79 to 1.18 in. (20
to 30 mm)]
(4) After adjusting, install the frame cover 2.
2 104357-00EN00
7-2-6 172663 0BKC2-EN0060

4) Inspection
Procedure
(1) If the tear in the end face is excessive, replace the
crawler.
(2) If the wear or breakage of the outer side of the crawler is

excessive or the core metal is exposed too much, replace
the crawler.
Standard Wear limit

B 1.18 in. (30 mm) 0.31 in. (8 mm)
10
3 104356-00X00
7-2-7 172663 0BKC2-EN0060

7-2-2 Removal and Reinstallation of Travel Motor
1) Removal
Procedure
port stopper 1.
078684-00X02
(2) Remove the crawler.

(Refer to Section "7-2-1 Removing and Reinstalling the
Crawler" for the removal procedure.)
104359-00X00

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 2
2 104360-00X00
7-2-8 172663 0BKC2-EN0060

Procedure
(4) Remove the motor cover 4, and under cover 5.
Note:
Remove the under cover if you are removing the travel motor
on the right side.
4
4
5 104361-00X00
(5) Remove the hydraulic hoses from the travel motor. a b

c
Note:
Before removing, mark the hoses to ensure that they are re-
T1
installed in their original positions. Ps
d
P1
P2
a. Hose Pa g. Hose Pf e
b. Hose T1 h. Hose T2 P3
c. Hose P1 i. Hose P3 f
Pf
d. Hose P2 j. Hose P2
h
e. Hose P3 k. Hose P1 g i
f. Hose Pf l. Hose Pa Travel motor (R)
j
T2
P3
Pf
P2
P1
k
Travel motor (L)
Ps
l 104362-00EN00
7-2-9 172663 0BKC2-EN0060

Procedure
(6) Remove the bolts 7 (x9) from the travel motor 6, and then
remove the travel motor.
Travel motor weight: 121.3 lbs (55 kg)
M14 bolt 7
Tightening torque: 86.8 to 108.6 ft·lbf (117.7.9 to 147.2 N·m)
Note:
Use lifting equipment when removing the travel motor.
6 104363-00X00
2) Reinstallation
Reinstall the travel motor in the reverse order to the removal procedure.
7-2-10 172663 0BKC2-EN0060

7-2-3 Disassembly and Reassembly of Idler and Grease Adjuster
1) Idler and grease adjuster components

10
7
6
3
6
7
10
12
11
4
5
9
8
1
8
13 9
14
19 15 5
4
16 2
17
18
17
25
24
23
22
21
20
104364-00X00
No. Part Q’ty No. Part Q’ty No. Part Q’ty

1 Idler 2 10 Nut (M24) 4 19 Adjust tube 2
2 Idler shaft 2 11 Plug 2 20 Grease nipple 2
3 Idler fork 2 12 Adjusting spring 2 21 Nipple valve 2
4 Seal collar 4 13 Water seal 2 22 Hard ball 2
5 Water seal 4 14 DRK seal 2 23 Spring 2
6 Washer 4 15 Backup ring 2 24 Spring holder plug 2
7 Spring washer 4 16 Piston 2 25 O-ring 2
8 Retaining ring C 4 17 Retaining ring C 4
9 Bearing 4 18 Tube holder 2
7-2-11 172663 0BKC2-EN0060

2) Removal
Procedure
(1) Remove crawler
104359-00X00
(2) Remove the body of the idler 1 from the track frame.
104365-00X00
(3) Remove adjusting spring 2 and 3 from the track frame.
104366-00X00
7-2-12 172663 0BKC2-EN0060

3) Removal
Procedure
(1) Remove crawler
104359-00X00
(2) Remove the body of the idler 1 from the track frame.
104365-00X00
(3) Remove adjusting spring 2 and 3 from the track frame.
104366-00X00
7-2-13 172663 0BKC2-EN0060

4) Disassembly the Idler

Procedure
(1) Remove nut 4 which fixes the idler 3 in place. Then,
3
remove the idler from the idler fork.
104367-00X00
(2) Insert idler shaft into idler wheel 1.

5
Type Engine oil SAE 30
Q'ty 0.137 Qts. (0.13 L)
(3) Remove the shaft 6 from the idler 3.
3 6
104368-00X00
(4) Remove collar 7, the water seals 8, bearings 9, and

retaining rings 10 from the idler 3.
6
8
9
10
3 10
9
8
7
104369-00X00
7-2-14 172663 0BKC2-EN0060

5) Assembly the Idler

Procedure
(1) Press fit collar 7 to one side of the shaft 6.
6
(2) Install the retaining rings 10 to the idler 3, and then install 8
7
the bearings 9.
9
10
Note:
Install on the opposite side from the idler plug hole.
(3) Install water seal 8.
3
Plug hole
104370-00EN00
(4) Turn the idler 3 around, and install the retaining rings 10 Press fit
and bearings 9. Then, use a press fitting tool to insert the
collar 7.
(5) Supply oil. Press-fit jig

Type Engine oil SAE 30
Q'ty 0.137 Qts. (0.13 L) 7 10
9
5
(6) After installing water seal 8, install plug 5 into idler 3 and
tighten it at a specified torque.
Apply locking agent: Loctite 572

3 Plug hole
6
104371-00EN00
(7) Fix the assembled idler 3 into the idler fork by using the
nut 4. 3

(8) Check
Gently rotate the idler two or three times by hand. Check
that there is no torque fluctuation, oil leaks, or oozing.
104367-00X00
7-2-15 172663 0BKC2-EN0060

6) Assembly the grease adjuster

Procedure
(1) Checks before assembling
• Check that there is no dent or flaw in piston 21. 16 (20䡚30mm)
• Check that there is no flaw in the lip of water seal 20.
• Replace DR seal 22 and backup ring 23 with new ones.
• Check that there is no burr in the groove of adjust tube 16.
• Clean adjust tube 16 completely.
(2) Supply grease by 0.79 to 1.18 in. (20 to 30 mm).
21 23 22 20
104372-00EN00
(3) Insert piston 21 completely to fill the nipple port of adjust

tube 16 with grease and release air from the nipple port.
Then, remove the grease overflowed from the port. Grease
Note:
Wipe up any grease that oozes out.
16 21 104373-00EN00
(4) Fill the nipple valve 19 with grease to release air.

19
Grease gun
104374-00EN00
(5) Install the nipple vale 19 to the adjuster tube 16.

19
Note:
Check that the O-ring is not protruding.
Tightening torque: 36.1 to 40.0 ft·lbf (49 to 54.2 N·m)
Grease gun
104374-00EN00
7-2-16 172663 0BKC2-EN0060

7) Assembly the idler fork

Procedure
(1) Install adjusting spring 10 and 11 to the track frame.
10
11
104376-00X00
(2) Install the idler fork to the track frame.
Note:
Install the idler fork to the track fApply Molytone grease to all
sides of the idler fork’s square pipe.rame.
Check that the idler fork slides smoothly.
104377-00X00
7-2-17 172663 0BKC2-EN0060

7-2-4 Disassembly and Reassembly of Carrier Roller
1) Carrier roller components

6
4
3
5
1
5
7
3
2
8 3
7
5
1
5
3
4
6
104378-00X00
No. Part Q’ty No. Part Q’ty

1 Carrier roller 2 5 Bearing 8
2 Carrier roller shaft 2 6 Bore plug 4
3 Retaining ring C 8 7 Oil seal 4
4 Internal snap ring 4 8 Bolt 4
7-2-18 172663 0BKC2-EN0060

2) Disassembly
Procedure
(1) Remove the frame cover, and loosen the nipple valve.
(2) Push the idler inwards towards the middle of the carrier,
and loosen the crawler tension.
104379-00X00
(3) Remove bolt 1 (x2), and remove the carrier roller 2 from
the track frame. 1
104380-00X00
(4) Remove the bore plug 3 and retaining rings 4. Then,

6
remove the carrier roller 5 form the carrier roller shaft 6.
4
5
4
3
104381-00X00
7-2-19 172663 0BKC2-EN0060

Procedure
(5) Remove the retaining ring 7, bearings 8, and oil seal 9
from the carrier roller 5. 9
8
5
8
7
104382-00X00
7-2-20 172663 0BKC2-EN0060

3) Reassembly
Procedure
(1) Install retaining ring C 4 onto carrier roller shaft 6.
5
(2) Install bearings 9 and internal snap ring C 7 into carrier
roller 5.
A 7
6 4
(3) Fill part A of the oil seal 9 with grease, and then press fit
to the carrier roller 5.
Note:
Check that there is no grease on the outside surface of the oil
seal.
104383-00X00
(4) Press fit the carrier roller shaft 6 to the carrier roller 5, and
then install the retaining ring C 4.
5
(5) Fill part B on the inside of the bore plug 3 with grease, and
then press fit it. 6
Notes:
B
Check that there is no grease on the outside surface of plug
or on the inside surface of the boss of the carrier roller. If there
is some grease on the surfaces, the plug may come off.
3
(6) Check
After reassemble, check that the carrier roller rotates
smoothly.
C
(7) Reassemble the other side in the same way, too.
4
104384-00X00
(8) Attach the carrier roller 2 to the track frame using bolts 1
(x2). 1
104380-00X00
7-2-21 172663 0BKC2-EN0060

7-2-5 Disassembly and Reassembly of Track Roller
1) Track roller components

9
1
20
3
4
17
19
18
17
4
16
10
11
21
10
11
10
11
15 21
23 11
10
10
11
14
22
13 13
9 12 12
1
8
3
4
5
11
7 10
5
4
2 104385-00X00

1 Retaining ring C 12 9 Plug 8 17 Ball bearing 8
2 Seal cover 8 10 Nut (M24) 16 18 Track roller shaft 4
3 O-ring 8 11 Spring washer 16 19 Roller 4
4 Seal 16 12 Grease nipple 4 20 Seal cover 4
5 Ball bearing 16 13 Rocking shaft 4 21 Washer 8
6 Shaft 8 14 Rocking plate A (outside) 2 22 Rocking plate B (outside) 2
7 Roller 8 15 Rocking plate A (inside) 2 23 Rocking plate B (inside) 2
8 Seal cover 8 16 Seal cover 4
7-2-22 172663 0BKC2-EN0060

2) Removal
Procedure
(1) Loosen the M24 nut 1 (inside and outside) which fixes the
track roller and rocking plate. Also loosen the M24 nut 3
which fixes the rocking shaft 2.
1 1
104386-00X00
(2) Use a crane to lift the track frame on the side of carrier on
which you want to remove the crawler. Lift until there is a
gap between the track rollers and crawler.
(3) Place a block under the track frame to support it.
Block 104348-00EN00
7-2-23 172663 0BKC2-EN0060

Procedure
(4) Remove the frame cover, and loosen the nipple valve.
(5) Push the idler inwards towards the middle of the carrier,
and loosen the crawler tension.
104379-00X00
(6) Remove the M24 nut 3 which fixes the rocking shaft 2.
Then, remove the rocking shaft 2.
(7) Remove the rocking plate together with the track roller
from the track frame.
2
104387-00X00
(8) Remove the M24 nut 1 which fixes the track roller. Then,
remove the rocking plate A (outside) 4 and the rocking
plate A (inside) 5.
Note:
Make sure to re-install in the correct direction. The shape of
the front and back of the rocking plate is different. 1
4
1 104388-00X00
7-2-24 172663 0BKC2-EN0060

Procedure
(9) Remove the threaded plug 7 from the roller 6, and then
drain the oil.
(10)Remove retaining ring C 8 from the roller 6, and then

8
remove the shaft 9.
9
7
6
104389-00X00
(11)Remove the seal covers 10 and 11, and the O-ring 12

from the roller 6.
(12)Remove the seals 13 and the ball bearings 14 from the

roller 6.
11
12
13
14
6
14
13
10
104390-00X00
(13)Remove the M24 nut 1 which fixes the track roller to the
track frame. Then, remove the track roller.
1
104391-00X00
7-2-25 172663 0BKC2-EN0060

Procedure
(14)Remove the threaded plug 7 from the roller 15, and then
drain the oil.
(15)Remove retaining ring C 8 from the roller 15, and then

remove the track roller shaft 17. 8
17
15
104392-00X00
(16)Remove the seal covers 18 and 19, and the O-ring 12

from the roller 15.
(17)Remove the seals 13 and the ball bearings 20 from the

roller 15. 19
12
13
20
15
20
13
18
104393-00X00
7-2-26 172663 0BKC2-EN0060

3) Reassembly
Procedure
(1) Using a jig for the track roller shaft, install the seal cover
Jig
10 to the roller shaft 9.
10
9
104394-00EN00
(2) Install the ball bearings 14 to both sides of the roller 6.
(3) Using a seal inserting tool, install seal 13 to the roller 6

and seal cover 10.
13
(4) Install the roller shaft 9 to the roller 6.
Note: 14
Wipe the seat surface with paper and apply engine oil #30
lightly there. Do not press the seat surface strongly. or it may
be broken.
13
6
13
10
9
104395-00X00
(5) Install the seal 13 to the seal cover 11.

8 7
(6) Turn the roller 6 around, apply engine oil to the O-ring 12, Oil
12
and install it to the seal cover 11. 11
Note:
Take care not to put dust. 13
(7) Using a jig for the shaft, press fit the seal cover 11.
(8) From the hole of the seal cover 11, pour in the specified
amount of oil. Then, insert the threaded plug 7.
Fixed type Rocking type

Type Engine oil SAE30 (Class CC) 6
Q'ty 0.10 Qts (0.09 L) 0.13 Qts (0.12 L)
(9) Install retaining ring C 8 104396-00EN00
7-2-27 172663 0BKC2-EN0060

4) Reassembling the rocking plates

Procedure
(1) Insert the bushes 21 into the track frame until they reach
the stepped end faces of the rocking shaft boss. Then,
22
install the dust seals 22. 21
21
Rocking shaft boss
22
104397-00EN00
(2) Install the track roller to the rocking plate A (outside) 4, 24

and rocking plate A (inside) 5. Then, temporarily fix in
place with the M24 nuts 1. In the same way, install the
Round hole
track roller to the rocking plate B (outside) 23, and rocking
plate B (inside) 24. 23
Round hole
Note: 1
Note that the dimensions (a) and (b) are different. 5
Dimension (a): 6.04 in. (153.5 mm)
Dimension (b): 6.75 in. (171.5 mm) 1
a
Install the rocking plates so that dimension (b) is towards the b
center of the vehicle. (b) has a round hole which can be used 4
as a marker. Round hole Round hole
Install the other track rollers without flanges to where the rock- 1
ing plates are installed.
b 1
a
104398-00EN00
(3) Install the rocking plates to the track frame, and fix in
place with the rocking shaft 2. Temporarily tighten with the
M24 nut 3.
Note:
Insert rocking shaft with grease nipple facing the outside of
the vehicle.
(When inserting rocking shaft, put grease in the space
between rocking shaft boss and shaft.)
3
1
(4) Fully tighten the M24 nuts 1 and 3.
M24 nuts 1 and 3

Apply locking agent: Loctite 262 or K-965 1 2
104399-00X00
7-2-28 172663 0BKC2-EN0060

Procedure
(5) Install the track rollers at the front and rear of the track
frame.
M24 nuts 1
Note:
Install the two track rollers with flanges at each end next to the
sprocket and idler.
104400-00X00
(6) Check
• Turn the track roller manually to form oil film on the slid-
ing surface.
• At that time, check that there is no fluctuation in torque
or oil leak.
• Check that the roller seal cover A is press-fitted to the
roller with each D shown in the figure set to the same
width.
7-2-29 172663 0BKC2-EN0060

5) For Jigs, refer to the following figures

Jig for installing track roller seals Jig for track roller shafts
C 6
2
1
1
C
88
C
2
1
C
C
1
4
φ29
φ25
0.1
0.1
φ30 +0.025
2
φ52
φ70
φ60
0
φ59.5
φ65.5
C
φ45
53
2
C
20 30
100 20°
Jig for installing seals for roller cover A

15
4.6
C
1
1
C
C
2
0.1
0.1
+0.025
φ44.5
2
φ５６
φ52
0
φ65.5
φ59.5
C
φ30
φ45
2
C
20 30
20°
100
104401-00EN00
7-2-30 172663 0BKC2-EN0060

7-2-6 Installation of Floating Seal
Procedure
(1) Inspection for Damage
• Check for flaws or breakages on the sliding surface of
the floating seal.
• Check for flaws, breakages or distortion on the O-ring.
• Check for fins or burrs on the collar and roller bush.
Note:
The fins or burrs will cause damage to the O-ring. Remove
any fin or burr with sand paper or the like.
(2) Use of Jigs Before insertion

• Clean the collar, roller, roller bush, etc. with oil or com-
pressed air.
Sliding surface
• Do not use a waste cloth to wipe the sliding surface of Floating seal
the floating seal. Use a paper cleaner instead.
• Installation using jigs :
Guide jig
Roller
Apply oil thinly.
Insertion & Completion
Insertion jig
Guide jig
Roller
* Thrust the insertion jig in until

it contacts with the guide jig.
104481-00EN00
7-2-31 172663 0BKC2-EN0060

Procedure
• Check that there is no inclination of the sliding surface
and no distortion in the O-ring.
B
Note: A
A & B should be parallel
Normal
B
A
Sliding surface inclined
B
A
O-ring twisted
104482-00EN00
(3) Inspection after Installation

• After putting oil into the roller, seal it. Then, turn the
roller manually 2 to 3 times to from an oil film on the
sliding surface.
• Turn the roller manually to check that the torque is not
excessively high.
• Check that there is no oil leak.
7-2-32 172663 0BKC2-EN0060

7-3 Controls
7-3-1 Travel lever, wagon control lever, and lock lever components
1) Components
Lever cluster (R) (Three-side flaps wagon type) Apply Epnoc No. 2
grease to the contact
surfaces.
Lever switch
Dump lever
Lever switch detailed view
Apply Epnoc No. 2 grease to the groove.
Lock lever
Lever cluster (R) (Swing wagon type)

Apply Epnoc No. 2
grease to the contact
surfaces.
Dump lever Lever switch
Lock lever
109602-00EN00
7-3-1 172663 0BKC2-EN0060

Lever cluster (L)
Apply Epnoc No. 2

Lever switch grease to the contact
Travel lever surfaces.
Lock lever
109603-00EN00
7-3-2 172663 0BKC2-EN0060

2) Adjustment of Lock Lever

Procedure
(1) The operating force for moving the lock lever from P to N
should be less than 75.6 to 118.8 lbs. (3.5 to 5.5 kg).
(2) The lock lever switch 1 should not allow the implements to M Lock lever switch
operate when the lock lever is in N position.
Lock lever
104403-00EN00
(3) Adjustment of Lock Lever

[1] Loosen the bolts 1 (x2), and temporarily tighten the guide Lock lever switch
plate 2.
[2] Actuate the lock lever, and adjust the guide plate 2 so that
the rod guide 3 moves smoothly. Tighten with the bolts 1 3
(x2).
[3] After adjusting, check the lever operating force again.
1
104404-00EN00
7-3-3 172663 0BKC2-EN0060

3) Adjustment of Lock Lever switch

Procedure
(1) Move the lock lever to the M position.
(2) Adjust so it is 30 mm when th switch is ON, and 37 mm

when the switch is OFF.
Nut
Nut
ON
OFF 1.2 in.
1.5 in. (30 mm)
(37 mm)
104405-00EN00
7-3-4 172663 0BKC2-EN0060

7-3-2 Accelerator pedal components
Front Rear
Accelerator sensor
Accelerator pedal
Accelerator pedal
Accelerator sensor
Stroke 78
(excluding play) Stroke 78
(excluding play)
0.7 in.
0.7 in.
(18 mm)
(18 mm)
Adjust the stopper bolt so that the Adjust the stopper bolt so that the
engine reaches 2830±10 rpm. engine reaches 2830±10 rpm.
104406-00JA00
7-3-5 172663 0BKC2-EN0060

7-3-3 Adjustment of Boom Swing Pedal

Bracket CMP (apply Epnoc grease to the
shaded area before installing the seat).
Limit switch
Seat reversing lever
Limit switch
A-A cross-section Returning spring
Viewed from C
Bearing C type retaining ring

B
A A
B-B cross-section
Limit switch 104407-00EN00
7-3-6 172663 0BKC2-EN0060

1) Adjusting the seat mount

Procedure
(1) Lift the seat reversing lever and turn the seat around.
Check that the seat turns smoothly.
(2) Lower the seat reversing lever. Check that the seat does
not turn when locked.

104408-00EN00
(3) Turn the seat and lock to make sure that the lever part of
the limit switch moves smoothly along the protrusion of
the seat bracket.
Round head screw

Tightening torque: 3.6 to 4.3 ft·lbf (4.9 to 5.88 N·m) Seat bracket
Protrusion
Round head screw
Limit switch
104409-00EN00
7-3-7 172663 0BKC2-EN0060

7-4 Hydraulic equipment
7-4-1 Removing and Reinstalling the hydraulic pump
1) Removal
Procedure
port stopper 1.
078684-00X02

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 2
2 104360-00X00
(3) Open bonnet A 4, and remove bonnet L 5.

4 5
104410-00X00
7-4-1 172663 0BKC2-EN0060

Procedure
(4) Remove battery clamp 6 and battery clamp rod 7. Next,
remove the battery cut-off cables A 8 and B9, together
with the battery positive cable b. Lastly, remove the bat- 6
tery 11.
7 10
Nuts
8
Top M8 U-nut
11
Bottom M8 U-nut
104287-00X00
(5) Remove intake hose A 13, intake hose B 14, and the hose
15 from the air cleaner 12, and then remove the air
cleaner itself. 13
12

15
14
104411-00X00
7-4-2 172663 0BKC2-EN0060

Procedure
(6) Remove DPF covers A 16 and B 17.
16
17
104412-00X00
(7) Remove the FO 19 and hose 20 from the fuel pre-filter 18.
18
19
20
104413-00X00
7-4-3 172663 0BKC2-EN0060

Procedure
(8) Remove the bolt 23 from the electrical device stay 22.
Next, remove the main harness 21 mounted on the track
frame side, and then shift the electrical device stay.
Note: 22
Take care when handling the main harness.
23
21
104414-00X00
(9) Remove the exhaust cover top 24 and bottom 25, as well
24
as the pump cover 26.
26
25
104415-00X00
7-4-4 172663 0BKC2-EN0060

Procedure
(10)Remove the exhaust pipe clamp bolt 28, and then remove
the exhaust pipe 27.
28

104416-00X00
(11)Remove the hydraulic hoses (x16) from the hydraulic

pump 29. b
29 d e
a. Hose P1 j. Hose P2
b. Hose P k. Hose Pp4
c. Hose T1 l. Hose Pp3
d. Hose B1 m. Hose PgC
g
e. Hose B3 n. Hose B2
a m
f. Hose S o. Hose T2 c
g. Hose Pp6 p. Hose Pp1 n k
h. Hose Pp5 q. Hose clip l j i h
i. Hose P4 o p q
f
Hose clip q
104417-00X00
(12)Remove the hydraulic pump bolts 30 (x2), and then

remove the hydraulic pump 29.
Note:
When removing the hydraulic pump, attach a rope and use lift-
ing equipment.
M14 bolt 30
30
29 104418-00X00
7-4-5 172663 0BKC2-EN0060

Procedure
(13)Remove the bolts 32 (x8) which fix the flywheel cover 31,
and then remove the flywheel cover from the engine.
31
32 104419-00X00
(14)Remove the hexagon bolts 34 (x3) which fix the coupling

33, and then remove the coupling from the engine.
M12 hexagon bolts 34

33
34 104420-00X00
2) Reinstallation
Reinstall the hydraulic pump in the reverse order to the removal procedure.
Apply grease to the spline of the hydraulic pump.

Grease type: molybdenum disulfide load bearing grease or equivalent
M14 U-bolt, (narrow)
7-4-6 172663 0BKC2-EN0060

7-4-2 Removing and Reinstalling the control valve (Three-side flaps wagon type)
1) Removal
Procedure
port stopper 1.
078684-00X02
(2) Remove the floormat 2, rear step 3, and rear footrest 4.

2
104421-00X00
7-4-7 172663 0BKC2-EN0060

Procedure

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 2
5 104422-00X00
(4) Remove the hydraulic hoses (x6) from the control valve 7.
d
a. Hose T d. Hose A1
c
b. Hose P e. Hose Pb1
c. Hose B1 f. Hose Pa1
b
Note: f
Attach the dust caps/plugs to the ends of the hydraulic hoses.
a
Make sure that you do not mix up control valve hoses when
re-installing. If some of the hydraulic hoses are difficult to
remove, first remove a few of the hoses, and then remove the
dump valve bracket. Lift it up, and then remove the remaining
hoses.
e
7 104423-00X00
7-4-8 172663 0BKC2-EN0060

Procedure
(5) Remove the bolts 8 (x3), and then remove the dump valve
bracket 9 together with the control valve 7.
Note:
Take care. The space for removing the control valve is narrow.
8
9
7
104424-00X00
(6) Remove the bolts 10 (x2) from the dump valve bracket 9,
and then remove the control valve 7.
7
10
104425-00X00
2) Reinstallation
Reinstall the control valve in the reverse order to the removal procedure.
30°
104426-00X00
Note:
Actuate the control lever, and check that the control valve is working properly.
7-4-9 172663 0BKC2-EN0060

7-4-3 Removing and Reinstalling the control valve (Swing wagon type)
1) Removal
Procedure
port stopper 1.
109382-00X00

2
104421-00X00
7-4-10 172663 0BKC2-EN0060

Procedure

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 2
5 104422-00X00
(4) Remove the hydraulic hoses (x6) from the control valve 7.
i
a. Hose Pb2 f. Hose A1
b. Hose Pb1 g. Hose T j h
c. Hose Pa2 h. Hose B1 f
d. Hose Pa1 i. Hose A2
e
e. Hose P j. Hose B2
g
Note:
Make sure that you do not mix up control valve hoses when
re-installing. If some of the hydraulic hoses are difficult to
remove, first remove a few of the hoses, and then remove the
dump valve bracket. Lift it up, and then remove the remaining a
hoses.
d
c
b
7
109383-00X00
7-4-11 172663 0BKC2-EN0060

Procedure
(5) Remove the bolts 8 (x3), and then remove the dump valve
bracket 9 together with the control valve 7.
Note:
Take care. The space for removing the control valve is narrow.
8
9
7
109384-00X00
(6) Remove the bolts 10 (x2) from the dump valve bracket 9,
and then remove the control valve 7.
7
10
109385-00X00
2) Reinstallation
Reinstall the control valve in the reverse order to the removal procedure.
30°
109386-00X00
Note:
Actuate the control lever, and check that the control valve is working properly.
7-4-12 172663 0BKC2-EN0060

7-4-4 Removal and Reinstallation of Pilot Valves
1) Remove the pilot valve

Procedure
(1) Remove the armrest L 1, top lever cover L 2, and bottom
lever cover L 3.
104427-00X00
(2) Remove the pilot hoses from the pilot valve 4.
a. Hose 3 e. Hose 1
4
b. Hose 2 f. Hose 4
c. Hose T g. Hose P
d. Hose I
f
Note:
Before removing, mark the hoses to ensure that they are re- e
installed in their original positions.
Hose clips d
a
b c 104428-00X00
7-4-13 172663 0BKC2-EN0060

Procedure
(3) Remove the bolts 5 (x4) from pilot valve 4, and then 4
remove the travel valve b. 5
104429-00X00
2) Reinstallation
Reinstall the pilot valves in the reverse order to the removal procedure.
7-4-14 172663 0BKC2-EN0060

3) Removing the wagon control lever (pilot valve R) (Three-side flaps wagon type)
Procedure
(1) Remove the armrest R 6, top lever cover R 7, bottom
lever cover R 8, and the lever grommet 9. 6
9
7
8 104430-00X00
(2) Remove the pilot hoses from the dump valve 10.
10
a. Hose T c. Hose 2
b. Hose P d. Hose 1
Note: d
c
a b
104431-00X00
7-4-15 172663 0BKC2-EN0060

Procedure
(3) Disconnect the vessel knob 11 harness from the seat har-
13
ness 12.
(4) Remove the bolts 13 (x4) from spacer L 14, and then 14
remove the dump valve 10 together with the spacer L 14.
10
11
12
104432-00X00
(5) Remove the vessel knob 11 and spacer L 14 from the

dump valve 10.
11
10
14 104433-00X00
4) Reinstallation
Reinstall the wagon control lever in the reverse order to the removal procedure.
67°
30°
104434-00X00
7-4-16 172663 0BKC2-EN0060

5) Removing the wagon control lever (pilot valve R) (Swing wagon type)
Procedure
(1) Remove the armrest R 1, top lever cover R 2, bottom
1
lever cover R 3.
3
109387-00X00
(2) Remove the pilot hoses from the dump valve 4.

4
a. Hose 1 d. Hose 3
b. Hose 4 e. Hose 2
c. Hose P f. Hose T
f
Note:
e
d
a
b
c 109388-00X00
7-4-17 172663 0BKC2-EN0060

Procedure
(3) Disconnect the dump valve 4 harness from the seat har-
ness 5.
(4) Remove the bolts 6 (x4) and then remove the dump valve 4
4.
6 5
109389-00X00
6) Reinstallation
Reinstall the wagon control lever in the reverse order to the removal procedure.
7-4-18 172663 0BKC2-EN0060

7-4-5 Removing and installing the solenoid valve (single/triple)
1) Removal
Procedure
(1) Remove the floormat 1, front step 2, front footrest 3, and
seat mount cover 4.
104435-00X00
and drain the hydraulic oil.
6

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 2
5 104422-00X00
7-4-19 172663 0BKC2-EN0060

Procedure
(3) Disconnect the main harness 8 from the solenoid valve
(single). 8
7
104436-00X00
(4) Disconnect the hydraulic hoses (x4) from the solenoid

a
valve (single).
a. Hose P c. Hose A
b. Hose T d. Hose A
7
Note:
c
b
d
104437-00X00
(5) Remove the bolts 9 (x2) which fix the solenoid valve (sin-
gle) 7, and then remove the solenoid valve (single) from
the track frame.
104438-00X00
7-4-20 172663 0BKC2-EN0060

Procedure
(6) Disconnect the main harness 8 from the solenoid valve
(triple) 10.
10
8
104439-00X00
(7) Disconnect the hydraulic hoses (x9) from the solenoid

valve (triple) 10.
a
a. Hose A1 f. Hose B3 i
b. Hose A1 g. Hose B2 c d
c. Hose A2 h. Hose B1
d. Hose A3 i. Hose B1
g
e. Hose T
b
Note:
f
10
h
e 104440-00X00
(8) Remove the bolts 11 (x3) which fix the solenoid valve (tri-
ple) 10, and then remove the solenoid valve (triple) from
the track frame.
10
11
104441-00X00
7-4-21 172663 0BKC2-EN0060

2) Reinstallation
Reinstall the solenoid valve in the reverse order to the removal procedure.
Solenoid valve (single)
45°
Solenoid valve (triple)
15°
104442-00EN00
7-4-22 172663 0BKC2-EN0060

7-4-6 Removing and Reinstalling the selector valve
1) Removal
Procedure
(1) Remove the floormat 1, seat mount cover 2, and GPS
cover 3. 1
2
3
104443-00X00

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 4
4 104286-00X00
7-4-23 172663 0BKC2-EN0060

Procedure
(3) Disconnect the main harness 7 and seat mount harness 8
from the selector valve b.
8
6
104444-00X00
(4) Disconnect the hydraulic hoses (x8) from the selector d

valve 6. a
a. Hose T2 c. Hose B1 c
b. Hose T1 d. Hose B2 b e
e. Hose P2 f. Hose A2
g. Hose P1 h. Hose A1
Note: h
installed in their original positions. f
g
6 104445-00X00
7-4-24 172663 0BKC2-EN0060

Procedure
(5) Remove the bolts 10 (x2) which fix the selector valve 9,
and then remove the selector bracket 8 together with the
selector valve 6.
10
104446-00X00
(6) Remove the bolts 11 (x2) which fix the selector valve 6,
and then remove the selector valve 6 from the selector 6
bracket 9.
11
104447-00X00
2) Reinstallation
Reinstall the selector valve in the reverse order to the removal procedure.
7-4-25 172663 0BKC2-EN0060

7-4-7 Removing and installing the line filter
1) Removal
Procedure
(1) Remove the floormat 1, seat mount cover 2, and GPS
cover 3.
1
104448-00X00

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 4
4 104286-00X00
(3) Remove the hydraulic hoses (x3) from the line filter 6.
Hose clips (19)

Hose clips (41) 6

Note:
104449-00X00
7-4-26 172663 0BKC2-EN0060

Procedure
(4) Remove the bolts 7 (x2) which fix the line filter 6, and then
remove the line filter 6 from the track frame.
6
104450-00X00
2) Reinstallation
Reinstall the line filter in the reverse order to the removal procedure.
15°
104451-00X00
7-4-27 172663 0BKC2-EN0060

7-4-8 Removing and installing the charge filter
1) Removal
Procedure
104452-00X00

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 4
4 104286-00X00
7-4-28 172663 0BKC2-EN0060

Procedure
(3) Remove the hydraulic hoses (x3) from the charge filter 6.
Note:
104453-00X00
(4) Remove the bolts 7 (x4) which fix the charge filter 6, and
then remove the charge filter 6 from the track frame.
6
104454-00X00
7-4-29 172663 0BKC2-EN0060

2) Reinstallation
Reinstall the charge filter in the reverse order to the removal procedure.
60°
7-4-30 172663 0BKC2-EN0060

7-4-9 Removing and Reinstalling the accumulator
1) Removal
Procedure
(1) Remove the floormat 1, front step 2, and front footrest 3.
104448-00X00

Q'ty 15.8 Gals (60 L)
Note:
draining.
Magnetic plug 4
4 104286-00X00
(3) Disconnect the hydraulic hoses (x2) from the connector 6.
Note:
(4) Remove the bushing 7 and connector 6 from the accumu-

lator 8.
6
7
8
104456-00X00
7-4-31 172663 0BKC2-EN0060

Procedure
(5) Loosen the bolt 9 which fixes the accumulator 8, and then
remove the accumulator 8.
8 104457-00X00
2) Reinstallation
Reinstall the accumulator in the reverse order to the removal procedure.
7-4-32 172663 0BKC2-EN0060

7-4-10 Removing and Reinstalling the dump cylinder (Three-side flaps wagon type)
1) Removal
Procedure
port stopper 1.
078684-00X02

Q'ty 15.8 Gals (60 L)
Note:
when draining.
Magnetic plug 2
2 104360-00X00
(3) Disconnect the hydraulic hoses (x2) from the dump cylin-
der 4.
Note:
Attach the dust caps/plugs to the ends of the hoses.
104458-00X00
7-4-33 172663 0BKC2-EN0060

Procedure
(4) Suspend the dump cylinder 4 with a rope, and remove pin
30 5. Then, remove the dump cylinder 4.
104459-00X00
2) Reinstallation
Reinstall the dump cylinder in the reverse order to the removal procedure.
7-4-34 172663 0BKC2-EN0060

7-4-11 Removing and Reinstalling the dump cylinder (Swing wagon type)
1) Removal
Procedure
port stopper 1.
109382-00X00

Q'ty 15.8 Gals (60 L)
Note:
when draining.
Magnetic plug 2
2 104360-00X00
der 4.
Note:
4
109390-00X00
7-4-35 172663 0BKC2-EN0060

Procedure
(4) Suspend the dump cylinder 4 with a rope, and remove pin
30 5. Then, remove the dump cylinder 4.
6
109391-00X00
2) Reinstallation
Reinstall the dump cylinder in the reverse order to the removal procedure.
7-4-36 172663 0BKC2-EN0060

7-4-12 Removing and Reinstalling the hydraulic oil tank
1) Removal
Procedure
port stopper 1
078684-00X02

Q'ty 15.8 Gals (60 L)
Note:
when draining.
Magnetic plug 2
2 104360-00X00
(3) Disconnect the temperature sensor 4 and main harness 5.
5
4
104460-00X00
7-4-37 172663 0BKC2-EN0060

Procedure
(4) Remove cover 6 only for swing wagon type.
(5) Disconnect the hydraulic hoses (x5) from the hydraulic oil 7
tank 7.
6
Hose clips (19) (Swing wagon type)
Hose clips (22)

Hose clips (35)

Hose clips (41)

104461-00EN00
Note:
(6) Remove the bolts 8 (x4) which fix the hydraulic oil tank 7,
and then remove the hydraulic oil tank.
M14 bolts
7
Note:
Use lifting equipment when removing the hydraulic oil tank. 8
104462-00X01
7-4-38 172663 0BKC2-EN0060

2) Reinstallation
Reinstall the hydraulic oil tank in the reverse order to the removal procedure.
60° 60°
45° 30°
104463-00X00
3) Refueling
Procedure
(1) Fill the hydraulic oil tank until the level indicated on the
gauge is between the upper and lower limits. Level indicated

Q'ty 29.6 Gals (28 L) Upper limit
Lower limit
Note:
Do not fill to above the upper limit line.
104464-00EN00
Confirmation posture
078656-00EN02
7-4-39 172663 0BKC2-EN0060

7-4-13 Disassembly and Reassembly of wagon swing motor
1) Removal
Procedure
port stopper 1.
109382-00X00

Q'ty 15.8 Gals (60 L)
Note:
when draining.
Magnetic plug 2
2 104360-00X00
(3) Disconnect hydraulic hoses (x5) from wagon swing motor

4. b c d
a
a. Hose Pb
b. Hose A
c. Hose M
d. Hose Db
e. Hose B
4 e
Note:
109392-00X00
7-4-40 172663 0BKC2-EN0060

Procedure
(4) Install eyebolt on swing motor 4.
(5) Loosen bolts 5 (x6) for holding swing motor 4.
(6) Hoist swing motor 4 with rope or sling belt to remove

swing motor 4.
4
109393-00X00
2) Reinstallation
Reinstall the swing motor in the reverse order to the removal procedure.
Bolt 5
7-4-41 172663 0BKC2-EN0060

7-4-14 Removal and Reinstallation of Swivel Joint
1) Removal
Procedure
port stopper 1.
109382-00X00

Q'ty 15.8 Gals (60 L)
Note:
when draining.
Magnetic plug 2
2 104360-00X00
7-4-42 172663 0BKC2-EN0060

Procedure
(3) Disconnect hydraulic hoses (x14) from swivel joint 4.
h
a. Hose Dr h. Hose Dr g
i
b. Hose G i. Hose B j f
c. Hose E j. Hose C
d. Hose A k. Hose B e
e. Hose B l. Hose D k
f. Hose G m. Hose A
g. Hose D n. Hose C l
4
d
n
Note: m
a b
c
109394-00X00
(4) Loosen four bolts 5 to remove swivel joint 4.
5 109395-00X00
7-4-43 172663 0BKC2-EN0060

2) Reinstallation
Reinstall the swivel joint in the reverse order of the removal procedure.
Bolt 5
3) Installation angle of connectors and joints
D
E C 40°
15°
F A
View from A
View from D
45°
View from E
60°
45°
View from B
30°
40°
View from F
View from C
109396-00EN00
7-4-44 172663 0BKC2-EN0060

7-4-15 Disassembly and Reassembly of swing bearing
1) Removal
Procedure
port stopper 1.
109382-00X00

Q'ty 15.8 Gals (60 L)
Note:
when draining.
Magnetic plug 2
2 104360-00X00
der 4.
Note:
4
109390-00X00
7-4-45 172663 0BKC2-EN0060

Procedure
(4) Hoist dump cylinder 4 with rope or sling belt and remove
two pins 30 5, 6 to remove dump cylinder 4.
6
109391-00X00
(5) Hoist wagon 7 with rope or sling belt and remove two pins
8 to remove wagon 7.
109397-00X00
7-4-46 172663 0BKC2-EN0060

Procedure
(6) Disconnect hydraulic hoses (x5) from wagon swing motor
9. b c d
a
a. Hose Pb
b. Hose A
c. Hose M
d. Hose Db
e. Hose B
9 e
Note:
109398-00X00
(7) Install eyebolt on swing motor 9.
(8) Loosen bolts 10 (x6) for holding swing motor 9.
(9) Hoist swing motor 9 with rope or sling belt to remove

swing motor 9.
9
10
109399-00X00
7-4-47 172663 0BKC2-EN0060

Procedure
(10)Disconnect greasing hose 11 from swing bearing.
11
109400-00X00
(11)Loosen bolts 12 (x20) holding the swing bearing.
(12)Hoist swing wagon frame 13 with rope or sling belt to

remove swing wagon frame 13.
12
13
109401-00X00
7-4-48 172663 0BKC2-EN0060

Procedure
(13)Turn swing wagon frame 14 upside down.
16
Note:
Place it on blocks. 15
14
(14)Loosen ten bolts 16 to remove swing bearing 15.
Block 109402-00EN00
7-4-49 172663 0BKC2-EN0060

2) Reinstallation
Reinstall the swing bearing in the reverse order of the removal procedure.
Precaution of reassembly
A soft zone is made at the starting point of the hardening on the inner and outer races of the swing bearing, and the
"S" mark is indicated on the upper surface of the inner race.
The outer race also has a soft zone at the steel ball insertion port area.
To decrease the load on this soft zone area, place the "S" mark of the inner race on the left side of the track frame
and install the outer race to place the soft zone (steel ball insertion port area) of it on the left side of the turning
frame, as shown to the right figure.
12
Soft zone of inner race
15
Steel ball insertion port

Soft zone of outer race
16 109403-00EN00
Note:
Apply grease to the swing bearing: Lithium soap group (extreme pressure type) multi-purpose grease NLGI No.2
Before installation, coat grease on each pin and pin bore for prevention from scuffing or seizure: Lithium soap group
(extreme pressure type) multi-purpose grease NLGI No.2
M12 bolt 12
M12 bolt 15
Apply locking agent: Locktite 262 or K-965
7-4-50 172663 0BKC2-EN0060

7-4-16 Piping Layout
1) Tank to pump and control valve (Three-side flaps wagon type)
B3
B1
PgC
A
F D
C B2
A1 B
Pp1
A2
A3
E
C
A1
Charge filter
Control valve
Accumulator
B
E A
P
104465-00EN00
7-4-51 172663 0BKC2-EN0060

2) Tank to pump and control valve (Swing wagon type)
B3
B1
A PgC
C F D
A1 B2
Pp1
B
A2
A3
E
A1 C
Hydraulic pump

Accumulator
Hydraulic oil tank
D
P
Charge filter E A
Control valve P
F
109406-00EN00
7-4-52 172663 0BKC2-EN0060

3) Return (Three-side flaps wagon type)
T1
T2
A
E
G
Control valve
Hydraulic pump
Hydraulic oil tank
G
F
Oil cooler

F B Line filter
C
A
D
T
T
E
B D 104466-00EN00
7-4-53 172663 0BKC2-EN0060

4) Return (Swing wagon type)
T1
T2
A
E
G
Control valve
Hydraulic pump
Hydraulic oil tank
G
F Solenoid valve (single)
Oil cooler

F B Line filter
C
A
D
T
T
E
B D 109407-00EN00
7-4-54 172663 0BKC2-EN0060

5) Pump to track frame (Three-side flaps wagon type)
P3
P2 P4
P1
C
D Hydraulic pump
I H
B
K
Travel motor (R)
B
A
C
D
T1
Ps
E
P1 Travel motor (L)
P2
F K
P3 L
J
F
Pf L T2 I
P3
Pf H
P2
E P1
B1
A
B1 J
A
G A
Ps G
104467-00EN00
7-4-55 172663 0BKC2-EN0060

6) Pump to track frame (Swing wagon type)
P3
P2 P4
P1
C
D Hydraulic pump
I H
B
K
Travel motor (R)
B
A
C
D
T1
Ps E
P1 K
P2 F Travel motor (L) L
J
P3
T2 I
F
Pf L P3
Pf H
P2
P1
B1
A
A
G A B1 J Ps G
109408-00EN00
7-4-56 172663 0BKC2-EN0060

7) Control valve to dump cylinder (Three-side flaps wagon type)

A
Dump cylinder
Control valve
B
A
A1
B1
104468-00EN00
7-4-57 172663 0BKC2-EN0060

8) Control valve to swivel joint (Swing wagon type)

F
E
B
D
A
G C C
A
G
Dr
G E
B
D
Swivel joint
D
C F
E
Control valve
B A2
B2
A1
B1
B2 A
109409-00EN00
7-4-58 172663 0BKC2-EN0060

9) Travel motor to swivel joint (Swing wagon type)
B
B
M
D Db
Pb
Swing motor
Swivel joint
E
D
B
C
A E A
Dr
G
109410-00EN00
7-4-59 172663 0BKC2-EN0060

10)Swivel joint to dump cylinder (Swing wagon type)
B
A
Dump cylinder
Swivel joint
B
A
B
D
109411-00EN00
7-4-60 172663 0BKC2-EN0060

11)Control piping (travel lever side) (Three-side flaps wagon type)
P
Pp6
4
Pp5 1
Pp4 T J
Pp3 2
H
C 3
D
B E F
A Hydraulic pump I
G
Selector valve
Pilot valve
F G I H
J
T1
T2 P2
B3 P1
E
A1 B1
B2
D
A2
B C
A 104469-00EN00
7-4-61 172663 0BKC2-EN0060

12)Control piping (travel lever side) (Swing wagon type)
P
Pp6
4
Pp5 T 1 J
Pp4
H
2
Pp3
C 3
B D E F
I
A Hydraulic pump G
Selector valve
Pilot valve
F G I H
J
T1
T2 P2
P1
B3
E A1 B1
A2 B2 D
B C
A 109412-00EN00
7-4-62 172663 0BKC2-EN0060

13)Control piping (wagon control lever side) (Three-side flaps wagon type)
1
2
P
C Valve
D
T
A
B
Control valve
C
A
B2 Pa1
D
B
Pb1
104470-00EN00
7-4-63 172663 0BKC2-EN0060

14)Control piping (wagon control lever side) (Swing wagon type)

Valve
T
2 Control valve
E
P
3
1
4
C
F D
B
A
B
A
B2
Pa2
D Pa1
C Pb2
Pb1
109413-00EN00
7-4-64 172663 0BKC2-EN0060

7-5 Wagon
7-5-1 Wagon components (Three-side flaps wagon type)
10
13
9 11
12
1
8
7
2
4
104471-00X00

1 Cylinder shaft pin 2 6 Pin 1 11 Rubber 4
2 Rubber 2 7 Flat head pin 4 12 Side flap 2
3 Wagon 1 8 Grease nipple 2 13 Flap lever 4
4 Block 1 9 Rubber 4
5 Pin 1 10 Rear flap 1
7-5-1 172663 0BKC2-EN0060

1
3
5
6 1
1 7
1
6
5 104472-00X00
No. Part Q’ty No. Part Q’ty

1 Pin 4 5 Spring 2
2 Arm 1 6 Drive rod for hook 2
3 Arm 1 7 Joint 2
4 Hook 2
7-5-2 172663 0BKC2-EN0060

1) Removal
Procedure
port stopper 1
078684-00X02
(2) Suspend flap 2 with a rope, release the locks on the right
and left, and then remove the flap 2.
104473-00X00
(3) Lower the wagon, and then lower the right/left flaps 3.
(4) Suspend flaps 3 with a rope, remove bolts 4 (x2), and

then remove the flaps 3.
104474-00X00
7-5-3 172663 0BKC2-EN0060

Procedure
(5) Suspend the wagon 5 with a rope, and remove pins 30 6,
and 7. Then, remove the wagon 5.
104475-00X00
2) Reinstallation
Reinstall the wagon in the reverse order to the removal procedure.
7-5-4 172663 0BKC2-EN0060

3) Adjustment
Procedure
(1) Lower the wagon to close the hook. Lock nut Adjusting bolt
(2) Adjust the adjuster bolt so that clearance generated by

the elongation of the spring of the hook actuation rod is
approximately 0.2 in. (4 mm.)
(3) Hold the bolt with the lock nut.
Adjust the clearance

to about 0.2 in. (4 mm).
Drive rod (for hook)
104476-00EN00
(4) Raise the wagon by about 10 degrees to check that the

rear flap can be released from the hook.
Apply multipurpose grease to all the sliding surfaces.
Hook
Hook should be
operated smoothly. Apply multipurpose grease.
104477-00EN00
7-5-5 172663 0BKC2-EN0060

7-5-2 Wagon components (Swing wagon type)
1
7
2
6
109404-00X00

1 Cylinder shaft pin 2 4 Pin 1 6 Rubber 2
2 Flat head pin 4 5 Pin 1 7 Grease nipple 2
3 Wagon 1
7-5-6 172663 0BKC2-EN0060

1) Removal
Procedure
port stopper 1.
109382-00X00
(2) Remove rod end pin 30 2 from dump cylinder.
(3) Suspend the wagon 4 with a rope, and remove pins 3.

Then, remove the wagon 4.
4
109405-00X00
2) Reinstallation
Reinstall the wagon in the reverse order to the removal procedure.
Note:
Coat grease on pin: Lithium soap group (extreme pressure type) multi-purpose grease NLGI No.2
7-5-7 172663 0BKC2-EN0060

7-5-3 Removing and installing the canopy
1) Removal
Procedure
(1) Remove the floormat 1. 1
104478-00X00
(2) Remove the front cover 2.
2 104479-00X00
7-5-8 172663 0BKC2-EN0060

Procedure
(3) Remove the bolts 4 (x9) and 5 (x3), and then remove the
canopy 3 by using lifting equipment.
3
5
104480-00X00
2) Reinstallation
Reinstall the canopy in the reverse order to the removal procedure.
Bolt 10.9 12 x 35 5 (x9)

Bolt 10.9 12 x 45 5 (x3)

7-5-9 172663 0BKC2-EN0060

CHAPTER 8
TROUBLESHOOTING
8-1 Troubleshooting .................................................................................. 8-1-1

8-1-1 Machine and Engine .................................................................. 8-1-1
8-1-2 HST relationship ........................................................................ 8-1-8
8-1-3 Electrical Equipment ................................................................ 8-1-16
8. TROUBLESHOOTING
8. Troubleshooting
8-1 Troubleshooting
8-1-1 Machine and Engine
(How to use the charts)
Trouble
A ψ Aa ψ Ab
B ψ Ba ψ Bb ψ Bc
C ψ Ca ψ Cb ψ Cc ψ Ce
Factors related to the trouble are enumerated

in the columns and instructions for corrective
procedures are given below. It is recommended
that the troubles be inspected and corrected
one by one according to the chart.
φ Inspection item
φ Remedy for failure 000951-00E
8-1-1 172663 0BKC2-EN0060

8. TROUBLESHOOTING
Black smoke
emission
HST pump
Does the work Hydraulic Relief set pressure
implement work normally? power source of control valve
4975 PSI (34.3 MPa)
Low output Refer to ”Low output”
Fuel Improper fuel
Replace
Improper Excessive Uneven injec-
Fuel system
injection control injection volume tion volume
Adjust Adjust Adjust or replace
Cooling water Low cooling Damage or Clogging of Excessive exhaust
Loose fan belt
system water level wear of fan belt radiator resistance
Supply Adjust Replace Clean Clean
Clogging or defect of Defective Clogging of Malfunction of Malfunction

radiator cap thermostat radiator hose cooling water pump of radiator
Clean or replace Replace Clean Replace Replace
Excessive intake Clogging of Clogging of
resistance air cleaner intake pipe
Clean or replace Clean
Excessive exhaust Clogging of DPF, silencer, Clogging of Clogging of Clogging of cylinder

resistance of the EGR system exhaust pipe exhaust manifold head exhaust port
Clean Clean Clean Clean
White smoke
emission
Mixing with low

Fuel Water in fuel
quality fuel or impurities
Replace Replace
Lube oil Improper grade

Replace
Excessive intake Clogging of air Clogging of
resistance cleaner intake pipe
Clean or replace Clean or replace
Improper
Fuel system
injection control
Adjust
Defective valve Damage or wear Damage or wear
Oil down
stem seal of valve stem of valve guide
Replace Replace Replace
Closed gap position fault and reverse Sticking, damage Scuffing or Scuffing or
Oil up
assembling of piston ring or wear of piston ring wear of piston wear of liners
Replace Replace Replace Replace
Gas leak from
head gasket
Excessive Replace
Malfunction of thermostat
cooling
Replace 023827-03EN00
8-1-2 172663 0BKC2-EN0060

8. TROUBLESHOOTING
Low output
Does wagon Hydraulic power Charge relief set

Low relief pressure
operate normally? source pressure
406 PSI (2.8 MPa)
HST pump
Excessive Clogging of Clogging of
Main relief set pressure
intake resistance air cleaner intake pipe
Clean Clean 4975 PSI (34.3 MPa)
Excessive Clogging of Clogging of exhaust

Clogging of mXIÀHU
exhaust resistance exhaust pipe port of cylinder head
Clean or replace Clean Clean
Defective fuel Clogging of

Air in fuel system Clogging of fuel pipe
system IXHO¿OWHU
Release the air Clean or replace Clean
Clogging of air release

port in fuel tank
Improper fuel Stick of fuel Abnormal fuel

injection pressure injection valve infection
Adjust Replace Replace
Malfunction of Clogging of
fuel pump chamber
Clean or replace
Low compression Improper clear- Defective seat of Seizing of intake Deterioration or

ance of intake or intake or exhaust or exhaust valve breakage of valve
pressure exhaust valve valve stem spring
Adjust Smooth or replace Replace Replace
Compression leak Stick, damage, or 6FXI¿QJRU 6FXI¿QJRUwear

from head gasket wear of piston ring wear of piston of liners
Replace Replace Replace Replace
Refer to
Overheating
“Overheating” 105062-00EN00
8-1-3 172663 0BKC2-EN0060

8. TROUBLESHOOTING
Overheating
HST pump
Does the work
Hydraulic Relief set pressure
implement work
power source of control valve
normally?
4975 PSI (34.3 MPa)
Damage or Excessive
Cooling water Low cooling Clogging of
Loose fan belt wear of fan exhaust
system water level radiator
belt resistance
Supply Adjust Replace Clean Clean
Clogging or Malfunction
Defective Clogging of Malfunction
defect of of cooling
thermostat radiator hose of radiator
radiator cap water pump
Clean or replace Replace Clean Replace Replace
Excessive intake Clogging of Clogging of

resistance air cleaner intake pipe
Clean or replace Clean
Clogging of Clogging of
Excessive exhaust Clogging of Clogging of
DPF, silencer, cylinder head
resistance exhaust pipe exhaust manifold
of the EGR system exhaust port
Clean Clean Clean Clean
Gas leak from Crack of

Cylinder head
head gasket cylinder head
Replace Replace
Improper
Fuel system Defective injector
injection control
Correct Repair or replace
Intake or exhaust Improper clear- Improper valve

valve opening/ ance of intake or opening/closing
closing timing exhaust valve timing
Adjust Adjust
Ring sticking
Piston ring
or breakage
Replace 023826-04EN 00
8-1-4 172663 0BKC2-EN0060

8. TROUBLESHOOTING
Starter motor does not turn Except seizure of engine and

or output is low. trouble of any work implement
Disconnection
Disconnection Connection
or connection Battery terminal Ground terminal
of wire failure of coupler
failure
Repair Repair Repair Repair
Insufficient specific
Battery Shortage of voltage Damaged battery
gravity of electrolyte
Recharge Supply electrolyte Replace
or recharge
Damage or rust of Internal contact Damaged

Starter switch
terminal failure of switch switch
Replace or repair Replace Replace
Power relay and Damage or rust Malfunction of

starter relay of terminal relay
Replace or repair Replace
Malfunction or
Damage or rust Defective Burnout of Layer
Starter motor poor contact of
of terminal brushes coil short-circuit
magnetic switch
Replace or repair Replace Replace starter Replace starter
motor motor
Defective engine
Clutch slipping
ECU
Replace Replace 075891-00EN00
Inspection procedures
When the starter motor cannot be started by turning the starter switch on, check it as follows.
(Battery, starter switch and wiring assumed to be normal.)
(1) Safety relay and starter motor magnetic switch

Connect the S-and B-terminals of the starter motor directly.
[1]When the starter motor turns: The safety relay is faulty.
[2]When the starter motor does not turn: Either the starter motor magnetic switch or the starter motor is faulty.
(2) Starter motor
Connect the B-and M-terminals of the starter motor directly. S
[1]When the starter motor turns: Magnetic switch is faulty. B
M
[2]When the starter motor does not turn: Starter motor is faulty.
000952-01E
8-1-5 172663 0BKC2-EN0060

8. TROUBLESHOOTING
Battery dies or battery

cannot be charged (during operation)
Charging failure Discharges
Disconnection Battery Ground Discon- Connection Starter

or connection Ѝ
terminal Ѝ terminal Ѝ nectionof Ѝ failure of switch
Ѝ ON
failure wire coupler
Repair Repair Repair Repair Turn off
Damaged Deterioration
Battery Ѝ Ѝ Wiring Ѝ Short-circuit
battery of battery
Replace Replace Replace
Starter Damage Internal contact

Ѝ ON Ѝ or rust of Ѝ Electrical
switch failure of switch Ѝ Alternator
terminal equipment
Turn on Repair or Replace
replace
Electrical Damaged
Ѝ Alternator Regulator
equipment diode
Replace
Short-circuit or Short-circuit
Loose fan belt
breakage of lead wire of coil
Adjust Replace Replace
alternator
Damaged diode Defective IC regulator

Replace Replace regulator
Defective
brushes
Replace
Burnout
of coil
Replace alternator
Layer short-circuit
Replace alternator 001159-01E
8-1-6 172663 0BKC2-EN0060

8. TROUBLESHOOTING
Wagon does not swing
Is vessel operation See “Wagon operating

normal ? failure”.
Control valve Defective control

valve
Replace
Defective
Swivel joint
swivel joint
Replace
Swing motor Defective swing

motor
Replace
Defective swing
Swing bearing
bearing
Replace 109604-00EN00
8-1-7 172663 0BKC2-EN0060

8. TROUBLESHOOTING
8-1-2 HST relationship
1) How to read the chart
㧦Trouble
㧦Inspection/repair instructions
㧦Check item
㧦Factors in trouble or treatment
000955-00E
8-1-8 172663 0BKC2-EN0060

8. TROUBLESHOOTING
2) Machine does not travel
Machine does not travel
Either forward
or reverse Turn the operator’s seat,
Does machine not travel
either forward or reverse? and check if the failure
condition changes.
Both forward and reverse

Does direction (forward/reverse) YES
Try to operate the crawler in the in which the machine
direction (forward/reverse) that cannot travel change?
causes the machine unable to
travel. Check that the load is
applied to the engine. Clean or replace selector valve.
NO
Clean or replace travel remote control valve.
Swap P1 and P2 of the travel

motor, and check if the
failure condition changes.
Does direction (forward/reverse) YES

in which the machine
cannot travel change?
NO
Clean or replace travel Clean or replace main relief

motor flushing valve. valve of hydraulic pump.
Is no load applied YES Does not wagon YES Is oil amount in hydraulic YES
to engine? work properly? oil tank inappropriate?
NO NO NO
Fill tank with hydraulic oil.
See the next page. See the next page.
YES
Is charge filter clogged?
NO
Clean or replace filter.
Is charge pressure normal? YES

406 PSI (208 MPa)
NO
Clean or replace triple solenoid
Clean or replace valve valve for traveling and implement.
assembly of pump.
107706-00EN00
8-1-9 172663 0BKC2-EN0060

8. TROUBLESHOOTING
3) Machine does not travel (continued)]

From the previous page. From the previous page.
YES Measure the pressure at the

Is crawler disengaged? pilot port Pp3 to Pp6 of the pump.
Wear a crawler
NO
YES Is pressure normal? Swap the pipes between the right/left

Is soil stuck in crawlers? YES
363 PSI (2.5 MPa) at 2830 rpm travel motors, and check if the
failure condition changes.
NO Clean crawlers.
NO
See “Parking brake releasing failure”. Does direction (forward/reverse) YES

Measure the pressure at P port in which the machine
of the travel remote control valve. cannot travel change?
(With engine being idled.)
If the failure is not resolved
NO
Measure the pressure at B1 p Repair or replace traveｌmotor valve Repair or replace pump.
ort of the triple solenoid valve
with the engine being idled.
Is pressure normal? YES

363 PSI (2.5 MPa) at 2830 rpm
406 PSI (2.8 MPa) or higher NO
Clean or replace connector filter
Repair or replace travel motor. of P port for remote control valve.
NO Measure the pressure at A3
port of the triple solenoid valve. Repair or replace remote control valve.
(With engine being idled.)
Clean or replace triple
solenoid valve for parking brake.

363 PSI (2.5 MPa) at 2830 rpm
NO
Clean or replace triple solenoid
Clean or replace valve assembly of pump. valve for traveling and implement.
107707-00EN00
8-1-10 172663 0BKC2-EN0060

8. TROUBLESHOOTING
4) Low power for traveling
Low power for traveling
Is crawler tension not YES

properly adjusted?
Adjust crawler tension.
NO
YES
Clean crawlers.
NO
Check the working condition that
requires more power
(forward/reverse/right/left).
Low power on all YES Is charge pressure proper? YES Measure the pressure at
work conditions? 406 PSI (208 MPa) Pp1 port of the pump.
NO NO
Clean or replace valve assembly of pump
363 PSI (2.5 MPa) at 2830 rpm
Is pressure of the main
relief valve normal? YES
5004 PSI (34.5 MPa) Repair or replace travel motor.
NO
NO Repair or replace travel motor. Clean or replace valve assembly of pump.
Clean or replace
main relief valve.
107708-00EN00
8-1-11 172663 0BKC2-EN0060

8. TROUBLESHOOTING
5) Excessive track deviation
Excessive track deviation
Is crawler tension not YES

properly adjusted?

NO
YES
Clean crawlers.
NO
Change the engine speed when the travel
lever is at full stroke position, and
check if the failure condition changes.
Jack up the machine, and

Track deviation occurs YES
measure the rotational
at any engine speed?
speed of both crawlers.
NO
Only when engine
speed is 2200 rpm or more.
Engine speed when Swap the pipes between the right/left
track deviation occurs? Any difference in rotational YES
speed of right/left crawlers? travel motors, and check if the
Adjust pump flow rate. failure condition changes.
Only when engine Adjust crawler tension.
NO
speed is less
Replace pump.
than 2200 rpm
Measure the pressure at the pilot port Excess wear on YES YES
undercarriage parts? Failure condition changes?
Pp3 to Pp6 of the pump
(when the travel lever is used).
NO Replace undercarriage parts Repair or replace pump.

NO
Repair or replace travel motor.

363 PSI (2.5 MPa) at 2830 rpm Big difference in wear YES
between right and left lugs?
NO Repair or replace pump. Replace crawlers.

NO
Clean or replace Clean or replace valve assembly of pump.

remote control valve.
107709-00EN00
8-1-12 172663 0BKC2-EN0060

8. TROUBLESHOOTING
6) Sluggish response
Sluggish response to travel
YES
Is not air bled from pump?
Bleed air.
NO
Check the working condition that
causes sluggish response
(forward/reverse/right/left).
Sluggish response YES Is charge pressure normal? YES

on all works? 406 PSI (208 MPa)
Measure the pressure at
NO NO
Pp1 port of the pump.
Turn the operator’s seat, and Clean or replace valve assembly of pump.
check if the failure condition changes.
363 PSI (2.5 MPa) at 2830 rpm
Failure condition YES Repair or replace pump.

NO
changes?
Clean or replace remote control valve. Clean or replace valve assembly of pump.
NO
Swap the pipes between the
right/left travel motors, and check
if the failure condition changes.
Failure condition YES

changes?
Repair or replace pump.
NO
Clean or replace travel motor flushing valve.

107710-00EN00
8-1-13 172663 0BKC2-EN0060

8. TROUBLESHOOTING
7) Implement failure
Wagon cannot be raised, or raising is slow.
Does payload on wagon YES

exceed maximum payload
capacity (2.5 t)?
Adjust payload on wagon.
NO
Is oil amount in hydraulic YES

oil tank inappropriate?
Fill tank with hydraulic oil.
NO
Measure the pressure at

pilot oil port (pb1) of
the control valve.
Is pilot oil pressure of control YES Is relief pressure of YES

valve normal? control valve normal?
363 PSI (2.5 MPa)
Repair or replace dump cylinder.
NO
NO
Clean, adjust, or replace

relief valve of control valve.
YES Measure the pressure at B2 port

Is charge pressure normal? of the triple solenoid valve
406 PSI (208 MPa) with the engine being idled.
NO
Is pressure normal? 406 PSI YES
(2.8 MPa) at 2830 rpm
Clean or replace valve assembly of pump.
Clean or replace triple
NO solenoid valve for implement.
Clean or replace remote

control valve of implement.
107710-00EN00
8-1-14 172663 0BKC2-EN0060

8. TROUBLESHOOTING
8) Switching failure between low/high speed
Switching failure between low/high speed
One of travel motors

Where is switching failure occurring?
Clean or replace spool for switching

low/high speed of travel motor.
Both travel motors
Clean or replace travel
motor flushing valve.
YES
Is charge pressure normal? 406 PSI (208 MPa)
Clean or replace valve assembly of pump.

NO
Measure the pressure at A

port of single solenoid valve.
YES
Is pressure normal? 406 PSI (208 MPa)
Clean or replace spool for switching

NO low/high speed of travel motor.
Clean or replace travel
motor flushing valve.
Clean or replace single solenoid valve.

107718-00EN00
8-1-15 172663 0BKC2-EN0060

8. TROUBLESHOOTING
8-1-3 Electrical Equipment
(1) How to read the chart
㧦Trouble
㧦Inspection/repair instructions
㧦Check item
㧦Factors in trouble or treatment
000955-00E
(2) Refer to the wiring diagram for the number of the connector terminal and lead wire color.
(3) Color marks of leads

W (White) B (Black) R (Red) Y (Yellow)
G (Green) L (Blue) Br (Brown) Lg (Light green)
O (Orange) Gr (Gray)
Combination of colors
Example : W R ..............(Red stripes on white background)
Marking color
Background color 001172-00E
8-1-16 172663 0BKC2-EN0060

8. TROUBLESHOOTING
1) LCD monitor failure
LCD monitor does not start with key switch ON.
Ensure the following conditions.

Battery cut switch is OFF (continuity state).
YES
Is fuse or slow blow fuse blown?
NO Replace fuse.
Disconnect the connectors from the

back of the monitor.
Check the voltage of the terminal (P).
YES Check the voltage YES

Is voltage 10 V or lower? Is voltage 10 V or lower?
of the battery.
NO NO Replace the battery.
Disconnect the connectors from the Replace harness.

back of the monitor. Check the
voltage of the terminal (O).
(Key switch ON)
YES Is relay (ACC-1) YES

Is voltage 10 V or lower?
disconnected?
NO NO
Insert relay again.
Disconnect the connectors from the Replace relay.
back of the monitor. Check the
continuity between the terminal Replace harness.
(B) and the body earth.
YES
Is there continuity?
NO
Replace the LCD monitor.
Grounding failure
106601-00EN00
8-1-17 172663 0BKC2-EN0060

8. TROUBLESHOOTING
2) Parking brake releasing failure

Parking brake cannot be released.

Cannot be released while engine is running.
Error code is not displayed in LCD monitor.
Right/left lock levers are in release position.
Operator’s seat is fixed to forward or reverse position.
YES YES
Is feed pump stopped? Is fuse (parking) blown?
NO Replace fuse.
NO
Disconnect the relay (safety), and Replace harness.
Can not wagon YES
then check the voltage of the
be operated? terminal (R/L). (Key switch ON)
NO
YES
Check if the machine can travel while

the parking switch is being hold. NO Replace cut-off switch.
Disconnect the relay (safety), and
YES
then check the voltage of the Is voltage 10 V or lower? See the next page.
terminal (R/W). (Key switch ON)
NO
Replace relay.
Replace harness.
YES YES
Does machine travel? Is relay (parking-2 off)
disconnected?
NO Insert relay again.
NO
Check the parking switch when it’s
turned off, and the “P” Disconnect the relay, and check the
lamp in the LCD monitor. voltage of the terminal (P).
(Key switch ON, parking switch OFF)
YES Disconnect the connector from the triple

Is parking lamp turned off? YES
solenoid valve, and check the voltage of Is voltage 10 V or lower?
the terminal (R/W) for SOL1 and SOL3.
(Key switch ON, parking switch OFF)
NO
NO
Replace harness.
Replace relay.
YES
Check the parking switch Is voltage 10 V or lower?
Replace harness.
when it’s turned off.
Replace harness.
NO
Replace triple solenoid valve.
YES
NO Replace relay (parking-2 off).
Replace parking switch. Replace relay (parking-3 lock).

Replace harness. Replace harness.
106602-00EN00
8-1-18 172663 0BKC2-EN0060

8. TROUBLESHOOTING
3) Parking brake releasing failure (continued)

From the previous page.
Is operator's seat fixed YES

to reverse position?
Disconnect the relay (forward), and

NO check the voltage of the terminal (Br).
(Key switch ON)
YES
NO Disconnect the relay (forward), and

check the voltage of the terminal (G).
Replace relay. (Key switch ON)
Replace harness.
Disconnect the relay (backward),
YES
Is voltage 10 V or lower? and check the voltage of the t
erminal (W/B). (Key switch ON)
NO
YES
and check the voltage of the Is voltage 10 V or lower?
terminal (Lg). (Key switch ON)
NO Replace harness.
YES Replace relay.
Replace harness.
Replace relay.
Disconnect the relay (forward),
and check the voltage of the Replace harness.
NO
terminal (Y/B). (Key switch ON)
Replace the seat switch (backward).
Replace harness.
YES
NO Replace the seat switch (forward).
Disconnect the relay (forward), Replace harness.

and check the voltage of the
terminal (G). (Key switch ON)
Disconnect the relay (forward),

YES and check the voltage of the
terminal (Br). (Key switch ON)
NO
Replace relay. Disconnect the relay (backward),
YES
Is voltage 10 V or lower? and check the voltage of the
Replace harness. terminal (Y/B). (Key switch ON)
NO
and check the voltage of the YES
terminal (Lg). (Key switch ON)
NO
Replace harness.
YES Replace relay.
Replace harness.
Replace relay.
NO
Replace the seat switch (backward). Replace harness.
Replace harness.
107712-00EN00
8-1-19 172663 0BKC2-EN0060

8. TROUBLESHOOTING
4) Wagon operating failure
Wagon does not operate properly.

Right/left lock levers are in release position.
YES
Is the fuse (vessel) blown?
Replace fuse.
NO
YES
Is fuse (parking) blown?
Replace fuse.
NO
Can the parking YES

brake be released?
NO Is the relay (vessel) YES

disconnected?
Insert relay again.
NO
See “Parking brake Disconnect the relay (vessel), and

releasing failure”. check the voltage of the terminal (O).
YES
Replace harness.
NO
Disconnect the relay (vessel),
terminal (Lg/Y). (Key switch ON,
wagon lock release switch ON)
Disconnect the connector from the

YES
Is voltage 10 V or lower? right lever, and check the voltage
of the terminal (G/Y). (Key switch ON)
NO
Disconnect the connector from the triple YES
solenoid valve, and check the voltage of the Is voltage 10 V or lower?
terminal (G/W) for SOL2. Key switch ON,
wagon lock release switch ON) Replace harness.
NO
Press the wagon lock release

YES switch to check if there is continuity.
Replace relay.
NO YES
Replace harness. Is there continuity?
Replace harness.
NO
Replace triple solenoid valve.
Replace wagon lock release switch.
106603-00EN00
8-1-20 172663 0BKC2-EN0060

8. TROUBLESHOOTING
5) Switching failure from low speed to high speed
Engine speed cannot be changed to high speed.

Disconnect the connector from the LCD

YES monitor, and check the voltage of the
Does the travel speed change?
terminal (L/W). (Key switch ON,
travel speed switch ON)
NO
YES
YES Is voltage 10 V or lower?
Is fuse (alarm/travel) brown?
Replace fuse. Replace harness.

NO
NO
Replace the LCD monitor.
Check high speed travel lamp in LCD monitor.
(Key switch ON, travel speed switch ON)

YES driving pilot oil pressure switch,
Is high speed travel lamp ON?
and check the voltage of the terminal (L/W).
NO
Check low speed travel lamp in LCD monitor.

YES
(Key switch ON, travel speed switch ON) Is voltage 10 V or lower?
Replace harness.
NO
Disconnect the relay (travel 2nd speed), Replace the driving
YES and check the voltage of the terminal (Br/W).
Is low speed travel lamp ON? pilot oil pressure switch.
Replace harness.
NO
Clean or replace the
single solenoid valve.
Is the relay (travel YES YES
2nd speed) disconnected? Is voltage 10 V or lower?
Replace travel speed switch.

Insert relay again. NO
NO
Replace harness.
Disconnect the relay (travel 2nd speed), Replace relay.
and check the voltage of the terminal
(Y/R). (Key switch ON)
YES
NO Replace harness.
Replace relay.
Replace harness.
106604-00EN00
8-1-21 172663 0BKC2-EN0060

8. TROUBLESHOOTING
6) Travel alarm (optional) operation failure
Travel alarm does not operate properly.

Travel alarm switch is ON.
YES
Is the fuse (vessel) blown?
NO Replace fuse.
YES
Is fuse (parking) blown?
NO Replace fuse.
Can the parking YES

brake be released?
NO Disconnect the connector from the

driving pilot oil pressure switch,
and check the voltage of the terminal (L).
See “Parking brake

releasing failure”. YES
NO Replace the travel alarm switch

Replace harness.
travel alarm, and check the
continuity between the
terminal (B) and the body earth.
YES
NO Replace the travel alarm.

Grounding failure
106605-00EN00
8-1-22 172663 0BKC2-EN0060

8. TROUBLESHOOTING
7) Operator’s seat turning failure
When operator’s seat is turned,

traveling direction is not changed.

Not working while engine is running.
Parking brake can be released with the
operator's seat facing reverse position.
YES
Is accelerator pedal switched?
NO
Replace harness. Disconnect the connector from the

selector valve, and check the
continuity of the terminal (Br).
(Key switch ON)
YES
NO Replace harness.

selector valve, and check the
continuity between the terminal
(B) and the body earth.
YES
Replace the selector valve.

NO
Grounding failure
106606-00EN00
8-1-23 172663 0BKC2-EN0060

8. TROUBLESHOOTING
8) Accelerator pedal switching failure
When operator’s seat is turned,

accelerator pedal is not switched.

Not working while engine is running.
Check if the parking brake can be released with

the operator's seat facing reverse position.
Can parking brake YES

be released?
NO
Is traveling direction YES
switched?
See “Parking brake
releasing failure”.
NO
Is relay (travel accel) YES
Replace harness. disconnected?
Insert relay again.

NO
Disconnect the relay (travel accel),

terminal (Br). (Key switch ON,
Fix seat to reverse position)
YES
Replace harness.
NO
Replace harness. 106607-00EN00
8-1-24 172663 0BKC2-EN0060

C30R-3
Service Manual
0BKC2-EN0060
1st Edition: Oct. 2017
Published by : Engineering & Development Dept.

Edited by : Customer Support Dept.
Finished by : YANMAR TECHNICAL SERVICE CO., LTD.
Copyright c 2017 YANMAR CONSTRUCTION EQUIPMENT CO., LTD. All Rights Reserved.
This manual may not be reproduced or copied in whole or in part, without the written consent of
YANMAR CONSTRUCTION EQUIPMENT CO., LTD.

Yanmar Crawler Carrier C30R-3 Service Manual 0BKC200EN60

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Yanmar Crawler Carrier C30R-3 Service Manual 0BKC200EN60

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

4-7-7 Alternator Standard Output ........................................................................................................................................ 4-7-6

6-4-3 Exploded view and Parts comprised .......................................................................................................................... 6-4-7

7-4-6 Removing and Reinstalling the selector valve.......................................................................................................... 7-4-23

GENERAL CAUTIONS FOR MAINTENANCE WORK

1-1 Correct Work...........................................................................................1-1

1. GENERAL CAUTIONS FOR

1. General Cautions for Maintenance Work

1-1 Correct Work

1-2 Safety Precautions

1-4 Cautions for Disassembly and Reassembly

(1) Clean the machine before disassembly.

1-1 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

One and a half threads

1-5 Cautions for Removal and Installation of Hydraulic Equipment

(1) Check that the hydraulic oil temperature is low enough.

1-6 Cautions for Removal and Installation of Hydraulic Piping

(1) Installation of hydraulic hose

1-2 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

1-7 Cautions for Handling Seals

(1) Clean out grooves of O-rings. Remove burrs or dust if any.

1-8 Correct Installation of Hydraulic Hose

Not good Good

Not good Good

1-3 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

Not good Good

(6) Use an elbow to prevent excessive twisting or bending of the hose.

Not good Good

Not good Good

1-4 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

Not good Good

Not good Good

Hose mark Hose mark

1-5 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

1-9 Specifications of Hydraulic Hose

Description ..................... Hose P 2 06 AB 075 W

4 Nominal dia. (inch)

The example hose, P 2 06 AB 075 W stands for :

1-6 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

Fitting type Code Fitting type Code

60° 60 degrees bent type. UNF UNF, thread with O-ring

45° 45 degrees bent type.

90° 90 degrees bent O-ring

Straight pipe thread with

30° 30 degrees bent type.

1-7 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

1-10 Air Release of Hydraulic Equipment

1. Air Release of Variable Displacement Piston Pumps

1) Disconnect harness 1 connected to the solenoid valve for the

Solenoid valve for parking brake

1-8 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

7) Reconnect harness 1 connected to the solenoid valve for the park-

Solenoid valve for parking brake

1-9 172663 0BKC2-EN0060

1. GENERAL CAUTIONS FOR

2. Air Release of Each Hydraulic Component

Charge Filter L

L 1 0SD NJIFP2)