Professional Documents
Culture Documents
CX250C LR
Tier 4
Crawler Excavator
SERVICE MANUAL
Co-
Order No. Jig name Remarks
de
1 Bushing removal jig
2 Bushing press-fit jig
3 Floating seal installation jig
Co-
Order No. Jig name Remarks
de
Tapered roller bearing/inner race
1
assembly jig
2 Oil seal assembly jig 1
3 Cylinder assembly jig
4 Brake piston assembly jig
Co-
Order No. Jig name Remarks
de
5 Oil seal assembly jig 2
6 Pinion shaft assembly jig
Co-
Order No. Jig name Remarks
de
7 Brake piston removal jig
Co-
Order No. Jig name Remarks
de
1 Joint disassembly jig
84402826 - May 2011
1003-15
List of special tools
Co-
Order No. Jig name Remarks
de
2 Special jig 1 (for bushing removal)
3 Special jig 2 (for locking ring installation)
Hydraulic Circuit
5-8840-2675-0 (5-8531-
380002626 Compression Gauge (adapter)
7002-0)
CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
KHV0512 Cylinder head assembly and disassembly jig (70)
KHV0513 Cylinder head assembly and disassembly jig (75)
KHV0514 Cylinder head assembly and disassembly jig (80)
KHV0515 Cylinder head assembly and disassembly jig (85)
KHV0516 Cylinder head assembly and disassembly jig (90)
KHV0517 Cylinder head assembly and disassembly jig (95)
KHV0518 Cylinder head assembly and disassembly jig (100)
KHV0519 Cylinder head assembly and disassembly jig (105)
KHV0520 Cylinder head assembly and disassembly jig (110)
KHV0521 Cylinder head assembly and disassembly jig (115)
KHV0522 Cylinder head assembly and disassembly jig (120)
CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
KHV0527 Seal ring insertion and calibration jig (105)
KHV0528 Seal ring insertion and calibration jig (110)
KHV0529 Seal ring insertion and calibration jig (115)
KHV0530 Seal ring insertion and calibration jig (120)
KHV0531 Seal ring insertion and calibration jig (125)
KHV0532 Seal ring insertion and calibration jig (130)
KHV0533 Seal ring insertion and calibration jig (135)
KHV0534 Seal ring insertion and calibration jig (140)
KHV0535 Seal ring insertion and calibration jig (145)
KHV0536 Seal ring insertion and calibration jig (150)
KHV0537 Seal ring insertion and calibration jig (160)
KHV0539 Seal ring insertion and calibration jig (170)
1004
HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Conditions applicable to diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC FLUID
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
ENGINE OIL
The "CASE Tutela LE ENGINE OIL" is recommended for
your engine. This oil ensures correct lubrication of your
engine in all working conditions.
If the "CASE Tutela LE ENGINE OIL" cannot be obtained,
use the oil corresponding to one of the following cate-
gories:
API CJ-4.
ACEA E6.
FUEL
IMPORTANT:
The fuel must conform to Interim Tier 4/Stage 3B Ex- EPA regulation ultra low sulfur fuel only.
haust Gas Control Regulations.
Use grade number 2-D (S15) fuel. IMPORTANT:
Using other types of fuel may lead to stalled engine out- If a serious problem occurs when other fuels are used,
put or deterioration in fuel economy. the warranty is invalidated.
During cold weather (lower than -7℃), it is temporarily
acceptable to use a mixture of No. 1-D (S15) and No. Using a non-recommended fuel may lead to damage of
2-D (S15). the fuel injection pump, injector, DPD, and other fuel
Consult the fuel supplier or the CASE dealer. supply systems or to the engine.
If the temperature drops below the fuel cloud point, out- CASE assumes no responsibility for these damages.
put deficiency or engine start problems may occur due Note that the warranty will not be applied for these dam-
to wax crystals. ages.
It is recommended that the following safety information
Conditions applicable to diesel fuel be considered in order to prevent damage to the engine
fuel supply system.
The diesel fuel used must:
- Some fuel suppliers mix old engine oil and diesel fuel.
- be free from dust particles, even minute ones,
- have the proper viscosity, Makers of larger engine permit the use of this kind of
- have a high cetane number, fuel.
- present great fluidity at low temperatures, However, do not use diesel fuel contaminated with en-
- have low sulphur content, gine oil in customer's engines.
- have very little residual carbon. Not only will this fuel damage the engine, it may also
have a negative impact on the exhaust gas purification
RECOMMENDED CONDITIONS function.
Before using diesel fuel, confirm with the supplier
THAT CAN BE APPLIED TO whether the fuel complies with the above specifications.
DIESEL FUEL IMPORTANT:
Consult the supplier or the CASE dealer regarding ap-
- JIS (Japanese Industrial Standards): No. 2 propriate use of fuel additives.
- DIN (Deutsche Industrie Normen): DIN 51601 Do not use fuel oil or gasoline as these may damage the
- SAE-J-313C: SAE (Society of Automotive Engineers) engine.
based on No. 2-D (S15)
- BS (British Standards) based on BS/2869-1970: Class IMPORTANT:
A-1 In order to prevent condensation during cold weather, fill
- EN 590 (less than 10 ppm sulfur) the fuel tank to full after the completing the day's work.
- Or fuel specified by the country using these standards
and this machine
1005
Conversion Table
Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Metric to U.S
MULTIPLY BY TO OBTAIN
square meter 10.763 91 square foot
AREA:
hectare 2.471 05 acre
newton 3.596 942 ounce force
FORCE:
newton 2.224 809 pound force
millimeter 0.039 370 inch
LENGTH: meter 3.280 840 foot
kilometer 0.621 371 mile
MASS: kilogram 2.204 622 pound
MASS/AREA: kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY: gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME: kg/cubic meter 1.685 555 lb/cubic yd.
POWER: kilowatt 1.341 02 horsepower
kilopascal 0.145 038 lb/sq. inch
PRESSURE: bar 14.50385 lb/sq. inch
megapascal (MPA) 145.0385 psi
TEMPERATURE: degree C 1.8 x C +32 degree F
newton meter 8.850 748 lb/inch
TORQUE:
newton meter 0.737 562 lb/foot
VELOCITY: kilometer/hr 0.621 371 miles/hr.
cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
VOLUME: quart (US liquid)
litre 1.056 814
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
litre/min. 0.264 172 gallon/min. (US liquid)
VOLUME/TIME:
litre/min 0.219 969 gallon/min. (Imperial)
U.S to Metric
MULTIPLY BY TO OBTAIN
square foot 0.092 903 square meter
AREA:
acre 0.404 686 hectare
ounce force 0.278 014 newton
FORCE:
pound force 4.448 222 newton
inch 25.4 millimeter
LENGTH: foot 0.304 8 meter
mile 1.609 344 kilometer
pound 0.453 592 kilogram
MASS: gram
ounce 28.35
MASS/AREA: ton/acre 2241 702 kilogram/hectare
MASS/ENERGY: lbs/hp/hr. 608.277 4 gr/kW/hr.
MASS/VOLUME: lb/cubic yd. 0.593 276 kg/cubic meter
POWER: horsepower 0.745 700 kilowatt
lb/sq. inch 6.894 757 kilopascal
PRESSURE: lb/sq. inch 0.069 bar
psi lb/sq. inch 0.070 303 kg/sq. cm
psi 0.006 895 megapascal (Mpa)
TEMPERATURE: degree F 1.8 F - 32 degree C
lb/inch 0.112 985 newton meter
TORQUE:
lb/foot 1.355 818 newton meter
VELOCITY: miles/hr. 1.609 344 kilometer/hr
cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yd. 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
VOLUME: quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME: gallon/min. 3.785 412 litre/min.
1900
Abbreviations
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B+ battery + terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multi–meter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
84402826 - May 2011
1900-3
Abbreviations
Abbreviation description
FT fuel temperature
FWD front
GEN generator
GND ground
HBCV hose burst check valves
HC hydrocarbon
HO2S superheat O2 sensor
HR hour
HRD high reach
IAC idle air control
IAT intake air temperature
IC integrated circuit
ID Plate ID plate (Name plate)
IMT intake manifold temperature
INL intake
INJ injection
ISO international organization for standardization
ISP intake shutter position
ITP intake throttle position
J/C joint connector
JIS japan Industrial Standard
KW a communication method (Keyword)
LED light emitting diode
LH left
LLC long life coolant
LM lifting magnet
M/V electromagnetic valve
MAF mass air flow
MAP manifold air pressure
Max maximum
MIL warning light (diagnostic)
milli-amp milli-amperage
Min minimum
MPU micro processing unit
high-strength N high-strength nut
NC normally closed
NO normally open
NOx nitrogen oxide
N-TDC top dead center revolution speed
PM particle material
O2S O2 sensor
OBD on-board diagnosis
OEM original equipment manufacturer
OPT option
OT oil temperature
P/L pilot light
PCV pump control valve/positive crankcase ventilation
P-I proportion-integration
PM particle material
PTO power take-off
PWM pulse width modulation wave
QOS quick on start system
QWS quick warming up system
R/L relay
RAM RAM (random access memory)
REF reference
RH right
ROM ROM (read only memory)
Abbreviation description
RP rail pressure
Rr rear
RWD rear
flush head S flush head screw
phillips pan head S phillips pan head screw
truss head S truss head screw
subassembly sub assembly
SAE society of atomotive engineers
SBF slow blow fuse
SCV suction control valve
SIG signal
SLD shield
SP pin special pin
ST starter/start
STD standards
SW switch
TDC top dead center
TEMP temperature
TP throttle position
TEMP temperature
UART universal asynchronous receiver transmitter
VB battery voltage
VGS Turbo variable geometry system turbo
high-strength W high-strength washer
toothed W toothed washer
W/H wire/harness
W/L warning light
W/S weld splice
WOT wide open throttle
2000
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 14
mm, 17 mm, 36 mm)
• Box wrench (24 mm)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank
5. Use a wrench (7 mm) to loosen the hose band (1) 8. Use a wrench (8 mm) to loosen the hose band (1)
on the radiator, and then remove the upper hose (2). on the inter cooler, and then remove the hose (2).
• Use caps to cover the line and hose to prevent the
entry of water, dust or dirt.
14. Use a wrench (14 mm) to remove the 1 nut (1), and
then remove the wiring (2) from the starter motor.
12. Use a wrench (17 mm) to remove the bolt (1), and
then remove the negative-side battery cable (2).
• When removing the terminal and harness, secure 15. Remove the hose band (1), and then remove the
them so that they do not interfere with the frame. fuel hose (2).
Also, cover with a rubber cap to protect against • Attach caps or plugs to the engine and hose to
sparks. prevent any entry of water, dust or dirt.
13. Use a wrench (8 mm) to remove the 1 nut (1), and 16. Remove the hose band (1), and then remove the
then remove the wiring (2) from the starter motor. fuel hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.
17. Use a wrench (13 mm) to remove the 2 bolts (1), 20. Loosen the hose band (1), and then remove the
and then remove the connector bracket (2). heater hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.
18. Use a wrench (13 mm) to remove the hose band (1)
from the bracket, and then remove the connectors
(2).
21. Use a wrench (7 mm) to loosen the hose band (1),
• Wrap the removed connectors in plastic after tying and then remove the radiator hose (2).
them together.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.
19. Loosen the hose band (1), and then remove the
heater hose (2).
22. Use a wrench (7 mm) to loosen the hose band (1),
• Attach caps or plugs to the engine and hose to and then remove the air hose (2).
prevent any entry of water, dust or dirt.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.
23. Use a wrench (9.5 mm) to loosen the hose band (1), 26. Use a wrench (13 mm) to remove the bolt (1), and
and then remove the air hose (2). then remove the radiator hose clamp (2).
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.
27. Install the 2 shackles (1), and then use the wire rope
(2) and crane to secure the engine.
25. Use a wrench (10 mm) to remove the nut (1), and
then remove the wiring from the alternator (2).
28. Use a box wrench (24 mm) to remove the 4 bolts 29. Use the wire rope (1) and crane to lift the engine.
(1) from the mount. Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.
Installation of Engine Assembly 2. Run the engine at no-load idling and check for any
water or oil leaks.
1. To install the engine, perform the reverse of the re- 3. Attach the hydraulic pump, covers, and counter-
moval procedure. weight.
After installing the engine, resupply coolant and en- For details, see the individual explanations for each
gine oil, perform fuel line air bleeding, and perform procedure.
filling for the air conditioner gas.
For details, see the individual explanations for each
procedure.
2001
• Be sure to stop the engine before beginning • Use caps to cover the intercooler and hoses to
work. prevent the entry of water, dust or dirt.
• As the fuel hose will be removed, strictly pro- Tightening torque for band (1) installation: 8.8 -
hibit open flames. 9.8 N·m
Items to prepare
• Wrenches (8 mm, 14 mm)
• Flathead screwdriver
• Cap
• Rag
• Cleaning fluid
CAUTION
• Be sure to release hydraulic pressure before
beginning work.
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 19 mm)
• Box wrench (12 mm)
• Pliers
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
• Wood planks, etc.
13. Use a wrench (14 mm) to remove the 3 bolts (1), 16. Use a wrench (17 mm) to remove the 4 bolts (1),
and then remove the brackets (2). the 8 washers (2) and the 4 rubber cushions (3).
18. Lift until the fixtures (1) at the bottom of the radiator
become disconnected.
• Keep away from fire. 1. Use a wrench (19 mm) to remove the 3 bolts (1),
and then remove the under cover (2).
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm)
• Hexagon wrench (10 mm)
• Pliers
• Screwdriver
• Eyebolts (M12 x 2) 2. Prepare the waste oil can (1).
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.
5. Use a hexagon wrench (10 mm) to remove the 2 7. Use a wrench (14 mm) to remove the 2 bolts (1),
upper hexagon socket head bolts (1) and 2 lower and then remove the fan guard (2).
bolts (1), and then use a wrench (8 mm) to loosen
the hose bands (2) and remove the lines (3) (4).
• Use caps to cover the oil cooler and lines to pre-
vent the entry of water, dust or dirt.
12. Install the 2 eyebolts (M12) (1) on the top of the oil
cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
6. Use a wrench (14 mm) to install the 3 bolts (1) and 8. Use a wrench (14 mm) to install the 3 bolts (1) and
install the bracket (2). install the bracket (2).
2004
5) Disengage the oil return pipe from the tur- 7) Disengage the water feed pipe from the tur-
bocharger assembly. bocharger assembly.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
6) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2004-4
Removal and Installation of Turbo Charger
1 Exhaust manifold
2 Turbocharger assembly
1 Exhaust manifold
2 Turbocharger assembly
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
4) Securely tighten the exhaust manifold stay to 6) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
Tightening torque: 52 N・m { 5.3 kgf・m /
38 lb・ft } Nut
Tightening torque: 50 N・m { 5.1 kgf・m /
37 lb・ft } Bolt
ANNOTATION:
• Tightening order
CAUTION
• Use new gaskets.
CAUTION
• Use new gaskets.
8) Connect the oil feed pipe to the turbocharger 10) Install the air intake hose to the turbocharger
assembly. assembly and the intercooler.
11) Install the air cleaner duct to the air cleaner
CAUTION assembly and the turbocharger assembly.
12) Connect the harness connector to the tur-
・ Use new gaskets. bocharger assembly.
Tightening torque: 17 N・m { 1.7 kgf・m / 2. Coolant Filling
12 lb・ft } Eyebolt 1) Loosen the valve using a wrench.
Tightening torque: 24 N・m { 2.4 kgf・m / 2) Replenish the coolant with the radiator.
17 lb・ft } Clip
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets.
2005
EGR valve Removal 3) Remove the EGR pipe A from the EGR cooler
A and exhaust manifold.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
1 EGR heat protector 6 EGR pipe D
1 EGR cooler C
2 EGR pipe C
3 EGR valve 1 EGR cooler C
4 EGR pipe D 2 EGR pipe C
3 EGR valve
4 EGR pipe D
CAUTION
• Use new gaskets.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B
14) Install the EGR heat protector to the EGR pipe 1) Loosen the valve using a wrench.
A. 2) Replenish the coolant with the radiator.
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets
1 Valve
2 Gasket
2006
Items to prepare
• Wrench (13 mm, 17 mm, 19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)
2. Use the liftcrane and lift up the engine hood (2) until 4. Wrap the nylon sling (2) around the engine hood (1),
the damper (1) is completely extended and there is and then use the liftcrane to lift the engine hood (1).
no force on it.
Loosen the ring (3) of the damper’s head section,
and then remove the gas damper (1).
2007
Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAUTION
• Be sure to stop the engine before beginning
work.
Items to prepare
• Wrench (10 mm)
• Wrench (13 mm)
• Wrench (14 mm)
• Cap
• Rag
• Cleaning fluid 2. Remove the connectors (1).
4. Use a wrench (19 mm) to loosen the 4 bolts (1), and Installation of Muffler
then remove the muffler.
1. When installing the bolts, tighten them to the spec-
ified torque.
When the tightening torque is not specified for a bolt
or other part, see "Materials Explanation - Tighten-
ing Torque - Torque Table (one page)".
2. Place the DPD muffler (1) in the bracket, and install
the gasket (2), bolt (3), nut (4), and washers (5) on
the flanges. Move the DPD muffler over until the
DPD muffler flange touches the exhaust pipe (6)
flange surface, and then use a wrench (13 mm) to
temporarily tighten the flanges together.
CAUTION
• Use caution when handling the DPD muf-
fler (1), DPD pressure sensor (7), and
DPD thermo-sensors (8) (9) and do not
subject them to any impacts etc.
• Do not reuse these parts if they are
dropped or fall.
4. Use a wrench (13 mm) to fully tighten the bolt (1), 6. Install the connectors (1).
nut (2), and washers (3) temporarily tightened in
Step 2.
2401
Primary specifications
Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary specifications
1. Primary specifications
Engine main specifications
Item Specifications
water pump Centrifugal impeller method
Pulley ratio 0.950
thermostat Wax pellet type
: 85.0 °C { 185 °F } With jiggle valve
Open valve temperatur
: 82.0 °C { 180 °F } Without jiggle valve
: 100.0 °C { 212 °F } With jiggle valve
Full-open temperature
: 95.0 °C { 203 °F } Without jiggle valve
generator
Item Specifications
Isuzu parts number 8980921161
Nominal output 24 V/50 A
Rated rotation count 5,000 r/min
Regulator type IC type
Regulated voltage 27.5 V - 29.5 V
weight : 9.5 kg { 20.9 lb }
starter
Type (Manufacturer) Nikko
voltage 24V
Rating Output 5 KW
Time 30 sec
Number of pinion teeth 13
Rotational direction (facing the pinion) Right
Weight (Approx.) : 8.0 kg { 17.6 lb }
Current/voltage 85 A or less/24 V
No-load characteristics
Revolution speed 3,300 r/min or more
Current/voltage 400 A/18.5 V
Load characteristics Torque 28.4 N・m {2.9kgf・m} or more
Revolution speed 1,250 r/min or more
Current/voltage 1,400 A or less/9 V
Locking characteristics
Torque 88.2 N・m {9.0kgf・m} or more
glow plug
Item Type
Preheat device model glow plug
Glow plug rated voltage/current 23 V/3.5 A
2415
1 Ventilation hose
2 Oil level gauge guide tube
4) Connect the oil level gauge guide tube to the Removal and Installation of
cylinder head cover.
Tightening torque: 19 N・m { 1.9 kgf・m / Cylinder Head
14 lb・ft }
Removal of Cylinder Head
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2415-5
Removal and Installation of Cylinder Head
13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.
1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
5. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.
2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D
2) Disengage the harness connector from the in- 3) Disengage the harness connector from the
take throttle valve. EGR valve.
4) Disconnect the harness connector from the
ANNOTATION:
IMT sensor.
• Pull the lock operation portion to release the 5) Remove the harness clip from the inlet pipe.
lock.
1 Boost sensor
1 Lock operation section 2 IMT sensor
2 Lock release 3 EGR valve
3 Lock 4 Harness clip
5 Boost temperature sensor
3) Remove the intake throttle valve from the inlet
pipe. 6) Remove the inlet pipe from the case.
12. Injection pipe Removal • Remove the eyebolt tightened together with
the fuel feed pipe.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector 3) Disengage the fuel leak-off pipe from the com-
and the common rail assembly. mon rail assembly.
CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.
4) Remove the fuel leak-off pipe from the case. 16. Cylinder head cover Removal
ANNOTATION: 1) Disengage the ventilation hose from the air
• Remove the clip. breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
1 Lower cover
2 Connector
CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.
CAUTION
• Be careful not to drop the bridge
2) Remove the rocker arm shaft from the cylinder cap into the engine.
head assembly.
2) Remove the bridge from the bridge guide.
ANNOTATION:
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
and the rocker arm assembly bracket tight- • After removing, organize to avoid a mix-up
ening bolts from both ends and remove with other installation locations.
them.
CAUTION
• Be careful not to remove the bolt
shown in the diagram.
1 Bridge cap
2 Bridge
1) Remove the cylinder head assembly from the Disassembly of Cylinder Head
cylinder block.
1. Engine hanger bracket Removal
ANNOTATION:
1) Remove the front engine hanger bracket from
• Loosening order of the head bolts the cylinder head assembly.
2) Remove the rear engine hanger bracket from
the cylinder head assembly.
CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
cylinder head, be careful not to
damage the gear.
1 EGR pipe D
2 Case
3 Gasket 1 Distance tube
4 Inlet cover 2 Washer
3 Exhaust manifold bracket
CAUTION 4 Exhaust manifold bracket
5 Exhaust manifold
• Do not forget to remove the bolts in-
dicated by the arrow in the diagram. 4. Thermostat Removal
1) Remove the water outlet pipe from the cylin-
der head assembly.
2) Remove the thermostat from the cylinder
head assembly.
3) Remove the gasket from the thermostat.
5. Overheat switch Removal
1) Remove the overheat switch from the cylinder
head assembly.
6. Engine coolant temperature sensor Removal
1) Remove the engine coolant temperature sen-
sor from the cylinder head assembly.
1 Overheat switch
2 Water temperature sensor
7. CMP sensor Removal 3) Remove the idle gear C from the cylinder head
assembly.
1) Remove the CMP sensor from the cylinder
head assembly.
1 Idle gear C
CAUTION 2 Idle gear shaft
• Be careful not to subject the sensor 9. Valve spring Removal
to shock.
1) 1. Press the valve spring using the special
8. Idle gear C Removal tool.
1 Nut
1 Injector sleeve
CAUTION
• Be careful not to damage the bot-
tom surface of the cylinder head.
• Do not reuse the removed injector
sleeve.
Special tool: oil seal installer (refer to section Special tool: bridge guide setting tool
1003) (refer to section 1003)
CAUTION
• Be careful not to damage the lip
section of the oil seal.
1 Cylinder head
2 Oil seal installer
4) Apply the engine oil to the cylinder head as- Special tool: nozzle sleeve setting tool
sembly. (refer to section 1003)
ANNOTATION:
• Apply engine oil to the injector sleeve con-
tact surface.
1 Punch bar
2 Ball
3 Guide sleeve
4 Injector sleeve
1 O-ring with white paint 5 Clamp
2 O-ring 6 Bolt
3 Loctite 620 application
4 Engine oil application
CAUTION
5) Install the injector sleeve to the cylinder head • Allow the cylinder head to float so
assembly using the special tool. that the ball comes out from the bot-
tom surface.
4) Install the valve seat insert to the cylinder Specified length: 17.0 - 17.9 mm {0.6693 -
head assembly using the press. 0.7047 in}
CAUTION
1 Dolly block • When replacing the valve guide, re-
2 Valve seat insert place it with the valve.
3 Press
6. Valve stem oil seal Installation
1) Install the valve spring seat to the cylinder
5. Valve guide Installation head assembly.
1) Apply the engine oil to the valve guide. 2) Apply the engine oil to the valve guide.
2) Install the valve guide to the cylinder head ANNOTATION:
assembly using the special tool.
• Apply engine oil to the outer circumference
of the valve guide.
CAUTION
• Use a new valve stem oil seal.
Co-
Order No. Jig name Remarks
de
1 Bushing removal jig
2 Bushing press-fit jig
3 Floating seal installation jig
Co-
Order No. Jig name Remarks
de
Tapered roller bearing/inner race
1
assembly jig
2 Oil seal assembly jig 1
3 Cylinder assembly jig
4 Brake piston assembly jig
Co-
Order No. Jig name Remarks
de
5 Oil seal assembly jig 2
6 Pinion shaft assembly jig
Co-
Order No. Jig name Remarks
de
7 Brake piston removal jig
Co-
Order No. Jig name Remarks
de
1 Joint disassembly jig
84402826 - May 2011
1003-15
List of special tools
Co-
Order No. Jig name Remarks
de
2 Special jig 1 (for bushing removal)
3 Special jig 2 (for locking ring installation)
Hydraulic Circuit
5-8840-2675-0 (5-8531-
380002626 Compression Gauge (adapter)
7002-0)
CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
KHV0512 Cylinder head assembly and disassembly jig (70)
KHV0513 Cylinder head assembly and disassembly jig (75)
KHV0514 Cylinder head assembly and disassembly jig (80)
KHV0515 Cylinder head assembly and disassembly jig (85)
KHV0516 Cylinder head assembly and disassembly jig (90)
KHV0517 Cylinder head assembly and disassembly jig (95)
KHV0518 Cylinder head assembly and disassembly jig (100)
KHV0519 Cylinder head assembly and disassembly jig (105)
KHV0520 Cylinder head assembly and disassembly jig (110)
KHV0521 Cylinder head assembly and disassembly jig (115)
KHV0522 Cylinder head assembly and disassembly jig (120)
CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
KHV0527 Seal ring insertion and calibration jig (105)
KHV0528 Seal ring insertion and calibration jig (110)
KHV0529 Seal ring insertion and calibration jig (115)
KHV0530 Seal ring insertion and calibration jig (120)
KHV0531 Seal ring insertion and calibration jig (125)
KHV0532 Seal ring insertion and calibration jig (130)
KHV0533 Seal ring insertion and calibration jig (135)
KHV0534 Seal ring insertion and calibration jig (140)
KHV0535 Seal ring insertion and calibration jig (145)
KHV0536 Seal ring insertion and calibration jig (150)
KHV0537 Seal ring insertion and calibration jig (160)
KHV0539 Seal ring insertion and calibration jig (170)
1004
HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Conditions applicable to diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC FLUID
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
ENGINE OIL
The "CASE Tutela LE ENGINE OIL" is recommended for
your engine. This oil ensures correct lubrication of your
engine in all working conditions.
If the "CASE Tutela LE ENGINE OIL" cannot be obtained,
use the oil corresponding to one of the following cate-
gories:
API CJ-4.
ACEA E6.
FUEL
IMPORTANT:
The fuel must conform to Interim Tier 4/Stage 3B Ex- EPA regulation ultra low sulfur fuel only.
haust Gas Control Regulations.
Use grade number 2-D (S15) fuel. IMPORTANT:
Using other types of fuel may lead to stalled engine out- If a serious problem occurs when other fuels are used,
put or deterioration in fuel economy. the warranty is invalidated.
During cold weather (lower than -7℃), it is temporarily
acceptable to use a mixture of No. 1-D (S15) and No. Using a non-recommended fuel may lead to damage of
2-D (S15). the fuel injection pump, injector, DPD, and other fuel
Consult the fuel supplier or the CASE dealer. supply systems or to the engine.
If the temperature drops below the fuel cloud point, out- CASE assumes no responsibility for these damages.
put deficiency or engine start problems may occur due Note that the warranty will not be applied for these dam-
to wax crystals. ages.
It is recommended that the following safety information
Conditions applicable to diesel fuel be considered in order to prevent damage to the engine
fuel supply system.
The diesel fuel used must:
- Some fuel suppliers mix old engine oil and diesel fuel.
- be free from dust particles, even minute ones,
- have the proper viscosity, Makers of larger engine permit the use of this kind of
- have a high cetane number, fuel.
- present great fluidity at low temperatures, However, do not use diesel fuel contaminated with en-
- have low sulphur content, gine oil in customer's engines.
- have very little residual carbon. Not only will this fuel damage the engine, it may also
have a negative impact on the exhaust gas purification
RECOMMENDED CONDITIONS function.
Before using diesel fuel, confirm with the supplier
THAT CAN BE APPLIED TO whether the fuel complies with the above specifications.
DIESEL FUEL IMPORTANT:
Consult the supplier or the CASE dealer regarding ap-
- JIS (Japanese Industrial Standards): No. 2 propriate use of fuel additives.
- DIN (Deutsche Industrie Normen): DIN 51601 Do not use fuel oil or gasoline as these may damage the
- SAE-J-313C: SAE (Society of Automotive Engineers) engine.
based on No. 2-D (S15)
- BS (British Standards) based on BS/2869-1970: Class IMPORTANT:
A-1 In order to prevent condensation during cold weather, fill
- EN 590 (less than 10 ppm sulfur) the fuel tank to full after the completing the day's work.
- Or fuel specified by the country using these standards
and this machine
1005
Conversion Table
Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Metric to U.S
MULTIPLY BY TO OBTAIN
square meter 10.763 91 square foot
AREA:
hectare 2.471 05 acre
newton 3.596 942 ounce force
FORCE:
newton 2.224 809 pound force
millimeter 0.039 370 inch
LENGTH: meter 3.280 840 foot
kilometer 0.621 371 mile
MASS: kilogram 2.204 622 pound
MASS/AREA: kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY: gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME: kg/cubic meter 1.685 555 lb/cubic yd.
POWER: kilowatt 1.341 02 horsepower
kilopascal 0.145 038 lb/sq. inch
PRESSURE: bar 14.50385 lb/sq. inch
megapascal (MPA) 145.0385 psi
TEMPERATURE: degree C 1.8 x C +32 degree F
newton meter 8.850 748 lb/inch
TORQUE:
newton meter 0.737 562 lb/foot
VELOCITY: kilometer/hr 0.621 371 miles/hr.
cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
VOLUME: quart (US liquid)
litre 1.056 814
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
litre/min. 0.264 172 gallon/min. (US liquid)
VOLUME/TIME:
litre/min 0.219 969 gallon/min. (Imperial)
U.S to Metric
MULTIPLY BY TO OBTAIN
square foot 0.092 903 square meter
AREA:
acre 0.404 686 hectare
ounce force 0.278 014 newton
FORCE:
pound force 4.448 222 newton
inch 25.4 millimeter
LENGTH: foot 0.304 8 meter
mile 1.609 344 kilometer
pound 0.453 592 kilogram
MASS: gram
ounce 28.35
MASS/AREA: ton/acre 2241 702 kilogram/hectare
MASS/ENERGY: lbs/hp/hr. 608.277 4 gr/kW/hr.
MASS/VOLUME: lb/cubic yd. 0.593 276 kg/cubic meter
POWER: horsepower 0.745 700 kilowatt
lb/sq. inch 6.894 757 kilopascal
PRESSURE: lb/sq. inch 0.069 bar
psi lb/sq. inch 0.070 303 kg/sq. cm
psi 0.006 895 megapascal (Mpa)
TEMPERATURE: degree F 1.8 F - 32 degree C
lb/inch 0.112 985 newton meter
TORQUE:
lb/foot 1.355 818 newton meter
VELOCITY: miles/hr. 1.609 344 kilometer/hr
cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yd. 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
VOLUME: quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME: gallon/min. 3.785 412 litre/min.
1900
Abbreviations
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B+ battery + terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multi–meter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
84402826 - May 2011
1900-3
Abbreviations
Abbreviation description
FT fuel temperature
FWD front
GEN generator
GND ground
HBCV hose burst check valves
HC hydrocarbon
HO2S superheat O2 sensor
HR hour
HRD high reach
IAC idle air control
IAT intake air temperature
IC integrated circuit
ID Plate ID plate (Name plate)
IMT intake manifold temperature
INL intake
INJ injection
ISO international organization for standardization
ISP intake shutter position
ITP intake throttle position
J/C joint connector
JIS japan Industrial Standard
KW a communication method (Keyword)
LED light emitting diode
LH left
LLC long life coolant
LM lifting magnet
M/V electromagnetic valve
MAF mass air flow
MAP manifold air pressure
Max maximum
MIL warning light (diagnostic)
milli-amp milli-amperage
Min minimum
MPU micro processing unit
high-strength N high-strength nut
NC normally closed
NO normally open
NOx nitrogen oxide
N-TDC top dead center revolution speed
PM particle material
O2S O2 sensor
OBD on-board diagnosis
OEM original equipment manufacturer
OPT option
OT oil temperature
P/L pilot light
PCV pump control valve/positive crankcase ventilation
P-I proportion-integration
PM particle material
PTO power take-off
PWM pulse width modulation wave
QOS quick on start system
QWS quick warming up system
R/L relay
RAM RAM (random access memory)
REF reference
RH right
ROM ROM (read only memory)
Abbreviation description
RP rail pressure
Rr rear
RWD rear
flush head S flush head screw
phillips pan head S phillips pan head screw
truss head S truss head screw
subassembly sub assembly
SAE society of atomotive engineers
SBF slow blow fuse
SCV suction control valve
SIG signal
SLD shield
SP pin special pin
ST starter/start
STD standards
SW switch
TDC top dead center
TEMP temperature
TP throttle position
TEMP temperature
UART universal asynchronous receiver transmitter
VB battery voltage
VGS Turbo variable geometry system turbo
high-strength W high-strength washer
toothed W toothed washer
W/H wire/harness
W/L warning light
W/S weld splice
WOT wide open throttle
2000
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 14
mm, 17 mm, 36 mm)
• Box wrench (24 mm)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank
5. Use a wrench (7 mm) to loosen the hose band (1) 8. Use a wrench (8 mm) to loosen the hose band (1)
on the radiator, and then remove the upper hose (2). on the inter cooler, and then remove the hose (2).
• Use caps to cover the line and hose to prevent the
entry of water, dust or dirt.
14. Use a wrench (14 mm) to remove the 1 nut (1), and
then remove the wiring (2) from the starter motor.
12. Use a wrench (17 mm) to remove the bolt (1), and
then remove the negative-side battery cable (2).
• When removing the terminal and harness, secure 15. Remove the hose band (1), and then remove the
them so that they do not interfere with the frame. fuel hose (2).
Also, cover with a rubber cap to protect against • Attach caps or plugs to the engine and hose to
sparks. prevent any entry of water, dust or dirt.
13. Use a wrench (8 mm) to remove the 1 nut (1), and 16. Remove the hose band (1), and then remove the
then remove the wiring (2) from the starter motor. fuel hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.
17. Use a wrench (13 mm) to remove the 2 bolts (1), 20. Loosen the hose band (1), and then remove the
and then remove the connector bracket (2). heater hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.
18. Use a wrench (13 mm) to remove the hose band (1)
from the bracket, and then remove the connectors
(2).
21. Use a wrench (7 mm) to loosen the hose band (1),
• Wrap the removed connectors in plastic after tying and then remove the radiator hose (2).
them together.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.
19. Loosen the hose band (1), and then remove the
heater hose (2).
22. Use a wrench (7 mm) to loosen the hose band (1),
• Attach caps or plugs to the engine and hose to and then remove the air hose (2).
prevent any entry of water, dust or dirt.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.
23. Use a wrench (9.5 mm) to loosen the hose band (1), 26. Use a wrench (13 mm) to remove the bolt (1), and
and then remove the air hose (2). then remove the radiator hose clamp (2).
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.
27. Install the 2 shackles (1), and then use the wire rope
(2) and crane to secure the engine.
25. Use a wrench (10 mm) to remove the nut (1), and
then remove the wiring from the alternator (2).
28. Use a box wrench (24 mm) to remove the 4 bolts 29. Use the wire rope (1) and crane to lift the engine.
(1) from the mount. Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.
Installation of Engine Assembly 2. Run the engine at no-load idling and check for any
water or oil leaks.
1. To install the engine, perform the reverse of the re- 3. Attach the hydraulic pump, covers, and counter-
moval procedure. weight.
After installing the engine, resupply coolant and en- For details, see the individual explanations for each
gine oil, perform fuel line air bleeding, and perform procedure.
filling for the air conditioner gas.
For details, see the individual explanations for each
procedure.
2001
• Be sure to stop the engine before beginning • Use caps to cover the intercooler and hoses to
work. prevent the entry of water, dust or dirt.
• As the fuel hose will be removed, strictly pro- Tightening torque for band (1) installation: 8.8 -
hibit open flames. 9.8 N·m
Items to prepare
• Wrenches (8 mm, 14 mm)
• Flathead screwdriver
• Cap
• Rag
• Cleaning fluid
CAUTION
• Be sure to release hydraulic pressure before
beginning work.
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 19 mm)
• Box wrench (12 mm)
• Pliers
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
• Wood planks, etc.
13. Use a wrench (14 mm) to remove the 3 bolts (1), 16. Use a wrench (17 mm) to remove the 4 bolts (1),
and then remove the brackets (2). the 8 washers (2) and the 4 rubber cushions (3).
18. Lift until the fixtures (1) at the bottom of the radiator
become disconnected.
• Keep away from fire. 1. Use a wrench (19 mm) to remove the 3 bolts (1),
and then remove the under cover (2).
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm)
• Hexagon wrench (10 mm)
• Pliers
• Screwdriver
• Eyebolts (M12 x 2) 2. Prepare the waste oil can (1).
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.
5. Use a hexagon wrench (10 mm) to remove the 2 7. Use a wrench (14 mm) to remove the 2 bolts (1),
upper hexagon socket head bolts (1) and 2 lower and then remove the fan guard (2).
bolts (1), and then use a wrench (8 mm) to loosen
the hose bands (2) and remove the lines (3) (4).
• Use caps to cover the oil cooler and lines to pre-
vent the entry of water, dust or dirt.
12. Install the 2 eyebolts (M12) (1) on the top of the oil
cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
6. Use a wrench (14 mm) to install the 3 bolts (1) and 8. Use a wrench (14 mm) to install the 3 bolts (1) and
install the bracket (2). install the bracket (2).
2004
5) Disengage the oil return pipe from the tur- 7) Disengage the water feed pipe from the tur-
bocharger assembly. bocharger assembly.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
6) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2004-4
Removal and Installation of Turbo Charger
1 Exhaust manifold
2 Turbocharger assembly
1 Exhaust manifold
2 Turbocharger assembly
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
4) Securely tighten the exhaust manifold stay to 6) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
Tightening torque: 52 N・m { 5.3 kgf・m /
38 lb・ft } Nut
Tightening torque: 50 N・m { 5.1 kgf・m /
37 lb・ft } Bolt
ANNOTATION:
• Tightening order
CAUTION
• Use new gaskets.
CAUTION
• Use new gaskets.
8) Connect the oil feed pipe to the turbocharger 10) Install the air intake hose to the turbocharger
assembly. assembly and the intercooler.
11) Install the air cleaner duct to the air cleaner
CAUTION assembly and the turbocharger assembly.
12) Connect the harness connector to the tur-
・ Use new gaskets. bocharger assembly.
Tightening torque: 17 N・m { 1.7 kgf・m / 2. Coolant Filling
12 lb・ft } Eyebolt 1) Loosen the valve using a wrench.
Tightening torque: 24 N・m { 2.4 kgf・m / 2) Replenish the coolant with the radiator.
17 lb・ft } Clip
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets.
2005
EGR valve Removal 3) Remove the EGR pipe A from the EGR cooler
A and exhaust manifold.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
1 EGR heat protector 6 EGR pipe D
1 EGR cooler C
2 EGR pipe C
3 EGR valve 1 EGR cooler C
4 EGR pipe D 2 EGR pipe C
3 EGR valve
4 EGR pipe D
CAUTION
• Use new gaskets.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B
14) Install the EGR heat protector to the EGR pipe 1) Loosen the valve using a wrench.
A. 2) Replenish the coolant with the radiator.
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets
1 Valve
2 Gasket
2006
Items to prepare
• Wrench (13 mm, 17 mm, 19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)
2. Use the liftcrane and lift up the engine hood (2) until 4. Wrap the nylon sling (2) around the engine hood (1),
the damper (1) is completely extended and there is and then use the liftcrane to lift the engine hood (1).
no force on it.
Loosen the ring (3) of the damper’s head section,
and then remove the gas damper (1).
2007
Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAUTION
• Be sure to stop the engine before beginning
work.
Items to prepare
• Wrench (10 mm)
• Wrench (13 mm)
• Wrench (14 mm)
• Cap
• Rag
• Cleaning fluid 2. Remove the connectors (1).
4. Use a wrench (19 mm) to loosen the 4 bolts (1), and Installation of Muffler
then remove the muffler.
1. When installing the bolts, tighten them to the spec-
ified torque.
When the tightening torque is not specified for a bolt
or other part, see "Materials Explanation - Tighten-
ing Torque - Torque Table (one page)".
2. Place the DPD muffler (1) in the bracket, and install
the gasket (2), bolt (3), nut (4), and washers (5) on
the flanges. Move the DPD muffler over until the
DPD muffler flange touches the exhaust pipe (6)
flange surface, and then use a wrench (13 mm) to
temporarily tighten the flanges together.
CAUTION
• Use caution when handling the DPD muf-
fler (1), DPD pressure sensor (7), and
DPD thermo-sensors (8) (9) and do not
subject them to any impacts etc.
• Do not reuse these parts if they are
dropped or fall.
4. Use a wrench (13 mm) to fully tighten the bolt (1), 6. Install the connectors (1).
nut (2), and washers (3) temporarily tightened in
Step 2.
2401
Primary specifications
Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Primary specifications
1. Primary specifications
Engine main specifications
Item Specifications
water pump Centrifugal impeller method
Pulley ratio 0.950
thermostat Wax pellet type
: 85.0 °C { 185 °F } With jiggle valve
Open valve temperatur
: 82.0 °C { 180 °F } Without jiggle valve
: 100.0 °C { 212 °F } With jiggle valve
Full-open temperature
: 95.0 °C { 203 °F } Without jiggle valve
generator
Item Specifications
Isuzu parts number 8980921161
Nominal output 24 V/50 A
Rated rotation count 5,000 r/min
Regulator type IC type
Regulated voltage 27.5 V - 29.5 V
weight : 9.5 kg { 20.9 lb }
starter
Type (Manufacturer) Nikko
voltage 24V
Rating Output 5 KW
Time 30 sec
Number of pinion teeth 13
Rotational direction (facing the pinion) Right
Weight (Approx.) : 8.0 kg { 17.6 lb }
Current/voltage 85 A or less/24 V
No-load characteristics
Revolution speed 3,300 r/min or more
Current/voltage 400 A/18.5 V
Load characteristics Torque 28.4 N・m {2.9kgf・m} or more
Revolution speed 1,250 r/min or more
Current/voltage 1,400 A or less/9 V
Locking characteristics
Torque 88.2 N・m {9.0kgf・m} or more
glow plug
Item Type
Preheat device model glow plug
Glow plug rated voltage/current 23 V/3.5 A
2415
1 Ventilation hose
2 Oil level gauge guide tube
4) Connect the oil level gauge guide tube to the Removal and Installation of
cylinder head cover.
Tightening torque: 19 N・m { 1.9 kgf・m / Cylinder Head
14 lb・ft }
Removal of Cylinder Head
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2415-5
Removal and Installation of Cylinder Head
13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.
1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
5. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.
2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D
2) Disengage the harness connector from the in- 3) Disengage the harness connector from the
take throttle valve. EGR valve.
4) Disconnect the harness connector from the
ANNOTATION:
IMT sensor.
• Pull the lock operation portion to release the 5) Remove the harness clip from the inlet pipe.
lock.
1 Boost sensor
1 Lock operation section 2 IMT sensor
2 Lock release 3 EGR valve
3 Lock 4 Harness clip
5 Boost temperature sensor
3) Remove the intake throttle valve from the inlet
pipe. 6) Remove the inlet pipe from the case.
12. Injection pipe Removal • Remove the eyebolt tightened together with
the fuel feed pipe.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector 3) Disengage the fuel leak-off pipe from the com-
and the common rail assembly. mon rail assembly.
CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.
4) Remove the fuel leak-off pipe from the case. 16. Cylinder head cover Removal
ANNOTATION: 1) Disengage the ventilation hose from the air
• Remove the clip. breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
1 Lower cover
2 Connector
CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.
CAUTION
• Be careful not to drop the bridge
2) Remove the rocker arm shaft from the cylinder cap into the engine.
head assembly.
2) Remove the bridge from the bridge guide.
ANNOTATION:
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
and the rocker arm assembly bracket tight- • After removing, organize to avoid a mix-up
ening bolts from both ends and remove with other installation locations.
them.
CAUTION
• Be careful not to remove the bolt
shown in the diagram.
1 Bridge cap
2 Bridge
1) Remove the cylinder head assembly from the Disassembly of Cylinder Head
cylinder block.
1. Engine hanger bracket Removal
ANNOTATION:
1) Remove the front engine hanger bracket from
• Loosening order of the head bolts the cylinder head assembly.
2) Remove the rear engine hanger bracket from
the cylinder head assembly.
CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
cylinder head, be careful not to
damage the gear.
1 EGR pipe D
2 Case
3 Gasket 1 Distance tube
4 Inlet cover 2 Washer
3 Exhaust manifold bracket
CAUTION 4 Exhaust manifold bracket
5 Exhaust manifold
• Do not forget to remove the bolts in-
dicated by the arrow in the diagram. 4. Thermostat Removal
1) Remove the water outlet pipe from the cylin-
der head assembly.
2) Remove the thermostat from the cylinder
head assembly.
3) Remove the gasket from the thermostat.
5. Overheat switch Removal
1) Remove the overheat switch from the cylinder
head assembly.
6. Engine coolant temperature sensor Removal
1) Remove the engine coolant temperature sen-
sor from the cylinder head assembly.
1 Overheat switch
2 Water temperature sensor
7. CMP sensor Removal 3) Remove the idle gear C from the cylinder head
assembly.
1) Remove the CMP sensor from the cylinder
head assembly.
1 Idle gear C
CAUTION 2 Idle gear shaft
• Be careful not to subject the sensor 9. Valve spring Removal
to shock.
1) 1. Press the valve spring using the special
8. Idle gear C Removal tool.
1 Nut
1 Injector sleeve
CAUTION
• Be careful not to damage the bot-
tom surface of the cylinder head.
• Do not reuse the removed injector
sleeve.
Special tool: oil seal installer (refer to section Special tool: bridge guide setting tool
1003) (refer to section 1003)
CAUTION
• Be careful not to damage the lip
section of the oil seal.
1 Cylinder head
2 Oil seal installer
4) Apply the engine oil to the cylinder head as- Special tool: nozzle sleeve setting tool
sembly. (refer to section 1003)
ANNOTATION:
• Apply engine oil to the injector sleeve con-
tact surface.
1 Punch bar
2 Ball
3 Guide sleeve
4 Injector sleeve
1 O-ring with white paint 5 Clamp
2 O-ring 6 Bolt
3 Loctite 620 application
4 Engine oil application
CAUTION
5) Install the injector sleeve to the cylinder head • Allow the cylinder head to float so
assembly using the special tool. that the ball comes out from the bot-
tom surface.
4) Install the valve seat insert to the cylinder Specified length: 17.0 - 17.9 mm {0.6693 -
head assembly using the press. 0.7047 in}
CAUTION
1 Dolly block • When replacing the valve guide, re-
2 Valve seat insert place it with the valve.
3 Press
6. Valve stem oil seal Installation
1) Install the valve spring seat to the cylinder
5. Valve guide Installation head assembly.
1) Apply the engine oil to the valve guide. 2) Apply the engine oil to the valve guide.
2) Install the valve guide to the cylinder head ANNOTATION:
assembly using the special tool.
• Apply engine oil to the outer circumference
of the valve guide.
CAUTION
• Use a new valve stem oil seal.
CAUTION
• Inspect the valve stem oil seal for 1 Spring pitch (small)
deformation or cracks. 2 Identification paint
• Confirm that the garter spring has
not come loose.
7. Exhaust valve Installation 2) Install the valve spring to the cylinder head
assembly.
1) Apply the engine oil to the exhaust valve.
2) Install the exhaust valve to the cylinder head ANNOTATION:
assembly. • Turn the valve spring to face the identifica-
ANNOTATION: tion paint application area towards the cylin-
der head assembly.
• Confirm that there is an E-mark on the valve.
3) Install the spring seat to the valve spring.
8. Inlet valve Installation 4) Press the valve spring using the special tool.
1) Apply the engine oil to the inlet valve.
2) Install the inlet valve to the cylinder head as-
sembly.
ANNOTATION:
• Confirm that there is an I-mark on the valve.
CAUTION
• Confirm that the split collar is in the
valve stem groove.
CAUTION
• Confirm that the spigot of the idle
gear shaft is firmly installed to the
cylinder head assembly. Between the idle gear C cover
1 end surface and cylinder head
chamfered edge section
CAUTION
• Be careful not to subject the sensor
to shock.
CAUTION
• Completely tighten the installation
bolt and nut when installing the
common rail assembly.
1 Distance tube
2 Washer 3) Install the case to the inlet cover.
3 Exhaust manifold bracket Tightening torque: 22 N・m {2.2 kgf・m / 16
4 Exhaust manifold bracket lb・ft}
5 Exhaust manifold ANNOTATION:
• Install it together with the EGR pipe D.
16. Inlet cover Installation
1) Apply the liquid gasket to the inlet cover.
ANNOTATION:
• Align with the inlet cover groove and apply
ThreeBond 1207.
Bead width: 3 - 6 mm {0.098 - 0.217 in}
CAUTION
• After applying liquid gasket, install
the inlet cover within 5 minutes.
2) Install the rear engine hanger bracket to the Installation of Cylinder Head
cylinder head assembly.
Tightening torque: 104 N・m {10.6 kgf・m 1. Cylinder head assembly Installation
/ 77 lb・ft} Rear engine hanger bracket
CAUTION
Tightening torque: 48 N・m {4.9 kgf・m / 35
lb・ft} • Clean the aligning surface of the cylinder
Rear engine hanger head and cylinder block before installing
the cylinder head assembly.
• Be careful not to damage the cylinder
head and cylinder block while cleaning.
CAUTION
• After applying liquid gasket, install
the cylinder head within 5 minutes.
CAUTION
• Be careful not to damage the cylin-
der head gasket.
ANNOTATION:
• Tightening order of the head bolts
CAUTION
• Confirm that the bridge moves
smoothly.
ANNOTATION:
• 1 to 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION:
• Apply molybdenum disulfide grease to the
seat surface and threaded portion of the CAUTION
M14 head bolts.
• Apply engine oil to the seat surface and • Be careful not to drop the bridge
threaded portion of the M10 head bolts. cap into the engine.
5) Tighten the head bolt using the torque wrench. 3. Camshaft Installation
Tightening torque: 157 N・m {16.0 kgf・m
/ 116 lb・ft} 1) Align 1st cylinder to the compression top dead
6) Tighten the head bolt using the torque wrench. center.
Tightening torque: 165 N・m {16.8 kgf・m
/ 122 lb・ft}
7) Tighten the head bolt using the special tool.
3) Install the camshaft bearing to the cylinder 8) Install the camshaft bearing cap to the cylinder
head assembly. head assembly.
4) Install the camshaft to the cylinder head as-
ANNOTATION:
sembly.
ANNOTATION: • Turn the camshaft bearing cap so that the
arrow mark on the top surface faces the en-
• Mesh together the idle gear C and the gine front side, and assemble in numerical
camshaft gear so that the alignment mark order.
on the camshaft gear matches the top sur-
Tightening torque: 28 N・m {2.8 kgf・m / 20
face of the cylinder head, and gently install
lb・ft} Apply engine oil
the camshaft.
5) Check alignment mark of the camshaft gear. 4. Rocker arm shaft Installation
• Insert the thickness gauge between the Tightening torque: 22 N・m {2.2 kgf・m / 16
bridge and valve. lb・ft}
3) Turn the adjust screw.
ANNOTATION:
• When the movement of the thickness gauge
becomes stiff, secure the adjust screw nut
of the rocker arm.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}
Adjustment table
1 2 3 4
Cylinder No. I- E- I- I-
E- E- I- E-
N X N N X X N X
First cylinder compression
O O O O
top dead center
Fourth cylinder compres-
4) Turn the adjust screw. O O O
sion top dead center
ANNOTATION:
• With the thickness gauge inserted, lightly
tighten the adjust screw of the bridge. 6. Common rail assembly Installation
• Confirm that the leading end of the adjust 1) Temporarily tighten the common rail bracket
screw and valve shaft end have made con- to the oil cooler assembly.
tact and the movement of the thickness
gauge has become stiff. ANNOTATION:
• Check if the valve shaft end on the opposite
• The installation bolt and common rail as-
side is floating or touching at an angle.
sembly are tightened together.
• If it is floating or touching at an angle, slightly
loosen the bridge adjust screw and adjust 2) Align the common rail assembly to the inlet
the valve shaft ends on both sides to touch cover.
properly. 3) Temporarily tighten the nut to the common rail
assembly.
Valve bridge clearance : less than 0.1 mm
{less than 0.0039 in} ANNOTATION:
ANNOTATION: • The stud bolts of the inlet cover are tight-
ened together.
• To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and 4) Temporarily tighten the bolt to the common rail
tighten the adjust screw nut. assembly.
5) Securely tighten the nut to the common rail 3) Temporarily tighten the fuel leak-off pipe to the
assembly. fuel supply pump.
Tightening torque: 22 N・m {2.2 kgf・m / 16
ANNOTATION:
lb・ft}
ANNOTATION: • Tighten the fuel feed pipe together.
CAUTION
7. Fuel leak off pipe assembly Installation
• Use new fuel pipes.
1) Temporarily tighten the fuel leak-off pipe to the
cylinder head assembly.
Tightening torque: 44 N・m {4.5 kgf・m / 33
CAUTION lb・ft}
2) Install the clip to the bracket.
• Use new gaskets. Tightening torque: 9 N・m {0.9 kgf・m / 78
lb・in}
2) Temporarily tighten the fuel leak-off pipe to the
9. Injector Installation
common rail assembly.
CAUTION
• Use new gaskets.
84402826 - May 2011
2415-30
Removal and Installation of Cylinder Head
CAUTION
• Be extremely careful not to damage
the injector nozzle.
CAUTION
• Use new injection pipes.
CAUTION
• Use new gaskets.
1 Rubber plug
Tightening torque: 14 N・m {1.4 kgf・m / 2 Liquid gasket
126 lb・in}
10. Injection pipe Installation
CAUTION
1) Securely tighten the injection pipe to the injec-
tor. • After applying the liquid gasket, in-
Tightening torque: 30 N・m {3.0 kgf・m / 22 stall the lower cover within 5 min-
lb・ft} utes.
2) Securely tighten the injection pipe to the com-
mon rail assembly. 2) Install the rubber plug to the cylinder head
Tightening torque: 25 N・m {2.5 kgf・m / 18 assembly.
lb・ft} 3) Install the gasket to the lower cover.
84402826 - May 2011
2415-31
Removal and Installation of Cylinder Head
4) Install the lower cover to the cylinder head 12. Glow plug Installation
assembly.
Tightening torque: 18 N・m {1.8 kgf・m / 13 1) Install the glow plug to the cylinder head as-
lb・ft} sembly.
5) Install the injector harness to the cylinder head Tightening torque: 20 N・m {2.0 kgf・m / 14
assembly. lb・ft}
ANNOTATION: CAUTION
• Tighten the bolts on the bracket and in- • Be careful not to exceed the speci-
stall the injector harness together with the fied torque when tightening.
bracket.
Tightening torque: 48 N・m {4.9 kgf・m / 35
lb・ft}
1 Lower cover
2 Connector
CAUTION
• Use new gaskets.
1 Boost sensor
1 Cylinder head cover
2 IMT sensor
2 Oil level gauge guide tube
3 EGR valve
3 Case
4 Harness clip
4 Cylinder block
5 Boost temperature sensor
5) Install the fan guide stay to the fan guide. 4) Temporarily tighten the EGR cooler A to the
Tightening torque: 45 N・m {4.6 kgf・m / 33 EGR pipe B.
lb・ft}
1 EGR valve
1 Fan guide stay 2 EGR pipe C
2 Fan guide 3 EGR cooler B
3 Fan guide bracket 4 EGR pipe B
4 Spacer 5 EGR cooler A
6 EGR pipe B
18. EGR valve Installation
5) Temporarily tighten the EGR pipe A to the
1) Install the EGR valve to the EGR pipe D. EGR cooler A and the exhaust manifold.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
CAUTION
• Use new gaskets.
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
ANNOTATION:
• Complete tightening order of the EGR
cooler assembly
2) Temporarily tighten the exhaust manifold stay 6) Connect the water feed pipe to the tur-
to the cylinder block and the turbocharger as- bocharger assembly.
sembly.
CAUTION
• Use new gaskets.
CAUTION
• Use new gaskets.
CAUTION
1 Water return pipe
• Use new gaskets.
2 Water feed pipe
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft} Eyebolt
Tightening torque: 24 N・m {2.4 kgf・m / 17 Tightening torque: 35 N・m {3.5 kgf・m / 25
lb・ft} Clip lb・ft} Eyebolt
9) Install the oil return pipe to the cylinder block. 12) Connect the oil feed pipe to the turbocharger
assembly.
CAUTION
CAUTION
• Use new gaskets.
• Use new gaskets.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft} Tightening torque: 17 N・m {1.7 kgf・m / 12
10) Connect the oil return pipe to the turbocharger lb・ft} Eyebolt
assembly. Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
CAUTION
• Use new gaskets.
CAUTION
• Use new gaskets.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
2. Bridge Inspection
1) Inspect the bridge.
ANNOTATION:
• Confirm that the bridge moves smoothly.
2) Check the clearance of the bridge cap.
Specified value: 0.020 - 0.057 mm {0.0008 -
0.0022 in} Between the bridge and bridge cap
Limit: 0.1 mm {0.0039 in} Between the bridge
and bridge cap
1 Bridge
2 Bridge guide
1 Idle gear C
CAUTION
• Use a seat cutter suitable for the
valve seat angle and valve stem di-
ameter.
CAUTION
• Replace the inlet valve and valve
guide if the measured value ex-
ceeds the limit value.
CAUTION
• After fixing the valve, remove all
compounds.
1 Valve
The position 10 mm under the
2
valve guide head
3 Valve guide
5. Exhaust valve Inspection
1) Measure the exhaust valve using the microm- CAUTION
eter.
• Replace the exhaust valve and
ANNOTATION: valve guide if the measured value
• Outer diameter of the valve stem exceeds the limit value.
Measurement part: 3 section(s) 4) Measure the exhaust valve using the microm-
Specified value: 8.00 mm {0.3150 in} Diame- eter.
ter
Limit: 7.88 mm {0.3102 in} Diameter ANNOTATION:
CAUTION
2) Install the exhaust valve to the valve guide. • Replace the exhaust valve and
3) Measure the valve guide clearance using the valve guide if the measured value
dial gauge. exceeds the limit value.
ANNOTATION:
5) Inspect the exhaust valve using the red lead
• Valve guide clearance primer.
Specified value: 0.064 - 0.096 mm {0.0025 - ANNOTATION:
0.0038 in}
Limit: 0.25 mm {0.0098 in} • Inspect the contact surface of the exhaust
valve and valve seat.
Specified value: 2.5 mm {0.0984 in} Contact
width
Limit: 3.0 mm {0.1181 in} Contact width
84402826 - May 2011
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Removal and Installation of Cylinder Head
CAUTION
• If the measured value exceeds the
limit value, fix the contact surface
of the valve seat using a sheet cut-
ter.
• If the contact position is not in the
center of the valve seat, fix the con-
tact surface of the valve seat using
a sheet cutter.
• If the contact surface is not smooth,
fix the contact surface of the valve
seat using a sheet cutter.
CAUTION
• After fixing the valve, remove all
compounds.
CAUTION
• Use a seat cutter suitable for the
valve seat angle and valve stem di-
ameter.
CAUTION
• Clean the each part of the cylinder head
assembly before inspecting.
• Be careful not to damage the cylinder
head while cleaning the cylinder head as-
sembly.
ANNOTATION:
• Fix it if it is possible.
2) Perform dye penetrant check.
ANNOTATION:
• Check if there is a problem which cannot be
detected by visual inspection.
3) Align the simple straight ruler to the cylinder
head assembly.
4) Measure the clearance using the feeler
gauge.
ANNOTATION:
Measurement part: 6 section(s)
• Flatness of the bottom of the cylinder head
Specified value: less than 0.05 mm {less than
0.0020 in}
Limit: 0.2 mm {0.0079 in}
CAUTION
• Replace the cylinder head if the
measured value exceeds the limit
value.
2425
Removal of Cylinder Block 1) Remove the fan guide from the fan guide
bracket.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
5. Cooling fan Removal 2) Remove the fan guide bracket from the engine
assembly.
1) Remove the cooling fan from the adapter.
7. Cooling fan belt Removal
1) Remove the cooling fan belt from the engine
assembly.
1 Cooling fan
2 Adapter
1 Adapter
2 Spacer
1 Felt 3 Fan pulley
2 Slinger 4 Water pump assembly
3 Crankshaft front oil seal 5 Gasket
7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2425-5
Removal and Installation of Cylinder Block
13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.
1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
13. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.
2) Remove the EGR valve from the EGR pipe D. 2) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D
2) Disengage the harness connector from the in- 3) Disengage the harness connector from the
take throttle valve. EGR valve.
4) Disconnect the harness connector from the
ANNOTATION:
IMT sensor.
• Pull the lock operation portion to release the 5) Remove the harness clip from the inlet pipe.
lock.
1 Boost sensor
1 Lock operation section 2 IMT sensor
2 Lock release 3 EGR valve
3 Lock 4 Harness clip
5 Boost temperature sensor
3) Remove the intake throttle valve from the inlet
pipe. 6) Remove the inlet pipe from the case.
20. Injection pipe Removal • Remove the eyebolt tightened together with
the fuel feed pipe.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector 3) Disengage the fuel leak-off pipe from the com-
and the common rail assembly. mon rail assembly.
CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.
4) Remove the fuel leak-off pipe from the case. 24. Cylinder head cover Removal
ANNOTATION: 1) Disengage the ventilation hose from the air
• Remove the clip. breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
1 Lower cover
2 Connector
CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.
CAUTION
• Be careful not to drop the bridge
cap into the engine.
2) Remove the rocker arm shaft from the cylinder 2) Remove the bridge from the bridge guide.
head assembly. ANNOTATION:
ANNOTATION:
• After removing, organize to avoid a mix-up
• Evenly loosen the rocker arm shaft bracket with other installation locations.
and the rocker arm assembly bracket tight-
ening bolts from both ends and remove
them.
CAUTION
• Be careful not to remove the bolt
shown in the diagram.
1 Bridge cap
2 Bridge
CAUTION 1 Bolt
• Since the idle gear C protrudes
from the bottom surface of the 3) Remove the supply pump gear from the fuel
cylinder head, be careful not to supply pump using the puller.
damage the gear.
2) Remove the cylinder head gasket from the • Do not hold the pipe of the fuel sup-
cylinder block. ply pump.
CAUTION
• Do not reuse the cylinder head gas-
ket.
CAUTION
• Fix the flywheel firmly so that it will
not rotate.
1 Oil pressure sensor
35. Crankshaft rear oil seal Removal
2 Oil port cover
3 Starter assembly 1) Remove the crankshaft rear oil seal from the
crankshaft using the special tool.
CAUTION
• Be careful not to subject the sensor
to shock.
1 CKP sensor
2 Flywheel housing
CAUTION
• Do not forget to remove the bolt
shown in the diagram.
CAUTION
• Be careful not to damage the oil
seal press fitting surface.
ANNOTATION:
• Remove the slinger and oil seal together.
• If the slinger of the remover is easy to come
off, the outer circumference of the jig can be
tightened using a clip band to improve the
workability.
1 Bolt
36. Oil pan Removal
1) Disengage the harness connector from the oil
level switch. 39. Idle gear Measurement
2) Remove the oil pan from the crankcase. 1) Align the dial gauge to the idle gear.
3) Remove the gasket from the oil pan.
ANNOTATION:
37. Oil strainer Removal
• Attach the dial gauge to the idle gear tooth
1) Remove the oil strainer from the crankcase. to be measured.
2) Remove the O-ring from the oil strainer.
2) Inspect the backlash.
ANNOTATION:
• Gently move the gear right and left to read
the inconsistency on the dial gauge.
CAUTION
• Measure the idle gear backlash be-
fore removing the idle gear A.
CAUTION
CAUTION
• Replace the idle gear if the mea-
sured value exceeds the limit value.
CAUTION
• Replace the thrust bearing if the
measured value is not within the
range of the standard value.
3) Remove the connecting rod bearing from the 2) Remove the crankcase from the cylinder
connecting rod bearing cap. block.
ANNOTATION: ANNOTATION:
• Organize the removed bearings by the cylin- • Loosening order
ders using tags, etc.
4) Remove the piston from the cylinder block.
ANNOTATION:
• Pull out the piston and connecting rod to-
gether to the cylinder head side.
CAUTION
• Be careful not to damage the oil jet.
5) Remove the crankshaft from the cylinder 46. Cylinder liner Removal
block.
1) Remove the cylinder liner from the cylinder
6) Remove the thrust bearing from the cylinder
block.
block.
7) Remove the crankshaft bearing from the cylin-
der block.
45. Piston oil jet Removal
1) Remove the piston oil jet from the cylinder
block.
CAUTION
• Do not tilt the cylinder liner when
storing.
ANNOTATION:
• A marking on a cylinder block indicates the 2. Cylinder liner Installation
cylinder block bore grade.
CAUTION
• Since the cylinder liner is thin, handle it
carefully.
• Do not tilt the cylinder liner when storing.
CAUTION
• Do not tap or apply excessive force
when inserting the liner.
1 Grade confirmation location
CAUTION
• After replacing the cylinder liner,
be sure to measure the protrusion
amount of the cylinder liner.
CAUTION
• Be careful not to deform or damage
the nozzle part of the piston oil jet.
1 Upper bearing
2 Oil hole
3 Grade identification color
4 Oil groove
5 Lower bearing
6 Grade identification color
5. Crankshaft Installation
1) Install the crankshaft bearing to the cylinder
block.
ANNOTATION:
• Install a bearing with an oil hole on the cylin-
3) Select the crankshaft bearing. der block.
ANNOTATION: CAUTION
• Refer to the bearing selection table. • Make sure there is no grime or oil on
the cylinder block contact surface
for the crankshaft bearing.
Bearing selection table
Grade combination Oil clearance 2) Apply the grease to the thrust bearing.
Cylin- Crank
ANNOTATION:
der block journal 1, 2, 4, 5 3
grade grade • Apply a small amount of grease to the thrust
: 0.041 - : 0.055 - bearing to prevent falling.
0.068 mm 0.082 mm
1 1 3) Install the thrust bearing to the cylinder block.
{0.0016 - {0.0022 -
0.0027 in} 0.0032 in} ANNOTATION:
: 0.039 -
0.065 mm
0.053 - 0.079 • Install the thrust bearing on the No.5 journal
1 2 mm {0.0021 - so that the oil groove faces the engine front.
{0.0015 -
0.0031 in}
0.0026 in}
: 0.043 - : 0.057 -
0.070 mm 0.084 mm
2 1
{0.0017 - {0.0022 -
0.0028 in} 0.0033 in}
: 0.041 - : 0.055 -
0.067 mm 0.081 mm
2 2
{0.0016 - {0.0022 -
0.0026 in} 0.0032 in}
CAUTION
• Be careful not to mistake the bear-
ing shape when installing the 4) Apply the engine oil to the crankshaft bearing.
crankshaft bearing. 5) Apply the engine oil to the crankshaft.
6) Put the crankshaft on the cylinder block.
1 2 - 3 mm
2 3 - 4 mm
CAUTION
• Do not apply grease to the M10 bolt.
ANNOTATION:
• Tightening order
16) Tighten the bolt using the torque wrench. 7) Install the special tool to the piston
Tightening torque: 132 N・m {13.5 kgf・m
/ 97 lb・ft} M14 bolt
17) Tighten the bolt using the special tool.
CAUTION
• Apply engine oil only to the inter-
nal diameter of the connecting rod
bearing.
CAUTION
• Set each cylinder to the bottom
dead center while working.
2) Apply the engine oil to the idle gear B shaft. 8. Oil pump assembly Installation
1) Install the oil pump to the cylinder block.
CAUTION
• Use new gaskets.
1 Idle gear B
2 Thrust collar
3 Bolt
CAUTION
• Confirm that the idle gear B turns
smoothly after installing.
1 Bolt
Tightening torque
: 96 N・m {9.8 kgf・m
Flywheel housing side
/ 71 lb・ft}
: 38 N・m {3.9 kgf・m
Cylinder block side
/ 28 lb・ft}
Supply pump bracket : 76 N・m {7.7 kgf・m
side / 56 lb・ft} 7) Install the O-ring to the cover.
8) Install the cover to the flywheel housing.
Tightening torque: 19 N・m {1.9 kgf・m / 14
ANNOTATION: lb・ft}
• Install the flywheel housing after aligning 11. Oil strainer Installation
with the knock pin position of the cylinder
block. 1) Install the O-ring to the oil strainer.
2) Install the oil strainer to the crankcase. 2) Install the gasket to the oil pan.
Tightening torque: 31 N・m {3.2 kgf・m / 23 3) Install the oil pan to the crankcase.
lb・ft} Tightening torque: 29 N・m {3.0 kgf・m / 22
lb・ft}
ANNOTATION:
• Tightening order
1 M10 bolt
2 M8 bolt
4) Connect the harness connector to the oil level
12. Oil pan Installation switch.
1) Apply the liquid gasket to the crankcase. 13. Crankshaft rear oil seal Installation
ANNOTATION: 1) Prepare the special tool.
1 Crankshaft
2 Crankshaft rear oil seal
3 Measurement location
4 Collar
5 Adapter ring
6 Sleeve
7 Adapter
2) Install the flywheel to the crankshaft. • Tighten together with the clip.
CAUTION Tightening torque: 6 N・m {0.6 kgf・m / 52
lb・in}
• Pay attention to the knock pin posi- 2) Connect the harness connector to the CKP
tion of the crankshaft. sensor.
ANNOTATION:
• Tightening order
1 CKP sensor
2 Flywheel housing
3) Tighten the bolt using the torque wrench.
Tightening torque: 78 N・m {8.0 kgf・m / 58 16. Starter assembly Installation
lb・ft} 1) Install the starter assembly to the flywheel
4) Tighten the bolt using the special tool. housing.
Tightening torque: 106 N・m {10.8 kgf・m
/ 78 lb・ft}
2) Connect the earth cable to the starter assem-
bly.
Tightening torque: 51 N・m {5.1 kgf・m / 37
lb・ft}
CAUTION
• Be careful not to let the O-ring get
twisted.
ANNOTATION:
1 Bolt
• After installing the supply pump gear, refer
to the diagram and make an alignment mark
on it. 7) Check alignment mark of the supply pump
gear.
ANNOTATION:
• Confirm that the alignment mark can be
seen through the plug hole on the left side
of the flywheel housing.
84402826 - May 2011
2425-31
Removal and Installation of Cylinder Block
1 Plug hole
2 Alignment mark
1 O-ring
CAUTION
4) Install the front cover to the cylinder block.
• If the alignment mark could not be
confirmed, adjust the position of CAUTION
the supply pump gear.
• Pay attention to the knock pin posi-
8) Securely tighten the fuel supply pump to the tion of the cylinder block.
cylinder block.
Tightening torque: 50 N・m {5.1 kgf・m / 37 Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Nut lb・ft}
Tightening torque: 76 N・m {7.7 kgf・m / 56
lb・ft} Bolt 19. Water pump assembly Installation
9) Connect the harness connector to the fuel 1) Install the water pump assembly to the front
supply pump. cover.
18. Front cover Installation
CAUTION
1) Clean the cylinder block using the scraper.
2) Apply the liquid gasket to the front cover. • Use new gaskets.
CAUTION
• After applying the liquid gasket, in-
stall the front cover within 5 min-
utes.
1 Bolt
2 Stud bolt
3 Oil relief valve
CAUTION
1 Adapter
2 Spacer • Apply only to the lip section of the
3 Fan pulley oil seal.
4 Water pump assembly
5 Gasket 3) Install the crankshaft front oil seal to the
adapter.
20. Crankshaft front oil seal Installation 4) Install the adapter to the crankshaft.
5) Install the adapter ring to the sleeve.
1) Prepare the special tool. 6) Install the sleeve to the adapter.
8) Tighten the center bolt using the wrench. 1) Install the crankshaft damper to the crankshaft
pulley.
ANNOTATION:
Tightening torque: 48 N・m {4.9 kgf・m / 35
• Tighten the center bolt until the sleeve lb・ft}
touches the adapter.
ANNOTATION:
• Tighten the bolts in a diagonal line order.
CAUTION
• Clean the aligning surface of the cylinder
head and cylinder block before installing
the cylinder head assembly.
• Be careful not to damage the cylinder
head and cylinder block while cleaning.
Bead height: 3.0 mm {0.1181 in} • Apply engine oil to the seat surface and
threaded portion of the M10 head bolts.
5) Tighten the head bolt using the torque wrench.
Tightening torque: 157 N・m {16.0 kgf・m
/ 116 lb・ft}
6) Tighten the head bolt using the torque wrench.
Tightening torque: 165 N・m {16.8 kgf・m
/ 122 lb・ft}
7) Tighten the head bolt using the special tool.
CAUTION
• After applying liquid gasket, install
the cylinder head within 5 minutes.
CAUTION
• Confirm that the bridge moves
smoothly.
ANNOTATION:
• 1 - 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION:
CAUTION
• Apply molybdenum disulfide grease to the
seat surface and threaded portion of the • Be careful not to drop the bridge
M14 head bolts. cap into the engine.
CAUTION
• Apply engine oil after cleaning the
1 Front cover marking bearing installation sections of the
0 degree marking on the crank- camshaft bearing and camshaft
2 bearing cap.
shaft damper
7) Install the camshaft bearing to the camshaft
2) Apply the engine oil to the camshaft bearing. bearing cap.
ANNOTATION: 8) Install the camshaft bearing cap to the cylinder
head assembly.
• Apply engine oil to the sliding surface of the
bearing. ANNOTATION:
7) Connect the harness connector to the fuel 5) Securely tighten the fuel leak-off pipe to the
pressure sensor. common rail assembly.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
7) Install the clip to the fuel leak-off pipe.
Tightening torque: 8 N・m {0.8 kgf・m / 69
lb・in}
1) Apply the engine oil to the bolt. 3) Install the clip to the bracket.
2) Temporarily tighten the injector to the cylinder Tightening torque: 6 N・m {0.6 kgf・m / 52
head assembly. lb・in}
CAUTION
• Be extremely careful not to damage
the injector nozzle.
CAUTION
• Use new gaskets.
3) Install the gasket to the lower cover. 33. Glow plug Installation
4) Install the lower cover to the cylinder head
1) Install the glow plug to the cylinder head as-
assembly.
sembly.
Tightening torque: 18 N・m {1.8 kgf・m / 13
Tightening torque: 20 N・m {2.0 kgf・m / 14
lb・ft}
lb・ft}
5) Install the injector harness to the cylinder head
assembly. CAUTION
ANNOTATION:
• Be careful not to exceed the speci-
• Tighten the bolts on the bracket and in- fied torque when tightening.
stall the injector harness together with the
bracket.
Tightening torque: 48 N・m {4.9 kgf・m / 35
lb・ft}
CAUTION
1 Injector harness terminal
2 Injector harness bracket • Confirm that the glow plug connec-
tor does not interfere with the sur-
rounding parts.
6) Connect the injector harness to the injector.
Tightening torque: 2 N・m {0.2 kgf・m / 18
34. Cylinder head cover Installation
lb・in}
1) Align the head cover gasket to the cylinder
CAUTION head cover.
2) Install the cylinder head cover to the lower
• Be careful not to damage the injec-
tor side stud bolts. cover.
Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.
1 Lower cover
2 Connector
CAUTION
• Use new gaskets.
1 Boost sensor
1 Cylinder head cover
2 IMT sensor
2 Oil level gauge guide tube
3 EGR valve
3 Case
4 Harness clip
4 Cylinder block
5 Boost temperature sensor
5) Install the fan guide stay to the fan guide. 40. EGR cooler assembly Installation
Tightening torque: 45 N・m {4.6 kgf・m / 33
1) Temporarily tighten the EGR pipe C to the
lb・ft}
EGR valve.
2) Temporarily tighten the EGR cooler B to the
EGR pipe C.
3) Temporarily tighten the EGR pipe B to the
EGR cooler B.
4) Temporarily tighten the EGR cooler A to the
EGR pipe B.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D
• Complete tightening order of the EGR 14) Install the EGR heat protector to the EGR pipe
cooler assembly A.
2) Temporarily tighten the exhaust manifold stay 6) Connect the water feed pipe to the tur-
to the cylinder block and the turbocharger as- bocharger assembly.
sembly.
CAUTION
• Use new gaskets.
CAUTION
• Use new gaskets.
CAUTION
1 Water return pipe
• Use new gaskets.
2 Water feed pipe
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft} Eyebolt
Tightening torque: 24 N・m {2.4 kgf・m / 17 Tightening torque: 35 N・m {3.5 kgf・m / 25
lb・ft} Clip lb・ft} Eyebolt
9) Install the oil return pipe to the cylinder block. 12) Connect the oil feed pipe to the turbocharger
assembly.
CAUTION
CAUTION
• Use new gaskets.
• Use new gaskets.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft} Tightening torque: 17 N・m {1.7 kgf・m / 12
10) Connect the oil return pipe to the turbocharger lb・ft} Eyebolt
assembly. Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
CAUTION
• Use new gaskets.
CAUTION
• Use new gaskets.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
1) Press the cooling fan belt. 1) Install the fan guide bracket to the engine as-
sembly.
ANNOTATION:
Tightening torque: 40 N・m {4.1 kgf・m / 30
• Measure the amount of cooling fan belt flex lb・ft}
by pressing on the point indicated by the ar- 2) Install the fan guide to the fan guide bracket.
row in the diagram with the specified pres- Tightening torque: 30 N・m {3.1 kgf・m / 22
sure. lb・ft}
standard : 98.0 N {10.0 kg / 22 lb}
Specified value : 6.0 - 8.0 mm {0.2362 -
0.3150 in} Amount of flex
1 Bolt
2 Washer
3 Rubber mount
4 Rubber mount
1 Crankshaft pulley 5 Guide tube
2 Generator 6 Fan guide
3 Fan pulley
45. Cooling fan Installation
2) Adjust the cooling fan belt to standard value 1) Install the cooling fan to the adapter.
using the adjust bolt. Tightening torque: 52 N・m {5.3 kgf・m / 38
Tightening torque: 76 N・m {7.7 kgf・m / 56 lb・ft}
lb・ft} Nut of the adjust plate
Tightening torque: 127 N・m {12.9 kgf・m
/ 93 lb・ft} Bolt of the bracket side
1 Cooling fan
2 Adapter
CAUTION
• Confirm the tightening of the oil pan
drain before adding engine oil.
CAUTION
• Be careful not to let coolant over- 1 Priming pump
flow splash on the exhaust system
2 Plug
parts.
3 Drain plug
• Coolant overflow should be wiped
off. 4 Case
5 Fuel filter element
3) Tighten the valve using a wrench.
1) Prepare the pan.
CAUTION 2) Turn ON the starter switch.
• Use new gaskets. ANNOTATION:
Tightening torque: 28 N・m {2.8 kgf・m / 20 • This is for the models with an electromag-
lb・ft} netic pump.
4) Replenish the coolant with the radiator. 3) Loosen the plug using the wrench.
4) Operate the priming pump.
Number of times: 20 count(s) or more
ANNOTATION:
• Confirm that fuel comes out from around the
plug.
5) Tighten the plug using the wrench.
6) Operate the priming pump.
Number of times: 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
specified time: 1 min
1 Valve 7) Loosen the plug using the wrench.
2 Gasket ANNOTATION:
• Remove the air in the fuel filter.
49. Battery ground cable Connect
8) Tighten the plug using the wrench.
1) Connect the battery ground cable to the bat- 9) Operate the priming pump.
tery. Number of times: 10 count(s) or more
50. Fuel Air bleed ANNOTATION:
CAUTION • Wait for the specified time after operating
the priming pump.
• To prevent engine failure, be sure to per-
form air removal after the installation or specified time: 1 min
removal of fuel system parts. 10) Loosen the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.
11) Tighten the plug using the wrench. 15) Operate the priming pump.
12) Operate the priming pump. Number of times the operation is performed:
Number of times: 10 count(s) or more 10 - 15 times
16) Start the engine.
ANNOTATION:
• Wait for the specified time after operating CAUTION
the priming pump.
• Do not accelerate the engine revo-
specified time: 1 min lution right after staring.
13) Loosen the plug using the wrench.
Idling: 5 s
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution gradually.
14) Tighten the plug using the wrench.
Tightening torque: 10 N・m {1.0 kgf・m / 89 Engine revolution hold: 3 min.
lb・in}
ANNOTATION:
CAUTION • Accelerate the engine revolution to maxi-
mum.
• Remove the fuel around the plug
thoroughly after tightening. • Lower the rotation.
CAUTION
• Replace the cylinder block if dam-
age such as a crack has been found
in the inspection.
CAUTION
• Replace the cylinder block if the
measured value exceeds the limit
value.
2445
Lubrication System
CAUTION
• After applying the liquid gasket, in-
stall the oil pan within 5 minutes.
CAUTION
• Confirm the tightening of the oil pan
drain before adding engine oil.
1 Spacer
2 Oil level switch
3 Spacer
7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2445-6
Lubrication System
13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.
1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
6. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.
2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.
1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D
2) Disengage the harness connector from the in- 6) Remove the inlet pipe from the case.
take throttle valve.
3) Remove the intake throttle valve from the inlet
pipe.
1 Case
2 Gasket
3 Inlet pipe
1 Boost temperature sensor
2 Boost sensor
11. Oil level gauge guide tube Removal
3 Inlet pipe
4 Gasket 1) Remove the oil level gauge from the oil level
5 Intake throttle valve gauge guide tube.
2) Disengage the oil level gauge guide tube from
10. Inlet pipe Removal the cylinder head cover.
3) Disengage the oil level gauge guide tube from
1) Disengage the harness connector from the the case.
boost sensor. 4) Remove the oil level gauge guide tube from
2) Disconnect the harness connector from the the cylinder block.
boost temperature sensor.
3) Disengage the harness connector from the
EGR valve.
4) Disconnect the harness connector from the
IMT sensor.
5) Remove the harness clip from the inlet pipe.
CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.
17. Cylinder head cover Removal 4) Remove the lower cover from the cylinder
head assembly.
1) Disengage the ventilation hose from the air
breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.
1 Lower cover
2 Connector
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
Special tool: sliding hammer (refer to 20. Rocker arm shaft Removal
section 1003)
1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.
CAUTION
• Be careful not to remove the bolt
shown in the diagram.
1 Sliding hammer
2 Fuel injector remover
3 Injector
CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.
CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
cylinder head, be careful not to
damage the gear.
CAUTION
• Be careful not to drop the bridge
cap into the engine.
1 Idle gear C
CAUTION
• Do not reuse the cylinder head gas-
ket.
2) Remove the fuel supply pump from the cylin- 25. Starter assembly Removal
der block.
1) Disengage the earth cable from the starter as-
sembly.
2) Remove the starter assembly from the fly-
wheel housing.
1 Bolt
CAUTION
• Be careful not to subject the sensor
to shock.
CAUTION
• Do not hold the pipe of the fuel sup-
ply pump.
1 CKP sensor
2 Flywheel housing
CAUTION CAUTION
• Fix the flywheel firmly so that it will • Be careful not to damage the oil
not rotate. seal press-fitting surface.
1 Felt
2 Slinger
3 Crankshaft rear oil seal 1 Bolt
1) Align the dial gauge to the idle gear. Specified value: 0.080 - 0.155 mm { 0.0031 -
0.0061 in }
ANNOTATION:
Limit: 0.20 mm { 0.0079 in }
• Attach the dial gauge to the idle gear tooth
to be measured. CAUTION
2) Inspect the backlash. • Replace the idle gear if the mea-
sured value exceeds the limit value.
ANNOTATION:
• Gently move the gear right and left to read
the inconsistency on the dial gauge.
CAUTION
• Measure the idle gear backlash be-
fore removing the idle gear A.
CAUTION
• Replace the idle gear if the mea-
sured value exceeds the limit value.
32. Idle gear A Removal
1) Remove the idle gear A from the idle gear A
shaft.
33. Oil pump assembly Removal
1) Remove the oil pump assembly from the cylin-
der block.
CAUTION
• Measure the play of the idle gear in
the axis direction before removing
the idle gear B.
1 Split pin
Installation of Oil Pump Assembly 2) Apply the engine oil to the idle gear A.
3) Install the idle gear A shaft to the idle gear A.
1. Oil pump assembly Installation 4) Align the idle gear A to alignment mark.
1) Install the oil pump to the cylinder block. ANNOTATION:
CAUTION • Align the L mark on the crank gear with the
O mark on the idle gear A.
• Use new gaskets.
5) Apply the engine oil to the bolt.
Tightening torque: 31 N・m {3.2 kgf・m / 23 ANNOTATION:
lb・ft}
• Apply engine oil to the threaded portion and
2. Idle gear A Installation seat surface on the idle gear A installation
1) Align 1st cylinder to the compression top dead bolt.
center.
1 Bolt
CAUTION
• After applying the liquid gasket, in-
stall the flywheel housing within 5
minutes.
Tightening torque
: 96 N・m {9.8 kgf・ m / 7) Install the O-ring to the cover.
Flywheel housing side
71 lb・ft} 8) Install the cover to the flywheel housing.
: 38 N・m {3.9 kgf・ m / Tightening torque: 19 N・m {1.9 kgf・m / 14
Cylinder block side
28 lb・ft} lb・ft}
Supply pump bracket : 76 N・m {7.7 kgf・ m /
side 56 lb・ft} 4. Oil pan Installation
1) Apply the liquid gasket to the crankcase.
ANNOTATION:
ANNOTATION:
• Install the flywheel housing after aligning
with the knock pin position of the cylinder • Apply ThreeBond 1207B to each joint of the
block. crankcase, flywheel housing and gear case.
ANNOTATION:
• Install the crankshaft rear oil seal and
slinger together.
• In order to install the crankshaft rear oil seal,
use the one(s) in the following table from
among the parts included in the kit.
CAUTION
• After applying the liquid gasket, in-
stall the oil pan within 5 minutes.
CAUTION
• Apply only to the lip section of the
oil seal.
4) Connect the harness connector to the oil level 3) Install the crankshaft rear oil seal to the
switch. adapter.
4) Install the adapter to the crankshaft.
5. Crankshaft rear oil seal Installation
5) Install the adapter ring to the sleeve.
1) Prepare the special tool. 6) Install the sleeve to the adapter.
7) Install the center bolt to the sleeve. 2) Install the flywheel to the crankshaft.
8) Tighten the center bolt using the wrench.
CAUTION
ANNOTATION:
• Pay attention to the knock pin posi-
• Tighten the center bolt until the sleeve tion of the crankshaft.
touches the adapter.
ANNOTATION:
• Tightening order
2) Connect the harness connector to the CKP 2) Install the fuel supply pump to the supply
sensor. pump bracket.
Tightening torque: 19 N・m {1.9 kgf・m / 14
lb・ft}
CAUTION
• Be careful not to let the O-ring get
twisted.
1 CKP sensor
2 Flywheel housing
• After installing the supply pump gear, refer 7) Check alignment mark of the supply pump
to the diagram and make an alignment mark gear.
on it.
ANNOTATION:
• Confirm that the alignment mark can be
seen through the plug hole on the left side
of the flywheel housing.
1 Plug hole
2 Alignment mark
CAUTION
• If the alignment mark could not be
confirmed, adjust the position of
the supply pump gear.
CAUTION
• Clean the aligning surface of the cylinder
head and cylinder block before installing
the cylinder head assembly.
• Be careful not to damage the cylinder
head and cylinder block while cleaning.
CAUTION
• After applying liquid gasket, install
the cylinder head within 5 minutes.
CAUTION
• Confirm that the bridge moves
smoothly.
ANNOTATION:
• Tightening order of the head bolts
ANNOTATION:
• 1 to 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION: CAUTION
• Apply molybdenum disulfide grease to the • Be careful not to drop the bridge
seat surface and threaded portion of the cap into the engine.
M14 head bolts.
• Apply engine oil to the seat surface and 12. Camshaft Installation
threaded portion of the M10 head bolts.
84402826 - May 2011
2445-25
Lubrication System
CAUTION
• Apply engine oil after cleaning the
1 Front cover marking bearing installation sections of the
0 degree marking on the crank- camshaft bearing and camshaft
2 bearing cap.
shaft damper
2) Apply the engine oil to the camshaft bearing. 7) Install the camshaft bearing to the camshaft
bearing cap.
ANNOTATION: 8) Install the camshaft bearing cap to the cylinder
• Apply engine oil to the sliding surface of the head assembly.
bearing. ANNOTATION:
CAUTION • Turn the camshaft bearing cap so that the
arrow mark on the top surface faces the en-
• Apply engine oil after cleaning the gine front side, and assemble in numerical
bearing installation sections of
order.
the camshaft bearing and cylinder
head. Tightening torque: 28 N・m {2.8 kgf・m / 20
lb・ft} Apply engine oil
3) Install the camshaft bearing to the cylinder
head assembly.
4) Install the camshaft to the cylinder head as-
sembly.
ANNOTATION:
• Mesh together the idle gear C and the
camshaft gear so that the alignment mark
on the camshaft gear matches the top sur-
face of the cylinder head, and gently install
the camshaft.
• Check if the valve shaft end on the opposite 5) Securely tighten the nut to the common rail
side is floating or touching at an angle. assembly.
• If it is floating or touching at an angle, slightly Tightening torque: 22 N・m {2.2 kgf・m / 16
loosen the bridge adjust screw and adjust lb・ft}
the valve shaft ends on both sides to touch
ANNOTATION:
properly.
Valve bridge clearance: less than 0.1 mm • Refer to the tightening order in the diagram
if the inlet cover is removed.
{less than 0.0039 in}
ANNOTATION:
• To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and
tighten the adjust screw nut.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}
Adjustment table
Cylinder No. 1 2 3 4
E- E- E- E-
IN IN IN IN
X X X X
First cylinder compres-
O O O O
sion top dead center
Fourth cylinder com-
pression top dead cen- O O O O
ter
CAUTION
• Use new gaskets.
84402826 - May 2011
2445-28
Lubrication System
3) Temporarily tighten the fuel leak-off pipe to the 18. Injector Installation
fuel supply pump.
CAUTION
ANNOTATION:
• When reusing an injector, do not change
• Tighten the fuel feed pipe together. the installation position.
CAUTION
1) Apply the engine oil to the bolt.
• Use new gaskets. 2) Temporarily tighten the injector to the cylinder
head assembly.
4) Securely tighten the fuel leak-off pipe to the
cylinder head assembly. CAUTION
Tightening torque: 12 N・m {1.3 kgf・m / 109
• Be extremely careful not to damage
lb・in} the injector nozzle.
5) Securely tighten the fuel leak-off pipe to the
common rail assembly.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
7) Install the clip to the fuel leak-off pipe.
Tightening torque: 8 N・m {0.8 kgf・m / 69
lb・in}
1 Injector
2 Installation bolt
3) Install the clip to the bracket. 4) Install the lower cover to the cylinder head
Tightening torque: 6 N・m {0.6 kgf・m / 52 assembly.
lb・in} Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
5) Install the injector harness to the cylinder head
assembly.
ANNOTATION:
• Tighten the bolts on the bracket and in-
stall the injector harness together with the
bracket.
Tightening torque: 48 N・m {4.9 kgf・m / 35
lb・ft}
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
1 Rubber plug
2 Liquid gasket
CAUTION
• After applying the liquid gasket, in- 1 Lower cover
stall the lower cover within 5 min- 2 Connector
utes.
2) Install the rubber plug to the cylinder head Install the connector to the lower cover.
assembly. Tightening torque: 2 N・m {0.2 kgf・m / 18
3) Install the gasket to the lower cover. lb・in}
84402826 - May 2011
2445-30
Lubrication System
CAUTION
• Be careful not to exceed the speci-
fied torque when tightening.
2) Install the glow plug connector to the glow 23. Oil level gauge guide tube Installation
plug. 1) Install the oil level gauge guide tube to the
Tightening torque: 1 N・m {0.1 kgf・m / 11 cylinder block.
lb・in} 2) Connect the oil level gauge guide tube to the
case.
CAUTION Tightening torque: 19 N・m {1.9 kgf・m / 14
• Confirm that the glow plug connec- lb・ft}
tor does not interfere with the sur- 3) Connect the oil level gauge guide tube to the
rounding parts. cylinder head cover.
Tightening torque: 19 N・m {1.9 kgf・m / 14
22. Cylinder head cover Installation lb・ft}
4) Install the oil level gauge to the oil level gauge
1) Align the head cover gasket to the cylinder guide tube.
head cover.
2) Install the cylinder head cover to the lower
cover.
Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.
1) Install the inlet pipe to the case. 25. Intake throttle valve Installation
Tightening torque: 24 N・m {2.4 kgf・m / 17
1) Install the intake throttle valve to the inlet pipe.
lb・ft}
Tightening torque: 24 N・m {2.4 kgf・m / 17
CAUTION lb・ft}
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B
13) Securely tighten the EGR pipe A to the EGR 1) Temporarily tighten the turbocharger assem-
cooler bly to the exhaust manifold.
A.
Tightening torque: 28 N・m {2.9 kgf・m / 21
lb・ft} No.8 in the diagram
14) Install the EGR heat protector to the EGR pipe
A.
1 Exhaust manifold
2 Turbocharger assembly
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
4) Securely tighten the exhaust manifold stay to 8) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
Tightening torque: 52 N・m {5.3 kgf・m / 38
lb・ft} Nut
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} Bolt
ANNOTATION:
• Tightening order
CAUTION
• Use new gaskets.
CAUTION
• Use new gaskets.
12) Connect the oil feed pipe to the turbocharger 31. Engine oil Filling
assembly.
1) Replenish the engine oil with the engine as-
CAUTION sembly.
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
• Confirm that fuel comes out from around the 15) Operate the priming pump.
plug. Number of times the operation is performed:
5) Tighten the plug using the wrench. 10 - 15 times
6) Operate the priming pump. 16) Start the engine.
Number of times: 10 count(s) or more CAUTION
ANNOTATION:
• Do not accelerate the engine revo-
• Wait for the specified time after operating lution right after staring.
the priming pump.
Idling: 5 s
Specified time: 1 min
7) Loosen the plug using the wrench. ANNOTATION:
ANNOTATION: • Accelerate the engine revolution gradually.
• Remove the air in the fuel filter. Engine revolution hold: 3 min.
8) Tighten the plug using the wrench. ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
• Lower the rotation.
1 Ball
2 Spring
1 Upper limit
2 Lower limit
ANNOTATION:
• If the oil level is under the lower limit, add
engine oil.
• Replace the engine oil if engine oil is dirty.
1 O-ring
2 O-ring
Installation of Oil Port Cover 3) Connect the oil feed pipe to the oil port cover.
1. Oil port cover Installation CAUTION
1) Install the O-ring to the oil port cover. • Use new gaskets.
CAUTION
• Use new gaskets.
1 Bolt - short
2 Bolt - long
2455
Cooling System
Removal and Installation of Water 2) Remove the fan guide bracket from the engine
assembly.
Pump Assembly
5. Cooling fan belt Removal
Removal of Water Pump Assembly 1) Remove the cooling fan belt from the engine
1. Battery ground cable Disconnect assembly.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
1 Adjuster bolt
2 Fixing bolt
3 Fixing bolt
1 Adapter
2 Spacer
3 Fan pulley
4 Water pump assembly
1 Bolt
5 Gasket
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
84402826 - May 2011
2455-3
Cooling System
Installation of Water Pump Assembly 6) Install the adapter to the water pump assem-
bly.
1. Water pump assembly Installation Tightening torque: 45 N・m {4.6 kgf・m / 33
1) Install the water pump assembly to the front lb・ft}
cover.
CAUTION
• Use new gaskets.
1 Adapter
2 Spacer
3 Fan pulley
4 Water pump assembly
5 Gasket
2) Connect the water hose to the water pump 1) Press the cooling fan belt.
assembly. ANNOTATION:
3) Connect the water return pipe to the water
pump assembly. • Measure the amount of cooling fan belt flex
Tightening torque: 35 N・m {3.6 kgf・m / 26 by pressing on the point indicated by the ar-
lb・ft} row in the diagram with the specified pres-
4) Install the fan pulley to the water pump assem- sure.
bly. Standard: 98.0 N {10.0 kg / 22 lb}
Tightening torque: 10 N・m {1.0 kgf・m / 87 Specified value : 6.0 - 8.0 mm {0.2362 -
lb・in} 0.3150 in}
5) Align the spacer to the adapter. Amount of flex
1 Crankshaft pulley
2 Generator
3 Fan pulley
84402826 - May 2011
2455-4
Cooling System
2) Adjust the cooling fan belt to standard value 5. Cooling fan Installation
using the adjust bolt.
1) Install the cooling fan to the adapter.
Tightening torque: 76 N・m {7.7 kgf・m / 56
Tightening torque: 52 N・m {5.3 kgf・m / 38
lb・ft}
lb・ft}
Nut of the adjust plate
Tightening torque: 127 N・m {12.9 kgf・m
/ 93 lb・ft} Bolt of the bracket side
1 Cooling fan
2 Adapter
1 Adjust bolt
2 Adjust plate side nut
3 Bracket side bolt
6. Coolant Filling
4. Fan guide Installation 1) Loosen the valve using a wrench.
2) Replenish the coolant with the radiator.
1) Install the fan guide bracket to the engine as-
sembly. CAUTION
Tightening torque: 40 N・m {4.1 kgf・m / 30
lb・ft} • Be careful not to let coolant over-
2) Install the fan guide to the fan guide bracket. flow splash on the exhaust system
Tightening torque: 30 N・m {3.1 kgf・m / 22 parts.
lb・ft} • Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets.
1 Bolt
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
1 Valve
2 Gasket
84402826 - May 2011
2455-5
Cooling System
CAUTION
• If any abnormality is found in the
inspection, replace the water pump
assembly.
1) Disengage the battery ground cable from the • Use new gaskets.
battery.
2) Install the thermostat to the cylinder head as-
2. Coolant Drain sembly.
1) Drain the coolant from the radiator.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
3. Thermostat Removal
1) Disengage the radiator upper hose from the
water outlet pipe.
2) Remove the water outlet pipe from the cylin-
der head assembly.
3) Remove the thermostat from the cylinder
head assembly.
4) Remove the gasket from the thermostat.
1 Thermostat
2 Cylinder head
CAUTION
• Be careful not to mistake the as-
sembly position and direction.
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets.
1 Valve
2 Gasket
Inspection
1. Thermostat Inspection
1) Inspect the thermostat.
ANNOTATION:
• Inspect the pellet, spring, shaft, jiggle valve,
and crimped sections for damage. 1 Piece of wood
2 Stirring rod
Inspection of Coolant
1. Coolant Inspection
WARNING
• If the coolant temperature is high, do not
perform the inspection.
• When removing the cap, be careful as the
coolant will burst out if the coolant tem-
perature is high.
CAUTION
1 Jiggle valve
• Be sure to use long life coolant which is
2) Prepare the container. specified or recommended by Isuzu.
• Using at an unspecified concentration
ANNOTATION: may result in freezing due to decreased
• Put water and the thermostat into a heatable antifreezing performance.
container. • Use a coolant concentration appropriate
for the usage environment.
3) Raise the water temperature.
ANNOTATION: ANNOTATION:
• In order to equalize the water temperature • Before using, dilute the specified long life coolant
in the container, stir well. to the specified concentration with soft tap water.
1 Radiator
2 Hydrometer
84402826 - May 2011
2455-9
Cooling System
Inspection of Cooling Fan Belt 2) Adjust the cooling fan belt to standard
value using the adjust bolt.
1. Cooling fan belt Inspection Tightening torque: 76 N・m {7.7 kgf・
1) Inspect the cooling fan belt. m / 56 lb・ft} Nut of the adjust plate
Tightening torque : 127 N ・ m {12.9
ANNOTATION: kgf・m / 93 lb・ft} Bolt of the bracket
side
• Inspect for wear or damage.
2) Cooling fan belt Adjustment
1) Press the cooling fan belt.
ANNOTATION:
• Measure the amount of cooling fan
belt flex by pressing on the point indi-
cated by the arrow in the diagram with
the specified pressure.
Standard: 98.0 N {10.0 kg / 22 lb}
Specified value: 6.0 - 8.0 mm {0.2362
- 0.3150 in} Amount of flex
1 Adjust bolt
2 Adjust plate side nut
3 Bracket side bolt
1 Crankshaft pulley
2 Generator
3 Fan pulley
1 Overheat switch
2 Water temperature sensor
1 Overheat switch
2 Water temperature sensor
2465
Removal of Exhaust Manifold 5) Disengage the oil return pipe from the tur-
bocharger assembly.
1. Coolant Drain
1) Drain the coolant from the radiator.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
7) Disengage the water feed pipe from the tur- 9) Disengage the harness connector from the
bocharger assembly. turbocharger assembly.
10) Remove the turbocharger assembly from the
ANNOTATION:
exhaust manifold.
• Remove the clip.
1 Exhaust manifold
2 Turbocharger assembly
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay 1 EGR heat protector
3) Remove the EGR pipe A from the EGR cooler 3) Remove the exhaust manifold bracket from
A and exhaust manifold. the cylinder head assembly.
1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D
1 Distance tube
2 Washer
3 Exhaust manifold bracket
4 Exhaust manifold bracket
5 Exhaust manifold 1 EGR cooler A
2 EGR pipe A
2. EGR cooler assembly Installation 3 Exhaust manifold
1) Temporarily tighten the EGR pipe C to the
EGR valve. ANNOTATION:
• Complete tightening order of the EGR 14) Install the EGR heat protector to the EGR pipe
cooler assembly A.
2) Temporarily tighten the exhaust manifold stay 5) Connect the water feed pipe to the tur-
to the cylinder block and the turbocharger as- bocharger assembly.
sembly.
ANNOTATION:
• Use new gaskets.
Tightening torque: 14 N・m {1.4 kgf・m /
119 lb・in} Clip
6) Connect the water return pipe to the tur-
bocharger assembly.
1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
CAUTION
• Use new gaskets.
8) Connect the oil feed pipe to the turbocharger 10) Install the air intake hose to the turbocharger
assembly. assembly and the intercooler.
11) Install the air cleaner duct to the air cleaner
CAUTION assembly and the turbocharger assembly.
12) Connect the harness connector to the tur-
• Use new gaskets. bocharger assembly.
Tightening torque: 17 N・m {1.7 kgf・m / 12 4. Battery ground cable Connect
lb・ft} Eyebolt
1) Connect the battery ground cable to the bat-
Tightening torque: 24 N・m {2.4 kgf・m / 17
tery.
lb・ft} Clip
5. Coolant Filling
1) Loosen the valve using a wrench.
2) Replenish the coolant with the radiator.
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
CAUTION
• Use new gaskets.
1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe
Inspection
1. Exhaust manifold Inspection
1) Inspect the exhaust manifold.
ANNOTATION:
• Inspect the exhaust manifold for cracks.
2. Align the simple straight ruler to the cylinder head
assembly.
3. Measure the clearance using the feeler gauge.
ANNOTATION:
• Flatness of the exhaust manifold
Specified value: 0.3 mm {0.0118 in}
Limit: 0.5 mm {0.0197 in}
CAUTION
• Replace the exhaust manifold if flatness
is above the limit value.
2470
CAUTION
• Before removing, be sure to check the
DPD pressure difference, status, and in-
spection/maintenance contents using a
scan tool.
• Do not reuse an exhaust gas tempera-
ture sensor which has been subjected to
shock such as being dropped.
1 Screw
4. Exhaust gas temperature sensor Removal
2. Exhaust differential pressure sensor Removal 1) Disengage the harness connector from the
exhaust gas temperature sensor.
CAUTION
ANNOTATION:
• Before performing work, be sure to
check the DPD differential pressure sen- • To prevent incorrect assembling, make an
alignment mark on the connector before dis-
sor precautions.
connecting.
1) Disengage the differential pressure hose from 2) Remove the exhaust gas temperature sensor
the exhaust differential pressure sensor. from the DPD assembly.
1 Bracket
2 Differential pressure pipe
CAUTION
• Do not subject the tip of the exhaust gas
temperature sensor to shock when in-
stalling.
• Remove the old anti-seize lubricant on
the sleeve nut.
• Apply the anti-seize lubricant on the
threaded portion of the sleeve nut.
• Apply Never-Seez High Temperature
Stainless Grade: anti-seize lubricant,
manufactured by Bostik in the United
states.
1 Oxidation catalyst assembly • Replace the oxidation catalyst assembly
2 Filter assembly if damage has been found in the sensor
3 Exhaust silencer assembly installation section of the oxidation cata-
lyst assembly.
5) Temporarily tighten the differential pressure 1) Temporarily tighten the exhaust gas tempera-
pipe to the DPD assembly. ture sensor to the DPD assembly.
CAUTION CAUTION
• Remove the old anti-seize lubricant • To avoid damaging the sensor in-
on the sleeve nut. stallation sections due to sensor
• Apply the anti-seize lubricant on the incorrect assembly, tighten it by
threaded portion of the sleeve nut. hand.
• Apply Never-Seez High Tempera-
ture Stainless Grade: anti-seize ANNOTATION:
lubricant, manufactured by Bostik
in the United states. • Exhaust gas temperature sensor identifica-
tion
84402826 - May 2011
2470-5
Disassembly, Removal and Installation of DPD Assembly
Connector CAUTION
Sensor type Screw size
color
Exhaust gas tempera- • Do not use a tool which causes vibra-
M12 x 1.75 Dark gray
ture sensor 1 tions such as an impact wrench when in-
Exhaust gas tempera- stalling and removing the DPD differen-
M12 x 1.25 Light gray tial pressure sensor.
ture sensor 2
• Do not reuse a DPD differential pressure
2) Securely tighten the exhaust gas temperature sensor which has been subjected to
sensor to the DPD assembly. shock such as being dropped.
Tightening torque: 30 N・m { 3.1 kgf・m / • Install or remove the DPD differen-
22 lb・ft } tial pressure sensor together with the
3) Connect the harness connector to the exhaust bracket.
gas temperature sensor. • Be sure not to loosen the 4 screws in-
stalled on the DPD differential pressure
CAUTION sensor.
• Replace the DPD differential pressure
• Be careful not to twist the harness. sensor if the 4 screws installed on the
DPD differential pressure sensor have
been loosened.
1 Screw
CAUTION
• Before performing work, be sure to
check the DPD differential pressure sen-
sor precautions.
Inspection
1. Filter assembly Inspection
1) Inspect the filter assembly.
ANNOTATION:
• Inspect the filter for erosion, crack, damage,
or clogging.
• Replace the filter assembly if light passes
through when shining light from the other
side of the filter.
1 Filter
2 Filter case
CAUTION
• Clean the filter when clogged be-
cause gradual accumulation or
firm, sticky calcination occurs on
the filter since ashes are non-
flammable unlike particle materials
(PM).
• When cleaning, use a DPD ash
removal device which blows com-
pressed air instantaneously.
• For further details on the cleaning
procedure, check the DPD ash re-
moval device handling manual.
ANNOTATION:
• Attach the filter on the DPD ash removal
device.
CAUTION
• Confirm that there is no air leakage
on the pipe connections by check-
ing the pressure gauge attached
to the pressure reducing valve to
avoid supplying air pressure to the
air tank over the limit value.
3001
WARNING 2. Drain out all the fuel from the fuel tank into a drum
can.
• Keep away from fire.
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (19 mm, 24 mm)
• Eyebolts (M12 x 4)
• Shackle (with the required lifting capacity) x 4 3. Use a wrench (19 mm) to remove the 8 bolts (1),
• Wire ropes (with the required breaking load) and then remove the top cover (2).
• Liftcrane (with the required lifting capacity)
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
• Wood planks
5. Use a wrench (19 mm) to remove the 6 bolts (1) and 6. Use a wrench (19 mm) to remove the 5 bolts (1)
clamps (2), and then remove the handle (3). from the fuel tank side cover (2), and then remove
the side cover.
13. Connect the 4 shackles (1) to the eyebolts, then use Installation of fuel tank
the wire ropes (2) and liftcrane to lift.
Thoroughly check that the location is safe before To install, perform the reverse of the removal procedure.
lowering the fuel tank (3) on wood planks. Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check of
the "Section 1002E• Tightening Torque • Retightening
Torque Table".
Finally, carefully check for any fuel leaks.
3004A
Removal of Fuel Supply Pump 1) Disengage the harness connector from the
fuel supply pump.
1. Battery ground cable Disconnect 2) Remove the fuel supply pump from the cylin-
1) Disengage the battery ground cable from the der block.
battery.
2. Engine harness Disconnect
1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:
• Disconnect each connector.
3. Fuel pipe Removal
1) Remove the fuel pipe from the fuel supply
pump and the common rail assembly.
ANNOTATION:
• Remove the clip.
1 Bolt
CAUTION
• Do not reuse the removed fuel pipe. 3) Remove the supply pump gear from the fuel
supply pump using the puller.
4. Fuel leak off pipe assembly Removal
1) Disengage the fuel leak-off pipe from the cylin-
der head assembly.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:
• Remove the eyebolt tightened together with
the fuel feed pipe.
3) Disengage the fuel leak-off pipe from the com-
mon rail assembly.
4) Remove the fuel leak-off pipe from the case.
ANNOTATION:
4) Remove the fuel supply pump from the supply
• Remove the clip. pump bracket.
CAUTION
• Do not hold the pipe of the fuel sup-
ply pump.
CAUTION
• Be careful not to let the O-ring get
twisted.
1 Plug hole
2 Alignment mark
CAUTION
• If the alignment mark could not be
confirmed, adjust the position of
the supply pump gear.
CAUTION CAUTION
• Use new gaskets. • Use new fuel pipes.
2) Temporarily tighten the fuel leak-off pipe to the Tightening torque: 44 N・m {4.5 kgf・m / 33
common rail assembly. lb・ft}
2) Install the clip to the bracket.
CAUTION Tightening torque: 9 N・m {0.9 kgf・m / 78
lb・in}
• Use new gaskets.
4. Engine harness Connect
3) Temporarily tighten the fuel leak-off pipe to the 1) Connect the engine harness to the engine as-
fuel supply pump. sembly.
ANNOTATION: ANNOTATION:
• Tighten the fuel feed pipe together. • Connect each connector.
CAUTION 5. Battery ground cable Connect
• Use new gaskets. 1) Connect the battery ground cable to the bat-
tery.
4) Securely tighten the fuel leak-off pipe to the
6. Fuel Air bleed
cylinder head assembly.
Tightening torque: 12 N・m {1.3 kgf・m / CAUTION
109 lb・in}
• To prevent engine failure, be sure to per-
form air removal after the installation or
removal of fuel system parts.
• Confirm that fuel comes out from around the 15) Operate the priming pump.
plug. Number of times the operation is Performed:
5) Tighten the plug using the wrench. 10 - 15 times
6) Operate the priming pump. 16) Start the engine.
Number of times: 10 count(s) or more CAUTION
ANNOTATION:
• Do not accelerate the engine revo-
• Wait for the specified time after operating lution right after staring.
the priming pump.
Idling: 5 s
Specified time: 1 min
7) Loosen the plug using the wrench. ANNOTATION:
ANNOTATION: • Accelerate the engine revolution gradually.
• Remove the air in the fuel filter. Engine revolution hold: 3 min.
8) Tighten the plug using the wrench. ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
• Lower the rotation.
3004B
Removal of Common Rail 3) Remove the intake throttle valve from the inlet
pipe.
Assembly
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Engine harness Disconnect
1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:
• Disconnect each connector.
3. Intake throttle valve Removal
1) Remove the air duct from the intake throttle
valve.
2) Disengage the harness connector from the in- 1 Boost temperature sensor
take throttle valve. 2 Boost sensor
3 Inlet pipe
ANNOTATION: 4 Gasket
• Pull the lock operation portion to release the 5 Intake throttle valve
lock.
4. Inlet pipe Removal
1) Disengage the harness connector from the
boost sensor.
2) Disconnect the harness connector from the
boost temperature sensor.
3) Disengage the harness connector from the
EGR valve.
4) Disconnect the harness connector from the
IMT sensor.
5) Remove the harness clip from the inlet pipe.
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
5 Boost temperature sensor
6) Remove the inlet pipe from the case. 2) Remove the injection pipe from the injector
and the common rail assembly.
CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.
1 Case
2 Gasket
3 Inlet pipe
3) Disengage the fuel leak-off pipe from the com- Installation of Common Rail
mon rail assembly.
4) Remove the fuel leak-off pipe from the case. Assembly
ANNOTATION: 1. Common rail assembly Installation
• Remove the clip. 1) Temporarily tighten the common rail bracket
to the oil cooler assembly.
ANNOTATION:
• The installation bolt and common rail as-
sembly are tightened together.
2) Align the common rail assembly to the inlet
cover.
3) Align the common rail assembly to the com-
mon rail bracket.
4) Temporarily tighten the nut to the common rail
assembly.
ANNOTATION:
• The stud bolts of the inlet cover are tight-
ened together.
1 Common rail assembly 5) Temporarily tighten the bolt to the common rail
2 Cylinder head assembly assembly.
3 Fuel leak-off pipe 6) Securely tighten the nut to the common rail
4 Fuel supply pump assembly.
Tightening torque: 22 N・m {2.2 kgf・m / 16
9. Common rail assembly Removal lb・ft}
1) Disengage the harness connector from the ANNOTATION:
fuel pressure sensor.
• Refer to the tightening order in the diagram
2) Remove the common rail assembly from the
if the inlet cover is removed.
inlet cover and the common rail bracket.
3) Remove the common rail bracket from the oil
cooler assembly.
8) Connect the harness connector to the fuel 7) Install the clip to the fuel leak-off pipe.
pressure sensor. Tightening torque: 8 N・m {0.8 kgf・m / 69
lb・in}
CAUTION ANNOTATION:
• Use new gaskets. • Apply to the injection pipe sleeve on the in-
jector side.
4) Securely tighten the fuel leak-off pipe to the 2) Temporarily tighten the injection pipe to the
cylinder head assembly. injector.
Tightening torque: 12 N・m {1.3 kgf・m / 3) Temporarily tighten the injection pipe to the
109 lb・in} common rail assembly.
5) Securely tighten the fuel leak-off pipe to the 4) Securely tighten the injection pipe to the injec-
common rail assembly. tor.
Tightening torque: 24 N・m {2.4 kgf・m / 17 Tightening torque: 30 N・m {3.0 kgf・m / 22
lb・ft} lb・ft}
6) Securely tighten the fuel leak-off pipe to the 5) Securely tighten the injection pipe to the com-
fuel supply pump. mon rail assembly.
Tightening torque: 24 N・m {2.4 kgf・m / 17 Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} lb・ft}
CAUTION
• Use new gaskets.
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
1 Cylinder head cover 5 Boost temperature sensor
2 Oil level gauge guide tube
3 Case
4 Cylinder block 7. Intake throttle valve Installation
84402826 - May 2011
3004B-7
Removal and Installation of Common Rail Assembly
10) Loosen the plug using the wrench. 15) Operate the priming pump.
Number of times the operation is Performed:
ANNOTATION:
10 - 15 times
• Remove the air in the fuel filter. 16) Start the engine.
11) Tighten the plug using the wrench. CAUTION
12) Operate the priming pump.
Number of times: 10 count(s) or more • Do not accelerate the engine revo-
lution right after staring.
ANNOTATION:
• Wait for the specified time after operating Idling: 5 s
the priming pump. ANNOTATION:
Specified time: 1 min
• Accelerate the engine revolution gradually.
13) Loosen the plug using the wrench.
Engine revolution hold: 3 min.
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution to maxi-
14) Tighten the plug using the wrench. mum.
Tightening torque: 10 N・m {1.0 kgf・m / 89
• Lower the rotation.
lb・in}
CAUTION
• Remove the fuel around the plug
thoroughly after tightening.
3005
Removal of Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Injector 3) Remove the intake throttle valve from the inlet
pipe.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Engine harness Disconnect
1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:
• Disconnect each connector.
3. Intake throttle valve Removal
1) Remove the air duct from the intake throttle
valve.
2) Disengage the harness connector from the in-
takethrottle valve. 1 Boost temperature sensor
ANNOTATION: 2 Boost sensor
3 Inlet pipe
• Pull the lock operation portion to release the 4 Gasket
lock.
5 Intake throttle valve
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
5 Boost temperature sensor
2) Disengage the injector harness from the injec- Special tool: fuel injector remover (refer
tor. to section 1003)
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
1 Lower cover
2 Connector
1 Sliding hammer
2 Fuel injector remover
3 Injector
CAUTION
• Use new gaskets.
CAUTION
• Be extremely careful not to damage
the injector nozzle.
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
1 Rubber plug
2 Liquid gasket
CAUTION
• After applying the liquid gasket, in-
stall the lower cover within 5 min-
utes.
CAUTION
• Use new gaskets.
1 Boost sensor
1 Cylinder head cover
2 IMT sensor
2 Oil level gauge guide tube
3 EGR valve
3 Case
4 Harness clip
4 Cylinder block
5 Boost temperature sensor
10) Loosen the plug using the wrench. 15) Operate the priming pump.
Number of times the operation is Performed:
ANNOTATION:
10 - 15 times
• Remove the air in the fuel filter. 16) Start the engine.
11) Tighten the plug using the wrench. CAUTION
12) Operate the priming pump.
Number of times: 10 count(s) or more • Do not accelerate the engine revo-
lution right after staring.
ANNOTATION:
• Wait for the specified time after operating Idling: 5 s
the priming pump. ANNOTATION:
Specified time: 1 min
• Accelerate the engine revolution gradually.
13) Loosen the plug using the wrench.
Engine revolution hold: 3 min.
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution to maxi-
14) Tighten the plug using the wrench. mum.
Tightening torque: 10 N・m {1.0 kgf・m / 89
• Lower the rotation.
lb・in}
CAUTION
• Remove the fuel around the plug
thoroughly after tightening.
4001A
Monitor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor Display Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Eco Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DPD Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnostic Trouble Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Economy Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Neutral Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Idling Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auto Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
One-touch Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick Warm-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Idling Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Travel Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Static Horsepower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Back/Side View Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Swing Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Free Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Energy saving / Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pump Standby Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Swing Relief Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Stroke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Boom Down Energy Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Auto Energy Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Overload Reduction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
End Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Breaker Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Crusher Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Monitor Control
Fuel Gauge
Summary
The fuel level is displayed as one of 9 levels, 0-8.
When the fuel level reaches Level 1, a warning is is-
sued.
If the sensor breaks down, the level becomes 0.
(When the sensor is normal, the Levels 1-8 are dis-
played.)
Configuration
*1 Monitor
*2 Computer B
*3 Computer A
• Refueling warning: When the gauge falls to Level
*4 Overhead 1, the "LOW FUEL" message is displayed on the
*5 Fuel sensor monitor and the buzzer sounds for 5 sec..
*6 Reserve (1 hour of work) • Monitor display: The following processing is used to
*7 Fuel tank prevent the monitor gauge from fluctuating due to
fluctuation of the fuel surface.
Sensor angle measurement period = 1 sec.
Operation explanation Gauge update period = 5 sec.
Gauge update judgment = Average of sensor angle
• Computer A reads out the resistance of the fuel level for past 20 sec. (20 times)
sensor installed in the fuel tank and communicates • Gauge display: For the work screen, an arc is dis-
it to the monitor. played at the center of the screen.
On the camera screen, displayed vertically on the
right edge of the screen.
Resistance [Ω] Fuel sensor [%]
• Trouble mode: If trouble occurs in the fuel level sen-
10 100 sor, the fuel gauge itself is not displayed.
38 50 If an abnormality occurs in monitor communication,
80 0 the display will not update.
84402826 - May 2011
4001A-3
Electrical and Engine Basic Functions
Operation explanation
1. When the key is turned ON, the coolant temperature meter indicates the current coolant temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the coolant temperature bar
graph is displayed on the left side.
3. The meter and bar graph are not displayed if coolant temperature sensor trouble is detected.
Remarks
The coolant temperature ranges are shown in the table below.
a Meter display
Operation explanation
1. When the key is turned ON, the oil temperature meter indicates the current oil temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the oil temperature meter is
not displayed.
3. The meter is not displayed if oil temperature sensor trouble is detected.
Remarks
The oil temperature ranges are shown in the table below.
Operation explanation
1. When the operator turns the key ON, the monitor screen brightness is set to "brightness (day)".
2. When the operator turns the working light ON, the monitor screen brightness is set to "brightness (night)" (=
working light-linked dimming).
• When working light-linked dimming is set to OFF on the rear screen, instead of using "brightness (night)" to
adjust the monitor screen brightness when the working light is ON, the brightness is judged using the solar
radiation sensor (= dimming level automatic adjustment).
• The brightness when the working light is OFF is set to "brightness (day)" regardless of whether working light-
linked dimming is set to ON or OFF.
3. The operator can set "brightness (day)" or "brightness (night)" in the menu screen.
• The screen brightness setting is stored inside the monitor, so the setting is saved even if a computer is re-
placed.
Eco Gauge
Purpose
Displays on the monitor whether energy-saving operation is being performed.(Eco function)
1 Eco gauge
2 Monitor
3 Computer A
Operation explanation
1. The eco gauge is displayed on the monitor.
2. The eco-saving performance is judged in levels from 0 to 9.(The higher the number, the better the eco perfor-
mance.)
In SP mode, the maximum is 4.
In H mode, the maximum is 6.
In A mode, the maximum is 8.
In low idle, the maximum is 9.
DPD Gauge
Purpose
Displays an icon and bar graph on the monitor during DPD regeneration.
1 DPD gauge
2 Monitor
3 Computer A
Operation explanation
1. DPD bar graph display conditions
1) The DPD clogging level is displayed on the DPD bar graph during normal operation.(5-level display)
When 5 white lamps are displayed, it indicates that the tank is full.
2) The regeneration progress is displayed on the DPD bar graph during DPD regeneration (5-level display).
The white lamps go off one by one, and when all have gone off, regeneration is complete.
2. DPD amber lamp display condition
1) The amber lamp turns on and flashes during manual DPD regeneration.
3. DPD green lamp display condition
1) The green lamp turns on and flashes during automatic DPD regeneration.
Operation explanation
1. If trouble occurs, the "!" symbol and the diagnostic trouble code (DTC) are displayed in the top right of the
monitor.
• When multiple cases of trouble occur, they are displayed in turn at 5-second intervals.
• At the same time, "ELEC. PROBLEM" and "CHECK ENGINE" are displayed.
• Up to 8 items can be displayed.
2. When the trouble is repaired, the diagnostic trouble code (DTC) goes off.
Clock
Purpose
Displays the time on the monitor.
Operation explanation
• The time is always displayed on the monitor.
• The clock continues to operate, without display, when the key is turned OFF. (Because it uses power from the
battery)
Operation explanation
1. The fuel economy gauge is displayed on the monitor after the key is turned ON.
2. When trouble occurs, the fuel economy gauge goes off and the diagnostic trouble code is displayed.
3. When the trouble is recovered from, the diagnostic trouble code goes off and the fuel economy gauge is dis-
played again.
Basic Operation
Neutral Start
Purpose
The engine will not start with the gate lever lifted.(It will not crank.)
This prevents accidental operation if the operation lever is touched when the engine is started.
Configuration
Operation explanation
1. Lower the gate lever.
2. The starter cut relay is excited and the excitation to the safety relay is cut off.
3. Engine cranking is prohibited.
4. If the gate lever is then raised, cranking is enabled.
Operation explanation
1. Start the engine.
2. When the engine speed rises to 500 min-1 or higher, engine start is judged.
3. Stop the engine.
4. When the engine speed drops to less than 200 min-1, engine stop is judged.
Preheating
Purpose
Before cranking, the insides of the engine cylinders are automatically heated to improve starting.(Warm-up opera-
tion)
Operation explanation
1. Turn the key ON.
2. When the key is turned ON, the pre-glow time is calculated based on the current coolant temperature. At the
same time, the glow relay is excited and the glow lamp is turned on.
3. After pre-glow is completed, the glow lamp goes off and the operator is prompted to begin cranking.
4. Perform cranking to start the engine.
5. When engine start and cranking stop are recognized, the after-glow time is calculated from the current coolant
temperature.
Throttle
Purpose
Indicates the target engine speed.
a Icon
Operation explanation
1. Turn the key ON.
2. The target engine speed is calculated based on the throttle VOL voltage signal.
3. An icon that indicates the work mode is displayed on the monitor.
Idling Start
Purpose
When the engine starts, the engine speed starts in low idle regardless of the throttle volume position.(Warm-up
operation, engine protection)
Operation explanation
1. Idling start operation condition
Because idling start is a warm-up operation, it operates when the engine is started.
2. Idling start end conditions
The operation ends under the following conditions.
1) When an operation lever is operated.(When one of the following pressure sensors is turned ON: upper,
swing, travel, option 1, or option 2)
2) When the throttle volume is operated.
3) When the one-touch idle switch is pressed.
Auto Idle
Purpose
Automatically put the engine into an idling state (1200 min-1) when the machine is not being operated. (Energy
saving)
Operation explanation
1. Operation conditions for auto idle
Operation starts when all the conditions below are satisfied.
1) The auto idle mode switch is pressed, turning the auto idle mode ON.
2) An operating lever is not operated for a continuous period of 5 sec. (The upper, swing, travel, option 1,
and option 2 pressure sensor are OFF for a continuous period of 5 sec.)
2. End conditions for auto idle
Operation ends under the following conditions.
1) An operation lever is operated during auto idle. (The upper, swing, travel, option 1, or option 2 pressure
sensor is ON.)
2) The throttle volume is operated.
3) The one-touch idle switch is pressed.
One-touch Idle
Purpose
Reduces the engine speed when the one-touch idle switch is pressed. (Energy saving)
Operation explanation
1. Operation conditions for one-touch idle
When the one-touch idle switch is pressed.
2. End conditions for one-touch idle
When the one-touch idle switch is pressed once more after the one-touch idle switch is pressed and the engine
has gone into low idle.
Auto Warm Up
Purpose
Incrementally raises the engine speed if the coolant temperature is low when the engine starts.
1. Operation conditions for auto warm up
Auto warm up operates if the coolant temperature is less than 50°C when the engine starts.
2. Summary
The engine speed increases incrementally as shown in the diagram.
1) Low idle; 5 min.
2) 1200 min-1; 3 min.
3) 1500 min-1; 3 min.
4) SP mode; 3 min.
Quick Warm-up
Summary
When the engine starts up, if the outside air temperature is low, a hydraulic load is put on to warm up the engine.
Configuration
Operation explanation
1. When the following conditions are all detected, quick warm-up starts.
• The engine must be starting up.
• The engine must not be warming up (Step 1: low idle 5 minutes).
• The machine must not be operating (upper, swing, travel, option 1, or option 2).
• The outside air temperature must be -15°C.
• The coolant temperature must be between 0 and 80°C.
• There must not be any sensor abnormality (P1, upper, swing, travel, option (1 or 2), coolant temperature,
outside air temperature.
• DPD regeneration must not be underway.
2. This control can be disabled with the Setup/Parameters screen.
3. When the engine starts, the speed incrementally increases according to the diagram below if the coolant tem-
perature is < 50°C. (If the coolant temperature is 50°C, a normal idling start occurs.)
4. When the quick warm-up starts, the system sets the pump flow proportional valve to the minimum flow (Current
740 mA).
5. After 1 sec., the system sets the boom 2 proportional valve current to 540 mA.
An icon that indicates the start of quick warm-up is displayed on the monitor for 2 sec..
84402826 - May 2011
4001A-19
Electrical and Engine Basic Functions
6. After 1 sec., if the system detects event (a) below for 20 sec. or longer, it raises the boom 2 proportional valve
target current at a pace of 2 mA/20 sec..
When event (b) is detected, the system sets the boom 2 proportional valve target current to 540 mA.
Also, if no event is detected, the system holds the boom 2 proportional valve target current in its current state.
(a) P1 pressure < 10 MPa
(b) P1 pressure > 15 MPa
7. If the system does not detect either of the above two conditions, it ends or stops quick warm-up.
Idling Stop
Purpose
Automatically stops the engine after a certain time has passed. (Energy saving)
Operation explanation
1. Operation conditions for idle stop mode
Idle stop operates after performance of 1 through 3.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the gate lever is raised, the engine speed is less than 1200 min-1, and the throttle volume, auto idle
switch and one-touch idle switch are not operated for a continuous period of 15 sec., an alarm displays
on the monitor screen and a buzzer sounds.
3) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.
2. Operations conditions for idle stop and auto idle mode
Idling stop operates after performance of 1 through 4.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the operation lever is not operated for a continuous period of 5 sec., the engine speed is reduced to
1200 min-1. (The upper, swing, travel, option 1, and option 2 pressure sensor are OFF for a continuous
period of 5 sec.)
3) If the throttle volume, auto idle switch and one-touch idle switch are not operated for a continuous period
of 3 min., an alarm displays on the monitor screen and a buzzer sounds.
4) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.
Idle up
Purpose
Raises the engine speed and maintains mechanical speed.
a Engine speed
Operation explanation
1. When the key is turned ON, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the
monitor goes to low speed.
2. When the travel speed switchover switch is pressed, the travel 2-switchover solenoid turns ON, and the travel
mode icon on the monitor goes to high speed.
3. When the travel speed switchover switch is pressed again, the travel 2-speed switchover solenoid turns OFF,
and the travel mode icon on the monitor goes to low speed.
* Even when the travel 2-speed switchover solenoid is ON, the tilting angle will automatically switch over to low
speed due to a travel motor function if the travel motor drive pressure becomes high.
However, the travel 2-speed switchover solenoid is ON.
Swing Brake
Purpose
The swing brake is turned OFF when either the upper or swing is operating. (Operational ability is increased)
Operation Explanation
1. The minimum milli-amp and maximum milli-amp is selected from the milli-amp set for each engine speed.
2. When the engine actual speed falls 30/min or more below the target engine speed, the milli-amp is gradually
lowered to the minimum.
3. When the engine actual speed is not 30/min or more below the target engine speed, the milli-amp is gradually
raised to the maximum.
4. When the engine speed is at a low speed, the milli-amp decreases.
5. When the engine speed is increasing after being at a low speed, the milli-amp increases.
Accessories
Working Light
Purpose
Press the working light switch to turn the working light on.(To improve visibility during night work.)
Operation explanation
1. When the key is turned ON, the working light is OFF.
2. When the working light switch is pressed, the working light relay turns ON, and the working light icon on the
monitor turns ON.
The boom light and cab light turn on.
3. When the working light switch is pressed again, the working light relay turns OFF, and the working light icon on
the monitor turns OFF.
The boom light and cab light turn off.
Radio Mute
Purpose
Enables the radio volume to be turned ON or OFF with a one-touch operation.
Operation explanation
1. Each time the radio mute switch (1) is pressed, the radio volume is switched between ON Û OFF.
2. When the key is switched ON, the radio always starts with mute off (normal radio volume).
Safety
Engine Emergency Stop
Purpose
Stops the engine in an emergency.
Operation explanation
1. If an emergency occurs while the engine is running, press the emergency stop switch.
2. When the ECM and computer A detect that the emergency stop switch is ON, the engine is stopped.
* To restart, make sure that the emergency stop switch is OFF, and then start cranking the engine.
Travel Alarm
Purpose
The travel alarm sounds when a travel operation is performed.(Safety function)
1 Computer A
2 Travel pressure sensor
3 Travel alarm
a Travel alarm
b Pressure sensor (travel)
c 10 sec.
a Options
Operation explanation
1. When the key is turned ON, the camera screen can be viewed by pressing the camera screen switch.
• Each time the camera screen switch is pressed, the screen alternates between the work screen and the
camera screen.
• In the camera screen, only the minimum required icons and gauges are displayed.
2. When the camera select switch is pressed in the camera screen, the screen display can be selected in the
order of rear → side → rear + side → rear.
• To perform camera selection, camera ON must be set in the camera setting screen.
• The camera select switch is enabled when multiple cameras are set.
The switch does not respond if there is only 1 rear camera.
3. If image interruption due to camera trouble (disconnection, etc.) is detected, the camera screen turns black
and ERROR is displayed.
* When the camera select switch is pressed in the work screen, the trip meter select switch function is activated.
* The camera screen switch is disabled if no cameras are mounted.
Swing Lock
Purpose
Turns the swing brake ON.
Operation explanation
1. Operation conditions for swing lock
1) Hold down the horn volume select switch, working light switch and auto idle switch at the same time for
3 sec.
* When the swing lock is ON and the key is OFF.Then, when the key is turned ON again, the swing lock stays
ON.
* When the swing lock and free swing are both ON, the swing lock is prioritized.
* When the swing lock is ON, the swing lock icon is displayed on the monitor.
* Even when an attachment operation or swing operation is performed while swing is ON, swing lock ON is
prioritized.(Be careful because if the swing operation is performed in this condition, the swing brake plate will
be dragged.)
2. End conditions for swing lock
1) While the swing lock is ON, hold down the horn volume select switch, working light switch and auto idle
switch at the same time for 3 sec.
Overload Warning
Summary
Overload warning device for lifting work with shovel
If the bottom pressure of the boom cylinder exceeds the stipulated pressure, it is judged that there is a danger of
the machine falling over and the monitor buzzer sounds (overload warning).
Configuration
Operation explanation
1. When the overload switch is turned ON, the buzzer sound starts and stops according to the conditions below.
When the overload switch is OFF, the buzzer does not sound.
1) Overload warning start: The boom bottom pressure is greater than or equal to the set pressure continu-
ously for 1 sec.
2) Overload warning stop: The boom bottom pressure is less than or equal to the set pressure -2 MPa
continuously for 1 sec.
2. The alarm pattern is a 1-second cycle - ON for 0.5 sec. and OFF for 0.5 sec.
Operability
Swing Speed Limit
Purpose
When the pump flow rises during a swing operation, the swing speed increases.
To prevent this, control of the pump flow is performed.(Swing speed control)
Operation explanation
1. Operation conditions for swing speed limit control
Control is executed when all the conditions below are satisfied.
1) Independent swing operation (swing pressure sensor ON)
2) When travel or option operations are not being performed (travel and option pressure sensors OFF)
3) Work mode is SP or H mode(except CX350C/CX370C/350X3)
2. Swing speed limit end conditions
The operation ends under the following conditions.
1) Ends immediately after a travel or option operation is performed (travel or option pressure sensor ON).
2) Ends gradually after an attachment operation is performed (upper pressure sensor ON).
Operation explanation
1. Operation conditions for pressure boost control (SP or H mode)
The operation starts when all the following conditions are satisfied.
1) When high-load work is being performed (P1 or P2 is high pressure, upper pressure sensor ON, swing
pressure sensor OFF)
2) When the work mode is SP or H mode.
2. End conditions for pressure boost control (SP or H mode)
The operation ends under the following conditions.
1) When 8 sec. or longer elapses after starting the pressure boost (pressure boost time expires)
* When the pressure boost time expires, pressure boost is not performed again unless the operation lever
is returned one time to neutral.
2) When an attachment operation is not performed (upper pressure sensor OFF)
3) When a travel or option operation is performed (travel or option pressure sensor ON)
* Pressure boost is not performed to protect the travel and option circuits.
3. Operation conditions for pressure boost control (A mode)
When the work mode is A mode, pressure boost is performed for the lifting work.
* When a travel or option operation is performed in A mode, the pressure boost is continued.
4. Time chart (when work mode = SP or H)
Free Swing
Purpose
Prevents swinging of the suspended load while swinging is stopped during lifting work.
Operation explanation
1. Operation conditions for free swing
1) When the free swing switch is pressed.
* The free swing is disabled during a swing lock.
* The free swing icon is displayed on the monitor.
2. End conditions for free swing
1) When the free swing switch is pressed during free swing.
Operation explanation
1. Operation conditions for pump standby
1) When an attachment, travel or swing operation is not being performed.(Upper, travel and swing pressure
sensors OFF)
2. End conditions for pump standby
1) When an attachment operation is performed.(Upper pressure sensor ON)
2) When a travel operation is performed.(Travel pressure sensor ON)
3) When a swing operation is performed.(Swing pressure sensor ON)
3. Operation for trouble
If an abnormality occurs in the upper, swing or travel pressure sensors, the P1 flow control proportional valve,
or the power save solenoid valve, the system judges that a machine operation is in progress.
Operation explanation
1. Operation conditions for swing relief cut
The operation starts when all the conditions below are satisfied.
Oil temperature is 30°C or higher
1) When a swing operation is performed. (Swing pressure sensor ON)
2) Within 1 sec. after start of swing
3) When travel or option operations are not being performed.(Travel and option pressure sensors OFF)
2. Swing relief cut end conditions
1) When a swing operation is not being performed.(Swing pressure sensor OFF)
2) When a travel or option operation is performed.(Travel or option pressure sensor ON)
Stroke Control
Summary
In order to improve fuel efficiency, the pump pressure is lowered by reducing the orifice loss.
A 3-stack proportional valve is used for control.
Arm 2 control
1. In normal operations, flow volume loss is reduced by suppressing the spool opening for Arm 2.
2. In the second half of leveling work, the spool opening is opened to reduce P2-arm bottom pressure loss and to
give priority to the arm for flow volume, thus suppressing flow volume loss.
Configuration
• The larger the proportional valve output current, the more the secondary pressure output is suppressed.
Operation explanation
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• Boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. When the system judges leveling to be starting, it releases the restriction on Arm 2.
4. If the events below occur when the system does not judge leveling to be starting, it releases the restriction
on Arm 2. When that is not the case, it restricts Arm 2.
• Boom-up lever operation is at half lever.
5. The operator stops arm-in full operation or travels.
6. The system restricts Arm 2.
* When Arm 2 is released from the restricted state, it is released gradually as a measure against shock from
the restriction release.
Boom 2 control
In leveling work, the boom spool is pressed back to reduce P1-arm bottom pressure loss and to allow more flow to
the arm and bucket.
Configuration
• When the output current is raised, the force pushing back the spool is increased.
Operation
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• The boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. If the system detects any of the events below when the system judges leveling to be starting, it issues the
Boom-2-down proportional valve instruction.
• The boom-up lever operation is at half lever.
• During bucket-close operation
4. When the system does not judge leveling to be starting, it does not issue the Boom-2-down proportional valve
instruction.
5. The operator stops arm-in full operation or travels.
6. The system stops the Boom-2-down proportional valve instruction.
* When the Boom-2-down proportional valve instruction changes, as a measure against vibration, the Boom-
2-down proportional valve command current value is lowered gradually (for both ON→OFF and OFF→ON).
Bucket control
Mostly in the second half of leveling and when collecting dirt and sand during digging, the spool opening is opened
so that a larger volume can flow.
Configuration
The larger the output current, the more the secondary pressure output is suppressed.
Operation explanation
1. The operator operates the shovel.
2. If any of the events below occurs, the system outputs current restricting the bucket secondary pressure.
• Not arm-in full operation
• The boom-up operation is not at half lever.
• During travel
Operation explanation
1. Operation conditions for boom down energy save
The operation starts when all the conditions below are satisfied.
1) When the work mode is H mode or lower.
2) When the boom down and swing operation is performed.Or when the swing operation is performed.
2. End conditions for boom down energy save
The operation ends when all the conditions below are satisfied.
1) When the work mode is SP mode.
2) When an operation other than boom down and swing is performed.Or when an operation other than swing
is performed.
* When control is established at the same time as auto energy save, the control that reduces the engine speed the
most is prioritized.
Operation explanation
1. Operation conditions for auto energy save.
1) When a machine operation is not being performed.
2. End conditions for auto energy save.
1) When a machine operation is performed.
* When control is established at the same time as boom down energy save, the control that reduces the engine
speed the most is prioritized.
End Attachment
Breaker Mode
Purpose
Maximum flow and maximum pressure settings can be set for each breaker used for up to 5 breakers.(Available for
models with an electromagnetic proportional relief valve only.)
Operation explanation
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 breaker mode, but more can be added in the flow setting screen.
2. The breaker can be used when breaker mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. The suitability of the flow volume to the breaker will be judged.
If the acceptable flow volume has been exceeded, the message “CHECK FLOW RATE” will display.
* This message only displays during breaker operation. The display ends if operation is stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.
Crusher Mode
Purpose
Maximum flow and maximum pressure settings can be set for each crusher used for up to 5 crushers.(Available for
models with an electromagnetic proportional relief valve only.)
Operation explanation
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 crusher mode, but more can be added in the flow setting screen.
2. The crusher can be used when crusher mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. When an arm in + crusher operation is performed, milli-amp control will be performed so that the arm-in oper-
ation will not be performed with 2 pumps flow.
* This is to prevent crusher operation from being stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.
Maintenance
Anti-theft
Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-theft
function is enabled.
The factory setting is for these knob terminals to be disconnected.
Anti-theft setting knob Connect VG (purple / green) and BG (black / green)
Password
Purpose
Locks the machine if is operated without authorization. (Anti-theft)
Operation explanation
1. When the anti-theft function is ON, turn the key ON.
2. Enter the correct password at the password input screen.
* If an incorrect password is input, "ERROR" is displayed and the buzzer buzzes.
If the correct password is then input, the lock is released.
3. The machine lock is released and the normal screen is displayed.
* If the “ERROR” message is ignored and the engine is started, the machine will lock.
Machine lock conditions
• The engine speed is fixed at low idle.
• The swing brake cannot be released.
• The travel alarm buzzes continuously.
* In addition, if the operator tries to operate the machine in the machine lock state, the engine will be stopped.
Machine operation judgment conditions
• The P1 or P2 pressure rises to 5 MPa or higher.
• The engine load ratio is 50 % or higher for 2 sec. cumulative.
• The upper, travel, P1, or P2 pressure sensor is removed.
Immobilizer Key
Purpose
Prevents starting of the engine with keys other than the designated key. (Anti-theft)
Operation explanation
• When the key is switched ON, the immobilizer computer performs verification of the key.
• If the key is verified as the designated key, cranking is performed.
• If the key is not verified as the designated key, cranking is not performed.
* At this time, cranking will not be performed even if the key is turned up to ST.
Operation explanation
The fuel pump rocker switch has three positions: Manual, OFF, and Auto.
• Auto mode
The switch is the toggle type. When it comes ON, the fuel feed starts.
When the fuel tank angle sensor reaches the full level (Level 8), the monitor relay is driven and the feed pump
power is switched OFF.
In place of that, the relay buzzes the buzzer to announce that the automatic feed has ended.
To silence the buzzer, the rocker switch must be switched to OFF or Manual.
• Manual mode
The switch is the momentary type. The feed pump only drives fuel feed while the switch is pressed.
Operation
1. The radiator reserve tank level switch is detected and an warning is issued.
• SW ON: 0.33 - 0.53 L
2. When the monitor receives the level drop signal, it carries out the following operation.
• Message: "LOW COOLANT" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7423" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
3. When 3 sec. have passed after the coolant level switch was detected going OFF, the low coolant level alarm
stops, the "LOW COOLANT" message goes off, and the buzzer stops.
Operation explanation
If clogging occurs in the return filter inside the hydraulic tank, a message is displayed on the monitor giving the
diagnostic trouble code and the warning buzzer sounds. (For breaker, multi-purpose machines only)
1. Configuration: When the clog detection pressure switch goes open, Computer A detects the clog and sends a
command to the monitor.
2. Clog detection: Starts 10 sec. after the engine starts.
When the clog switch contact opens, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
However, detection does not occur in the following cases.
• During breaker operation: Because pulsation is severe (In other words, no warning is issued while the breaker
is operating.)
• When the oil temperature is less than 30°C: Because the hydraulic oil viscosity is high and accurate detection
is not possible.
• When the clog detection switch is broken: For details, see the sections below.
3. Warning: When the monitor receives the filter clog command, it carries out the following operation.
• Message: "RETURN FILTER" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7423" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
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Electrical and Engine Basic Functions
• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
4. Clog switch trouble detection: Before engine starting, the contact point of the clog detection switch should be
closed (B contact point).
However, if the circuit is open (continuously for 1 sec.), it is judged that the clog detection switch is disconnected,
the "Electrical system abnormality" message and diagnostic trouble code "7063" are displayed, and the buzzer
sounds for 5 sec..
5. Time chart:
Operation explanation
1. When the clog detection pressure switch comes ON, Computer A detects the clog and sends a command to
the monitor via Computer B
2. Clog detection starts 10 sec. after the engine starts.
3. When the clog switch comes ON, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
4. When the monitor receives the filter clog command, it carries out the following operations.
• Message: "AIR FILTER" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7424" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
Operation explanation
1. Turn the key ON.
• Control is performed by Computer A and is displayed on the monitor via Computer B.
2. When the system detects the following, it issues the fuel filter clog warning.
• The fuel filter clog signal from the ECM is ON continuously for 5 sec. or longer.
• The clog is judged by the ECM and only the results are sent to the computer via the CAN.
• The signal is sent with values of 0-2.
DPD Regeneration
Purpose
The DPD (Diesel Particle Diffuser) is a device that purifies particulate matter (PM) from exhaust gases.
Particulate matter is collected in the DPD filter, and when a certain amount has accumulated, that particulate matter
is automatically combusted to regenerate the filter.
During normal work, the amount of PM accumulated is displayed on the DPD gauge.
Configuration
Operation explanation
There are the following 4 regeneration methods.
• Automatic regeneration: The filter is automatically regenerated during machine operation.
The machine can work normally.
• Manual regeneration: If automatic regeneration is incomplete or the amount of accumulated PM is large, the filter
is regenerated with a switch.
The machine cannot operate.
• Forced manual regeneration: During automatic regeneration, it is possible to interrupt automatic regeneration and
switch to manual regeneration.
• Slow regeneration: When manual regeneration is interrupted for a prolonged period, it is necessary to combust
the PM slower than normal.
The diagnostic trouble code is displayed and service engineer operation is required. The machine cannot operate.
1. Switch the key ON and operate.
The system displays the current amount of PM accumulated on the DPD bar graph.
The PM accumulated on the filter continually self-combusts due to high-temperature exhaust gases during
engine operation.
2. When the work was at low load, because the exhaust gas temperature is low, the PM does not self combust
but accumulates.
When the DPD differential pressure is high or every 8 hours, the ECM forces up the exhaust gas temperature
to combust the accumulated PM. (See Automatic Regeneration.)
3. Normally, the above continuous regeneration and automatic regeneration keep the accumulated amount of PM
from going above a certain amount, but if the operating conditions are such that the accumulated amount of
PM becomes excessive, in order to avoid the risk of damage to the DPD assembly due to excessive tempera-
ture rise during regeneration, the ECM prohibits automatic regeneration and requests the operator to perform
manual regeneration.
The operator receives this request and starts regeneration. (See Manual Regeneration.)
4. While automatic regeneration is stopped, the operator can execute manual regeneration at any time with switch
operation. (See Forced Manual Regeneration.)
5. If the operator ignores the manual regeneration request and continues to work, this causes (excess PM collec-
tion) and the ECM issues the diagnostic trouble code.
When this point is reached, regeneration by the operator is no longer possible and special regeneration using
service tools has become necessary. (See Slow Regeneration.)
6. If any of the following troubles occurs during regeneration, the hydraulic pressure load is stopped.
Excess PM collection
When the accumulated amount of PM exceeds the limit and the excess PM collected state is reached, the system
behaves as follows.
• Ends the hydraulic pressure assist load.
• Lights the red lamp.
• Lights up the DPD gauge all red.
• Displays the "CHECK ENGINE" message.
Slow regeneration
Regeneration through a process that raises the temperature slower than for normal regeneration.
Automatic Regeneration
Summary
The filter is automatically regenerated during machine operation. The machine can work normally.
The ECM determines the amount of PM accumulated from the difference in pressure before and after the DPD filter.
When a certain amount has accumulated, the ECM regenerates the filter automatically.
Also, if the operating time since the last regeneration reaches a certain level, the ECM automatically regenerates
the filter.
Configuration
Operation explanation
1. Conditions for the start of automatic regeneration: When the automatic regeneration request comes from the
ECM, if the following conditions are met, automatic regeneration is started.
• Engine is starting
• The engine coolant temperature is at least 70°C but less than 100°C.
• The difference in pressure before and after the DPD filter has been stable for a certain period of time.
• The gate bar limit switch is ON (hydraulic operation is enabled).
• There is no sensor or DPD related abnormality.
2. Start of automatic regeneration: If the conditions above are met, the computer starts the following control.
• Lights the DPD green lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
• Stops the auto idle/idle stop control.
3. Stopping automatic regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and automatic regeneration is stopped.
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Electrical and Engine Basic Functions
While automatic regeneration is stopped, the DPD green lamp goes out.
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes OFF (hydraulic operation is disabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped.
4. Ending automatic regeneration: The computer receives the automatic regeneration end signal from the ECM
and ends the control.
• Puts out the DPD green lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.
Manual Regeneration
Summary
If automatic regeneration is incomplete or the amount of accumulated PM is large, the ECM requests manual re-
generation.
The machine cannot be operated during manual regeneration.
The computer controls the regeneration assist load.
Configuration
Operation explanation
1. Requesting manual regeneration: When the manual regeneration request comes from the ECM to the com-
puter, it displays the following items on the monitor.
• Flashes the DPD amber lamp (2-second cycle at first, high-speed 0.6-second cycle afterward)
• Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
2. Manual regeneration start conditions: When the following conditions are all met and the DPD switch is pressed,
the computer sets the engine speed to 1000 min-1 and starts manual regeneration.
• The gate bar limit switch is OFF (hydraulic operation is disabled).
• The engine coolant temperature is at least 70°C but less than 100°C.
• There is no sensor or DPD related abnormality.
• When released, automatically goes to 1000 min-1.
3. Start of manual regeneration: If the conditions above are met, Computer A starts the following control.
• Lights the DPD amber lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
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Electrical and Engine Basic Functions
Operation explanation
1. With automatic regeneration stopped and with the gate bar open, if the DPD switch is held down for 3 sec.,
Computer A sends the forced manual regeneration start request signal to the ECM via the DPD relay.
2. When the ECM receives the forced manual regeneration start request signal, the following is displayed on the
monitor.
• Lights up the amber lamp for 3 sec..
3. If the system meets the following conditions, the ECM judges that manual regeneration is necessary, puts out
the amber lamp, and returns to the automatic regeneration stopped state.
• If the state of it being impossible to complete automatic regeneration has continued or longer than 8 hours
• If the ECM judges that manual regeneration is not necessary
4. If the ECM judges that manual regeneration is necessary, the system receives the manual regeneration request
signal from the ECM, and waits for the manual regeneration switch to be pressed.
• After 10 sec., it flashes the amber lamp (2-second cycle).
Displays the "PUSH DPD SWITCH TO ACTIVATE" message on the monitor.
• The operator presses the DPD switch during this time.
• If the operator does not press the DPD switch at least 10 sec., the ECM puts out the amber lamp and returns
to the automatic regeneration stopped state.
(From here on is the same process as from 2 in manual regeneration.)
5. Lowers the engine speed to 1000 min-1 and starts manual regeneration.
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Electrical and Engine Basic Functions
6. Start of manual regeneration: If the conditions above are met, the computer starts the following control.
• Lights the DPD amber lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
• Stops the auto idle/idle stop control.
• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
7. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
8. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.
9. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• The computer set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., the computer sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., the computer sets the pump flow proportional valve to 600 mA.
• After 30 sec., the computer controls the pump flow proportional valve so that the DPD exhaust gas temper-
ature (before DOC) is constant at 270°C. (Lowers it gradually 50 mA/second. update period 15 sec., update
width 5 mA)
4001B
Service Support
Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECK Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MACHINE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FAULT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WORK HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HYDRAULIC HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SETUP Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MACHINE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Throttle Volume Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Password Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Option Flow Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Screen Brightness Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Service Support
Screen Operations
Screen Display List
1 Travel speed select switch 3 Menu screen display switch 5 Wiper switch
2 Attachment select switch 4 Working light switch 6 Auto idling switch
BOOST PRESS. kPa Boost pressure BOOM-UP PILOT Boom-up pilot pres-
MPa
BAROMETRIC PRESS. sure
kPa Barometric pressure ARM-CLOSE PI-
PRESS. MPa Arm-in pilot pressure
BOOST TEMP. °C Boost temperature LOT PRESS.
Suction air tempera- BUCKET-CLOSE Bucket-close pilot
AIR INLET TEMP. °C MPa
ture PILOT PRESS. pressure
FUEL TEMP. °C Fuel temperature P.SOL;BOOM-
mA Boom-down solenoid
MANIFOLD IN- DOWN
°C Manifold temperature P.SOL;BOOM-UP mA Boom-up solenoid
NER TEMP.
COOLANT TEMP. °C Coolant temperature P.SOL;ARM-
mA Arm-in solenoid
HYD.OIL TEMP. °C Oil temperature CLOSE
P.SOL;BUCKET- Bucket-close sole-
mA
3. Pressure and solenoid CLOSE noid
P.SOL;OFFSET-
mA Offset left solenoid
LEFT
SOL;BUCKET Bucket-open sole-
on/off
OPEN noid
UPPER PILOT
MPa Upper pilot pressure
PRESS.
SWING PILOT
MPa Swing pilot pressure
PRESS.
TRAVEL PILOT
MPa Travel pilot pressure
PRESS.
OPT.LINE
on/off 1st option operation
PRESS SW.
2ND OPT.LINE
on/off 2nd option operation
PRESS SW.
TRAVEL ALARM
on/off Travel alarm
OUT.
POWER SAVE
on/off Power save solenoid
SOL.
SWING BRAKE
on/off Swing brake solenoid
SOL.
FREE SWING
on/off Free swing solenoid
SOL.
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4001B-5
Service Support
7. Fuel 8. Engine
3. End attachment
WIPER-INT. OPER-
hour Wiper (INT) time
ATION TIME
WIPER-CNT. OPER-
hour Wiper (CNT) time
ATION TIME
WASHER OPERA- Washer operation
hour
TION TIME time
WORKING LAMP Working light ON
hour
ON TIME time
RADIO MUTE TIME hour Radio mute time
DISPLAY-MODE1 No camera screen
hour
TIME selection time
DISPLAY-MODE2 Camera screen dis-
hour
TIME play 1 selection time
DISPLAY-MODE3 Camera screen dis-
hour
TIME play 2 selection time
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4001B-11
Service Support
To switch to a page from 1 to 7, press the monitor switch ROTATION < R1 hour S 1025
R1 REV. SPEED <
hour 1025 S < 1225
R2
while the WORK HISTORY screen is displayed R2 REV. SPEED <
hour 1225 S < 1425
and select the desired page. R3
R3 REV. SPEED <
hour 1425 S < 1625
R4
R4 REV. SPEED <
hour 1625 S < 1825
R5
R5 REV. SPEED <
hour 1825 S < 2025
R6
R6 REV. SPEED hour 2025 S
DENSITY < D1 hour D< D1
RATIO < R1 hour R < 30 D1 DENSITY < D2 hour D1 D < D2
R1 RATIO < R2 hour 30 R < 40 D2 DENSITY < D3 hour D2 D < D3
R2 RATIO < R3 hour 40 R < 50 D3 DENSITY < D4 hour D3 D < D4
R3 RATIO < R4 hour 50 R<60 D4 DENSITY < D5 hour D4 D < D5
R4 RATIO < R5 hour 60 R < 70 D5 DENSITY < D6 hour D5 D < D6
R5 RATIO < R6 hour 70 R < 80 D6 DENSITY hour D6 D
R6 RATIO hour 80 R
13. DOC temperature distribution
15. Supply pump inlet pressure distribution 17. DPD differential pressure distribution
ITEM-1 - -
ITEM-2 - - 1. P1 pressure
ITEM-3 - -
ITEM-4 - -
ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
PRESS. < P1 hour P< 10
P1 PRESS. < P2 hour 10 P< 15
P2 PRESS. < P3 hour 15 P< 20
P3 PRESS. < P4 hour 20 P< 25
P4 PRESS. < P5 hour 25 P< 30
P5 PRESS. < P6 hour 30 P< 35
P6 PRESS. hour 35 P
2. P2 pressure 4. N2 pressure
3. N1 pressure 5. P1 + P2 pressure
MACHINE
Fix the selection.
TERRITORY ITEM-1 min-1 Auto idling speed
ITEM-2 ms*100 Auto idle time
0 JAPAN Transient load minimum milli-
ITEM-3 mA
1 NA amp (normally 50 mA)
2 - Semi-transient load minimum
ITEM-4 mA
3 EU milli-amp
4 IHI Eco gauge update period (nor-
ITEM-5 ms*100
5 TURK mally 1000 ms)
6 CHINA
2. Work mode milli-amp
BRAND
0 SUMITOMO
1 LBX
2 CASE
3 IHI
LANGUAGE
0 Japanese
1 English
2 Thai
3 Chinese
4 German ITEM-1 mA SP mode milli-amp (Hi)
5 French ITEM-2 mA SP mode milli-amp (Low)
6 Italian ITEM-3 mA H mode milli-amp (Hi)
7 Spanish ITEM-4 mA H mode milli-amp (Low)
8 Portuguese ITEM-5 mA A mode milli-amp (Hi)
9 Dutch ITEM-6 mA A mode milli-amp (Low)
10 Danish ITEM-7 mA Minimum milli-amp
11 Norwegian
12 Swedish
13 Finnish
14 Turkish
15 Arabic
16 Malay
17 Indonesian
18 Russian
19 Canadian French
20 Pictographs only
84402826 - May 2011
4001B-21
Service Support
Setting
Model Select
Summary
The model information is input to set the control parameters specific to the model.
Configuration
• Screen
Operation explanation
Move up and down to move the cursor, left and right to select a model, set the throttle to H mode, and decide with
the menu switch.
• · Reset by holding down the left and right. (The display changes to "?" for all items.)
* From Ver. 1.8.6
Without a reset, only the LANGUAGE and UNIT can be changed.
Other changes always require a complete reset.
Setting items, values and details
Select "SET UP" on the service screen and input the following items.
The setting item values and setting details are given below.
Explanation of item
Pag-
Item name Explanation Remarks
e
MACHINE Model
TERRITORY Destination
BRAND Brand
LANGUAGE Language
1 UNIT Unit 0: {MPa, °C}, 1: {psi, °F}, 2: {kgf/cm2, °C}
-
-
-
-
-
-
OVERLOAD WARNING Load warning
Interference preven-
ANTI INTERFERENCE Not currently supported
tion
ATT. TYPE Attachment type Used for interference prevention·crane·overload warning
2
OPTION LINE Option Line
GENERATOR Lifting magnet Not currently supported
-
-
-
Pag-
Item name Explanation Remarks
e
-
Currently not supported; used for Computer ST trouble diag-
REMOTE SUPPORT Remote Support
nosis
Fuel abnormality Currently not supported; used for density sensor trouble di-
FMS
warning agnosis
3 RESERVE 1 Free Swing
RESERVE 2 Reserve 2 Not currently supported
RESERVE 3 Reserve 3 Not currently supported
-
-
-
Explanation of number
1. Model (Machine)
Omitted
2. Destination (Territory)
3. Brand
4. Language
• Can be changed with "LANGUAGE" on the menu screen.
5. Unit
9. Option line
Operation explanation
1. Switch the key ON and select (Select Model). (See Select Model.)
2. Set all the model selection items and set the throttle volume to H mode, then finalize the selections.
3. The system performs the initial adjustment of the throttle volume. (*1)
• The adjustment results are retained in memory even after the key is switched OFF.
Password Setting
Summary
Set the anti-theft password.
Configuration
• Monitor: Connected to Computer B
• Anti-theft setting knob: On the cab main harness
Operation explanation
1. With the key OFF, connect the anti-theft setting knob.
2. After connecting the knob, when you switch ON the key, the system displays the password setting screen.
3. After setting the 4-digit password, if you switch the key ON→OFF→ON→OFF, the system switches ON the
anti-theft function.
• All the key switching operations should be done within 2 sec.
4. When the anti-theft function comes ON, the monitor sets off the buzzer and the key icon is displayed.
* See Anti-theft (password type).
• For details on the clock, see the clock section. 1. When the key is turned ON, --:-- is displayed on
the monitor.
Configuration 2. The operator can set the time with "CLOCK AD-
JUST" on the menu screen.
Move left and right to move the cursor, up and
down to change the time, and decide with the
menu switch.
3. The system displays the time on the monitor.
• Since the clock data is stored in the monitor, the
time is retained even if Computer B is replaced.
When the monitor is replaced, it is necessary to
set the clock again.
Parameter Settings
* The following covers software Version 1.8.7.
Summary
Control parameters can be changed using the monitor.
For example, the time until auto idle is started or the current and speed for work mode can be set.
The items up to the 3rd page of the setting screen can overwrite the parameters changed with the key OFF.
Configuration
The diagram below shows the items that can be checked with each page of the setting screen.
Pag-
Item name Unit Explanation Remarks
e
Lo-IDLE ENGINE SPEED min-1 Low idle engine speed
AUTO IDLE TIME sec Auto idle time
AUTO IDLE ENGINE
min-1 Auto idling speed
SPEED
IDLE SHUT DOWN TIME min Idle shut-down time 10 minutes max.
AUTO POWER BOOST Y/N Auto pressure boost function
Milli-amp for pump horsepower control
1 PUMP POWER AT START mA proportional valve (mA); when ATT op-
erations start
Milli-amp for pump horsepower control
PUMP POWER DOWN mA proportional valve (mA); negative offset
amount
Flow control (breaker mode) with en-
REV. LIMIT AT BREAKER Y/N Not currently supported
gine speed
Can only be changed for 20
ENABLE POWER SAVE Y/N Power save function
tons - 29 tons.
Cannot be switched OFF on
ENABLE TRAVEL ALARM Y/N Travel alarm function
North American models
TRV. ALARM-ON TIME sec Travel alarm sounding time Range = 1..30, Step = 1
Previous travel speed data hold func-
MEMORIZE TRV. SPEED Y/N
tion
ENABLE EPF Y/N EPF Yes/No
2 OVERLOAD PRESS. MPa Overload set pressure
MAINTENANCE MES-
Y/N Service due message
SAGE
FORCED DIM. BY W.LAMP Y/N working light linked dimming
AUTO CLOCK ADJUST Y/N For automatic adjustment Not currently supported
TIME DIFFERENCE WITH -
hour Not currently supported
UTC
ITEM-1 Y/N Eco gauge display
ITEM-2 - -
ITEM-3 - -
ITEM-4 - -
3 ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
Pag-
Item name Unit Explanation Remarks
e
Milli-amp for pump horsepower control
ITEM-1 mA
proportional valve (SP_Hi)
Milli-amp for pump horsepower control
ITEM-2 mA
proportional valve (SP_Low)
Milli-amp for pump horsepower control
ITEM-3 mA
proportional valve (H_Hi)
Milli-amp for pump horsepower control
ITEM-4 mA
proportional valve (H_Low)
4
Milli-amp for pump horsepower control
ITEM-5 mA
proportional valve (A_Hi)
Milli-amp for pump horsepower control
ITEM-6 mA
proportional valve (A_Low)
Milli-amp for pump horsepower control
ITEM-7 mA
proportional valve (Min)
ITEM-8 - -
ITEM-9 - -
ITEM-1 Y/N Quick warm-up control ON/OFF
ITEM-2 - Development parameter
ITEM-3 - Development parameter
ITEM-4 - Development parameter
5 ITEM-5 - Development parameter
ITEM-6 - Development parameter
ITEM-7 - Development parameter
ITEM-8 - Development parameter
ITEM-9 - Development parameter
ITEM-1 min-1 Engine speed (SP)
ITEM-2 min-1 Engine speed (H)
ITEM-3 min-1 Engine speed (A)
ITEM-4 - -
6 ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
Operation explanation
1. Select an item with the cursor, then input the number with ←→.
2. Decide the selection with the menu switch, then press the menu switch again to leave the screen.
2. The operator selects the breaker or the crusher the settings are made in increments of 0.5 MPa.
from the "Attachment selection". (When (See (Number table) pressure adjustment range
multi-purpose circuit is selected with model se- below.)
lection: For a breaker or crusher, "Attachment • No maximum pressure can be set that exceeds
selection" is not displayed and the selection can- the relief valve pressure setting range.
not be changed.) • When an item that had been set is reset, four
For a breaker, the system sets the item immedi- hyphens (---) are displayed for either the "SET
ately below to "Breaker No." and for a crusher, MAX FLOW" or the "SET MAX PRESSURE"
"Crusher No.". and when you exit the options adjustment
At the same time, the system switches the option screen, the information that had been set is
line switching solenoid to ON for a breaker or OFF reset.
for a crusher. • If the pressure adjustment is not selected with
3. The operator selects a number from 1 to 5 with the model selection, the option flow setting ends
the "Breaker No. (or Crusher No.)" item. after just setting the maximum flow.
The system displays the maximum flow and max- • When multi-purpose circuit is selected with
imum pressure corresponding to that number model selection, when the flow volume for 2
in the two items immediately below "SET MAX pumps flow is set with breaker mode, "CHECK
FLOW" and "SET MAX PRESSURE". FLOW RATE" is displayed on the monitor.
Once that flow volume is decided, the "CHECK
• The factory setting is that the maximum flow and FLOW RATE" display goes out.
maximum pressure setting are only for Breaker
1 and Crusher 1. 5. When the operator has changed the maximum
(* The pressure is not adjusted, so for pressure flow or maximum pressure, the system redoes the
adjustment model setting, the icon does not ap- option relief pressure proportional valve adjust-
pear even if the ATT select switch is pressed. ment again.
The icon appears for the model setting only with The system displays "ADJUST PRESSURE" on
flow setting.) the monitor.
Other breakers, 2-5, and crushers, 2-5, are not 6. The operator checks that the work mode is SP
set. and that the oil temperature is 30°C minimum and
When an breaker or crusher is selected that has operates the breaker (crusher).
not been set, four hyphens (---) are displayed for The system displays "ADJUSTING PRESSURE"
the "SET MAX FLOW" and "SET MAX PRES- on the monitor.
SURE". At the same time, the "PRESSURE SETTING"
• If the maximum flow and maximum pressure and "CURRENT PRESSURE" items are dis-
have not yet been set, that breaker or crusher played.
cannot be selected with a work screen.
To put it the other way, everything set here can • When the operator stops the operation, the dis-
play returns to "BREAKER OPERATION RE-
be selected with a work screen.
QUIRED".
Since the X3 has only one ATT selection switch,
when the flow volume is set here for all the • When the work mode is not SP, "SET IN
SP-MODE" is displayed instead of "ADJUST-
breakers or crushers, care is required because
ING PRESSURE".
selecting the target ATT requires pressing the
switch a number of times. • During one-touch idle or while the engine is
stopped, "INCREASE ENGINE RPM" is dis-
* When items that had been set are reset, the played instead of "ADJUSTING PRESSURE".
reset items can no longer be selected. • When the operator operates in SP mode, if the
oil temperature is less than 30°C, "INCREASE
4. The operator sets the maximum flow from the OIL TEMP." is displayed instead of "ADJUST-
"SET MAX FLOW" item and sets the maximum ING PRESSURE".
pressure from the "SET MAX PRESSURE" item. At the same time, the "TARGET OIL TEMP." and
• As selection options for the maximum flow, the "CURRENT OIL TEMP." items are displayed.
system has available 20 levels for the flow vol- • During adjustment, if any operation other than
ume, 10 for without 2 pumps flow and 10 for with breaker (crusher) operation is done, the sys-
2 pumps flow. tem stops the adjustment, displays "BREAKER
• However, the maximum flow depends on the OPERATING REQUIRED" on the monitor, and
model. Even though 20 levels are displayed waits for operation of the breaker (crusher) in-
for all models, the flow volumes for the levels dependently.
depend on the model. (See (Number table) flow 7. The operator continues operating the breaker
adjustment levels below.) (crusher).
• When the flow volume is set, if a stand-alone The system waits for the pressure to stabilize for
option operation is executed, the flow propor- 2 sec., then starts the adjustment.
tional valve command current value is output The system continues to compare the actual P1
to achieve that flow volume. (Breaker mode or pressure and the target set pressure and when
crusher mode processing is executed.) the difference between them is no more than 0.5
• The range in which the maximum pressure can
be set depends on the model, but for all models,
84402826 - May 2011
4001B-33
Service Support
MPa (*) continuously for at least 5 sec., it judges Screen Brightness Setting
the adjustment to be complete.
The system displays "PRESSURE ADJUSTING. <Summary>
COMPLETE" on the monitor and puts out the Decides the brightness of the backlight through oper-
"PRESSURE ADJUSTING INCOMPLETE" dis- ation that is linked to the working light and solar radi-
play. ation sensor.
<Operation explanation>
• During adjustment, the system updates the op- The screen brightness can be selected on the menu
tion relief pressure proportional valve current screen.
every 500 ms in increments of 5 mA. Dimming setting can be changed on the service
• If the pedal continues to be held down even after screen.
the setting value is finalized, the setting value is
updated every 5 sec.. 1. Working Light OFF: Normal (with key ON),
• If the pressure adjustment does not end within "Brightness (day)" setting
30 sec., "PRESSURE ADJUSTING INCOM- 2. Working Light ON: The monitor brightness is re-
PLETE" is displayed on the monitor. duced and the display changes automatically to
the "Brightness (night)" setting.
8. When the operator presses the menu switch to 3. Brightness settings: "Brightness (day)" and
exit the option line setting screen, the system "Brightness (night)" can be set on the menu
stores the settings into memory. screen.
4. Dimming by solar radiation sensor: When the
• If the setting screen was entered from the menu
screen, the display returns to the menu screen. working light-linked dimming is set OFF on the
If the setting screen was entered from the menu screen, the dimming level is adjusted au-
main screen by holding down the ATT select tomatically to the ambient brightness by the solar
switch for 1 sec., the display returns to the main radiation sensor.
screen.
4001C
Each of these are controlled by the ECM based on various signals to control the injection timing and
injection amount in accordance with the working condition.
Fuel injector
The fuel injector has adopted the 7-hole nozzle, and adjusts the fuel injection amount and injection timing
by opening or closing the electromagnetic valve on the injector head portion.
The ECM corrects variation in the fuel injection amount from fuel injector to fuel injector in accordance
with the ID code data in the memory.
When adjusting the fuel injector, the ID code date must be recorded in the ECM.
Fuel filter with sedimenter
The fuel filter with sedimenter removes the water by using the difference in the relative density between
diesel oil and water, and notifies the operator through the indicator when it becomes full of water.
Preheat system
The preheat system consists of the ECM, glow relay, glow plug and glow indicator light.
The preheat system is activated when the engine coolant temperature is low to help engine start.
Lubricating system
It uses and oil filter with a full-flow bypass, and cools down the pistons using the water-cooled oil cooler
and the oil jet.
DPD
An integrated DPD oxidation catalyst is installed for reducing exhaust gas.
3) Fuel system
Fuel system diagram
CAUTION
• Since the high-precision fuel system has been adopted, take care to prevent any foreign
matter from entering the fuel system.
Common rail
1 Pressure sensor
2 Pressure limiter
CAUTION
• There is a gauze filter assembled inside the union of the fuel supply pump, but the union
should not be removed to prevent any foreign matter from entering.
1 Union
2 Gauze filter
3 Supply pump
4 Strainer
5 Joint bolt
Injector
1 ID plate
2 Terminal stud
3 Injector drive section
4 Injector assembly
5 Gasket
6 O-ring
Leak-off pipe installation sec-
7
tion
Fuel filter
1 Priming pump
2 Plug
3 Case
4 Drain plug
4) Cooling system
The coolant system is the forced-circulation system, and its main components are the water pump, thermo-
stat and radiator.
Water pump
The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.
Thermostat
The thermostat is the wax pellet type, and consists of 2 units.
One unit is the bottom bypass type and its initial open valve temperature is 82°C {185 °F}, and the other
unit is the inline type and its initial open valve temperature is 85°C {185 °F}.
The structure allows the water temperature to be fine adjusted, and it is assembled inside the thermostat
housing unit.
5) Lubrication system
A full-flow bypass integrated filter element, water cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.
1 Driven gear assembly 4 Oil pump drive gear 7 Driven gear assembly
2 Oil pump body 5 Oil pump body 8 Oil pump drive gear
3 Drive gear assembly 6 Drive gear assembly
7) Exhaust system
9) Electrical system
Charging system
The main components of the charging system are the battery, generator, and battery discharge indicator
light circuit.
Generator is a self-rectifier type with a regulator built in.
Generator
The generator is the brushless type.
The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator,
bearing, pulley, etc.
The moving parts are the rotor and pulley.
The field coil is fixed to the rear bracket.
6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated
in the stator coil to a direct current.
3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode.
In addition, 3 small diodes that are referred to as trio-diode are used to supply the field current.
This generator has 3 terminals of B terminal (direct current output terminal), L terminal and R terminal.
Since the L terminal is connected to the field coil, it works as an input terminal together with the R terminal
until the generator starts generating power.
Also, it functions as an output terminal. (current capacity is 1 A)
When the L terminal voltage reaches the battery voltage, the charge light turns off.
Since the both bearings are sealed, periodic lubrications are not required.
The IC regulator cannot be disassembled, so it should be handled as an assembly.
Starter system
The starter is 5 kW and uses a reduction type.
Gear housing and armature end bearing housing are made of aluminum.
Brush assembly is an replaceable type.
Starter circuit is started using a battery.
The battery cable is connected to a large terminal on the starter.
The wiring is connected from the terminal to the engine control switch and the starter relay.
Starter
The starter is an outer gearing mesh method reduction starter adopting the magnetic shift type.
When the starter switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch
closes and the armature rotates.
At the same time, the pinion is pushed to the front via the shift lever to mesh with the ring gear.
When the ring gear rotates, the crankshaft is turned to start the engine.
After the engine is started, the plunger returns, the pinion separates from the ring gear, and the armature
stops rotating when the starter switch is turned OFF.
When the engine rotation becomes faster than the pinion, the pinion is caused to turn in reverse, but the
pinion just idles due to the one-way clutch function, so the armature is not driven.
Preheat system
The preheat system has adopted the QOS system glow plug type.
Also, the energization control is performed by the ECM.
Correction
Engine coolant temperature
correction
Barometric Pressure
a Fuel temperture boost pres-
sure correction
Correction between sylinders
Q-key correction
QR correction
*1 Idle speed
Starting Q specified engine
*2
speed
*3 Minimum firing engine speed
System realization engine
*4
speed
*1 Highland
Fuel flow
Water temperature
If the ECM is equipped with an emergency stop function by a high engine coolant temperature, it stops
the engine when the temperature has reached 105 °C {221 °F}.
Fuel flow
Water temperature
・Boost Press.
a ・Coolant Temp,
・Barometric Press.
Each sensor
a Accelerator, Boost, Water
temperature, etc.
Fuel system
The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before
supplied to the common rail.
At this time, the fuel amount to be supplied to the common rail is controlled by regulating the suction
control valve based on the signal from the ECM.
Fuel filter clog warning function and engine RPM restriction function
When the clogged fuel filter is kept used, the ECM detects DTC P0093, and the output restriction is im-
plemented.
The first stage
In order to notify a filter clogging before DTC P0093 is detected, the first stage alarm is issued when the
output value from the fuel filter pressure sensor falls below the specified threshold value.
The alarm stops when the output value exceeds the threshold value.
The second stage
The second stage alarm is issued when the output value from the fuel filter pressure sensor falls below
the threshold value even after the first stage alarm occurs.
The second stage alarm remains as issued until the starter switch is turned OFF.
At the same time as the second stage alarm is issued, the target engine RPM is reduced gradually at a
constant rate.
When the output value from the sensor exceeds the specified threshold value, reduction of the restricted
engine RPM is stopped, and the regulation is continued maintaining the restricted engine RPM at that
time.
When the output value from the sensor falls below the threshold value again, the restricted engine RPM
is reduced further.
When the starter switch is turned OFF and then turned back ON, the restriction is once cancelled.
1 Supply pump
2 Warning light
3 Monitor
4 Monitor, CAN communication
5 Fuel tank
6 Pre-filter
7 Electromagnetic pump
8 Fuel filter pressure sensor
9 Main filter
1 First stage
2 Second stage
*1 Lamp
*2 Starter SW
*3 Engine Speed (r/min)
84402826 - May 2011
4001C-34
Function, Structure, Operation
EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas
to the intake air, the combustion temperature is lowered and the generation of NOx is suppressed.
The EGR amount is controlled by opening and closing the EGR valve provided between the exhaust
manifold and intake manifold.
The EGR amount is determined from the engine RPM and engine load ratio and the EGR valve is operated
to control the EGR amount.
By installing the EGR cooler on the path of the EGR gas, high-temperature gas is cooled by the EGR
cooler and then mixed with fresh air to further lower the burning temperature in order to reduce NOx
amount.
Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the
opposite direction to increase the EGR amount.
EGR control
The ECM controls the EGR valve lift amount by operating the motor according to the engine status such
as the engine RPM and engine load.
The valve lift amount is detected by the EGR position sensor.
Darker portions in the diagram represent large valve lift amounts and the darkest portion represents the
lift amount of nearly 100 %.
Accelerator position
Engine speed
*1 No idle EGR
*1 Without EGR
*2 Wiht EGR
Turbocharger control
The turbocharger is a system that provides efficient supercharge to archive the turbo effect by overcoming
the turbo’s weakness of low exhaust energy during low engine revolution.
The turbocharger optimizes the turbine revolution by varying the nozzle opening angle within the turbine
housing to adjust the turbo inlet area according to the revolution and load of the engine and control the
supercharging pressure.
The ECM sends the target nozzle opening angle based on the information from each sensor to the turbo
control unit through CAN communication to control the boost pressure properly in accordance with the
engine load requirements.
The turbo control unit drives the turbo actuator based on the information received from the ECM and
controls the nozzle vane through the control rod.
The turbo actuator has a position sensor installed.
The turbo control unit performs feedback control based on the information from the position sensor, etc.
The actual nozzle opening angle is determined at this time, and the nozzle vane opening angle is optimally
adjusted through the nozzle control rod.
*1 Turbine wheel
*2 Nozzle
*3 Turbo actuator
*4 Exhaust gas inlet
*5 Control rod
*6 Exhaust gas outlet
When the regulation mode switch input is present in addition to the mode map switch, the following 2
types of control methods are available.
H, S, L and B of the mode map switch change as follows depending on the APS input.
Meaning of mode map switch and each mode In the APS, a change toward the engine RPM decrease
direction can be made from each mode point.
The specified engine RPM for H, S, L and B are determined depending on the calibration of the ECM.
CAN communication
When CAN controller does not exist on the actual unit side
Outer switch
Operation mode Control
MAP0 MAP1 MAP2
OFF OFF OFF
H OFF ON ON Basic operations
ON ON ON
S ON OFF OFF Maximum rotation count control #1
L OFF ON OFF Maximum rotation count control #2
I OFF OFF ON Constant rotation operation #1
B ON ON OFF Maximum rotation count control #3
LM ON OFF ON Constant rotation operation #2
I, LM and H modes
H, S, L, and B modes
*1 Idle speed
*2 Max. speed
*1 Idle speed
*2 Max. speed
Accelerator position switch, with APS learning control If the APS learning control is available, for example,
when the ignition cycle ends with the accelerator position as 2 V (1), the accelerator position learning
causes the 2 V status to be recognized as the opening angle 0 % and the control range is set to 2 V to 4
V (2).
Idling control
By operating the idling control change switch during the warm-up operation, the minimum idling RPM can
be adjusted.
In addition, by operating the idling control change switch, the minimum idling RPM can be automatically
set to the optimum value in accordance with the engine coolant temperature.
ANNOTATION:
• The specifications vary depending on the actual unit, so availability of functions also differ.
Idling control change switch
By operating the idling control change switch, the idling control functions can be switched.
The idling control switch
By operating idling control switch, the idling RPM can be adjusted.
ANNOTATION:
• As for the installation positions of the idling control change switch and idling control switch, refer to the
manual of the actual unit.
The engine RPM upper limit varies depending on the engine model, actual unit specifications and en-
gine warming-up condition.
Up
While the Up side of the switch is pressed, the engine RPM is increased and the idling RPM can be raised.
Down
While the Down side of the switches is pressed, the engine RPM is decreased and the idling RPM can
be lowered.
However, the engine RPM cannot be decreased below the minimum idling RPM.
Control during starter switch OFF state
There are 2 types of controls provided when the starter switch is turned OFF after the idling control switch
is operated, and either one of them is performed depending on the specification.
The engine RPM adjusted by the idling control switch is recorded in the ECM, and the next operation is
performed with the engine RPM at the time when the starter switch is turned OFF.
The engine RPM adjusted by the idling control switch is not recorded in the ECM, and the next operation
is performed with the default engine RPM.
As for confirmation and questions regarding the specifications, contact an Isuzu service related person.
Idle manual control
Preheat control
QOS system
The ECM determines the glow time according to the engine coolant temperature, and activates the glow
relay and the QOC indicator light..
The QOS system is a system to facilitate engine start in a low temperature as well as reducing the
amount of white smoke and noise generated immediately after engine start.
When the starter switch is turned ON, the ECM detects the temperature of the engine coolant based
on the signal sent from the water temperature sensor to change the glow time, so the engine can be
always started under the optimum conditions.
Also, the after-glow function can stabilize the idling immediately after engine start.
a LCD or Lamp
DPD
DPD uses the oxidation catalyst to clean NOx and HC, and uses a dedicated filter to collect PM emitted
from the engine.
When PM has accumulated on the filter, the filter regeneration is performed.
The ECM detects the accumulation status of PM from the DPD differential pressure sensor or mileage.
When the accumulated amount of PM or mileage has reached a certain value, automatic regeneration
of the filter is performed.
During regeneration, the filter is heated up to burn the accumulated PM.
To adjust the burning temperature to the optimum value, the ECM detects the exhaust temperature
using the the exhaust temperature sensor and control fuel injection to raise the temperature to burn the
accumulated PM.
When regeneration has started, it must complete within a certain period of time.
After regeneration has completed, the purification status of the filter can be determined by checking the
exhaust differential pressure.
When excessive amount of accumulated PM has been detected, regeneration is not performed because
burning cannot be controlled, but the check engine warning light is turned ON instead.
ECM
About ECM function
The ECM constantly monitors the information sent from various sensors, and controls the each system
of the powertrain.
The ECM performs the diagnostic functions of the system, detects operational problems of the system,
warns the operator via the monitor, and records the DTC.
The DTC identifies the area where the problem has occurred to assist the repair operation performed
by the technician.
The ECM outputs voltages (e.g., 5 V) to supply power to various sensors and switches.
The ECM controls the output circuit by controlling the ground or power supply circuit via one of the
devices.
ANNOTATION:
• As for the ECM installation position, refer to the manual of the actual unit.
*1 Starter switch ON
*2 Starter switch OFF
Supply pump
The supply pump highly pressurizes the fuel using the engine torque, and force-feeds the fuel to the
common rail.
Also, the suction control valve, fuel temperature sensor, feed pump, etc, are installed on the supply pump.
Common rail
The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel
to each cylinder.
The fuel pressure sensor and the pressure limiter are installed on the common rail.
1 Pressure limiter
2 Fuel pressure sensor
3 Common rail
Pressure limiter
The pressure limiter is activated when the pressure in the common rail becomes abnormally high to re-
lease the pressure inside the common rail.
1 Pressure limiter
Injector
The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection.
The ECM internally boosts the voltage for driving the injector to apply it to the injector, and uses it for fuel
injection amount control and injection timing control by regulating the energizing time of the injector.
Overheat switch
The overheat switch is installed on the water outlet pipe, and is turned ON when the engine coolant
temperature exceeds 105°C {221 °F}.
1 Camshaft gear
2 Rotational direction
3 CMP sensor
Boost sensor
The boost sensor detects the boost using the pressure hose between the boost sensor and intake pipe
to convert into the voltage signal and sends it to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is
lower.
The ECM calculates the boost from the voltage signal sent from the sensor, and uses it to control the fuel
injection, etc.
IMT sensor
The IMT sensor is a variable resistance installed on the intake manifold to measure the intake temperature
of the intake manifold.
When the sensor is cold, the sensor resistance is high.
When the intake temperature rises, the sensor resistance decreases.
For low sensor resistance, the ECM detects a low voltage of the signal circuit.
Turbo actuator
The turbo actuator is installed on the turbocharger.
The ECM communicates with the turbo control unit based on the engine load, etc., and the turbo control
unit controls the turbo actuator.
The nozzle control of the turbocharger is activated by the operation of the motor built into to the turbo
actuator to control the variable nozzle.
The ECM performs control that changes the boost pressure by adjusting the variable nozzle opening
angle in accordance with the load requirement for the engine.
*1 Turbine wheel
*2 Nozzle
*3 Turbo actuator
*4 Exhasut gas inlet
*5 Control rod
*6 Exhasut gas outlet
Monitor
By turning ON the diagnostic switch, the DTC is indicated by blinking.
ANNOTATION:
• As for the installation position of the monitor, refer to the manual of the actual unit.
DLC
DLC is the connector for communication and connection between the trouble diagnosis scanning tool and
various controllers.
ANNOTATION:
• As for the DLC installation position, refer to the manual of the actual unit.
Diagnostic switch
The diagnostic switch shorts the DLC terminal No.1 and No.4 or No.5 and flashes the monitor to indicate
the DTC.
ANNOTATION:
• As for the installation position and shape of the diagnostic switch, refer to the manual of the actual unit.
Memory clear switch
This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and the
memory clear switch.
ANNOTATION:
• As for the installation position of the memory clear switch, refer to the manual of the actual unit.
Mode change switch (0, 1, 2)
The operation can be performed at the engine RPM specified for each mode by switching the mode
change switch.
ANNOTATION:
• As for the installation position of the mode change switch, refer to the manual of the actual unit.
1 Starter switch
2 Engine stop switch
3 Fuel meter
4 Memory clear switch
5 Mode switch
6 Water temperature gauge
7 Oil temperature gauge
8 Hour meter
*1 Boost sensor *10 Starter cut relay *19 Intake thrttle motor
*2 EGR position sensor *11 Hour meter relay *20 Fuel injector 1 (Cylinder #1)
*3 Intake throttle position sensor *12 Starter *21 Fuel injector 1 (Cylinder #3)
*4 Fuel temperature sensor *13 Tacho meter *22 Fuel injector 1 (Cylinder #2)
*5 CMP sensor *14 TOOL *23 Fuel injector 1 (Cylinder #5)
*6 Boost temperature sensor *15 OEM unit *24 Fuel injector 1 (Cylinder #6)
*7 Oil pressure sensor *16 Terminator *25 Fuel injector 1 (Cylinder #4)
*8 Water temperature sensor *17 Turbo unit *26 Suction control valve
*9 IMT sensor *18 EGR DC motor *27 ECM
60 pin connector
94 pin connector
4001E
Symptom
• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc.
Use of low-viscosity fuel such as kerosene causes wear on the supply pump plunger and may result in the
discharge abnormalities and cause start failure.
In such cases, replacement of the supply pump is required.
When a start failure has occurred, check with the customer about the fuel used.
If low-viscosity fuel such as kerosene has been used, instruct the customer not to use low-viscosity fuel because
the malfunction recurs even after replacing the supply pump.
A mixed oil biofuel containing long-term storage fuel and organic substances is easily oxidizable.
An oxidized fuel causes wear on the camshaft related parts in the supply pump and may result in start failure
due to discharge abnormalities.
In such cases, replacement of the supply pump is required.
Since the replacement of the supply pump due to the use of mixed oil biofuel containing long-term storage
fuel and organic substances is at the customer’s expense, instruct the customer not to use mixed oil biofuel
containing long-term storage fuel and organic substances.
When using fuel with a high water content, add the larger sedimenter to the pre-fuel filter to prevent water from
entering into the fuel system.
Abnormalities of the supply pump, non-pressure fuel supply
The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a con-
dition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute
pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to
the supply pump abnormalities.
ANNOTATION:
• Since the crankshaft position sensor abnormalities will not be diagnosed unless cranking is performed 14
revolutions or more, crank for more than 14 seconds at 60 r/min or more.
84402826 - May 2011
4001E-6
Symptom
For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC
may not be detected.
For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft
position sensor related DTC is detected.
Absolute pressure
*1 Non-criteria range
*2 P0093 Criteria range
*3 Range in P0093 is established
Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing
degradation Abnormalities of the injector, no fuel injection
System down due to failure Engine body abnormalities such as seizure, insufficient compression pressure, and
other mechanical failures, etc.
ACG failure Failure related to the actual unit equipment such as the oil pressure pump, etc.
Effect of the post-installed accessories such as wireless devices and lights, etc.
ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions,
bending, etc.
Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
84402826 - May 2011
4001E-7
Symptom
Engine stalling
1. Engine stalling Description of Symptom
Engine cranks but takes a long time to start.
The engine ultimately operates, or starts but stops soon.
2. Engine stalling Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Check whether the actual unit has a significant load.
The ECM and monitor are operating correctly.
Since the crankshaft position sensor abnormalities will not be diagnosed with cranking less than 14 revolutions,
crank for more than 14 seconds at 60 r/min or more.
DTC check.
For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC may
not be detected.
For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft po-
sition sensor related DTC is detected.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
Check whether fuel is contained.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is an improper connection of connectors.
Particularly for the crankshaft position sensor and camshaft position sensor.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumu-
lates easily.
Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any
plugs for air removal.
Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout.
Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion
direction of the actual unit.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as filter clogging and air intake piping abnormalities, etc.
Abnormalities of the supply pump, non-pressure fuel supply
The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a con-
dition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute
pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to
supply pump abnormalities.
Absolute pressure
*1 Non-criteria range
*2 P0093 Criteria range
*3 Range in P0093 is established
Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing
degradation
Abnormalities of the injector, no fuel injection
System down due to failure
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
ACG failure
Failure related to the actual unit equipment such as the oil pressure pump, etc.
Effect of the post-installed accessories such as wireless devices and lights, etc.
ECM failure
Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending,
etc.
Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
Repair if abnormalities are found.
84402826 - May 2011
4001E-11
Symptom
• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc.
Abnormalities of the supply pump, non-pressure fuel supply
Switch input circuit system abnormalities Abnormalities of the sensor input circuit system such as the acceler-
ator position sensor, harness, and water temperature sensor
Accelerator position sensor system abnormalities
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
Failure related to the actual unit equipment such as the oil pressure pump, etc.
Effect of the post-installed accessories such as wireless devices and lights, etc.
Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending,
etc.
Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
Repair if abnormalities are found.
Abnormal noise
1. Abnormal noise Description of Symptom
Engine combustion noise is abnormal.
2. Abnormal noise Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Refer to the actual unit manual and inspect the abnormal noise.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Proper wiring connections, tightening, and disconnection
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as EGR valve abnormalities, etc.
Abnormalities of the injector, no fuel injection
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
Failure related to the actual unit equipment such as the oil pressure pump, etc.
ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions,
bending, etc.
Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
Repair if abnormalities are found.
Fuel flow
*1 Warning indication
*2 DTC set
*1 Highland
4001F
Functional Inspection
1 Compression gauge
2 Compression gauge adapter
ANNOTATION:
SST: compression gauge adapter (refer to • Measure the compression pressure.
section 1003) • Rotate the starter, and read the indication
of the compression pressure when the com-
pression gauge needle stabilizes at approx-
imately 200 min-1 { 200 rpm }.
• Measure the compression pressure of all
cylinders.
Specified value: 2840.0 - 3240.0 kPa { 28.96
- 33.04 kgf/cm2 / 412 - 470 psi }
Limit: 1960.0 kPa { 19.99 kgf/cm2 / 284 psi }
84402826 - May 2011
4001F-5
Functional Inspection
Difference between each cylinder:294.0 kPa 1) Turn the emergency stop switch to OFF.
{ 3.00 kgf/ cm2 / 43 psi }
ANNOTATION:
CAUTION • If the actual unit does not have an emer-
gency stop switch setting, do not perform
• Note that air will burst out through
the glow plug hole during rotation. this operation.
2) Inspect the overheat switch circuit.
ANNOTATION:
ANNOTATION:
• When the starter switch is turned to ON with • If the actual unit does not have a overheat
the injector harness connector removed, the switch setting, do not perform this operation.
ECM determines a malfunction and records
a DTC, so make sure the DTC has been 3) Repair the circuit if a problem is discovered.
cleared after the inspection is completed. 4) Check the DTC.
ANNOTATION:
Inspection of the starting system
• If the DTC is detected, inspect the corre-
1. Starting system check Description of Function sponding DTC.
This diagnosis chart is an organized approach to
identifying a condition that causes the status for 5) Check the SCV F/B display using a trouble
when an engine does not start. diagnosis scan tool while cranking the engine.
The appropriate system diagnosis can be per- Standard: 900 mA
formed with this diagnostic chart. 6) Repair the SCVLO drive circuit if it is below
the standard value.
• The battery should be fully charged when per- 7) Remove the harness connector from the SCV.
forming this diagnosis. 8) Crank the engine.
• The battery cable should be securely connected
when performing this diagnosis. ANNOTATION:
• The rotation speed during cranking should be nor- • If the engine starts, diagnose the DTC
mal when performing this diagnosis. P0090.
• The appropriate fuel should be sufficiently sup-
plied when performing this diagnosis. 9) Inspect the fuel system if the engine does not
• No fuel leaks should be found when performing start.
this diagnosis. 10) Inspect the engine coolant temperature sen-
• No air should be mixed into the fuel when perform- sor.
ing this diagnosis. 11) Inspect the fuel pressure sensor.
• The air cleaner element should be clean when 12) Inspect the EGR position sensor.
performing this diagnosis. 13) Inspect the injector.
• The fuel filter should be clean when performing 14) Inspect the engine mechanical timing.
this diagnosis. 15) Inspect the installation status of the flywheel.
16) Inspect the air intake system.
2. Starting system check Inspection 17) Inspect the exhaust piping for collapsing,
Inspection when the starter operates and cranks but damage, and exhaust leakage.
the engine does not start 18) Repair or replace the part found to have a
problem.
ANNOTATION: ANNOTATION:
• If the QOS does not operate, the QOS in- • Turn the command to ON and check the
dicator light will illuminate when the starter voltage value of the DMM.
switch is turned to ON by the light check Standard: 18 V
function. 18) Inspect the circuit if it is below the standard
• The QOS indicator light turns off within 10 value.
seconds.
• No fuse should be blown.
5) Inspect the circuit if the QOS indicator light • No open circuit should be found between
does not illuminate or turn off. the fuse and glow relay.
• No fuse should be blown. • No open circuit should be found between
• No open circuit should be found between the glow relay and glow plug.
the fuse and QOS indicator light. • No open circuit should be found between
• No open circuit or short circuit should be the glow relay and ECM.
found between the QOS indicator light and 19) Repair or replace the circuit if a problem is
ECM. discovered.
• The QOS indicator light should not have a 20) Replace the ECM.
burned-out bulb. Removal of ECM
6) Repair or replace the circuit if a problem is Installation of ECM
discovered. 21) After replacing the ECM, perform EGR learn-
7) Inspect the glow relay. ing.
Functional inspection of the DPD 11) Inspect the exhaust differential pressure sen-
sor.
1. DPD control system check Description of Function
The ECM detects the condition of PM accumula- • Damage on the DPD differential pressure
tions from the DPD differential pressure sensor. sensor
The DPD differential pressure sensor changes the • Foreign matter or contamination which inter-
signal voltage in accordance with changes in the feres with the DPD differential pressure sen-
exhaust gas pressure difference between the front sor inlet
and the rear of the DPD filter. • Wrong detection or slow response for the
When the DPD differential pressure sensor reaches DPD differential pressure sensor
to a certain amount of PM accumulation, or a certain 12) Inspect the exhaust system.
period of operating hours, DPD automatic regener- 13) Inspect the air intake system.
ation starts. 14) Start the engine and maintain idling for 30 sec-
If the automatic regeneration cannot be completed onds.
due to working, the DPD manual regeneration indi- 15) Confirm that the DPD manual regeneration in-
cator light in the monitor panel blinks to prompt the dicator light blinks.
driver to perform manual regeneration.
When regeneration has once started, it must be ANNOTATION:
completed within a certain period of time. • If it is not blinking, use the trouble diagno-
After completion of DPD regeneration, purification sis scan tool to confirm DPD accumulation
status of the filter is determined based on the ex- status and DPD time status and applicable
haust differential pressure. area based on the DPD status table.
When the ECM detects excessive amount of PM ac-
cumulation, it becomes so hot that it is eroded dur- • Compare DPD accumulation status and
ing regeneration process and cannot control com- DPD time status and use the DPD status ta-
bustion; therefore, DPD regeneration is not allowed ble to determine DPD regeneration process
to start. status.
2. DPD control system check Inspection • To use the DPD status table, confirm the
Inspection for determining the failure location in the data display values on the trouble diagnosis
DPD system scan tool and readings in the DPD status
table.
1) Perform the inspection of the engine control
system.
2) Turn the starter switch ON for 30 seconds.
3) Check that the monitor panel functions nor-
mally.
• DPD automatic regeneration indicator light
illuminates in green
• DPD manual regeneration indicator light il-
luminates in orange DPD Ac-
cumula-
ANNOTATION:
tion Sta-
• If it does not illuminate, inspect the circuit of tus
the DPD indicator light.
• Not all are displayed depending on actual
unit manufacturers.
4) Turn the starter switch OFF for 30 seconds.
5) Inspect the amount of engine oil.
6) Connect the trouble diagnosis scan tool to the
DTC.
7) Start the engine. DPD Distance Status
8) Display the scan tool data DPD regeneration
switch using a trouble diagnosis scan tool. Range
9) Check if the data displayed on the DPD regen- A Normal range
eration switch of the trouble diagnosis scan DPD amber lamp binks but
tool is turned to ON or OFF when changing B manual regeneration is possi-
each switch. ble.
ANNOTATION: Exhaust differential pressure is
C excessive high range and man-
• If the ON or OFF operation does not link, ual regeneration is inhibited.
inspect the DPD switch and harness. Time status is abnormal range
10) Inspect the installation condition of the DPD D and manual regeneration is in-
differential pressure sensor. hibited.
• If no error message has been displayed, in- 23) Replace the ECM if any problem can be seen
spect the DPD filter for damage, cracks, or through the inspections above.
melting. ECM Removal
• If no error message has been displayed, in- ECM Installation
spect the oxidation catalyst for degradation, 24) Set the injector ID code on the ECM.
damage, cracks, melting, or excessive sed- 25) Perform the unit difference learning of the fuel
iment. supply pump to the ECM.
Inspection of the monitor warning Inspection if the monitor does not show an abnor-
mality display when the starter switch is switched
light illumination circuit system ON
1. Inspection of the monitor warning light illumination 1) Perform the OBD system check.
circuit system Description of Function 2) Inspect the monitor bulb.
The monitor is supplied with power supply voltage 3) Replace the valve if a problem is discovered.
via the starter switch and shows an abnormality dis- 4) Inspect the monitor circuit.
play due to a signal from the ECM.
The ECM makes the monitor show an abnormality • No open circuit or high resistance should be
display during a lamp check when the starter switch found between the fuse and monitor.
is ON and when the DTC is set. • No open circuit or high resistance should be
It also blinks the monitor depending on the detected found between the monitor and ECM.
DTC when the body ground terminal and diagnostic 5) Repair the circuit if a problem is discovered.
switch terminal of the DLC are shorted. 6) Replace the ECM.
A monitor circuit is incorporated inside the ECM and Removal of ECM
monitors operation of the light. Installation of ECM
2. Inspection of the monitor warning light illumination 7) After replacing the ECM, perform EGR learn-
circuit system Inspection ing.
4001G
Maintenance precautions
1 Injector pipe
2 Fuel pressure sensor
3 Pressure limiter
4 Common rail
4004
Items to prepare
• Wrenches (8 mm, 14 mm, 17 mm)
• Rag
• Cleaning fluid
4. Use a wrench (14 mm) to remove the bolt (7), and Installation of Starter Motor
then remove the wiring (8).
Tighten bolts and nuts to the specified torque.
For bolts for which the torque is not specified, see "Stan-
dard Torque Data for Cap Screws and Nuts".
4005
Removal of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Items to prepare
• Wrenches (10 mm, 17 mm, 22 mm)
• Rag
• Cleaning fluid
5. Use a wrench (8 mm) to remove the nut (6), then Installation of Alternator
remove the wiring (5).
To install, perform the reverse of the removal procedure.
Adjust the fan belt according to the "Fan Belt Installa-
tion" tension adjustment procedures in "Fan Belt Re-
placement".
4008
Preheating System
CAUTION
• Confirm that the glow plug connec-
tor does not interfere with the sur-
rounding parts.
CAUTION
• Replace the glow plug if the mea-
sured value is not within the range
of standard value.
• Use a set of 4 glow plugs from the
same manufacturer.
4020A
1 Air conditioner sunlight sensor 6 Rocker switch 11 Air conditioner control panel
2 Monitor display 7 Wiper motor 12 Engine emergency stop switch
3 Knob 8 Radio 13 Rocker switch
4 Cigar lighter 9 Throttle volume 14 Gate lock limit switch
5 Wiper controller 10 Key cylinder
Air conditioner
1 Cup holder 5 Throttle volume 9
control panel
Engine emer-
2 Starter switch 6 Tilt lever right 10
gency stop switch
Rocker switch
3 7 Tilt lever left 11 Gate lever
space
4 Radio 8 Ashtray
Specification;
For +24 VDC
Battery relay
Sumitomo part
No.; KHR1241
Specification;
5.0 kW -24 V
Starter motor
Isuzu part No.;
898070-3211
Specification;
50 A -24 V
Alternator
Isuzu part No.;
898092-1161
Model;
130E41R
Battery
Sumitomo part
No.; KHR3944
Sumitomo part
Washer motor No.; KHR2261
(tank + motor)
Specification;
Fusible link 65 A
(fuse box) Sumitomo part
No.; KHR1592
Specification;
Fusible link 50 A
(safety relay) Sumitomo part
No.; KHR3850
Model; 7224-
Fuse 8511 (20 A)
(computer) 7224-8512 (15
A)
Model;
RA30Y2
Throttle vol-
30SKB1KΩK
ume
Sumitomo part
No.; KHR2751
Specification;
24 VDC
Starter switch Sumitomo
part No.;
KHR20050
Sumitomo
Fuel level sen-
part No.;
sor
KHR10670
Specification;
24 VDC
Charge fuel
Sumitomo
pump
part No.;
KHH11880
Sumitomo
Reserve tank
part No.;
limit switch
KHH10840
Sumitomo
Vacuum sen-
part No.;
sor
KHH10330
Common rail
Common rail accessory
pressure sen- Common rail
sor Isuzu part No.;
898027-4560
Supply pump
accessory
Fuel tempera-
Supply pump
ture sensor
Isuzu part No.;
897306-0448
Supply pump
accessory
Suction control
Supply pump
valve
Isuzu part No.;
897306-0448
Engine coolant
Isuzu part No.;
temperature
897363-9360
sensor
Sumitomo
Computer A part No.;
KHR29000
Specification;
24 VDC
Relay
Sumitomo part
No.; KHR3802
Sumitomo
Feed pump part No.;
KHR12840
Sumitomo
Feed pump
part No.;
switch
KHR12900
Specification;
Lamp
24 V 70 W
(front right
Sumitomo part
housing)
No.; KHR2475
Specification;
Lamp 24 V 70 W
(boom) Sumitomo part
No.; KHR0957
Specification;
24 V 70 W
Lamp
Sumitomo
(cab top)
part No.;
KHR16240
Model;
SD107023
Monitor display Sumitomo
part No.;
KHR23591
Specification;
Pressure sen- 50.0 MPa
sor Sumitomo
(P1) (P2) part No.;
KHR10290
Pressure sen-
sor Specification;
(N1) (N2) 5.0 MPa
(swing) (upper) Sumitomo
(travel) (arm in) part No.;
(bucket close) KHR26940
(boom up)
Specification;
Pressure
0.49 MPa
switch
Sumitomo
(option) (2nd
part No.;
option)
KHR21490
Pressure Sumitomo
switch part No.;
(filter) KHR14470
Sumitomo
5 stack sole-
part No.;
noid valve
KHJ14520
2 stack sole-
Sumitomo
noid valve
part No.;
(knob switch
KHJ14780
type)
Horsepower
Sumitomo part
control propor-
No.; LJ00684
tional valve
Model; KAB
555
KAB seat Sumitomo
part No.;
KHN13560
Hydraulic oil
Sumitomo part
temperature
No.; KHR2433
sensor
Model; With 4
Knob; Right switches
(with one- Sumitomo
touch switch) part No.;
KHJ24640
Model; With 4
Knob; Left
switches
(with horn
Sumitomo
switch and ra-
part No.;
dio mute)
KHJ24630
Sumitomo part
No.; KHR3852
Travel alarm Basic fre-
quency; 2560
Hz
Sumitomo
part No.;
KHR21430
Horn (low)
Basic fre-
quency; 350
Hz
Sumitomo
part No.;
KHR21440
Horn (high)
Basic fre-
quency; 415
Hz
Sumitomo
Wiring Sys-
tems part No.;
Diode 6098-0017,
6098-0061
Sumitomo part
No.; KHP1796
Sumitomo
Lever lock limit
part No.;
switch
KHR14930
Specification;
Lamp 24 V, 10 W
(room lamp) Sumitomo part
No.; KHN2714
Specification;
Accessory 12 VDC
socket Sumitomo part
No.; KHR2501
Specification;
24 VDC
Cigar lighter 24
Sumitomo
V
part No.;
KHR11210
Limit switch
Sumitomo part
(front window)
No.; KHR2950
(door)
Sumitomo
Wiper motor part No.;
KHN25780
Sumitomo
Solar radiation
part No.;
sensor
KHR10540
Sumitomo
Receiver dryer
part No.;
(switch)
KHR13590
Air conditioner
compressor Sumitomo part
(magnetic No.; KHR3197
clutch)
Motor actuator
Sumitomo
(air mix)
part No.;
(mode) (inside/
KHR27530
outside air)
Sumitomo
EVA sensor part No.;
KHR27650
Relay
Sumitomo part
(compressor)
No.; KHR2836
(blower OFF)
Sumitomo
Blower motor part No.;
KHR27850
Sumitomo
Blower amp part No.;
KHR27840
Sumitomo
Air conditioner
part No.;
switch panel
KHR27250
Sumitomo
Beacon switch part No.;
KHR15480
Sumitomo
Glow relay part No.;
KHH13260
Sumitomo
Horn volume
part No.;
select switch
KHR28540
3 stack propor-
tional valve Sumitomo
(boom up, part No.;
arm in, bucket KHJ23870
close)
DPD exhaust
Isuzu part No.;
gas pressure
897360-3682
differential
Sumitomo
pressure sen-
part No.;
sor
KHH13330
(Isuzu)
Sumitomo part
VGS TURBO
No.; -
4020B
Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Computer A
Monitor
4020C
Code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lever Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Symbol List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Code table
Overall
Block diagram
Computer A
Computer B
ECM
Monitor
Air Conditioner
Lever Lock
Horn
Working lights
Option
Other
Diode Resistor
4021
4022
4023B
3) Diagnosis
Fully understand the description given by the customer using the Engine Control System Check Sheet.
ANNOTATION:
• When questioning, do not ask randomly but focus on the system that is inferred to be defective based on
the malfunction phenomenon.
Determine failure information accurately.
Have concrete understanding based on 5W1H.
Low air temperature, at start or on a steady basis, near the engine parts, metallic sound, etc.
Check points
• Failure symptoms
• Month and Date, Time, Frequency of occurrence
• Road conditions
• Working conditions, Operation conditions, Weather
• Feeling of symptom
Engine control system check sheet
When receiving the actual unit from the customer at the service factory, the failure symptoms and the data
on occurrence of failure must be confirmed with the customer based on the engine control check sheet.
• Failure symptoms may not be able to be reproduced at the service factory.
• The customer's complaint may not always be a malfunction.
• Notification of incorrect malfunction conditions to the person in charge of repairs may result in unneces-
sary man-hours for repairs.
• The check sheet assists actual unit diagnosis, repair, and repair confirmation at the vehicle servicing
station.
1 Failure symptoms
Failure frequency・failure con-
2
ditions
4) Preparatory check
Visual inspection of engine room
When implementing the diagnostic procedures, carefully make a visual inspection of the engine room.
This inspection can often lead to solving a problem without taking extra steps.
• Visually inspect all air hoses for punched holes, cuts, disconnections, and appropriate piping.
• Visually inspect the hoses that are difficult to see behind other components.
• For every harness in the engine room, visually inspect that all harnesses are properly connected.
Inspect that there are no burned or worn areas, that the harnesses are properly fastened and that they
are not in contact with sharp edges or the hot exhaust manifold or pipes.
Checking the machine maintenance status
If the maintenance of the actual machine is not performed correctly, the monitor may illuminate.
Restricted oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity
can trigger actual unit faults that were not previously monitored prior to OBD.
Poor vehicle maintenance cannot be classified as a non-machine failure, but since the sensitivity of OBD
system checks is high, actual unit maintenance schedules must be further closely followed.
Non-OEM parts
All the OBD system checks are adjusted to operate with the genuine parts.
Therefore, when a commercially sold sensor or switch, etc. is installed, a wrong diagnosis is made, and
the monitor comes on.
Accordingly, if general commercially-available sensors or switches are installed, this will cause mistakes in
diagnosis and the monitor to show an abnormality display.
If a commercially-available electronic device such as a mobile phone, stereo or anti-theft device is inappro-
priately installed, an EMI may be emitted to the control system.
As the result, false sensor information is generated causing the monitor to come on.
When conducting a trouble diagnoses, either turn OFF the power for all commercially sold parts or remove
them, and then check the failure again.
NOTE
Related system failure
Many OBD system checks go into the backup operation mode based on the instruction from the ECM which
is given when the ECM detects a failure in the related systems or components.
When the backup operation mode is activated, the output is reduced to protect the actual unit.
5) Trouble diagnosis
Basic knowledge of tools required
ANNOTATION:
• When performing the diagnostic procedure, lack of basic knowledge regarding this powertrain could result
in an incorrect diagnosis or damage to the powertrain components.
Do not attempt to diagnose a problem related to the powertrain without having the basic knowledge.
A basic understanding of hand tools, such as the trouble diagnosis scan tools, is required to utilize the
service manual effectively.
About the diagnostic test performed on the actual unit
Past failures
• The diagnostic tests of the previous ignition cycle have been completed.
• The diagnostic tests of the current ignition cycle have passed.
• Problems identified in the diagnostic tests currently do not exist.
Current failures
• The diagnostic tests of the previous ignition cycle have been completed.
• Problems identified in the diagnostic tests currently exist.
• Problems exist in the current ignition cycle.
Glossary
DTC
Every time the starter switch is turned ON, the ECM performs the self-test on most of the wiring and com-
ponents, records any detected system failure in the memory of the ECM, and performs the backup control,
depending on the DTC.
Also, abnormalities that affect travel will cause the monitor to show an abnormality display to inform the
operator.
Ignition cycle
Because the actual unit activates with a method to satisfy a predetermined diagnosis standard, an ignition
cycle is defined as turning the starter switch ON, running, then turning the starter switch OFF.
Monitor
In general, the monitor shows an abnormality display when a malfunction occurs in electronic control such
as the ECM and a DTC is detected.
DLC
The equipment for communicating with the control unit is the Data Link Connector (DLC).
The DLC is also provided to establish a connection with the scan tool.
Identification of recorded
DTC Reading the serial data
ANNOTATION:
• The installation position of the DLC and existence or nonexistence of the DLC vary depending on the
actual unit, so refer to the manual of the actual unit.
ECM OFF
Turn the ECM off starter switch off and the ECM power supply completely tops in approximately 10 seconds
to disable the ECM.
General diagnostic operations of the components monitor
To run the engine normally, a general diagnosis of the components is required.
Input components
Inspect the input components to see whether an open in the circuit or outside range value exists.
Crankshaft position sensor
Camshaft position sensor
Water temperature sensor
Boost sensor
Fuel pressure sensor
Accelerator position sensor
Output components
The output components are inspected to diagnose whether responses to commands from the control unit
are appropriate.
Inspect whether the circuits have disconnections and whether their values are within the range.
Suction control valve
Light, Relay control
Magnetic valve
Monitor
a At code "23"
b At code "413"
CAUTION
• When conditions such as the running state of the actual unit or the engine, water tempera-
ture, switches and gear position are not met, or when a DTC has been detected, each test
may possibly not operate.
ECM reflash
The ECM can be updated by overwriting its control program using the most recent control data issued every
3 months.
Normal reflash
The ECM is reflashed by automatically searching for the ECM part number compatible with the part number
currently reflashed.
Forced reflash
The ECM is reflashed by specifying an arbitrary ECM part number.
In this case, a password dedicated for forced reflash is necessary.
Campaign reflash The ECM is reflashed by selecting the part number during a campaign carried out by the
manufacturer.
Rewriting injector QR code
The injector QR code that is required when replacing the injector can be rewritten.
This allows fuel compensation to be performed on each injector to optimize the engine condition.
Engine replacement mode
This should be used when changing back to the old ECM part number which requires hardware changes
such as addition of actual unit wiring is performed along with engine replacement, etc.
ECM replacement
When replacing the ECM within the same model, the data can be updated from the current ECM to a trouble
diagnosis scan tool and then downloaded it from the trouble diagnosis scan tool to the new ECM after
replacement.
Factory shipment settings
Based on the engine serial number, data such as ECM injector QR code can be downloaded to ECM.
Actuator test
The injector test, fuel injection test, rail pressure test, glow plug test, and EGR control test are performed
to inspect the operation and function of each target component.
CAUTION
• When conditions such as the running state of the actual unit or the engine, water tempera-
ture, switches and gear position are not met, or when a DTC has been detected, each test
may possibly not operate.
CAUTION
• When using the trouble diagnosis scan tool, refer to the separate instruction manual for the
trouble diagnosis scan tool.
4023D
Removal and Installation of 2) Remove the suction control valve from the fuel
supply pump.
Suction Control Valve
Removal of Suction Control Valve
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Suction control valve Removal
CAUTION
• Before removing the suction control
valve, clean the surrounding area.
1 Relief valve
2 Union
3 Fuel temperature sensor
4 Suction control valve
1 O-ring
CAUTION
• To prevent engine failure, be sure to per-
form air removal after the installation or
removal of fuel system parts.
1 O-ring
CAUTION
• Remove the fuel around the plug
thoroughly after tightening.
CAUTION
• Do not accelerate the engine revo-
lution right after staring.
Idling: 5 s
ANNOTATION:
• Accelerate the engine revolution gradually.
Engine revolution hold: 3 min.
ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
• Lower the rotation.S
1 Overheat switch
2 Water temperature sensor
1 Fuel filter pressure sensor
Resistance (kΩ)
Temperature °C (°F)
1) Disengage the battery ground cable from the • Be careful not to subject the sensor
battery. to shock.
1 CKP sensor
2 Flywheel housing
CAUTION
• Be careful not to subject the sensor
to shock. 2. Battery ground cable Connect
1) Connect the battery ground cable to the bat-
tery.
CAUTION
• Replace the oil pressure sensor if
there is no continuity.
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
5 Boost temperature sensor
1 Boost sensor
2) Connect the harness connector to the boost 2 IMT sensor
sensor. 3 EGR valve
4 Harness clip
2. Battery ground cable Connect 5 Boost temperature sensor
1) Connect the battery ground cable to the bat-
tery.
3. Boost sensor Inspection
1) Inspect the boost sensor.
ANNOTATION:
• Stains on the unit
• Damage on the unit
• Malfunction of the terminal
CAUTION
• Do not clean the sensor unit since
damage may be caused inside the
sensor.
CAUTION
• Do not use a tool which causes vibra-
tions such as an impact wrench when in-
stalling and removing the DPD differen-
tial pressure sensor.
• Do not reuse a DPD differential pressure
sensor which has been subjected to
shock such as being dropped.
• Install or remove the DPD differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
1 Boost sensor stalled on the DPD differential pressure
2 IMT sensor sensor.
3 EGR valve • Replace the DPD differential pressure
4 Harness clip sensor if the 4 screws installed on the
5 Boost temperature sensor DPD differential pressure sensor have
been loosened.
1 Screw
CAUTION
• Before performing work, be sure to
check the DPD differential pressure sen-
sor precautions.
3) Remove the exhaust differential pressure sen- Exhaust differential pressure sensor
sor from the DPD assembly. Installation
CAUTION 1. Exhaust differential pressure sensor Safety
Information
• Remove the DPD differential pres-
sure sensor with the attached CAUTION
bracket.
• Do not use a tool which causes vibra-
tions such as an impact wrench when in-
stalling and removing the DPD differen-
tial pressure sensor.
• Do not reuse a DPD differential pressure
sensor which has been subjected to
shock such as being dropped.
• Install or remove the DPD differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
stalled on the DPD differential pressure
sensor.
• Replace the DPD differential pressure
sensor if the 4 screws installed on the
DPD differential
DPD differential pressure sen- • pressure sensor have been loosened.
1
sor
1 Screw
CAUTION
• Before performing work, be sure to
check the DPD differential pressure sen-
sor precautions.
ANNOTATION:
• 0-point correction
1. Turn OFF the starter switch.
2. Turn ON the starter switch.
CAUTION
• Do not start the engine.
1. Exhaust gas temperature sensor Safety Information • Do not subject the tip of the exhaust gas
temperature sensor to shock when in-
CAUTION stalling.
• Remove the old anti-seize lubricant on
• Before removing, be sure to check the the sleeve nut.
DPD pressure difference, status, and in- • Apply the anti-seize lubricant on the
spection/maintenance contents using a threaded portion of the sleeve nut.
scan tool. • Apply Never-Seez High Temperature
• Do not reuse an exhaust gas tempera- Stainless Grade: anti-seize lubricant,
ture sensor which has been subjected to manufactured by Bostik in the United
shock such as being dropped. states.
• Replace the oxidation catalyst assembly
2. Exhaust gas temperature sensor Removal if damage has been found in the sensor
installation section of the oxidation cata-
1) Disengage the harness connector from the
lyst assembly.
exhaust gas temperature sensor.
ANNOTATION: 1) Temporarily tighten the exhaust gas tempera-
ture sensor to the DPD assembly.
• To prevent incorrect assembling, make an
alignment mark on the connector before dis- CAUTION
connecting.
• To avoid damaging the sensor in-
2) Remove the exhaust gas temperature sensor stallation sections due to sensor
from the DPD assembly. incorrect assembly, tighten it by
hand.
ANNOTATION:
• Exhaust gas temperature sensor identifica-
tion
Screw Connector
Sensor type
size color
Exhaust gas tempera- M12 x
Dark gray
ture sensor 1 1.75
Exhaust gas tempera- M12 x
Light gray
ture sensor 2 1.25
CAUTION
• Be careful not to twist the harness.
4023G
Engine-side Trouble
Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC U0001 (Flash Code 84) CAN-Bus Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DTC U0073 (Flash Code 84) Control Module Communication Bus Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DTC P0089 (Flash Code 151)Fuel Pressure Regulator Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DTC P0093 (Flash Code 227) Fuel System Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DTC U0101 (Flash Code 85) Lost Communication with TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC U0110 (Flash Code 87) Lost Communication with VNT System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance. . . . . . . . . . . . . . . . . . . . . . . 33
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance . . . . . . . . . . . . . . . . 34
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 . . . . . . . . . . . 36
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DTC P0560 (Flash Code 155) System Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DTC P0563 (Flash Code 35) System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DTC P0602 (Flash Code 154) Control Module Programming Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error . . . . . . . . . . . . . . . 43
DTC P0606 (Flash Code 51) ECM/PCM Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine-side Trouble
DTC U0001 (Flash Code 84) DTC P0016 (Flash Code 16)
CAN-Bus Malfunction Crankshaft Position - Camshaft
1. DTC U0001 Diagnostics Position Correlation
1) Turn OFF the starter switch. 1. DTC P0016 Priority DTC
2) Disconnect the harness connector from the DTC P0335
ECM. DTC P0336
3) Measure the resistance between the CAN- DTC P0340
High side terminal and CAN-Low side termi- 2. DTC P0016 Diagnostics
nal.
1) Inspect the CKP sensor.
ANNOTATION: Refer to "1.Engine 1B.Mechanical(4HK1X)
CKP sensor Inspection".
• Measure the resistance between the termi- 2) If a problem is discovered, replace the crank-
nals of the ECM harness connector.
shaft position sensor.
Resistance: about 120.0 Ω Refer to "1.Engine 1B.Mechanical(4HK1X)
4) If it is outside the standard range, inspect CKP sensor Removal".
the CANLow circuit and CAN-High circuit be- Refer to "1.Engine 1B.Mechanical(4HK1X)
tween the ECM and the control unit of the ac- CKP sensor Installation".
tual unit. 3) Inspect the CMP sensor.
Refer to "1.Engine 1B.Mechanical(4HK1X)
• There should be no short to the battery or CMP sensor Inspection".
ignition power supply. 4) If a problem is discovered, replace the
• There should be no open circuit or high re- camshaft position sensor.
sistance. Refer to "1.Engine 1B.Mechanical(4HK1X)
• There should be no short to GND. CMP sensor Removal".
5) If a problem is discovered, repair the CAN Refer to "1.Engine 1B.Mechanical(4HK1X)
circuit. CMP sensor Installation".
6) If the CAN circuit is normal, replace the control 5) Inspect the flywheel.
unit of the actual unit.
• The sensor rotor should not be damaged.
7) Connect the harness connector to the ECM.
• The ring gear should be installed correctly.
8) Disconnect the harness connector from the
control unit of the actual unit. 6) If a problem is discovered, repair the flywheel.
9) Measure the resistance between the CAN- 7) Inspect the camshaft gear.
High side terminal and CAN-Low side termi-
nal. • The camshaft gear should not be damaged
• The camshaft gear should be installed cor-
ANNOTATION: rectly.
• Measure the resistance between the termi- 8) If a problem is discovered, repair the camshaft
nals of the ECM harness connector. gear.
Resistance: about 120.0 Ω 3. DTC P0016 Confirm Resolution
10) If it is outside the standard range, replace the
1) Clear the DTC using the trouble diagnosis
ECM.
scan tool.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
2) Turn the starter switch OFF for 30 seconds or
Removal".
longer.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
3) Start the engine.
Installation".
11) Set the injector ID code on the ECM. ANNOTATION:
12) Perform the unit difference learning of the fuel
supply pump to the ECM. • When the engine does not start, crank the
engine for 10 seconds.
2. DTC U0001 Confirm Resolution
4) Perform a test-run.
1) Clear the DTC using the trouble diagnosis 5) Use the trouble diagnosis scan tool to confirm
scan tool. that a DTC has not been detected.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0045 (Flash Code 33) 14) If the voltage is outside the standard range,
inspect the position sensor power supply cir-
Turbocharger Boost Control cuit between the turbo actuator and the turbo
Solenoid Circuit control unit.
• There should be no open circuit or high re-
1. DTC P0045 Priority DTC
sistance.
DTC P0563
• There should be no short to the battery
2. DTC P0045 Diagnostics
power supply or ignition power supply cir-
1) Turn OFF the starter switch. cuit.
2) Inspect the turbocharger assembly. • There should be no short to GND.
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
15) If a problem is discovered, repair the position
bocharger assembly Inspection".
sensor power supply circuit.
3) If a problem is discovered, replace the tur-
16) If the circuit is normal, inspect to the turbo
bocharger assembly.
control unit harness connector for a contact
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
failure.
bocharger assembly Removal".
17) If a problem is discovered, repair the harness
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
connector.
bocharger assembly Installation".
18) If the harness connector is normal, replace the
4) Disconnect the harness connector from the
turbo control unit.
turbo actuator.
19) If the voltage is within the standard range,
5) Connect the test light between the motor op-
measure the voltage between the position
eration terminal and GND of the turbo actuator
sensor signal terminal of the turbo actuator
harness connector.
harness connector and GND.
6) Turn ON the starter switch.
7) Check if the test light does not come on or ANNOTATION:
remains on.
• Measurement of voltage value should be
ANNOTATION: taken on each terminal.
• The inspection with a test light should be Voltage: 4.0 - 6.0 V
performed on each terminal. 20) If the voltage is outside the standard range,
• When it is normal, the test light comes on inspect the position sensor signal circuit be-
after the key switch is turned ON, and then tween the turbo actuator and the turbo control
goes out after a few seconds. unit.
8) If the test light does not come on or remains • There should be no open circuit or high re-
on, inspect the motor operation circuit be- sistance.
tween the turbo • There should be no short to the battery
actuator and turbo control unit. power supply or ignition power supply cir-
cuit.
• There should be no open circuit or high re-
• There should be no short to GND.
sistance.
• There should be no short to the battery 21) If a problem is discovered, repair the position
power supply or ignition power supply cir- sensor signal circuit.
cuit. 22) If the circuit is normal, inspect to the turbo
• There should be no short to GND. control unit harness connector for a contact
failure.
9) If a problem is discovered, repair the motor
23) If a problem is discovered, repair the harness
operation circuit.
connector.
10) If the test light operates properly, inspect to
24) If the harness connector is normal, replace the
see if a short with other circuit exists in the
turbo control unit.
motor operation circuit between the turbo ac-
25) If the voltage is within the standard range, in-
tuator and turbo control unit.
spect to see if there is a short circuit with the
11) If a problem is discovered, repair the motor
position sensor.
operation circuit.
12) Turn ON the starter switch.
13) Measure the voltage between the position
sensor power supply terminal and GND of the
turbo actuator harness connector.
Voltage: 8.0 - 11.0 V
DTC U0073 (Flash Code 84) 12) Replace the ECM if the resistance value is
within the range of standard value.
Control Module Communication Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Bus Off Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
1. DTC U0073 Diagnostics Installation".
13) Set the injector ID code on the ECM.
1) Turn OFF the starter switch. 14) Perform the unit difference learning of the fuel
2) Measure the resistance between the termi- supply pump to the ECM.
nals of the termination resistor harness con- 15) Turn OFF the starter switch.
nector. 16) Connect the harness connector to the ECM.
ANNOTATION: 17) Turn ON the starter switch.
18) Measure the voltage between the CAN-High
• Make a measurement from the back with the terminal and GND of the termination resistor
harness connector connected. harness connector.
• Confirm that the parallel resistance of the 19) Measure the voltage between the CAN-Low
120 Ω resistor in the termination resistor and terminal and GND of the termination resistor
that of the 120 Ω resistor in the ECM are harness connector.
both 60Ω. Roltage: 1.5 - 3.5 V
Resistance: 50.0 - 70.0 Ω 20) If the voltage is outside the standard range,
3) Disconnect the harness connector from termi- replace the ECM.
nation resistor if the resistance value is out- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
side the standard range. Removal".
4) Measure the resistance of the termination re- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
sistor. Installation".
Resistance: 110.0 - 130.0 Ω 21) Set the injector ID code on the ECM.
5) If the resistance value is outside the standard 22) Perform the unit difference learning of the fuel
range, replace the termination resistor. supply pump to the ECM.
6) Connect the harness connector to the termi- 23) Turn OFF the starter switch.
nation resistor . 24) Connect the harness connector to the control
7) Disconnect the harness connector from the unit of the actual unit.
control unit of the actual unit. 25) Turn ON the starter switch.
8) Measure the resistance between the termi- 26) Measure the voltage between the CAN-High
nals of the termination resistor harness con- terminal and GND of the termination resistor
nector. harness connector.
27) Measure the voltage between the CAN-Low
ANNOTATION: terminal and GND of the termination resistor
• Make a measurement from the back with the harness connector.
harness connector connected. Voltage: 1.5 - 3.5 V
28) If the voltage is outside the standard range,
Resistance: 50.0 - 70.0 Ω replace the control unit of the actual unit.
9) If the resistance value is within the standard 29) If the voltage is within the standard range, re-
range, replace the control unit of the actual place the termination resistor.
unit.
10) Disconnect the harness connector from the 2. DTC U0073 Confirm Resolution
ECM. 1) Use the trouble diagnosis scan tool to clear
11) Measure the resistance between the termi- the DTC.
nals of the termination resistor harness con- 2) Turn the starter switch OFF for 30 seconds.
nector. 3) Start the engine.
ANNOTATION: 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to check
• Make a measurement from the back with the if a DTC has been detected.
harness connector connected.
Resistance: 110.0 - 130.0 Ω
DTC P0087 (Flash Code 225) Fuel 15) If the harness connector and each circuit are
normal, replace the fuel pressure sensor.
Rail/System Pressure - Too Low Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal".
1. DTC P0087 Priority DTC
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0088
Common rail assembly Installation".
DTC P0089
DTC P0091 ANNOTATION:
DTC P0092
DTC P0192 • Do not replace the fuel pressure sensor sep-
DTC P0193 arately. When a problem is found, replace
DTC P0201 the common rail assembly.
DTC P0202 16) If the fuel rail pressure sensor display is within
DTC P0203 the standard range, start the engine.
DTC P0204 17) Perform the injector stop test with the trouble
DTC P2146 diagnosis scan tool.
DTC P2149 18) Command each injector OFF, and confirm that
2. DTC P0087 Diagnostics the engine RPM changes on each injector.
1) Start the engine. 19) If any injector does not change the engine
2) Rev the engine a few times in neutral while RPM when OFF is instructed, replace the rel-
checking for a DTC with the trouble diagnosis evant injector.
scan tool. Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Check to see if the DTC P0087 is detected. Injector Removal".
4) If the DTC P0087 is not detected, replace the Refer to "1.Engine 1C.Fuel System(4HK1X)
fuel filter element. Injector Installation".
20) When the injector has been replaced, set the
ANNOTATION: injector ID code on the ECM.
21) Inspect to see if there is clogging with the fuel
• An intermittent problem due to foreign mat- system between the fuel tank and the fuel sup-
ter in the fuel is suspected.
ply pump.
Refer to "1.Engine 1C.Fuel System(4HK1X) 22) If a problem is discovered, repair the clogging
Fuel filter element Removal". of the fuel system.
Refer to "1.Engine 1C.Fuel System(4HK1X) 23) Inspect the fuel hose between the fuel tank
Fuel filter element Installation". and the fuel supply pump for a cut and crack.
5) Turn OFF the starter switch. 24) If a problem is discovered, replace the fuel
6) Wait for the specified period of time until the hose.
fuel pressure is released from the common
ANNOTATION:
rail.
Specified time: 2 min • The fuel hose between the fuel tank and the
7) Turn ON the starter switch. fuel supply pump becomes negative pres-
8) Check the fuel rail pressure sensor display sure state when the engine is running.
with the trouble diagnosis scan tool. • When the fuel hose is not connected se-
Voltage: 0.9 - 1.0 V curely, the air can enter.
9) If the fuel rail pressure sensor display is out- • When the engine RPM or the engine load
side the standard range, inspect the fuel pres- increases while the air has intruded in the
sure sensor harness connector for a contact fuel system, fluctuation in the common rail
failure. pressure is caused, and DTC P0087 may
10) If a problem is discovered, repair the harness be detected.
connector.
11) Inspect the ECM harness connector for a con- 25) Check that an appropriate clamp is used be-
tact failure. tween the fuel tank and the fuel supply pump.
12) If a problem is discovered, repair the harness 26) If a problem is discovered, replace the clamp.
connector. 27) Operate the priming pump until the handle be-
13) Inspect each circuit for high resistance. comes heavy.
14) Repair the circuit if a problem is discovered. ANNOTATION:
• When a leak exists in the fuel system be-
tween the priming pump and the fuel sup-
ply pump, the pressing weight of the priming
pump does not become heavy.
28) Start the engine.
29) Inspect the high-pressure side of the fuel sys-
tem and check for fuel leak between the fuel
supply pump and common rail.
59) If the suction control valve harness connector DTC P0088 (Flash Code 118) Fuel
and the ECM harness connector are normal
and there is no high resistance in each circuit, Rail/System Pressure - Too High
replace the fuel supply pump and the fuel filter
1. DTC P0088 Priority DTC
element.
DTC P0089
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0091
Fuel supply pump Removal".
DTC P0092
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0192
Fuel supply pump Installation".
DTC P0193
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0201
Fuel filter element Removal".
DTC P0202
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0203
Fuel filter element Installation".
DTC P0204
ANNOTATION: DTC P2146
DTC P2149
• When replacing the fuel supply pump, it is 2. DTC P0088 Diagnostics
required to also replace the fuel filter ele-
ment at the same time. 1) Start the engine.
2) Rev the engine a few times in neutral while
60) Perform the unit difference learning of the fuel checking the actual fuel rail pressure display
supply pump to the ECM. with the trouble diagnosis scan tool.
3. DTC P0087 Confirm Resolution 3) Check the actual fuel rail pressure display with
the trouble diagnosis scan tool.
1) Clear the DTC using the trouble diagnosis Standard value :(-5) - 5 MPa
scan tool. 4) If it is at or below the standard value, replace
2) Turn the starter switch OFF for 30 seconds or the fuel filter element.
longer.
3) Start the engine. ANNOTATION:
4) Perform a test-run.
• An intermittent problem due to foreign mat-
5) Use the trouble diagnosis scan tool to confirm ter in the fuel is suspected.
that a DTC has not been detected.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
5) Turn OFF the starter switch.
6) Wait for the specified period of time until the
fuel pressure is released from the common
rail.
Specified time: 2 min
7) Turn ON the starter switch.
8) Check the fuel rail pressure sensor display
with the trouble diagnosis scan tool.
Voltage: 0.9 - 1.0 V
9) If the fuel rail pressure sensor display is out-
side the standard range, inspect the fuel pres-
sure sensor harness connector for a contact
failure.
10) If a problem is discovered, repair the harness
connector.
11) Inspect the ECM harness connector for a con-
tact failure.
12) If a problem is discovered, repair the harness
connector.
13) Inspect each circuit for high resistance.
14) If a problem is discovered, repair the circuit.
42) Check to see if there is any foreign matter in 53) Inspect the suction control valve harness con-
the fuel tank or any foreign matter which can nector for a contact failure.
cause fuel clogging. 54) If a problem is discovered, repair the harness
43) If a problem is discovered, repair it. connector.
44) Replace the fuel filter element. 55) Inspect the ECM harness connector for a con-
Refer to "1.Engine 1C.Fuel System(4HK1X) tact failure.
Fuel filter element Removal". 56) If a problem is discovered, repair the harness
Refer to "1.Engine 1C.Fuel System(4HK1X) connector.
Fuel filter element Installation". 57) Inspect each circuit for high resistance.
45) If the negative pressure is at or below the stan- 58) Repair the circuit if a problem is discovered.
dard value, pinch the fuel hose at a position as 59) If the suction control valve harness connector
close as possible to the fuel tank, so that the and the ECM harness connector are normal
fuel does not flow. and there is no high resistance in each circuit,
replace the fuel supply pump and the fuel filter
ANNOTATION: element.
• The fuel pipe can be disconnected and Refer to "1.Engine 1C.Fuel System(4HK1X)
clogged with a plug. Fuel supply pump Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
46) Start the engine and use the idling control Fuel supply pump Installation".
switch to increase the RPM to the highest Refer to "1.Engine 1C.Fuel System(4HK1X)
level. Fuel filter element Removal".
47) Check the pressure gauge. Refer to "1.Engine 1C.Fuel System(4HK1X)
Specified value : 27.0 kPa {203 mmHg / 8 Fuel filter element Installation".
inHg}
ANNOTATION:
ANNOTATION:
• When replacing the fuel supply pump, it is
• When the pressure gauge is likely to indi- required to also replace the fuel filter ele-
cate a value exceeding the standard value ment at the same time.
during inspection, release the fuel being
blocked. 60) Perform the unit difference learning of the fuel
• Air mixture is checked with the negative supply pump to the ECM.
pressure amount while the fuel flow is being 3. DTC P0088 Confirm Resolution
blocked.
1) Clear the DTC using the trouble diagnosis
48) If the standard negative pressure cannot be scan tool.
generated, inspect to see if there is a cut or 2) Turn the starter switch OFF for 30 seconds or
crack with the fuel hose. longer.
49) If a problem is discovered, replace the fuel 3) Start the engine.
hose. 4) Perform a test-run.
50) Inspect to see if appropriate clamp is used. 5) Use the trouble diagnosis scan tool to confirm
51) If a problem is discovered, replace the clamp that a DTC has not been detected.
with an appropriate one.
52) Turn OFF the starter switch.
DTC P0089 (Flash Code 151)Fuel 13) If a problem is discovered, repair the harness
connector.
Pressure Regulator Performance 14) Inspect each circuit for high resistance.
15) Repair the circuit if a problem is discovered.
1. DTC P0089 Priority DTC
16) Turn the starter switch OFF for 30 seconds or
DTC P0091
longer.
DTC P0092
17) Start the engine.
DTC P0192
18) Rev the engine a few times in neutral while
DTC P0193
checking the actual fuel rail pressure display
DTC P0201
with the trouble diagnosis scan tool.
DTC P0202
19) Use the trouble diagnosis scan tool to check
DTC P0203
if the actual fuel rail pressure display shows a
DTC P0204
value within the standard range at a sufficient
DTC P2146
rate.
DTC P2149
Standard values: (-5) - 5 MPa
2. DTC P0089 Diagnostics
ANNOTATION:
1) Wait for the specified period of time until the
fuel pressure is released from the common • If possible, compare with other actual unit
rail. equipped with the same model engine.
Specified time: 2 min
2) Check the fuel rail pressure sensor display 20) If it is within the standard range, replace the
with the trouble diagnosis scan tool. fuel filter element.
Coltage: 0.9 - 1.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
3) If the fuel rail pressure sensor display is out- Fuel filter element Removal".
side the standard range, inspect the fuel pres- Refer to "1.Engine 1C.Fuel System(4HK1X)
sure sensor harness connector for a contact Fuel filter element Installation".
failure. 21) If it is outside the standard range, replace the
4) If a problem is discovered, repair the harness fuel supply pump and the fuel filter element.
connector. Refer to "1.Engine 1C.Fuel System(4HK1X)
5) Inspect the ECM harness connector for a con- Fuel supply pump Removal".
tact failure. Refer to "1.Engine 1C.Fuel System(4HK1X)
6) If a problem is discovered, repair the harness Fuel supply pump Installation".
connector. Refer to "1.Engine 1C.Fuel System(4HK1X)
7) Inspect each circuit for high resistance. Fuel filter element Removal".
8) Repair the circuit if a problem is discovered. Refer to "1.Engine 1C.Fuel System(4HK1X)
9) If the harness connector and each circuit are Fuel filter element Installation".
normal, replace the fuel pressure sensor. ANNOTATION:
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal". • When replacing the fuel supply pump, it is
Refer to "1.Engine 1C.Fuel System(4HK1X) required to also replace the fuel filter ele-
Common rail assembly Installation". ment at the same time.
DTC P0091 (Flash Code 247) Fuel 12) If a problem is discovered, repair the High side
circuit.
Pressure Regulator Control Circuit 13) Turn the starter switch OFF for 30 seconds or
Low 14)
longer.
Connect the test light between the suction
1. DTC P0091 Diagnostics control valve Low side circuit and battery
power supply.
1) Check the rail pressure regulator feedback 15) Turn ON the starter switch.
current display with the trouble diagnosis scan 16) Check if the test light comes on and then goes
tool. off.
Current: 300 - 900 mA 17) If it does not turn off, inspect the Low side
2) If it is at or above the standard value, inspect circuit between the ECM and suction control
to see if there is a short circuit to the battery valve.
or ignition power supply with the High side cir-
cuit between the ECM and the suction control • There should be no open circuit or high re-
valve. sistance.
• There should be no short to the battery or
ANNOTATION: ignition power supply.
• When the High side circuit is shorted to the 18) If a problem is discovered, repair the Low side
voltage, the engine stalls and does not start. circuit.
3) If a problem is discovered, repair the High side 19) Inspect the suction control valve harness con-
circuit. nector for a contact failure.
4) If it is within the standard range, inspect to 20) If a problem is discovered, repair the harness
see if there is a short circuit to the GND with connector.
the Low side circuit between the ECM and the 21) If the harness connector is normal, replace the
suction control valve. suction control valve.
Refer to "1.Engine 1C.Fuel System(4HK1X)
ANNOTATION: Suction control valve Removal".
• When the Low side circuit is shorted to Refer to "1.Engine 1C.Fuel System(4HK1X)
GND, DTC P0091 may not be detected. Suction control valve Installation".
• When the Low side circuit is shorted to 22) Inspect the ECM harness connector for a con-
GND, the engine stalls and does not start. tact failure.
23) If a problem is discovered, repair the harness
5) If a problem is discovered, repair the Low side connector.
circuit. 24) If the harness connector is normal, replace the
6) Turn the starter switch OFF for 30 seconds or ECM.
longer. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
7) Disconnect the harness connector from the Removal".
suction control valve. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) Connect the test light between the suction Installation".
control valve High side circuit and a normal 25) Set the injector ID code on the ECM.
GND. 26) Perform the unit difference learning of the fuel
9) Turn ON the starter switch. supply pump to the ECM.
10) Check if the test light comes on and then goes
off. 2. DTC P0091 Confirm Resolution
11) If it does not turn off, inspect the High side cir- 1) Clear the DTC using the trouble diagnosis
cuit between the ECM and the suction control scan tool.
valve. 2) Turn the starter switch OFF for 30 seconds or
• There should be no open circuit or high re- longer.
sistance. 3) Start the engine.
• There should be no short to GND. 4) Perform a test-run.
• There should be no short to the LOW side 5) Use the trouble diagnosis scan tool to confirm
circuit. that a DTC has not been detected.
DTC P0092 (Flash Code 247) Fuel 12) If a problem is discovered, repair the High side
circuit.
Pressure Regulator Control Circuit 13) Turn the starter switch OFF for 30 seconds or
High 14)
longer.
Connect the test light between the suction
1. DTC P0092 Diagnostics control valve Low side circuit and battery
power supply.
1) Check the rail pressure regulator feedback 15) Turn ON the starter switch.
current display with the trouble diagnosis scan 16) Check if the test light comes on and then goes
tool. off.
Current: 300 - 900 mA 17) If it does not turn off, inspect the Low side
2) If it is at or above the standard value, inspect circuit between the ECM and suction control
to see if there is a short circuit to the battery valve.
or ignition power supply with the High side cir-
cuit between the ECM and the suction control • There should be no open circuit or high re-
valve. sistance.
• There should be no short to the battery or
ANNOTATION: ignition power supply.
• When the High side circuit is shorted to the 18) If a problem is discovered, repair the Low side
voltage, the engine stalls and does not start. circuit.
3) If a problem is discovered, repair the High side 19) Inspect the suction control valve harness con-
circuit. nector for a contact failure.
4) If it is within the standard range, inspect to 20) If a problem is discovered, repair the harness
see if there is a short circuit to the GND with connector.
the Low side circuit between the ECM and the 21) If the harness connector is normal, replace the
suction control valve. suction control valve.
Refer to "1.Engine 1C.Fuel System(4HK1X)
ANNOTATION: Suction control valve Removal".
• When the Low side circuit is shorted to Refer to "1.Engine 1C.Fuel System(4HK1X)
GND, DTC P0092 may not be detected. Suction control valve Installation".
• When the Low side circuit is shorted to 22) Inspect the ECM harness connector for a con-
GND, the engine stalls and does not start. tact failure.
23) If a problem is discovered, repair the harness
5) If a problem is discovered, repair the Low side connector.
circuit. 24) If the harness connector is normal, replace the
6) Turn the starter switch OFF for 30 seconds or ECM.
longer. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
7) Disconnect the harness connector from the Removal".
suction control valve. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) Connect the test light between the suction Installation".
control valve High side circuit and a normal 25) Set the injector ID code on the ECM.
GND. 26) Perform the unit difference learning of the fuel
9) Turn ON the starter switch. supply pump to the ECM.
10) Check if the test light comes on and then goes
off. 2. DTC P0092 Confirm Resolution
11) If it does not turn off, inspect the High side cir- 1) Clear the DTC using the trouble diagnosis
cuit between the ECM and the suction control scan tool.
valve. 2) Turn the starter switch OFF for 30 seconds or
• There should be no open circuit or high re- longer.
sistance. 3) Start the engine.
• There should be no short to GND. 4) Perform a test-run.
• There should be no short to the LOW side 5) Use the trouble diagnosis scan tool to confirm
circuit. that a DTC has not been detected.
DTC P0093 (Flash Code 227) Fuel 6) If fuel leak is found, replace the corresponding
injector.
System Leak Detected Refer to "1.Engine 1C.Fuel System(4HK1X)
Injector Removal".
1. DTC P0093 Priority DTC
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0087
Injector Installation".
DTC P0091
7) When the injector has been replaced, set the
DTC P0092
injector ID code on the ECM.
DTC P0192
8) Turn OFF the starter switch.
DTC P0193
9) Wait for the specified period of time until the
DTC P0201
fuel pressure is released from the common
DTC P0202
rail.
DTC P0203
Specified time: 2 min
DTC P0204
10) Turn ON the starter switch.
DTC P2146
11) Check the fuel rail pressure sensor display
DTC P2149
with the trouble diagnosis scan tool.
2. DTC P0093 Diagnostics
Voltage: 0.9 - 1.0 V
1) Inspect for fuel leaks on the high-pressure 12) If the fuel rail pressure sensor display is out-
side between the fuel supply pump and injec- side the standard range, inspect the fuel pres-
tor. sure sensor harness connector for a contact
failure.
• There should be no fuel leakage from the 13) If a problem is discovered, repair the harness
fuel supply pump. connector.
• There should be no fuel leakage from the 14) Inspect the ECM harness connector for a con-
common rail. tact failure.
• There should be no fuel leakage from the 15) If a problem is discovered, repair the harness
pressure limiter valve. connector.
• There should be no fuel leakage from the 16) Inspect each circuit for high resistance.
fuel pressure sensor. 17) Repair the circuit if a problem is discovered.
• There should be no fuel leakage from the 18) If the harness connector and each circuit are
fuel pipe between the fuel supply pump and normal, replace the fuel pressure sensor.
common rail. Refer to "1.Engine 1C.Fuel System(4HK1X)
• There should be no fuel leakage from the Common rail assembly Removal".
fuel pipe between the common rail and in- Refer to "1.Engine 1C.Fuel System(4HK1X)
jector. Common rail assembly Installation".
• There should be no fuel leakage from the
sleeve nut of the fuel pipe. ANNOTATION:
2) If fuel leak if found, fix the problem. • Do not replace the fuel pressure sensor sep-
arately.
ANNOTATION: When a problem is found, replace the com-
• The fuel may leak to the bottom section of mon rail assembly.
the cylinder head cover from the high pres-
sure pipe inlet. 19) If the fuel rail pressure sensor display is within
the standard range, start the engine.
• The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder 20) Perform the injector stop test with the trouble
head cover. diagnosis scan tool.
21) Command each injector OFF, and confirm that
• Inspect for fuel leaks into the engine oil.
the engine RPM changes on each injector.
• Remove and inspect the high pressure pipe
joint connected to the injector for a fuel leak- 22) If any injector does not change the engine
age from the sleeve nut. RPM when OFF is instructed, replace the rel-
evant injector.
• When foreign matter has been attached,
replace the injector and the high pressure Refer to "1.Engine 1C.Fuel System(4HK1X)
pipe. Injector Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Remove each glow plug from the cylinder Injector Installation".
head assembly. 23) When the injector has been replaced, set the
Refer to "1.Engine 1B.Mechanical(4HK1X) injector ID code on the ECM.
Cylinder head assembly Removal". 24) Inspect to see if there is clogging with the fuel
4) Inspect for fuel leaks into the combustion system between the fuel tank and the fuel sup-
chamber. ply pump.
5) Inspect to see if there is a cylinder from which 25) If a problem is discovered, repair clogging.
fuel leaks into the combustion chamber. 26) Inspect to see if there is cut or crack with the
fuel hose in the fuel system between the fuel
tank and the fuel supply pump.
27) If a problem is discovered, replace the fuel 37) Remove the air using the priming pump, and
hose. crank the engine for the specified period of
time or shorter.
ANNOTATION: Specified time: 5 s
• The fuel hose between the fuel tank and ANNOTATION:
the supply pump becomes negative pres-
sure state when the engine is running. • Repeat this until the engine starts.
• When the fuel hose is not connected se-
38) Leave the engine idling for the specified pe-
curely, the air can enter.
riod of time or longer.
• When the engine RPM or the engine load
Specified time: 1 min
increases while the air has intruded in the
39) While keeping the engine rotating at the spec-
fuel system, fluctuation in the common rail
ified engine RPM for the specified period of
pressure is caused, and DTC P0093 may
time, check the pressure gauge.
be detected.
Specified time: 1 min
28) Check that an appropriate clamp is used be- Rotational speed: 2500 min-1 {2500 r/min}
tween the fuel tank and the fuel supply pump. 40) Check if the pressure gauge shows a negative
29) If a problem is discovered, replace the clamp pressure value at or above the standard value
with an appropriate one. during inspection.
30) Operate the priming pump until the handle be- Specified value : 17.0 kPa {128 mmHg / 5
comes heavy. inHg}
ANNOTATION: ANNOTATION:
• When a leak exists in the fuel system be- • Fuel clogging is checked with the negative
tween the priming pump and the fuel sup- pressure amount in the fuel system.
ply pump, the pressing weight of the priming
41) If the negative pressure is at or above the
pump does not become heavy.
standard value, inspect to see if there is dam-
31) Start the engine. age or twisting with the fuel system between
32) Inspect the high-pressure side of the fuel sys- the fuel supply pump and the fuel tank.
tem and check for fuel leak between the fuel 42) If a problem is discovered, repair the fuel sys-
supply pump and common rail. tem.
43) Inspect the fuel tank bent hose.
ANNOTATION: 44) If a problem is discovered, repair the bent
• The fuel may leak to the bottom section of hose.
the cylinder head cover from the high pres- 45) Check to see if there is any foreign matter in
sure hose inlet. the fuel tank or any foreign matter which can
• The engine oil level increases when the fuel cause fuel clogging.
leaks to the bottom portion of the cylinder 46) If a problem is discovered, repair it.
head cover. 47) Replace the fuel filter element.
• Inspect for fuel leaks into the engine oil. Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
33) If fuel leak if found, fix the problem. Refer to "1.Engine 1C.Fuel System(4HK1X)
34) Turn OFF the starter switch. Fuel filter element Installation".
35) Remove the fuel hose on the fuel supply pump 48) If the negative pressure is at or below the stan-
side from the fuel filter. dard value, pinch the fuel hose at a position as
ANNOTATION: close as possible to the fuel tank, so that the
fuel does not flow.
• Use a pan to catch the fuel from the re-
moved fuel hose. ANNOTATION:
• Clean the pressure gauge and connection • The fuel pipe can be disconnected and
hose before connecting to the fuel pipe. clogged with a plug.
• The fuel supply pump may be damaged due
to foreign matter that has entered in the con- 49) Start the engine and use the idling control
nection hose. switch to increase the RPM to the highest
level.
36) Connect the pressure gauge between the fuel 50) Check the pressure gauge.
filter and the removed fuel hose. Specified value : 27.0 kPa {203 mmHg / 8
ANNOTATION: inHg}
• Confirm that the fuel system is connected ANNOTATION:
securely. • When the pressure gauge is likely to indi-
cate a value exceeding the standard value
during inspection, release the fuel being
blocked.
• Air mixture is checked with the negative DTC U0101 (Flash Code 85) Lost
pressure amount while the fuel flow is being
blocked. Communication with TCM
51) If the standard negative pressure cannot be 1. DTC U0101 Diagnostics
generated, inspect to see if there is a cut or
1) Inspect the CAN-Low circuit and CAN-High
crack with the fuel hose.
circuit between the ECM and the control unit
52) If a problem is discovered, replace the fuel
of the actual unit.
hose.
53) Inspect to see if appropriate clamp is used. • There should be no short to the battery or
54) If a problem is discovered, replace the clamp ignition power supply.
with an appropriate one. • There should be no open circuit or high re-
55) Turn OFF the starter switch. sistance.
56) Inspect the suction control valve harness con- • There should be no short to GND.
nector for a contact failure.
57) If a problem is discovered, repair the harness 2) If a problem is discovered, repair the CAN
connector. circuit.
58) Inspect the ECM harness connector for a con- 3) If the CAN circuit is normal, connect all har-
tact failure. nesses.
59) If a problem is discovered, repair the harness 4) Clear the DTC using the trouble diagnosis
connector. scan tool.
60) Inspect each circuit for high resistance. 5) Turn the starter switch OFF for 30 seconds or
61) Repair the circuit if a problem is discovered. longer.
62) If the suction control valve harness connector 6) Perform a test-run.
and the ECM harness connector are normal 7) Check the DTC.
and there is no high resistance in each circuit, 8) If a DTC has been detected, replace the con-
replace the fuel supply pump and the fuel filter trol unit of the actual unit.
element. 9) Connect all harnesses.
Refer to "1.Engine 1C.Fuel System(4HK1X) 10) Clear the DTC using the trouble diagnosis
Fuel supply pump Removal". scan tool.
Refer to "1.Engine 1C.Fuel System(4HK1X) 11) Turn the starter switch OFF for 30 seconds or
Fuel supply pump Installation". longer.
Refer to "1.Engine 1C.Fuel System(4HK1X) 12) Perform a test-run.
Fuel filter element Removal". 13) Check the DTC.
Refer to "1.Engine 1C.Fuel System(4HK1X) 14) If a DTC has been detected, replace the ECM.
Fuel filter element Installation". Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
ANNOTATION: Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
• When replacing the fuel supply pump, it is 15) Set the injector ID code on the ECM.
required to also replace the fuel filter ele-
16) Perform the unit difference learning of the fuel
ment at the same time.
supply pump to the ECM.
63) Perform the unit difference learning of the fuel
2. DTC U0101 Confirm Resolution
supply pump to the ECM.
1) Clear the DTC using the trouble diagnosis
3. DTC P0093 Confirm Resolution
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0102 (Flash Code 91) Mass DTC P0103 (Flash Code 91) Mass
Air Flow Circuit Low Input Air Flow Circuit High Input
1. DTC P0102 Priority DTC 1. DTC P0103 Priority DTC
DTC P0560 DTC P0560
2. DTC P0102 Diagnostics 2. DTC P0103 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
mass air flow sensor. mass air flow sensor.
3) Inspect to see if there is an open circuit or high 3) Check the mass air flow sensor display with
resistance in the 12 V power supply circuit be- the trouble diagnosis scan tool.
tween the ECM and the mass air flow sensor. Voltage: 0.1 V
4) If a problem is discovered, repair the 12 V 4) If it is at or above the standard value, inspect
power supply circuit. the signal circuit between the ECM and the
5) Connect the test cable with fuse between the mass air flow sensor.
12 V power supply circuit and the signal circuit
of the mass air flow sensor harness connector. • There should be no short to the battery or
6) Check the mass air flow sensor display with ignition power supply.
the trouble diagnosis scan tool. • There should be no short to the 12 V or 5 V
Voltage: 4.9 V power supply.
7) If it is at or above the standard value, inspect 5) If a problem is discovered, repair the Signal
to see if there is a contact failure with the mass circuit.
air flow sensor harness connector. 6) Inspect to see if there is an open circuit or
8) If a problem is discovered, repair the harness high resistance in the GND circuit between the
connector. ECM and the mass air flow sensor.
9) If the harness connector is normal, replace the 7) If a problem is discovered, repair the GND
mass air flow sensor. circuit.
10) Inspect the signal circuit between the ECM 8) Inspect the mass air flow sensor harness con-
and the mass air flow sensor. nector for a contact failure.
9) If a problem is discovered, repair the harness
• There should be no open circuit or high re-
connector.
sistance.
10) If the harness connector is normal, replace the
• There should be no short to GND.
mass air flow sensor.
11) If a problem is discovered, repair the Signal 11) Inspect the ECM harness connector for a con-
circuit. tact failure.
12) Inspect the ECM harness connector for a con- 12) If a problem is discovered, repair the harness
tact failure. connector.
13) If a problem is discovered, repair the harness 13) If the harness connector is normal, replace the
connector. ECM.
14) If the harness connector is normal, replace the Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ECM. Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". Installation".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 14) Set the injector ID code on the ECM.
Installation". 15) Perform the unit difference learning of the fuel
15) Set the injector ID code on the ECM. supply pump to the ECM.
16) Perform the unit difference learning of the fuel
3. DTC P0103 Confirm Resolution
supply pump to the ECM.
1) Clear the DTC using the trouble diagnosis
3. DTC P0102 Confirm Resolution
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC U0110 (Flash Code 87) Lost DTC P0112 (Flash Code 22)
Communication with VNT System Intake Air Temperature Sensor
1. DTC U0110 Priority DTC Circuit Low
DTC P0045
DTC U0001 1. DTC P0112 Priority DTC
2. DTC U0110 Diagnostics DTC P0641
2. DTC P0112 Diagnostics
1) Turn OFF the starter switch.
2) Remove the harness connector from the turbo 1) Turn OFF the starter switch.
control unit. 2) Disconnect the harness connector from the
3) Turn ON the starter switch. intake air temperature sensor.
4) Measure the voltage between the CAN-High 3) Check the intake air temperature sensor dis-
circuit and GND of the turbo control unit har- play with the trouble diagnosis scan tool.
ness connector. Voltage: 4.5 V
5) Measure the voltage between the CAN-High 4) If it is at or above the standard value, replace
circuit and GND of the turbo control unit har- the intake air temperature sensor.
ness connector. 5) Inspect to see if there is a short circuit to the
Voltage: 1.5 - 3.5 V GND with the signal circuit between the ECM
6) If it is outside the standard range, inspect to and the intake air temperature sensor.
see if there is an open circuit or high resis- 6) If a problem is discovered, repair the signal
tance with the CAN-High circuit between the circuit.
turbo control unit and the ECM. 7) Turn OFF the starter switch.
7) If a problem is discovered, repair the CAN- 8) Disconnect the harness connector from the
High circuit. ECM.
8) Inspect to see if there is an open circuit or high 9) Inspect the ECM harness connector for a con-
resistance with the CAN-Low circuit between tact failure.
the turbo control unit and the ECM. 10) If a problem is discovered, repair the harness
9) If a problem is discovered, repair the CAN- connector.
Low circuit. 11) If the harness connector is normal, replace the
10) Inspect the turbo control unit harness connec- ECM.
tor for a contact failure. Refer to "1.Engine 1J.Electrical(4HK1) ECM
11) If a problem is discovered, repair the harness Removal".
connector. Refer to "1.Engine 1J.Electrical(4HK1) ECM
12) Replace the turbo control unit. Installation".
12) Set the injector ID code on the ECM.
3. DTC U0110 Confirm Resolution 13) Perform the unit difference learning of the fuel
supply pump to the ECM.
1) Clear the DTC using the trouble diagnosis
scan tool. 3. DTC P0112 Confirm Resolution
2) Turn the starter switch OFF for 30 seconds or
longer. 1) Clear the DTC using the trouble diagnosis
3) Start the engine. scan tool.
4) Perform a test-run. 2) Turn the starter switch OFF for 30 seconds or
5) Use the trouble diagnosis scan tool to confirm longer.
that a DTC has not been detected. 3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0113 (Flash Code 22) 15) Check the intake air temperature sensor dis-
play with the trouble diagnosis scan tool.
Intake Air Temperature Sensor Voltage: 0.1 V
Circuit High 16) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
1. DTC P0113 Priority DTC tance with the GND circuit between the ECM
DTC P0641 and the intake air temperature sensor.
2. DTC P0113 Diagnostics
ANNOTATION:
1) Turn OFF the starter switch.
• The intake air temperature sensor shares
2) Disconnect the harness connector from the
the GND circuit with other sensors.
intake air temperature sensor.
• The DTC set on a sensor which shares this
3) Turn ON the starter switch.
circuit may be detected.
4) Measure the voltage between the intake air
temperature sensor signal circuit and a nor- 17) If a problem is discovered, repair the GND
mal GND. circuit.
Voltage: 5.5 V 18) Inspect to see if there is an open circuit or
5) If it is at or above the standard value, inspect high resistance in the signal circuit between
the signal circuit between the ECM and the the ECM and the intake air temperature sen-
intake air temperature sensor. sor.
19) If a problem is discovered, repair the signal
• There should be no short to the battery or circuit.
ignition power supply
20) Inspect the ECM harness connector for a con-
• There should be no short to the 12 V power tact failure.
supply.
21) If a problem is discovered, repair the harness
6) If a problem is discovered, repair the signal connector.
circuit. 22) If the harness connector is normal, replace the
7) Connect the test cable with fuse between the ECM.
intake air temperature sensor signal circuit Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and the GND circuit. Removal".
8) Check the intake air temperature sensor dis- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
play with the trouble diagnosis scan tool. Installation".
Voltage: 0.1 V 23) Set the injector ID code on the ECM.
9) If it is at or below the standard value, inspect to 24) Perform the unit difference learning of the fuel
see if there is a short circuit to the 5 V power supply pump to the ECM.
supply circuit with the signal circuit between
3. DTC P0113 Confirm Resolution
the ECM and the intake air temperature sen-
sor. 1) Clear the DTC using the trouble diagnosis
10) If a problem is discovered, repair the signal scan tool.
circuit. 2) Turn the starter switch OFF for 30 seconds or
11) Inspect the intake air temperature sensor har- longer.
ness connector for a contact failure. 3) Start the engine.
12) If a problem is discovered, repair the harness 4) Perform a test-run.
connector. 5) Use the trouble diagnosis scan tool to confirm
13) If the harness connector is normal, replace the that a DTC has not been detected.
intake air temperature sensor.
14) Connect the test cable with fuse between the
intake air temperature sensor signal circuit
and a normal GND.
DTC P0117 (Flash Code 23) DTC P0118 (Flash Code 23)
Engine Coolant Temperature Engine Coolant Temperature
Sensor Circuit Low Sensor Circuit High
1. DTC P0117 Priority DTC 1. DTC P0118 Priority DTC
DTC P0697 DTC P0697
2. DTC P0117 Diagnostics 2. DTC P0118 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
water temperature sensor. water temperature sensor.
3) Check the coolant temperature sensor display 3) Turn ON the starter switch.
with the trouble diagnosis scan tool. 4) Measure the voltage between the water tem-
Voltage: 4.5 V perature sensor signal circuit and normal
4) If it is at or above the standard value, replace GND.
the water temperature sensor. Voltage: 5.5 V
Refer to "1.Engine 1D.Cooling(4HK1X) En- 5) If it is at or above the standard value, inspect
gine coolant temperature sensor Removal". to see if there is a short circuit to the battery
Refer to "1.Engine 1D.Cooling(4HK1X) En- or ignition power supply with the signal circuit
gine coolant temperature sensor Installation". between the ECM and the water temperature
5) Inspect to see if there is a short circuit to the sensor.
GND with the signal circuit between the ECM 6) If a problem is discovered, repair the signal
and water temperature sensor. circuit.
6) If a problem is discovered, repair the signal 7) Connect the test cable with fuse between the
circuit. water temperature sensor signal Circuit and
7) Inspect the ECM harness connector for a con- GND circuit.
tact failure. 8) Check the coolant temperature sensor display
8) If a problem is discovered, repair the harness with the trouble diagnosis scan tool.
connector. Voltage: 0.1 V
9) If the harness connector is normal, replace the 9) If it is at or below the standard value, inspect to
ECM. see if there is a short circuit to the 5 V power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM supply circuit with the signal circuit between
Removal". the ECM and the water temperature sensor.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 10) If a problem is discovered, repair the signal
Installation". circuit.
10) Set the injector ID code on the ECM. 11) Inspect to see if there is a contact failure with
11) Perform the unit difference learning of the fuel the water temperature sensor harness con-
supply pump to the ECM. nector.
12) If a problem is discovered, repair the harness
3. DTC P0117 Confirm Resolution connector.
1) Clear the DTC using the trouble diagnosis 13) If the harness connector is normal, replace the
scan tool. water temperature sensor.
2) Turn the starter switch OFF for 30 seconds or Refer to "1.Engine 1D.Cooling(4HK1X) En-
longer. gine coolant temperature sensor Removal".
3) Start the engine. Refer to "1.Engine 1D.Cooling(4HK1X) En-
4) Perform a test-run. gine coolant temperature sensor Installation".
5) Use the trouble diagnosis scan tool to confirm 14) Connect the test cable with fuse between the
that a DTC has not been detected. water temperature sensor signal circuit and
normal GND.
15) Check the coolant temperature sensor display
with the trouble diagnosis scan tool.
Voltage: 0.1 V
16) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
tance with the water temperature sensor GND
circuit.
ANNOTATION:
• The water temperature sensor shares the
GND circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
17) If a problem is discovered, repair the GND
circuit.
84402826 - May 2011
4023G-20
Engine-side Trouble
18) Inspect to see if there is a breakage or high re- DTC P0122 (Flash Code 43)
sistance in the signal circuit of the water tem-
perature sensor. Throttle Position Sensor Circuit
19) If a problem is discovered, repair the signal
circuit.
Low
20) Inspect the ECM harness connector for a con- 1. DTC P0122 Priority DTC
tact failure. DTC P1655
21) If a problem is discovered, repair the harness 2. DTC P0122 Diagnostics
connector.
22) If the harness connector is normal, replace the 1) Turn OFF the starter switch.
ECM. 2) Disconnect the harness connector from the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM intake throttle valve.
Removal". 3) Turn ON the starter switch.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 4) Measure the voltage between the intake throt-
Installation". tle position sensor 5 V power supply circuit
23) Set the injector ID code on the ECM. and a normal GND.
24) Perform the unit difference learning of the fuel Voltage: 4.9 V
supply pump to the ECM. 5) If it is at or below the standard value, inspect
to see if there is an open circuit or high re-
3. DTC P0118 Confirm Resolution sistance with the 5 V power supply circuit be-
tween the ECM and the intake throttle position
1) Clear the DTC using the trouble diagnosis
sensor.
scan tool.
2) Turn the starter switch OFF for 30 seconds or ANNOTATION:
longer.
3) Start the engine. • The intake throttle position sensor shares
4) Perform a test-run. the 5 V power supply circuit with other sen-
5) Use the trouble diagnosis scan tool to confirm sors.
that a DTC has not been detected. • The DTC set on a sensor which shares this
circuit may be detected.
6) If a problem is discovered, repair the 5 V
power supply circuit.
7) Connect the test cable with fuse between the
intake throttle position sensor 5 V power sup-
ply circuit and the signal circuit.
8) Check the intake throttle position sensor dis-
play with the trouble diagnosis scan tool.
Voltage: 4.9 V
9) If it is at or above the standard value, inspect
to see if there is a contact failure with the in-
take throttle valve harness connector.
10) If a problem is discovered, repair the harness
connector.
11) If the harness connector is normal, replace the
intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Installation".
12) Inspect the signal circuit between the ECM
and intake throttle position sensor.
• There should be no open circuit or high re-
sistance.
• There should be no short to GND.
13) If a problem is discovered, repair the signal
circuit.
14) Inspect the ECM harness connector for a con-
tact failure.
15) If a problem is discovered, repair the harness
connector.
16) If the harness connector is normal, replace the DTC P0123 (Flash Code 43)
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Throttle Position Sensor Circuit
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
High
Installation". 1. DTC P0123 Priority DTC
17) Set the injector ID code on the ECM. DTC P1655
18) Perform the unit difference learning of the fuel 2. DTC P0123 Diagnostics
supply pump to the ECM.
1) Turn OFF the starter switch.
3. DTC P0122 Confirm Resolution 2) Disconnect the harness connector from the
intake throttle valve.
1) Clear the DTC using the trouble diagnosis
3) Check the intake throttle position sensor dis-
scan tool.
play with the trouble diagnosis scan tool.
2) Turn the starter switch OFF for 30 seconds or
Voltage: 0.1 V
longer.
4) If it is at or above the standard value, inspect
3) Start the engine.
the signal circuit between the ECM and the
4) Perform a test-run.
intake throttle position sensor.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected. • There should be no short to the battery or
ignition power supply.
• There should be no short to the 5 V power
supply.
5) If a problem is discovered, repair the signal
circuit.
6) Inspect the intake throttle valve harness con-
nector for a contact failure.
7) If a problem is discovered, repair the harness
connector.
8) If the harness connector is normal, replace the
intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Installation".
9) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the intake throttle position sensor.
ANNOTATION:
• The intake throttle position sensor shares
the GND circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
10) If a problem is discovered, repair the GND
circuit.
11) Check the ECM harness connector for a con-
tact failure.
12) If a problem is discovered, repair the harness
connector.
13) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
14) Set the injector ID code on the ECM.
15) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0123 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or DTC P0182 (Flash Code 211) Fuel
longer.
3) Start the engine. Temperature Sensor Circuit Low
4) Perform a test-run.
1. DTC P0182 Priority DTC
5) Use the trouble diagnosis scan tool to confirm
DTC P1655
that a DTC has not been detected.
2. DTC P0182 Diagnostics
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the
fuel temperature sensor.
3) Check the fuel temperature sensor display
with the trouble diagnosis scan tool.
Voltage: 4.5 V
4) If it is at or above the standard value, replace
the fuel temperature sensor.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Installation".
ANNOTATION:
• Do not replace the fuel temperature sensor
separately.
If a problem is found, replace the fuel supply
pump.
5) Inspect to see if there is a short circuit to the
GND with the signal circuit between the ECM
and fuel temperature sensor.
6) If a problem is discovered, repair the signal
circuit.
7) Inspect the ECM harness connector for a con-
tact failure.
8) If a problem is discovered, repair the harness
connector.
9) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0182 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0183 (Flash Code 211) Fuel 14) Connect the test cable with fuse between the
fuel temperature sensor signal circuit and nor-
Temperature Sensor Circuit High mal GND.
15) Check the fuel temperature sensor display
1. DTC P0183 Priority DTC
with the trouble diagnosis scan tool.
DTC P1655
Voltage: 0.1 V
2. DTC P0183 Diagnostics
16) If it is at or below the standard value, inspect
1) Turn OFF the starter switch. to see if there is an open circuit or high resis-
2) Disconnect the harness connector from the tance with the GND circuit between the ECM
fuel temperature sensor. and fuel temperature sensor.
3) Turn ON the starter switch.
ANNOTATION:
4) Measure the voltage between the fuel temper-
ature sensor signal circuit and normal GND. • The fuel temperature sensor shares the
Voltage: 5.5 V GND circuit with other sensors.
5) If it is at or above the standard value, inspect • The DTC set on a sensor which shares this
to see if there is a short circuit to the battery circuit may be detected.
or ignition power supply with the signal circuit
between the ECM and the fuel temperature 17) If a problem is discovered, repair the GND
sensor. circuit.
6) If a problem is discovered, repair the signal 18) Inspect to see if there is an open circuit or
circuit. high resistance in the signal circuit between
7) Connect the test cable with fuse between the ECM and the fuel temperature sensor.
the fuel temperature sensor signal circuit and 19) If a problem is discovered, repair the signal
GND circuit. circuit.
8) Check the fuel temperature sensor display 20) Inspect the ECM harness connector for a con-
with the trouble diagnosis scan tool. tact failure.
Voltage: 0.1 V 21) If a problem is discovered, repair the harness
9) If it is at or below the standard value, inspect to connector.
see if there is a short circuit to the 5 V power 22) If the harness connector is normal, replace the
supply circuit with the signal circuit between ECM.
the ECM and the fuel temperature sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
10) If a problem is discovered, repair the signal Removal".
circuit. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
11) Inspect to see if there is a contact failure with Installation".
the fuel temperature sensor harness connec- 23) Set the injector ID code on the ECM.
tor. 24) Perform the unit difference learning of the fuel
12) If a problem is discovered, repair the harness supply pump to the ECM.
connector. 3. DTC P0183 Confirm Resolution
13) If the harness connector is normal, replace the
fuel temperature sensor. 1) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1C.Fuel System(4HK1X) scan tool.
Fuel supply pump Removal". 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1C.Fuel System(4HK1X) longer.
Fuel supply pump Installation". 3) Start the engine.
4) Perform a test-run.
ANNOTATION:
ANNOTATION:
• Do not replace the fuel temperature sensor
separately. • Run the engine for 3 minutes or longer.
If a problem is found, replace the fuel supply 5) Use the trouble diagnosis scan tool to confirm
pump. that a DTC has not been detected.
DTC P0192 (Flash Code 245) Fuel 10) Inspect to see if there is an open circuit or high
resistance with the 5 V power supply circuit
Rail Pressure Sensor Circuit Low between the ECM and fuel pressure sensor.
1. DTC P0192 Priority DTC ANNOTATION:
DTC P0641
2. DTC P0192 Diagnostics • The fuel pressure sensor shares the 5 V
power supply circuit with other sensors.
1) Turn OFF the starter switch. • The DTC set on a sensor which shares this
2) Disconnect the harness connector from the circuit may be detected.
fuel pressure sensor.
3) Check the fuel rail pressure sensor display 11) If a problem is discovered, repair the 5 V
with the trouble diagnosis scan tool. power supply circuit.
Voltage: 4.5 V 12) Inspect the ECM harness connector for a con-
4) If it is at or below the standard value, inspect to tact failure.
see if there is a short circuit to the GND with 13) If a problem is discovered, repair the harness
the signal circuit between the ECM and the connector.
fuel pressure sensor. 14) If the harness connector is normal, replace the
5) If a problem is discovered, repair the signal ECM.
circuit. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
6) Measure the voltage between the fuel pres- Removal".
sure sensor 5 V power supply circuit and nor- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
mal GND. Installation".
Voltage: 4.5 V 15) Set the injector ID code on the ECM.
7) If it is at or above the standard value, inspect 16) Perform the unit difference learning of the fuel
to see if there is a contact failure with the fuel supply pump to the ECM.
pressure sensor harness connector. 3. DTC P0192 Confirm Resolution
8) If a problem is discovered, repair the harness
connector. 1) Clear the DTC using the trouble diagnosis
9) If the harness connector is normal, replace the scan tool.
fuel pressure sensor. 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1C.Fuel System(4HK1X) longer.
Common rail assembly Removal". 3) Start the engine.
Refer to "1.Engine 1C.Fuel System(4HK1X) 4) Perform a test-run.
Common rail assembly Installation". 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
ANNOTATION:
• Do not replace the fuel pressure sensor sep-
arately.
When a problem is found, replace the com-
mon rail assembly.
DTC P0193 (Flash Code 245) Fuel 15) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
Rail Pressure Sensor Circuit High ECM and the fuel pressure sensor.
1. DTC P0193 Priority DTC ANNOTATION:
DTC P0641
2. DTC P0193 Diagnostics • The fuel pressure sensor shares the GND
circuit with other sensors.
1) Turn OFF the starter switch. • The DTC set on a sensor which shares this
2) Disconnect the harness connector from the circuit may be detected.
fuel pressure sensor.
3) Turn ON the starter switch. 16) If a problem is discovered, repair the GND
4) Measure the voltage between the fuel pres- circuit.
sure sensor signal circuit and normal GND. 17) Inspect to see if there is an open circuit or
Voltage: 5.5 V high resistance in the signal circuit between
5) If it is at or above the standard value, inspect the ECM and the fuel pressure sensor.
to see if there is a short circuit to the battery 18) If a problem is discovered, repair the signal
or ignition power supply with the signal circuit circuit.
between the ECM and the fuel pressure sen- 19) Inspect the ECM harness connector for a con-
sor. tact failure.
6) If a problem is discovered, repair the signal 20) If a problem is discovered, repair the harness
circuit. connector.
7) Measure the voltage between the fuel pres- 21) If the harness connector is normal, replace the
sure sensor signal circuit and normal GND. ECM.
Voltage: 4.5 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) If it is at or above the standard value, inspect Removal".
to see if there is a short circuit to the 5 V power Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply circuit with the signal circuit between Installation".
the ECM and the fuel pressure sensor. 22) Set the injector ID code on the ECM.
9) If a problem is discovered, repair the signal 23) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
10) Connect the test cable with fuse between the 3. DTC P0193 Confirm Resolution
fuel pressure sensor signal circuit and GND
circuit. 1) Clear the DTC using the trouble diagnosis
11) Check the fuel rail pressure sensor display scan tool.
with the trouble diagnosis scan tool. 2) Turn the starter switch OFF for 30 seconds or
Voltage: 0.1 V longer.
12) If it is at or below the standard value, inspect 3) Start the engine.
to see if there is a contact failure with the fuel 4) Perform a test-run.
pressure sensor harness connector. 5) Use the trouble diagnosis scan tool to confirm
13) If a problem is discovered, repair the harness that a DTC has not been detected.
connector.
14) If the harness connector is normal, replace the
fuel pressure sensor.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Installation".
ANNOTATION:
• Do not replace the fuel pressure sensor sep-
arately.
When a problem is found, replace the com-
mon rail assembly.
DTC P0201 (Flash Code 271) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 1 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0201 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the first cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the first cylin- mediate connector.
der injector charge voltage circuit and normal
GND. • There should be no open circuit or high re-
sistance.
Voltage: 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 1 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the first cylinder injector circuit between the
6) If a problem is discovered, repair the control injector and the injector intermediate connec-
circuit. tor is normal, replace the first cylinder injector.
7) Measure the voltage between the solenoid Refer to "1.Engine 1C.Fuel System(4HK1X)
control circuit of the first cylinder injector and Injector Removal".
normal GND. Refer to "1.Engine 1C.Fuel System(4HK1X)
Voltage: 16.0 V Injector Installation".
8) If it is at or above the standard value, inspect 25) When the injector has been replaced, set the
to see if there is a short circuit to the battery injector ID code on the ECM.
or ignition power supply with the control circuit 26) Disconnect the harness connector from the
between the ECM and the injector harness ECM.
intermediate connector. 27) Inspect the ECM harness connector for a con-
9) If a problem is discovered, repair the control tact failure.
circuit. 28) If a problem is discovered, repair the harness
10) Measure the voltage between the solenoid connector.
control circuit of the first cylinder injector and 29) If the harness connector is normal, replace the
normal GND. ECM.
Voltage: 12.0 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
11) If it is at or below the standard value, inspect Removal".
to see if there is an open circuit or high resis- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
tance with the control circuit between the ECM Installation".
and injector harness intermediate connector. 30) Set the injector ID code on the ECM.
12) If a problem is discovered, repair the control 31) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
13) Inspect the injector harness intermediate con-
nector for a contact failure. 2. DTC P0201 Confirm Resolution
14) If a problem is discovered, repair the injector 1) Clear the DTC using the trouble diagnosis
harness intermediate connector. scan tool.
15) Remove the cylinder head cover. 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1B.Mechanical(4HK1X) longer.
Cylinder head cover Removal". 3) Start the engine.
16) Inspect the injector harness tightening nut for 4) Perform a test-run.
looseness. 5) Use the trouble diagnosis scan tool to confirm
17) If the injector harness tightening nut is loose, that a DTC has not been detected.
tighten it.
DTC P0202 (Flash Code 272) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 2 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0202 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the second cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the second mediate connector.
cylinder injector charge voltage circuit and
normal GND. • There should be no open circuit or high re-
sistance.
Voltage: 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 2 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the second cylinder injector circuit between
6) If a problem is discovered, repair the control the injector and the injector intermediate con-
circuit. nector is normal, replace the second cylinder
7) Measure the voltage between the solenoid injector.
control circuit of the second cylinder injector Refer to "1.Engine 1C.Fuel System(4HK1X)
and normal GND. Injector Removal".
Voltage: 16.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
8) If it is at or above the standard value, inspect Injector Installation".
to see if there is a short circuit to the battery 25) When the injector has been replaced, set the
or ignition power supply with the control circuit injector ID code on the ECM.
between the ECM and the injector harness 26) Disconnect the harness connector from the
intermediate connector. ECM.
9) If a problem is discovered, repair the control 27) Inspect the ECM harness connector for a con-
circuit. tact failure.
10) Measure the voltage between the solenoid 28) If a problem is discovered, repair the harness
control circuit of the second cylinder injector connector.
and normal GND. 29) If the harness connector is normal, replace the
Voltage: 12.0 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(4HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the control circuit between the ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and injector harness intermediate connector. Installation".
12) If a problem is discovered, repair the control 30) Set the injector ID code on the ECM.
circuit. 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con- supply pump to the ECM.
nector for a contact failure.
14) If a problem is discovered, repair the injector 2. DTC P0202 Confirm Resolution
harness intermediate connector. 1) Clear the DTC using the trouble diagnosis
15) Remove the cylinder head cover. scan tool.
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Turn the starter switch OFF for 30 seconds or
Cylinder head cover Removal". longer.
16) Inspect the injector harness tightening nut for 3) Start the engine.
looseness. 4) Perform a test-run.
17) If the injector harness tightening nut is loose, 5) Use the trouble diagnosis scan tool to confirm
tighten it. that a DTC has not been detected.
DTC P0203 (Flash Code 273) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 3 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0203 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the third cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the third cylin- mediate connector.
der injector charge voltage circuit and normal
GND. • There should be no open circuit or high re-
sistance.
Voltage: 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 2 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the third cylinder injector circuit between the
6) If a problem is discovered, repair the control injector and the injector intermediate connec-
circuit. tor is normal, replace the third cylinder injec-
7) Measure the voltage between the solenoid tor.
control circuit of the third cylinder injector and Refer to "1.Engine 1C.Fuel System(4HK1X)
normal GND. Injector Removal".
Voltage: 16.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
8) If it is at or above the standard value, inspect Injector Installation".
to see if there is a short circuit to the battery 25) When the injector has been replaced, set the
or ignition power supply with the control circuit injector ID code on the ECM.
between the ECM and the injector harness 26) Disconnect the harness connector from the
intermediate connector. ECM.
9) If a problem is discovered, repair the control 27) Inspect the ECM harness connector for a con-
circuit. tact failure.
10) Measure the voltage between the solenoid 28) If a problem is discovered, repair the harness
control circuit of the third cylinder injector and connector.
normal GND. 29) If the harness connector is normal, replace the
Voltage: 12.0 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(4HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the control circuit between the ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and injector harness intermediate connector. Installation".
12) If a problem is discovered, repair the control 30) Set the injector ID code on the ECM.
circuit. 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con- supply pump to the ECM.
nector for a contact failure.
14) If a problem is discovered, repair the injector 2. DTC P0203 Confirm Resolution
harness intermediate connector. 1) Clear the DTC using the trouble diagnosis
15) Remove the cylinder head cover. scan tool.
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Turn the starter switch OFF for 30 seconds or
Cylinder head cover Removal". longer.
16) Inspect the injector harness tightening nut for 3) Start the engine.
looseness. 4) Perform a test-run.
17) If the injector harness tightening nut is loose, 5) Use the trouble diagnosis scan tool to confirm
tighten it. that a DTC has not been detected.
DTC P0204 (Flash Code 274) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 4 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0204 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the fourth cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the fourth cylin- mediate connector.
der injector charge voltage circuit and normal
GND. • There should be no open circuit or high re-
sistance.
Voltage: 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 1 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the fourth cylinder injector circuit between
6) If a problem is discovered, repair the control the injector and the injector intermediate con-
circuit. nector is normal, replace the fourth cylinder
7) Measure the voltage between the solenoid injector.
control circuit of the fourth cylinder injector Refer to "1.Engine 1C.Fuel System(4HK1X)
and normal GND. Injector Removal".
Voltage: 16.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
8) If it is at or above the standard value, inspect Injector Installation".
to see if there is a short circuit to the battery 25) When the injector has been replaced, set the
or ignition power supply with the control circuit injector ID code on the ECM.
between the ECM and the injector harness 26) Disconnect the harness connector from the
intermediate connector. ECM.
9) If a problem is discovered, repair the control 27) Inspect the ECM harness connector for a con-
circuit. tact failure.
10) Measure the voltage between the solenoid 28) If a problem is discovered, repair the harness
control circuit of the third cylinder injector and connector.
normal GND. 29) If the harness connector is normal, replace the
Voltage: 12.0 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(4HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the control circuit between the ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and injector harness intermediate connector. Installation".
12) If a problem is discovered, repair the control 30) Set the injector ID code on the ECM.
circuit. 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con- supply pump to the ECM.
nector for a contact failure.
14) If a problem is discovered, repair the injector 2. DTC P0204 Confirm Resolution
harness intermediate connector. 1) Clear the DTC using the trouble diagnosis
15) Remove the cylinder head cover. scan tool.
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Turn the starter switch OFF for 30 seconds or
Cylinder head cover Removal". longer.
16) Inspect the injector harness tightening nut for 3) Start the engine.
looseness. 4) Perform a test-run.
17) If the injector harness tightening nut is loose, 5) Use the trouble diagnosis scan tool to confirm
tighten it. that a DTC has not been detected.
DTC P0237 (Flash Code 32) Turbo 11) If the harness connector is normal, replace the
boost sensor.
Charger Boost Sensor Circuit Low Refer to "1.Engine 1F.Induction(4HK1X)
Boost sensor Removal".
1. DTC P0237 Priority DTC
Refer to "1.Engine 1F.Induction(4HK1X)
DTC P1655
Boost sensor Installation".
2. DTC P0237 Diagnostics
12) Inspect the signal circuit between the ECM
1) Turn OFF the starter switch. and the boost sensor.
2) Disconnect the harness connector from the
boost sensor. • There should be no open circuit or high re-
sistance.
3) Turn ON the starter switch.
4) Measure the voltage between the 5 V power • There should be no short to GND.
supply circuit of the boost sensor harness con- 13) If a problem is discovered, repair the signal
nector and a normal GND. circuit.
Voltage: 4.5 V 14) Inspect the ECM harness connector for a con-
5) If it is at or below the standard value, inspect tact failure.
to see if there is an open circuit or high re- 15) If a problem is discovered, repair the harness
sistance with the 5 V power supply circuit be- connector.
tween the ECM and the boost sensor. 16) If the harness connector is normal, replace the
ECM.
ANNOTATION:
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• The boost sensor shares the 5 V power sup- Removal".
ply circuit with other sensors. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• The DTC set on a sensor which shares this Installation".
circuit may be detected. 17) Set the injector ID code on the ECM.
18) Perform the unit difference learning of the fuel
6) If a problem is discovered, repair the 5 V supply pump to the ECM.
power supply circuit.
7) Connect the test cable with fuse between the 3. DTC P0237 Confirm Resolution
5 V power supply circuit and the signal circuit
1) Clear the DTC using the trouble diagnosis
of the boost sensor harness connector.
scan tool.
8) Check the boost pressure sensor display with
2) Turn the starter switch OFF for 30 seconds or
the trouble diagnosis scan tool.
longer.
Voltage: 4.5 V
3) Start the engine.
9) If it is at or above the standard value, inspect
4) Perform a test-run.
to see if there is a contact failure with the boost
5) Use the trouble diagnosis scan tool to confirm
sensor harness connector.
that a DTC has not been detected.
10) If a problem is discovered, repair the harness
connector.
DTC P0238 (Flash Code 32) Turbo 8) Inspect the boost sensor harness connector
for a contact failure.
Charger Boost Sensor Circuit High 9) If a problem is discovered, repair the harness
connector.
1. DTC P0238 Priority DTC
10) If the harness connector is normal, replace the
DTC P1655
boost sensor.
2. DTC P0238 Diagnostics
Refer to "1.Engine 1F.Induction(4HK1X)
1) Turn OFF the starter switch. Boost sensor Removal".
2) Disconnect the harness connector from the Refer to "1.Engine 1F.Induction(4HK1X)
boost sensor. Boost sensor Installation".
3) Check the boost pressure sensor display with 11) Inspect the ECM harness connector for a con-
the trouble diagnosis scan tool. tact failure.
Voltage: 0.1 V 12) If a problem is discovered, repair the harness
4) If it is at or above the standard value, inspect connector.
the signal circuit between the ECM and the 13) If the harness connector is normal, replace the
boost sensor. ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• There should be no short to the battery or Removal".
ignition power supply. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• There should be no short to the 5 V power Installation".
supply. 14) Set the injector ID code on the ECM.
5) If a problem is discovered, repair the signal 15) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
6) Inspect to see if there is an open circuit or 3. DTC P0238 Confirm Resolution
high resistance in the GND circuit between the
ECM and the boost sensor. 1) Clear the DTC using the trouble diagnosis
scan tool.
ANNOTATION: 2) Turn the starter switch OFF for 30 seconds or
• The boost sensor shares the GND circuit longer.
with other sensors. 3) Start the engine.
4) Perform a test-run.
• The DTC set on a sensor which shares this 5) Use the trouble diagnosis scan tool to confirm
circuit may be detected. that a DTC has not been detected.
7) If a problem is discovered, repair the GND
circuit.
DTC P0336 (Flash Code 15) DTC P0340 (Flash Code 14)
Crankshaft Position Sensor Circuit Camshaft Position Sensor Circuit
Range/Performance 1. DTC P0340 Priority DTC
DTC P0601
1. DTC P0336 Priority DTC DTC P0651
DTC P0335 2. DTC P0340 Diagnostics
DTC P0340
DTC P0641 1) Turn OFF the starter switch.
2. DTC P0336 Diagnostics 2) Disconnect the harness connector from the
camshaft position sensor.
1) Inspect the crankshaft position sensor circuit. 3) Turn ON the starter switch.
• There should be enough clearing from the 4) Measure the voltage between the 5 V
wiring or component of the fuel injection power supply circuit and normal GND of the
unit. camshaft position sensor harness connector.
• There should be enough clearing from addi- voltage: 4.5 V
tionally installed electronic components. 5) If it is at or below the standard value, inspect
• There should be enough clearing from the to see if there is an open circuit or high re-
solenoids and relays. sistance with the 5 V power supply circuit be-
tween the ECM and the camshaft position
2) If a problem is discovered, repair the crank- sensor.
shaft position sensor circuit. 6) If a problem is discovered, repair the 5 V
3) Turn OFF the starter switch. power supply circuit.
4) Disconnect the harness connector from the 7) Measure the voltage between the signal cir-
ECM. cuit and normal GND of the camshaft position
5) Inspect the ECM harness connector for a con- sensor harness connector.
tact failure. voltage: 5.5 V
6) If a problem is discovered, repair the harness 8) If it is at or above the standard value, inspect
connector. to see if there is a short circuit to the battery
7) Disconnect the harness connector from the or ignition power supply with the signal circuit
crankshaft position sensor. between the ECM and the camshaft position
8) Inspect the crankshaft position sensor har- sensor.
ness connector for a contact failure. 9) If a problem is discovered, repair the signal
9) If a problem is discovered, repair the harness circuit.
connector. 10) Measure the voltage between the signal cir-
10) Inspect the CKP sensor. cuit of the camshaft position sensor harness
Refer to "1.Engine 1B.Mechanical(4HK1X) connector and a
CKP sensor Inspection". normal GND again.
11) If a problem is discovered, replace the crank- voltage: 4.5 V
shaft position sensor. 11) If it is at or below the standard value, inspect
Refer to "1.Engine 1B.Mechanical(4HK1X) the signal circuit between the ECM and the
CKP sensor Removal". camshaft position sensor.
Refer to "1.Engine 1B.Mechanical(4HK1X)
CKP sensor Installation". • There should be no open circuit or high re-
sistance.
3. DTC P0336 Confirm Resolution • There should be no short to GND.
1) Clear the DTC using the trouble diagnosis 12) If a problem is discovered, repair the signal
scan tool. circuit.
2) Turn the starter switch OFF for 30 seconds or 13) Connect the test light between the signal cir-
longer. cuit and normal GND of the camshaft position
3) Start the engine. sensor harness connector.
4) Perform a test-run. 14) Measure the voltage between the probe of the
5) Use the trouble diagnosis scan tool to confirm test light and a normal GND.
that a DTC has not been detected. voltage: 4.5 V
15) If it is at or above the standard value, inspect
to see if there is a short circuit to the 5 V power
supply circuit with the signal circuit between
the ECM and the camshaft position sensor.
16) If a problem is discovered, repair the signal
circuit.
17) Measure the voltage between the 5 V power
supply circuit and GND circuit of the camshaft
position sensor harness connector.
voltage: 4.5 V
18) If it is at or above the standard value, inspect DTC P0404 (Flash Code 45)
to see if there is a contact failure with the
camshaft position sensor harness connector. Exhaust Gas Recirculation Control
19) If a problem is discovered, repair the harness
connector.
Circuit Range/Performance
20) If the harness connector is normal, inspect the 1. DTC P0404 Priority DTC
camshaft position sensor. DTC P0409
Refer to "1.Engine 1B.Mechanical(4HK1X) 2. DTC P0404 Diagnostics
CMP sensor Inspection".
21) If a problem is discovered, replace the 1) Remove the EGR valve assembly from the
camshaft position sensor. engine.
Refer to "1.Engine 1B.Mechanical(4HK1X) Refer to "1.Engine 1H.Aux. Emission Control
CMP sensor Removal". Devices(4HK1X) EGR valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Inspect the EGR valve.
CMP sensor Installation". • There should be nothing to limit flow inside
22) Inspect the camshaft gear. the EGR valve.
• The camshaft gear should not be damaged • There should be no excessive accumulates
• The camshaft gear should be installed cor- inside the EGR valve.
rectly. • There should be no bending with the valve
shaft or valve itself inside the EGR valve.
23) If a problem is discovered, repair the camshaft
gear. 3) Turn OFF the starter switch.
24) Inspect the GND circuit between the ECM and 4) Disconnect the harness connector from the
the camshaft position sensor for an open cir- EGR valve.
cuit and high resistance. 5) Inspect the EGR valve harness connector for
a contact failure.
ANNOTATION: 6) If a problem is discovered, repair the harness
connector.
• The camshaft position sensor shares the
7) Disconnect the harness connector from the
GND circuit with other sensors.
ECM.
• The DTC set on a sensor which shares this
8) Inspect the ECM harness connector for a con-
circuit may be detected.
tact failure.
25) If a problem is discovered, repair the GND 9) If a problem is discovered, repair the harness
circuit. connector.
26) Inspect the ECM harness connector for a con- 10) Inspect to see if there is an open circuit or high
tact failure. resistance in the EGR control circuit.
27) If a problem is discovered, repair the harness 11) If a problem is discovered, repair the EGR
connector. control circuit.
28) If the harness connector is normal, replace the 12) Inspect the EGR solenoid circuit between the
ECM. ECM and EGR valve.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". • There should be no short to GND.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM • There should be no short to the battery or
ignition power supply circuit.
Installation".
29) Set the injector ID code on the ECM. • There should be no short between the cir-
cuits.
30) Perform the unit difference learning of the fuel
supply pump to the ECM. • There should be no short to EGR position
sensor circuit.
3. DTC P0340 Confirm Resolution
13) If a problem is discovered, repair the EGR
1) Clear the DTC using the trouble diagnosis solenoid circuit.
scan tool. 14) If the EGR solenoid circuit is normal, replace
2) Turn the starter switch OFF for 30 seconds or the EGR valve.
longer. Refer to "1.Engine 1H.Aux. Emission Control
3) Start the engine. Devices(4HK1X) EGR valve Removal".
4) Perform a test-run. Refer to "1.Engine 1H.Aux. Emission Control
5) Use the trouble diagnosis scan tool to confirm Devices(4HK1X) EGR valve Installation".
that a DTC has not been detected. 15) Restore the actual unit.
16) Turn ON the starter switch.
17) Clear the DTC using the trouble diagnosis
scan tool.
18) Turn the starter switch OFF for 30 seconds or
longer.
19) Start the engine.
20) Perform a test-run.
21) Check the DTC using the trouble diagnosis DTC P0409 (Flash Code 44)
scan tool.
22) If the DTC P0404 has been detected, replace Exhaust Gas Recirculation Sensor
the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Circuit
Removal". 1. DTC P0409 Priority DTC
Refer to "1.Engine 1J.Electrical(4HK1X) ECM DTC P1655
Installation". 2. DTC P0409 Diagnostics
23) Set the injector ID code on the ECM.
24) Perform the unit difference learning of the fuel 1) Turn OFF the starter switch.
supply pump to the ECM. 2) Disconnect the harness connector from the
EGR valve.
3. DTC P0404 Confirm Resolution 3) Turn ON the starter switch.
4) Use the trouble diagnosis scan tool to check
1) Clear the DTC using the trouble diagnosis
if any of the EGR position 1, EGR position 2,
scan tool.
and EGR position 3 shows ON.
2) Turn the starter switch OFF for 30 seconds or
5) If there is a data display showing ON, inspect
longer.
the signal circuit between the ECM and EGR
3) Start the engine.
valve of the EGR showing ON.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm • There should be no short to the battery or
that a DTC has not been detected. ignition power supply.
• There should be no short to the 5 V power
supply.
6) If a problem is discovered, repair the signal
circuit.
7) Measure the voltage between the EGR posi-
tion sensor 5 V power supply circuit and a nor-
mal GND.
Voltage: 4.5 V
8) If it is at or below the standard value, inspect
to see if there is an open circuit or high re-
sistance with the 5 V power supply circuit be-
tween the ECM and the EGR position sensor.
ANNOTATION:
• The EGR position sensor shares the 5 V
power supply circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
9) If a problem is discovered, repair the 5 V
power supply circuit.
10) Measure the voltage between the EGR posi-
tion sensor 5 V power supply circuit and the
GND circuit.
voltage: 4.5 V
11) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
tance with the GND circuit between the ECM
and EGR position sensor.
ANNOTATION:
• The EGR position sensor shares the GND
circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
12) If a problem is discovered, repair the GND
circuit.
13) While momentarily disconnecting the test ca-
ble with fuse from the EGR position sensor
1 signal circuit and 5 V power supply circuit,
check the EGR position 1 display with the
trouble diagnosis scan tool.
14) While momentarily disconnecting the test ca- DTC P0426 (Flash Code 143)
ble with fuse from the EGR position sensor
2 signal circuit and 5 V power supply circuit, Catalyst Temperature Sensor
check the EGR position 2 display with the
trouble diagnosis scan tool.
Circuit Range/Performance
15) While momentarily disconnecting the test ca- Sensor 1
ble with fuse from the EGR position sensor
3 signal circuit and 5 V power supply circuit, 1. DTC P0426 Priority DTC
check the EGR position 3 display with the DTC P0093
trouble diagnosis scan tool. DTC P0427
16) Check to see if there is a data display which DTC P1093
does not display ON when the EGR position 2. DTC P0426 Diagnostics
sensor signal circuit and 5 V power supply 1) Inspect the exhaust gas temperature sensor
circuit are shorted. 1.
17) If there is a data display which does not dis- Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
play ON, inspect the EGR position sensor cir- haust gas temperature sensor Inspection".
cuit which does not display ON. 2) If a problem is discovered, replace the ex-
• There should be no open circuit or high re- haust gas temperature sensor 1.
sistance between ECM and EGR position Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
sensor. haust gas temperature sensor Removal".
• There should be no short to GND between Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
ECM and EGR position sensor. haust gas temperature sensor Installation".
3) Inspect the DPD filter for a damage.
18) If a problem is discovered, repair the EGR Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
position sensor circuit. assembly Inspection".
19) Inspect the EGR valve harness connector for 4) If a problem is discovered, replace the DPD
a contact failure. filter.
20) If a problem is discovered, repair the harness Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
connector. assembly Disassembly".
21) In the EGR solenoid circuit between the ECM Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
and EGR valve, inspect to see if there is a assembly Reassembly".
short circuit with the EGR position sensor. 5) Perform the DPD regeneration data reset with
22) If a problem is discovered, repair the EGR the trouble diagnosis scan tool.
solenoid circuit.
23) If the EGR solenoid circuit is normal, replace 3. DTC P0426 Confirm Resolution
the EGR valve. 1) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1H.Aux. Emission Control scan tool.
Devices(4HK1X) EGR valve Removal". 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1H.Aux. Emission Control longer.
Devices(4HK1X) EGR valve Installation". 3) Start the engine.
24) Inspect the ECM harness connector for a con- 4) Perform a test-run.
tact failure. 5) Use the trouble diagnosis scan tool to confirm
25) If a problem is discovered, repair the harness that a DTC has not been detected.
connector.
26) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
27) Set the injector ID code on the ECM.
28) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0409 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0427 (Flash Code 48) DTC P0428 (Flash Code 48)
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Low Sensor 1 Circuit High Sensor 1
1. DTC P0427 Priority DTC 1. DTC P0428 Priority DTC
DTC P0697 DTC P0697
2. DTC P0427 Diagnostics 2. DTC P0428 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
exhaust gas temperature sensor 1. exhaust gas temperature sensor 1.
3) Check the exhaust temperature sensor (be- 3) Turn ON the starter switch.
fore the filter) display with the trouble diagno- 4) Measure the voltage between the exhaust gas
sis scan tool. temperature sensor 1 signal circuit and nor-
Voltage: 4.5 V mal GND.
4) If it is at or above the standard value, replace Voltage: 5.5 V
the exhaust gas temperature sensor 1. 5) If it is at or above the standard value, inspect
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- to see if there is a short circuit to the battery
haust gas temperature sensor Removal". or ignition power supply with the signal circuit
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- between the ECM and the exhaust gas tem-
haust gas temperature sensor Installation". perature sensor 1.
5) Inspect to see if there is a short circuit to the 6) If a problem is discovered, repair the signal
GND with the signal circuit between the ECM circuit.
and the exhaust gas temperature sensor 1. 7) Connect the test cable with fuse between the
6) If a problem is discovered, repair the signal exhaust gas temperature sensor 1 signal cir-
circuit. cuit and GND circuit.
7) Inspect the ECM harness connector for a con- 8) Check the exhaust temperature sensor (be-
tact failure. fore the filter) display with the trouble diagno-
8) If a problem is discovered, repair the harness sis scan tool.
connector. Voltage: 0.1 V
9) If the harness connector is normal, replace the 9) If it is at or below the standard value, inspect to
ECM. see if there is a short circuit to the 5 V power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM supply circuit with the signal circuit between
Removal". the ECM and the exhaust gas temperature
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sensor 1.
Installation". 10) If a problem is discovered, repair the signal
10) Set the injector ID code on the ECM. circuit.
11) Perform the unit difference learning of the fuel 11) Inspect to see if there is a contact failure with
supply pump to the ECM. the exhaust gas temperature sensor 1 har-
ness connector.
3. DTC P0427 Confirm Resolution 12) If a problem is discovered, repair the harness
1) Clear the DTC using the trouble diagnosis connector.
scan tool. 13) If the harness connector is normal, replace the
2) Turn the starter switch OFF for 30 seconds or exhaust gas temperature sensor 1.
longer. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
3) Start the engine. haust gas temperature sensor Removal".
4) Perform a test-run. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
5) Use the trouble diagnosis scan tool to confirm haust gas temperature sensor Installation".
that a DTC has not been detected. 14) Connect the test cable with fuse between the
exhaust gas temperature sensor 1 signal cir-
cuit and normal GND.
15) Check the exhaust temperature sensor (be-
fore the filter) display with the trouble diagno-
sis scan tool.
Voltage: 0.1 V
16) If it is at or above the standard value, inspect
to see if there is an open circuit or high resis-
tance with the signal circuit between the ECM
and the exhaust gas temperature sensor 1.
17) If a problem is discovered, repair the signal
circuit.
18) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the exhaust gas temperature sensor DTC P0522 (Flash Code 294) Oil
1.
Pressure Sensor Circuit Low
ANNOTATION:
1. DTC P0522 Priority DTC
• The exhaust gas temperature sensor 1 DTC P0697
shares the GND circuit with other sensors. 2. DTC P0522 Diagnostics
• The DTC may be detected on a sensor
which shares this circuit. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the oil
19) If a problem is discovered, repair the GND pressure sensor.
circuit. 3) Turn ON the starter switch.
20) Inspect the ECM harness connector for a con- 4) Measure the voltage between the 5 V power
tact failure. supply circuit and normal GND of the oil pres-
21) If a problem is discovered, repair the harness sure sensor harness connector.
connector. Voltage: 4.5 V
22) If the harness connector is normal, replace the 5) If it is at or below the standard value, inspect
ECM. to see if there is an open circuit or high re-
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sistance with the 5 V power supply circuit be-
Removal". tween the ECM and the oil pressure sensor.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 6) If a problem is discovered, repair the 5 V
Installation". power supply circuit.
23) Set the injector ID code on the ECM. 7) Connect the test cable with fuse between the
24) Perform the unit difference learning of the fuel 5 V power supply circuit and signal circuit of
supply pump to the ECM. the oil pressure sensor harness connector.
3. DTC P0428 Confirm Resolution 8) Check the oil pressure sensor display with the
trouble diagnosis scan tool.
1) Clear the DTC using the trouble diagnosis Voltage: 4.5 V
scan tool. 9) If it is at or above the standard value, inspect
2) Turn the starter switch OFF for 30 seconds or to see if there is a contact failure with the oil
longer. pressure sensor harness connector.
3) Start the engine and warm it up until the 10) If a problem is discovered, repair the harness
coolant temperature exceeds the standard connector.
value. 11) If the harness connector is normal, replace the
Specified value: 70 °C {158 °F} oil pressure sensor.
4) Repeatedly rev the engine in neutral to in- Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
crease the engine rpm while checking the ex- pressure sensor Removal".
haust temperature sensor (in front of the filter) Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
display with the trouble diagnosis scan tool. pressure sensor Installation".
5) Use the trouble diagnosis scan tool to confirm 12) Inspect the signal circuit between the ECM
that the exhaust temperature sensor (before and the oil pressure sensor.
the filter) display does not exceed the stan-
dard value. • There should be no open circuit or high re-
Voltage: 4.8 V sistance.
6) Use the trouble diagnosis scan tool to confirm • There should be no short to GND.
that a DTC has not been detected. 13) If a problem is discovered, repair the signal
circuit.
14) Inspect the ECM harness connector for a con-
tact failure.
15) If a problem is discovered, repair the harness
connector.
16) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
17) Set the injector ID code on the ECM.
18) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0522 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
84402826 - May 2011
4023G-38
Engine-side Trouble
23) If it is at or above the standard value, inspect DTC P0563 (Flash Code 35)
to see if there is a contact failure with the drop-
ping register harness connector. System Voltage High
24) If a problem is discovered, repair the harness
1. DTC P0563 Diagnostics
connector.
25) Inspect to see if there is an open circuit or 1) Check if the battery charger has been recently
high resistance in the voltage supply circuit connected to the battery.
between the ECM and the dropping register. 2) Start the engine, and idle it.
26) If a problem is discovered, repair the voltage 3) Check the ignition voltage display with the
supply circuit. trouble diagnosis scan tool.
27) Inspect the ECM harness connector for a con- Voltage: 32.0 V
tact failure. 4) If it is at or above the standard value, inspect
28) If a problem is discovered, repair the harness the charging system.
connector. Refer to "1.Engine 1J.Electrical(4HK1X) Gen-
29) If the harness connector is normal, replace the erator Reassembly".
ECM. 5) If a problem is discovered, repair the charging
Refer to "1.Engine 1J.Electrical(4HK1X) ECM system.
Removal". 6) If the charging system is normal, replace the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM ECM.
Installation". Refer to "1.Engine 1J.Electrical(4HK1X) ECM
30) Set the injector ID code on the ECM. Removal".
31) Perform the unit difference learning of the fuel Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply pump to the ECM. Installation".
7) Set the injector ID code on the ECM.
2. DTC P0560 Confirm Resolution
8) Perform the unit difference learning of the fuel
1) Clear the DTC using the trouble diagnosis supply pump to the ECM.
scan tool.
2. DTC P0563 Confirm Resolution
2) Turn the starter switch OFF for 30 seconds or
longer. 1) Clear the DTC using the trouble diagnosis
3) Start the engine. scan tool.
4) Perform a test-run. 2) Turn the starter switch OFF for 30 seconds or
5) Use the trouble diagnosis scan tool to confirm longer.
that a DTC has not been detected. 3) Start the engine, and idle it.
4) Check the ignition voltage display with the
trouble diagnosis scan tool, and confirm that
the value does not exceed the standard value.
voltage: 32.0 V
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0601 (Flash Code 53) DTC P0602 (Flash Code 154)
Internal Control Module Memory Control Module Programming
Check Sum Error Error
1. DTC P0601 Diagnostics 1. DTC P0602 Diagnostics
1) Replace the ECM. 1) Confirm that the connecting sections of all
Refer to "1.Engine 1J.Electrical(4HK1X) ECM tools are securely connected.
Removal". 2) Confirm that the programming device is oper-
Refer to "1.Engine 1J.Electrical(4HK1X) ECM ating normally.
Installation". 3) Use the trouble diagnosis scan tool to confirm
2) Set the injector ID code on the ECM. that the correct injector ID code has been en-
3) Perform the unit difference learning of the fuel tered to the ECM.
supply pump to the ECM.
ANNOTATION:
2. DTC P0601 Confirm Resolution
• When the injector ID code has been cor-
1) Clear the DTC using the trouble diagnosis rectly input, clear the DTC using the trouble
scan tool. diagnosis scan tool.
2) Turn the starter switch OFF for 30 seconds or
4) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine. longer.
5) Turn ON the starter switch.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm 6) Use the trouble diagnosis scan tool to check
that a DTC has not been detected. if a DTC has been detected.
7) If a DTC has been detected, replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
8) Set the injector ID code on the ECM.
9) Perform the unit difference learning of the fuel
supply pump to the ECM.
2. DTC P0602 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0604 (Flash Code 153) DTC P0606 (Flash Code 51)
Internal Control Module Random ECM/PCM Processor
Access Memory (RAM) Error 1. DTC P0606 Diagnostics
1. DTC P0604 Diagnostics 1) Replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
1) Replace the ECM. Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". Installation".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 2) Set the injector ID code on the ECM.
Installation". 3) Perform the unit difference learning of the fuel
2) Set the injector ID code on the ECM. supply pump to the ECM.
3) Perform the unit difference learning of the fuel
supply pump to the ECM. 2. DTC P0606 Confirm Resolution
2. DTC P0604 Confirm Resolution 1) Clear the DTC using the trouble diagnosis
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0638 (Flash Code 14) If a problem is discovered, repair the solenoid
circuit.
61) Throttle Actuator Control 15) If the solenoid circuit is normal, replace the
Range/Performance intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
1. DTC P0638 Priority DTC take throttle valve Removal".
DTC P0122 Refer to "1.Engine 1B.Mechanical(4HK1X) In-
DTC P0123 take throttle valve Installation".
2. DTC P0638 Diagnostics 16) Restore the actual unit.
17) Turn ON the starter switch.
1) Remove the air intake hose from the intake 18) Turn the starter switch OFF for 30 seconds or
throttle valve. longer.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal". ANNOTATION:
2) Inspect the intake throttle valve.
• The starter switch must be once turned ON
• The intake throttle valve flow should not be and then turned OFF before clearing the
limited. DTC.
• There should be no excessive deposit inside 19) Clear the DTC using the trouble diagnosis
the throttle bore of the intake throttle valve.
scan tool.
• There should be no bending with the butter- 20) Turn the starter switch OFF for 30 seconds or
fly valve of the intake throttle valve.
longer.
• The intake throttle valve should not be 21) Start the engine.
locked.
22) Use the trouble diagnosis scan tool to check
3) If a problem is discovered, replace the intake if a DTC has been detected.
throttle valve. 23) If a DTC has been detected, replace the ECM.
Refer to "1.Engine 1B.Mechanical(4HK1X) In- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
take throttle valve Removal". Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
take throttle valve Installation". Installation".
4) Turn OFF the starter switch. 24) Set the injector ID code on the ECM.
5) Disconnect the harness connector from the 25) Perform the unit difference learning of the fuel
intake throttle valve. supply pump to the ECM.
6) Inspect the intake throttle valve harness con-
3. DTC P0638 Confirm Resolution
nector for a contact failure.
7) If a problem is discovered, repair the harness 1) Turn ON the starter switch.
connector. 2) Turn the starter switch OFF for 30 seconds or
8) Disconnect the harness connector from the longer.
ECM.
9) Inspect the ECM harness connector for a con- ANNOTATION:
tact failure. • The starter switch must be once turned ON
10) If a problem is discovered, repair the harness and then turned OFF before clearing the
connector. DTC.
11) Inspect the intake throttle valve circuit for high
resistance. 3) Clear the DTC using the trouble diagnosis
12) Repair the circuit if a problem is discovered. scan tool.
13) Inspect the solenoid circuit between the ECM 4) Turn the starter switch OFF for 30 seconds or
and the intake throttle valve. longer.
5) Start the engine.
• There should be no short to GND. 6) Perform a test-run with the intake throttle so-
• There should be no short to the battery or lenoid drive duty of 20 % or above.
ignition power supply. 7) Use the trouble diagnosis scan tool to confirm
• There should be no short between the sole- that a DTC has not been detected.
noid circuits.
• There should be no short to intake throttle
position sensor circuit.
DTC P0641 (Flash Code 55) 18) If it is at or below the standard value, turn the
starter switch OFF.
Sensor Reference Voltage 1 19) Disconnect the harness connector from the
Circuit 20)
fuel pressure sensor.
Turn ON the starter switch.
1. DTC P0641 Diagnostics 21) Measure the voltage between the accelerator
position sensor 5 V power supply circuit and
1) Turn OFF the starter switch. GND of the accelerator position sensor har-
2) Disconnect the harness connector from the ness connector.
accelerator position sensor. Voltage: 4.5 V
3) Turn ON the starter switch. 22) If it is at or above the standard value, replace
4) Measure the voltage between the accelerator the fuel pressure sensor.
position sensor 5 V power supply circuit and Refer to "1.Engine 1C.Fuel System(4HK1X)
GND of the accelerator position sensor har- Common rail assembly Removal".
ness connector. Refer to "1.Engine 1C.Fuel System(4HK1X)
Voltage: 5.5 V Common rail assembly Installation".
5) If it is at or above the standard value, inspect
to see if there is a short circuit to the battery or ANNOTATION:
ignition power supply with the accelerator po-
• Do not replace the fuel pressure sensor sep-
sition sensor 5 V power supply circuit between
arately.
the ECM and the accelerator position sensor.
When a problem is found, replace the com-
6) If a problem is discovered, repair the acceler-
mon rail assembly.
ator position sensor 5 V power supply circuit.
7) Inspect to see if there is a short circuit to the 23) If it is at or below the standard value, inspect
battery or ignition power supply with the crank- to see if there is a short circuit to the GND with
shaft position sensor 5 V power supply circuit the accelerator position sensor 5 V power sup-
between the ECM and the crankshaft position ply circuit between the ECM and the acceler-
sensor. ator position sensor.
8) If a problem is discovered, repair the crank- 24) If a problem is discovered, repair the acceler-
shaft position sensor 5 V power supply circuit ator position sensor 5 V power supply circuit.
between the ECM and the crankshaft position 25) Inspect to see if there is a short circuit to the
sensor. GND with the crankshaft position sensor 5 V
9) Inspect to see if there is a short circuit to the power supply circuit between the ECM and the
battery or ignition power supply with the fuel crankshaft position sensor.
pressure sensor 5 V power supply circuit be- 26) If a problem is discovered, repair the crank-
tween the ECM and the fuel pressure sensor. shaft position sensor 5 V power supply circuit.
10) If a problem is discovered, repair the fuel pres- 27) Inspect to see if there is a short circuit to the
sure sensor 5 V power supply circuit. GND with the fuel pressure sensor 5 V power
11) If it is at or below the standard value, measure supply circuit between the ECM and the fuel
the voltage between the 5 V power supply cir- pressure sensor.
cuit and GND of the accelerator position sen- 28) If a problem is discovered, repair the fuel pres-
sor harness connector. sure sensor 5 V power supply circuit.
Voltage: 4.5 V 29) Replace the ECM.
12) If it is at or above the standard value, replace Refer to "1.Engine 1J.Electrical(4HK1X) ECM
the throttle accelerator switch assembly. Removal".
13) If it is at or below the standard value, turn the Refer to "1.Engine 1J.Electrical(4HK1X) ECM
starter switch OFF. Installation".
14) Disconnect the harness connector from the 30) Set the injector ID code on the ECM.
crankshaft position sensor. 31) Perform the unit difference learning of the fuel
15) Turn ON the starter switch. supply pump to the ECM.
16) Measure the voltage between the accelerator
position sensor 5 V power supply circuit and 2. DTC P0641 Confirm Resolution
GND of the accelerator position sensor har- 1) Clear the DTC using the trouble diagnosis
ness connector. scan tool.
Voltage: 4.5 V 2) Turn the starter switch OFF for 30 seconds or
17) If it is at or above the standard value, replace longer.
the crankshaft position sensor. 3) Start the engine.
Refer to "1.Engine 1B.Mechanical(4HK1X) 4) Perform a test-run.
CKP sensor Removal". 5) Use the trouble diagnosis scan tool to confirm
Refer to "1.Engine 1B.Mechanical(4HK1X) that a DTC has not been detected.
CKP sensor Installation".
DTC P0651 (Flash Code 56) 12) Disconnect the harness connector from the
atmospheric pressure sensor.
Sensor Reference Voltage 2 13) Turn ON the starter switch.
Circuit 14) Measure the voltage between the camshaft
position sensor 5 V power supply circuit and
1. DTC P0651 Diagnostics GND of the camshaft position sensor harness
connector.
1) Turn OFF the starter switch. Voltage: 4.5 V
2) Disconnect the harness connector from the 15) If it is at or above the standard value, replace
camshaft position sensor. the atmospheric pressure sensor.
3) Turn ON the starter switch. 16) If it is at or below the standard value, inspect
4) Measure the voltage between the camshaft to see if there is a short circuit to the GND with
position sensor 5 V power supply circuit and the camshaft position sensor 5 V power sup-
GND of the camshaft position sensor harness ply circuit between the ECM and the camshaft
connector. position sensor.
Voltage: 5.5 V 17) If a problem is discovered, repair the camshaft
5) If it is at or above the standard value, inspect position sensor 5 V power supply circuit.
to see if there is a short circuit to the battery or 18) Inspect to see if there is a short circuit to the
ignition power supply with the camshaft posi- GND with the atmospheric pressure sensor 5
tion sensor 5 V power supply circuit between V power supply circuit between the ECM and
the ECM and the camshaft position sensor. the atmospheric pressure sensor.
6) If a problem is discovered, repair the camshaft 19) If a problem is discovered, repair the atmo-
position sensor 5 V power supply circuit. spheric pressure sensor 5 V power supply cir-
7) Inspect to see if there is a short circuit to the cuit.
battery or ignition power supply with the atmo- 20) Replace the ECM.
spheric pressure sensor 5 V power supply cir- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
cuit between the ECM and atmospheric pres- Removal".
sure sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) If a problem is discovered, repair the atmo- Installation".
spheric pressure sensor 5 V power supply cir- 21) Set the injector ID code on the ECM.
cuit. 22) Perform the unit difference learning of the fuel
9) If it is at or below the standard value, mea- supply pump to the ECM.
sure the voltage between the camshaft posi-
tion sensor 5 V power supply circuit and GND 2. DTC P0651 Confirm Resolution
of the camshaft position sensor harness con-
1) Clear the DTC using the trouble diagnosis
nector.
scan tool.
Voltage: 4.5 V
2) Turn the starter switch OFF for 30 seconds or
10) If it is at or above the standard value, replace
longer.
the camshaft position sensor.
3) Start the engine.
Refer to "1.Engine 1B.Mechanical(4HK1X)
4) Perform a test-run.
CMP sensor Removal".
5) Use the trouble diagnosis scan tool to confirm
Refer to "1.Engine 1B.Mechanical(4HK1X)
that a DTC has not been detected.
CMP sensor Installation".
11) If it is at or below the standard value, turn the
starter switch OFF.
DTC P0685 (Flash Code 416) DTC P0687 (Flash Code 416)
ECM/PCM Power Relay Control ECM/PCM Power Relay Control
Circuit/Open Circuit High
1. DTC P0685 Diagnostics 1. DTC P0687 Diagnostics
1) Turn the starter switch OFF for 30 seconds or 1) Turn OFF the starter switch.
longer. 2) Remove the main relay.
2) Replace the main relay with a glow relay or 3) Turn ON the starter switch.
normal relay. 4) Use the trouble diagnosis scan tool to see if
3) Turn ON the starter switch. DTC P0685 is detected.
4) Use the trouble diagnosis scan tool to check 5) If the DTC P0685 is not detected, repair the
if a DTC is detected. short circuit to the battery power supply of the
5) If a DTC has not been detected, replace the power supply circuit between the ECM and
main relay. main relay.
6) Inspect the body grounding terminal for a con- 6) Turn the starter switch OFF for 30 seconds or
tact failure. longer.
7) If a problem is discovered, repair the terminal. 7) Replace the main relay with a glow relay or
8) Inspect the slow blow fuse. normal relay.
9) If a problem is discovered, replace the slow 8) Turn ON the starter switch.
blow fuse. 9) Use the trouble diagnosis scan tool to check
if DTC P0687 has been detected.
ANNOTATION:
10) If the DTC P0687 is not detected, replace the
• When the fuse is blown again, repair the main relay.
cause of slow-blow fuse meltdown.
2. DTC P0687 Confirm Resolution
10) Turn OFF the starter switch.
1) Clear the DTC using the trouble diagnosis
11) Disconnect the harness connector from the
scan tool.
ECM.
2) Turn the starter switch OFF for 30 seconds or
12) Inspect the ECM harness connector for a con-
longer.
tact failure.
3) Turn ON the starter switch.
13) If a problem is discovered, repair the harness
4) Use the trouble diagnosis scan tool to confirm
connector.
that a DTC has not been detected.
14) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
15) Set the injector ID code on the ECM.
16) Perform the unit difference learning of the fuel
supply pump to the ECM.
2. DTC P0685 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Turn ON the starter switch.
4) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P0697 (Flash Code 57) 17) If it is at or above the standard value, replace
the oil pressure sensor.
Sensor Reference Voltage 3 Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
Circuit pressure sensor Removal".
Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
1. DTC P0697 Diagnostics pressure sensor Installation".
18) If it is at or below the standard value, turn the
1) Turn OFF the starter switch. starter switch OFF.
2) Disconnect the harness connector from the 19) Disconnect the harness connector from the
DPD differential pressure sensor. fuel filter pressure sensor.
3) Turn ON the starter switch. 20) Turn ON the starter switch.
4) Measure the voltage between the DPD differ- 21) Measure the voltage between the DPD differ-
ential pressure sensor 5 V power supply cir- ential pressure sensor 5 V power supply cir-
cuit and GND of the DPD differential pressure cuit and GND of the DPD differential pressure
sensor harness connector. sensor harness connector.
Voltage: 5.5 V Voltage: 4.5 V
5) If it is at or above the standard value, inspect 22) If it is at or above the standard value, replace
to see if there is a short circuit to the battery or the fuel filter pressure sensor.
ignition power supply with the DPD differential Refer to "1.Engine 1C.Fuel System(4HK1X)
pressure sensor 5 V power supply circuit be- Fuel filter pressure sensor Removal".
tween the ECM and the DPD differential pres- Refer to "1.Engine 1C.Fuel System(4HK1X)
sure sensor. Fuel filter pressure sensor Installation".
6) If a problem is discovered, repair the DPD 23) If it is at or below the standard value, inspect
differential pressure sensor 5 V power supply to see if there is a short circuit to the GND
circuit. with the DPD differential pressure sensor 5 V
7) Inspect to see if there is a short circuit to the power supply circuit between the ECM and the
battery or ignition power supply with the oil DPD differential pressure sensor.
pressure sensor 5 V power supply circuit be- 24) If a problem is discovered, repair the DPD
tween the ECM and oil pressure sensor. differential pressure sensor 5 V power supply
8) If a problem is discovered, repair the oil pres- circuit.
sure sensor 5 V power supply circuit. 25) Inspect to see if there is a short circuit to the
9) Inspect to see if there is a short circuit to the GND with the oil pressure sensor 5 V power
battery or ignition power supply with the fuel supply circuit between the ECM and oil pres-
filter pressure sensor 5 V power supply circuit sure sensor.
between the ECM and the fuel filter pressure 26) If a problem is discovered, repair the oil pres-
sensor. sure sensor 5 V power supply circuit.
10) If a problem is discovered, repair the fuel filter 27) Inspect to see if there is a short circuit to the
pressure sensor 5 V power supply circuit. GND with the fuel filter pressure sensor 5 V
11) If it is at or below the standard value, mea- power supply circuit between the ECM and
sure the voltage between the DPD differential fuel filter pressure sensor.
pressure sensor 5 V power supply circuit and 28) If a problem is discovered, repair the fuel filter
GND of the DPD differential pressure sensor pressure sensor 5 V power supply circuit.
harness connector. 29) Replace the ECM.
Voltage: 4.5 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
12) If it is at or above the standard value, replace Removal".
the DPD differential pressure sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- Installation".
haust differential pressure sensor Removal". 30) Set the injector ID code on the ECM.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 31) Perform the unit difference learning of the fuel
haust differential pressure sensor Installa- supply pump to the ECM.
tion".
13) If it is at or below the standard value, turn the 2. DTC P0697 Confirm Resolution
starter switch OFF.
1) Clear the DTC using the trouble diagnosis
14) Disconnect the harness connector from the oil
scan tool.
pressure sensor.
2) Turn the starter switch OFF for 30 seconds or
15) Turn ON the starter switch.
longer.
16) Measure the voltage between the DPD differ-
3) Start the engine.
ential pressure sensor 5 V power supply cir-
4) Perform a test-run.
cuit and GND of the DPD differential pressure
5) Use the trouble diagnosis scan tool to confirm
sensor harness connector.
that a DTC has not been detected.
Voltage: 4.5 V
DTC P1093 (Flash Code 227) Fuel • The fuel hose between the fuel tank and the
fuel supply pump becomes negative pres-
Rail Pressure (FRP) Too Low sure state when the engine is running.
1. DTC P1093 Priority DTC • When the fuel hose is not connected se-
curely, the air can enter.
DTC P0087
DTC P0091 • When the engine RPM or the engine load
increases while the air has intruded in the
DTC P0092
fuel system, fluctuation in the common rail
DTC P0192
pressure is caused, and DTC P1093 may
DTC P0193
be detected.
DTC P0201
DTC P0202 16) Check that an appropriate clamp is used be-
DTC P0203 tween the fuel tank and the fuel supply pump.
DTC P0204 17) If a problem is discovered, replace the clamp.
DTC P2146 18) Operate the priming pump until the handle be-
DTC P2149 comes heavy.
2. DTC P1093 Diagnostics
ANNOTATION:
1) Turn OFF the starter switch.
2) Wait for the specified period of time until the • When a leak exists in the fuel system be-
fuel pressure is released from the common tween the priming pump and the fuel sup-
rail. ply pump, the pressing weight of the priming
Specified time: 2 min pump does not become heavy.
3) Turn ON the starter switch. 19) Start the engine.
4) Use the trouble diagnosis scan tool to check 20) Inspect the high-pressure side of the fuel sys-
if the fuel rail pressure sensor display is within tem and check for fuel leak between the fuel
the standard range. supply pump and common rail.
Voltage: 0.9 - 1.0 V
5) If the fuel rail pressure sensor display is out- ANNOTATION:
side the standard range, inspect the fuel pres- • The fuel may leak to the bottom section of
sure sensor harness connector for a contact the cylinder head cover from the high pres-
failure. sure hose inlet.
6) If a problem is discovered, repair the harness • The engine oil level increases when the fuel
connector. leaks to the bottom portion of the cylinder
7) Inspect the ECM harness connector for a con- head cover.
tact failure. • Inspect for fuel leaks into the engine oil.
8) If a problem is discovered, repair the harness
connector. 21) If fuel leak if found, fix the problem.
9) Inspect each circuit for high resistance. 22) Turn OFF the starter switch.
10) Repair the circuit if a problem is discovered. 23) Remove the fuel hose on the fuel supply pump
11) If the harness connector and each circuit are side from the fuel filter.
normal, replace the fuel pressure sensor. ANNOTATION:
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal". • Use a pan to catch the fuel from the re-
Refer to "1.Engine 1C.Fuel System(4HK1X) moved fuel hose.
Common rail assembly Installation". • Clean the pressure gauge and connection
hose before connecting to the fuel pipe.
ANNOTATION: • The fuel supply pump may be damaged due
• Do not replace the fuel pressure sensor sep- to foreign matter that has entered in the con-
arately. nection hose.
When a problem is found, replace the com- 24) Connect the pressure gauge between the fuel
mon rail assembly. filter and the removed fuel hose.
12) Inspect to see if there is clogging with the fuel ANNOTATION:
system between the fuel tank and the fuel sup-
ply pump. • Confirm that the fuel system is connected
13) If a problem is discovered, repair the clogging securely.
of the fuel system. 25) Remove the air using the priming pump, and
14) Inspect the fuel hose between the fuel tank crank the engine for the specified period of
and the fuel supply pump for a cut and crack. time or shorter.
15) If a problem is discovered, replace the fuel Specified time: 5 s
hose.
ANNOTATION:
ANNOTATION:
• Repeat this until the engine starts.
26) Leave the engine idling for the specified pe- 40) If a problem is discovered, replace the fuel
riod of time or longer. hose.
specified time: 1 min 41) Inspect to see if appropriate clamp is used.
27) While keeping the engine rotating at the spec- 42) If a problem is discovered, replace the clamp
ified engine RPM for the specified period of with an appropriate one.
time, check the pressure gauge. 43) Turn OFF the starter switch.
Specified time: 1 min 44) Inspect the suction control valve harness con-
Rotational speed: 2500 min-1 {2500 r/min} nector for a contact failure.
28) Check if the pressure gauge shows a negative 45) If a problem is discovered, repair the harness
pressure value at or above the standard value connector.
during inspection. 46) Inspect the ECM harness connector for a con-
Specified value: 17.0 kPa {128 mmHg / 5 tact failure.
inHg} 47) If a problem is discovered, repair the harness
connector.
ANNOTATION: 48) Inspect each circuit for high resistance.
• Fuel clogging is checked with the negative 49) Repair the circuit if a problem is discovered.
pressure amount in the fuel system. 50) If the suction control valve harness connector
and the ECM harness connector are normal
29) If the negative pressure is at or above the and there is no high resistance in each circuit,
standard value, inspect to see if there is dam- replace the fuel supply pump and the fuel filter
age or twisting element.
with the fuel system between the fuel supply Refer to "1.Engine 1C.Fuel System(4HK1X)
pump and the fuel tank. Fuel supply pump Removal".
30) If a problem is discovered, repair the fuel sys- Refer to "1.Engine 1C.Fuel System(4HK1X)
tem. Fuel supply pump Installation".
31) Inspect the fuel tank bent hose. Refer to "1.Engine 1C.Fuel System(4HK1X)
32) If a problem is discovered, repair the bent Fuel filter element Removal".
hose. Refer to "1.Engine 1C.Fuel System(4HK1X)
33) Check to see if there is any foreign matter in Fuel filter element Installation".
the fuel tank or any foreign matter which can
cause fuel clogging. ANNOTATION:
34) If a problem is discovered, repair it.
• When replacing the fuel supply pump, it is
35) Replace the fuel filter element. required to also replace the fuel filter ele-
Refer to "1.Engine 1C.Fuel System(4HK1X) ment at the same time.
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X) 51) Perform the unit difference learning of the fuel
Fuel filter element Installation". supply pump to the ECM.
36) If the negative pressure is at or below the stan- 52) If the negative pressure is normal, turn OFF
dard value, pinch the fuel hose at a position as the starter switch.
close as possible to the fuel tank, so that the 53) Restore the fuel system.
fuel does not flow. 54) Start the engine.
55) Perform the injector stop test with the trouble
ANNOTATION: diagnosis scan tool.
• The fuel pipe can be disconnected and 56) Check to see if any injector does not change
clogged with a plug. the engine RPM when OFF is instructed.
57) If any injector does not change the engine
37) Start the engine and use the idling control RPM when OFF is instructed, replace the rel-
switch to increase the RPM to the highest evant injector.
level. Refer to "1.Engine 1C.Fuel System(4HK1X)
38) Check the pressure gauge. Injector Removal".
Specified value: 27.0 kPa {203 mmHg / 8 Refer to "1.Engine 1C.Fuel System(4HK1X)
inHg} Injector Installation".
ANNOTATION: 58) When the injector has been replaced, set the
injector ID code on the ECM.
• When the pressure gauge is likely to indi- 59) If the engine RPM changes when OFF is in-
cate a value exceeding the standard value structed to all injectors, replace the pressure
during inspection, release the fuel being limiter valve.
blocked. Refer to "1.Engine 1C.Fuel System(4HK1X)
• Air mixture is checked with the negative Common rail assembly Removal".
pressure amount while the fuel flow is being Refer to "1.Engine 1C.Fuel System(4HK1X)
blocked. Common rail assembly Installation".
39) If the standard negative pressure cannot be ANNOTATION:
generated, inspect to see if there is a cut or
crack with the fuel hose.
• The pressure limiter valve may be fixed DTC P1112 (Flash Code 295)
open, or the operation pressure may de-
crease. Boost Temperature Sensor Circuit
• Do not replace the pressure limiter valve
separately. When a problem is found, re-
Low
place the common rail assembly. 1. DTC P1112 Priority DTC
DTC P0651
3. DTC P1093 Confirm Resolution
2. DTC P1112 Diagnostics
1) Clear the DTC using the trouble diagnosis
1) Turn OFF the starter switch.
scan tool.
2) Remove the harness connector from the
2) Turn the starter switch OFF for 30 seconds or
boost temperature sensor.
longer.
3) Check the boost temperature sensor display
3) Start the engine.
with the trouble diagnosis scan tool.
4) Perform a test-run.
Voltage: 4.5 V
5) Use the trouble diagnosis scan tool to confirm
4) If it is at or above the standard value, replace
that a DTC has not been detected.
the boost temperature sensor.
Refer to "1.Engine 1F.Induction(4HK1X)
Boost temperature sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1X)
Boost temperature sensor Installation".
5) Inspect to see if there is a short circuit to the
GND with the signal circuit between the ECM
and boost temperature sensor.
6) If a problem is discovered, repair the signal
circuit.
7) Inspect the ECM harness connector for a con-
tact failure.
8) If a problem is discovered, repair the harness
connector.
9) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P1112 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P1261 (Flash Code 34) DTC P1262 (Flash Code 34)
Injector Positive Voltage Control Injector Positive Voltage Control
Circuit Group 1 Circuit Group 2
1. DTC P1261 Diagnostics 1. DTC P1262 Diagnostics
1) Replace the ECM. 1) Replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation". Installation".
2) Set the injector ID code on the ECM. 2) Set the injector ID code on the ECM.
3) Perform the unit difference learning of the fuel 3) Perform the unit difference learning of the fuel
supply pump to the ECM. supply pump to the ECM.
2. DTC P1261 Confirm Resolution 2. DTC P1262 Confirm Resolution
1) Clear the DTC using the trouble diagnosis 1) Clear the DTC using the trouble diagnosis
scan tool. scan tool.
2) Turn the starter switch OFF for 30 seconds or 2) Turn the starter switch OFF for 30 seconds or
longer. longer.
3) Start the engine. 3) Start the engine.
4) Perform a test-run. 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected. that a DTC has not been detected.
DTC P1293 (Flash Code 211) Fuel 11) If the harness connector is normal, replace the
fuel filter pressure sensor.
Pressure Sensor Circuit Low Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter pressure sensor Removal".
1. DTC P1293 Priority DTC
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0697
Fuel filter pressure sensor Installation".
2. DTC P1293 Diagnostics
12) Inspect the signal circuit between the ECM
1) Turn OFF the starter switch. and the fuel filter pressure sensor.
2) Disconnect the harness connector from the
fuel filter pressure sensor. • There should be no open circuit or high re-
sistance.
3) Turn ON the starter switch.
4) Measure the voltage between the 5 V power • There should be no short to GND.
supply circuit of the fuel filter pressure sensor 13) If a problem is discovered, repair the signal
harness connector and normal GND. circuit.
Voltage: 4.5 V 14) Inspect the ECM harness connector for a con-
5) If it is at or below the standard value, inspect tact failure.
to see if there is an open circuit or high re- 15) If a problem is discovered, repair the harness
sistance with the 5 V power supply circuit be- connector.
tween the ECM and the fuel filter pressure 16) If the harness connector is normal, replace the
sensor. ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ANNOTATION:
Removal".
• The fuel filter pressure sensor shares the 5 Refer to "1.Engine 1J.Electrical(4HK1X) ECM
V power supply circuit with other sensors. Installation".
• The DTC set on a sensor which shares this 17) Set the injector ID code on the ECM.
circuit may be detected. 18) Perform the unit difference learning of the fuel
supply pump to the ECM.
6) If a problem is discovered, repair the 5 V
power supply circuit. 3. DTC P1293 Confirm Resolution
7) Connect the test cable with fuse between the
1) Clear the DTC using the trouble diagnosis
5 V power supply circuit and signal circuit of
scan tool.
the fuel filter pressure sensor harness con-
2) Turn the starter switch OFF for 30 seconds or
nector.
longer.
8) Check the fuel filter pressure sensor display
3) Start the engine.
with the trouble diagnosis scan tool.
4) Perform a test-run.
Voltage: 4.5 V
5) Use the trouble diagnosis scan tool to confirm
9) If it is at or above the standard value, inspect
that a DTC has not been detected.
to see if there is a contact failure with the fuel
filter pressure sensor harness connector.
10) If a problem is discovered, repair the harness
connector.
DTC P1294 (Flash Code 211) Fuel 8) Inspect to see if there is a contact failure with
the fuel filter pressure sensor harness con-
Pressure Sensor Circuit High nector.
9) If a problem is discovered, repair the harness
1. DTC P1294 Priority DTC
connector.
DTC P0697
10) If the harness connector is normal, replace the
2. DTC P1294 Diagnostics
fuel filter pressure sensor.
1) Turn OFF the starter switch. Refer to "1.Engine 1C.Fuel System(4HK1X)
2) Disconnect the harness connector from the Fuel filter pressure sensor Removal".
fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Check the fuel filter pressure sensor display Fuel filter pressure sensor Installation".
with the trouble diagnosis scan tool. 11) Inspect the ECM harness connector for a con-
Voltage: 0.1 V tact ailure.
4) If it is at or above the standard value, inspect 12) If a problem is discovered, repair the harness
the signal circuit between the ECM and the connector.
fuel filter pressure sensor. 13) If the harness connector is normal, replace the
ECM.
• There should be no short to the battery or Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ignition power supply. Removal".
• There should be no short to the 5 V power Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply. Installation".
5) If a problem is discovered, repair the signal 14) Set the injector ID code on the ECM.
circuit. 15) Perform the unit difference learning of the fuel
6) Inspect to see if there is an open circuit or supply pump to the ECM.
high resistance in the GND circuit between the 3. DTC P1294 Confirm Resolution
ECM and the fuel filter pressure sensor.
1) Clear the DTC using the trouble diagnosis
ANNOTATION: scan tool.
• The fuel filter pressure sensor shares the 2) Turn the starter switch OFF for 30 seconds or
GND circuit with other sensors. longer.
• The DTC set on a sensor which shares this 3) Start the engine.
circuit may be detected. 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
7) If a problem is discovered, repair the GND that a DTC has not been detected.
circuit.
DTC P1404 (Flash Code 45) 9) Inspect the ECM harness connector for a con-
tact failure.
Exhaust Gas Recirculation (EGR) 10) If a problem is discovered, repair the harness
Closed Position Performance 11)
connector.
Inspect the EGR valve circuit between the
1. DTC P1404 Priority DTC ECM and the EGR valve for an open circuit
DTC P0404 and high resistance.
DTC P0409 12) If a problem is discovered, repair the EGR
2. DTC P1404 Diagnostics valve circuit.
13) Inspect the solenoid circuit between the ECM
1) Remove the EGR valve assembly from the and EGR valve.
engine.
Refer to "1.Engine 1H.Aux. Emission Control • There should be no short to GND.
Devices(4HK1X) EGR valve Removal". • There should be no short to the battery or
2) Inspect the EGR valve. ignition power supply.
• There should be no short to other circuits.
• There should be nothing to limit flow inside • There should be no short to EGR position
the EGR valve. sensor circuit.
• There should be no excessive accumulates
inside the EGR valve. 14) If a problem is discovered, repair the solenoid
• There should be no bending with the valve circuit.
shaft or valve itself inside the EGR valve. 15) If the circuit is normal, replace the EGR valve.
Refer to "1.Engine 1H.Aux. Emission Control
3) If a problem is discovered, repair or replace Devices(4HK1X) EGR valve Removal".
the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control
Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1X) EGR valve Installation".
Devices(4HK1X) EGR valve Removal".
Refer to "1.Engine 1H.Aux. Emission Control 3. DTC P1404 Confirm Resolution
Devices(4HK1X) EGR valve Installation".
1) Clear the DTC using the trouble diagnosis
4) Turn OFF the starter switch.
scan tool.
5) Disconnect the harness connector from the
2) Turn the starter switch OFF for 30 seconds or
EGR valve.
longer.
6) Inspect the EGR valve harness connector for
3) Start the engine.
a contact failure.
4) Perform a test-run.
7) If a problem is discovered, repair the harness
5) Use the trouble diagnosis scan tool to confirm
connector.
that a DTC has not been detected.
8) Disconnect the harness connector from the
ECM.
DTC P1455 (Flash Code 132) PM 15) Use the trouble diagnosis scan tool to check if
the boost pressure and atmospheric pressure
Over Accumulation are operating properly.
16) Inspect the air cleaner element.
1. DTC P1455 Diagnostics
Refer to "1.Engine 1F.Induction(4HK1X) Air
1) Check with the operator if the DPD light has cleaner element Inspection".
blinked before. 17) If a problem is discovered, replace the air
2) If necessary, explain DPD regeneration. cleaner element.
18) Check the intake duct for a clogging, hole, and
• Check with the operator if the engine oper- leakage.
ating time was short. 19) If a problem is discovered, replace the intake
• Ckeck with the operator if the idling time was duct.
too long. 20) Inspect the intake throttle valve for fixing.
3) Inspect the DPD differential pressure sensor 21) If a problem is discovered, replace the intake
hose. throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
• There should be no incorrect piping or dis- take throttle valve Removal".
connection. Refer to "1.Engine 1B.Mechanical(4HK1X) In-
4) If a problem is discovered, repair the hose. take throttle valve Installation".
5) Inspect the DPD differential pressure sensor. 22) Inspect the turbocharger assembly.
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
• DPD differential pressure sensor unit should bocharger assembly Inspection".
not be damaged. 23) If a problem is discovered, replace the tur-
• There should be no dirt or foreign matter bocharger assembly.
blocking the DPD differential pressure sen- Refer to "1.Engine 1F.Induction(4HK1X) Tur-
sor entrance. bocharger assembly Removal".
• There should be no detection error or slow Refer to "1.Engine 1F.Induction(4HK1X) Tur-
response from the DPD differential pressure bocharger assembly Installation".
sensor. 24) Inspect the quality of fuel.
6) If a problem is discovered, replace the DPD ANNOTATION:
differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- • An appropriate fuel is used.
haust differential pressure sensor Removal". 25) Turn the starter switch ON for 30 seconds.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa- ANNOTATION:
tion".
• Do not start the engine.
7) When the DPD differential pressure sensor
• This is for the DPD differential pressure sen-
has been replaced, perform the 0-point cor- sor to relearn.
rection.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 26) Clear the DTC using the trouble diagnosis
haust differential pressure sensor Inspection". scan tool.
8) Inspect the exhaust system. 27) Perform the DPD regeneration data reset with
the trouble diagnosis scan tool.
• There should be no absence or damage of 28) Turn the starter switch OFF for 30 seconds or
the exhaust pipe gasket. longer.
• There should be no exhaust gas leak from 29) Start the engine.
the exhaust system. 30) Check the exhaust temperature (before the
• The exhaust system should not be modified. filter) display with the trouble diagnosis scan
• There should be no damage or excessive tool.
deposits on the oxidation catalyst. 31) Confirm that the exhaust temperature is at or
9) If a problem is discovered, repair or replace below the standard value.
the exhaust system. Specified value: 130 °C {266 °F}
10) Inspect the DPD assembly. 32) If it is at or above the standard value, idle the
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD engine until it falls to or below the standard
assembly Inspection". value.
11) If a problem is discovered, replace the DPD 33) Check the exhaust differential pressure dis-
assembly. play when the exhaust temperature (in front
12) If the DPD assembly has been replaced, use of the filter) display has reached the standard
the trouble diagnosis scan tool to perform value with the engine revolution increased to
DPD regeneration data reset. the maximum revolution speed without load.
13) Inspect the mass air flow sensor with the trou- Specified value: 150 °C {302 °F}
ble diagnosis scan tool.
14) If a problem is discovered, replace the mass
air flow sensor.
34) Use the trouble diagnosis scan tool to check if DTC P1471 (Flash Code 149)
the exhaust differential pressure data display
is at or below the standard value. DPD Insufficient Regeneration
Specified value: 7.5 kPa {0.08 kgf/cm2 / 1.1
1. DTC P1471 Diagnostics
psi}
35) If it is at or above the standard value, replace 1) Inspect the DPD differential pressure sensor
the DPD filter. hose.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Disassembly". • There should be no incorrect piping or dis-
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD connection.
assembly Reassembly". 2) If a problem is discovered, repair the hose.
36) If the DPD filter has been replaced, use the 3) Inspect the DPD differential pressure sensor.
trouble diagnosis scan tool to perform DPD
regeneration data reset. • DPD differential pressure sensor unit should
37) When a DTC has been detected, clear it using not be damaged.
the trouble diagnosis scan tool. • There should be no dirt or foreign matter
38) Turn the starter switch OFF for 30 seconds or blocking the DPD differential pressure sen-
longer. sor entrance.
39) Perform the DPD forced slow regeneration • There should be no detection error or slow
with the trouble diagnosis scan tool. response from the DPD differential pressure
sensor.
ANNOTATION:
4) If a problem is discovered, replace the DPD
• After the DPD forced slow regeneration is differential pressure sensor.
completed, replace the engine oil. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
40) Check the exhaust temperature (before the haust differential pressure sensor Removal".
filter) display with the trouble diagnosis scan Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
tool. haust differential pressure sensor Installa-
41) Confirm that the exhaust temperature is at or tion".
below the standard value. 5) When the DPD differential pressure sensor
Specified value: 130 °C {266 °F} has been replaced, perform the 0-point cor-
42) If it is at or above the standard value, idle the rection.
engine until it falls to or below the standard Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
value. haust differential pressure sensor Inspection".
43) Check the exhaust differential pressure dis- 6) Inspect the exhaust system.
play when the exhaust temperature (in front • There should be no absence or damage of
of the filter) display has reached the standard the exhaust pipe gasket.
value with the engine revolution increased to • There should be no exhaust gas leak from
the maximum revolution speed without load. the exhaust system.
Specified value: 150 °C {302 °F} • The exhaust system should not be modified.
44) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at 7) If a problem is discovered, repair or replace
or below the standard value. the exhaust system.
Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3 8) Inspect the exhaust gas temperature sensor.
psi} Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
45) If it is at or above the standard value, perform haust gas temperature sensor Inspection".
ash removal. 9) If a problem is discovered, replace the ex-
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD haust gas temperature sensor.
assembly Inspection". Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust gas temperature sensor Removal".
2. DTC P1455 Confirm Resolution Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
1) Turn ON the starter switch. haust gas temperature sensor Installation".
2) Use the trouble diagnosis scan tool to confirm 10) Inspect the air cleaner element.
that a DTC has not been detected. Refer to "1.Engine 1F.Induction(4HK1X) Air
cleaner element Inspection".
11) If a problem is discovered, replace the air
cleaner element.
12) Inspect the air intake system.
• There should be no crush, limited flow, or
damage of the duct between the air cleaner
and intake manifold.
• The intake system should not be modified.
• There should be no air leak with the intake
system.
13) If a problem is discovered, repair the intake 20) If the situation falls in the area C or D, use
system. the trouble diagnosis scan tool to perform the
14) Use the trouble diagnosis scan tool to inspect DPD forced slow regeneration.
the mass air flow sensor.
15) If a problem is discovered, replace the mass ANNOTATION:
air flow sensor. • When a DTC has been detected, clear it
16) Turn the starter switch ON for 30 seconds. using the trouble diagnosis scan tool.
ANNOTATION: • After the DPD forced slow regeneration is
completed, replace the engine oil.
• Do not start the engine.
21) Check the exhaust temperature (before the
• This is for the DPD differential pressure sen-
sor to relearn. filter) display with the trouble diagnosis scan
tool.
17) Start the engine. 22) Confirm that the exhaust temperature is at or
18) Use the trouble diagnosis scan tool to check below the standard value.
the DPD accumulation status and the DPD Specified value: 130 °C {266 °F}
time status, and confirm the corresponding 23) If it is at or above the standard value, idle the
area from the DPD status table. engine until it falls to or below the standard
value.
24) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum revolution speed without load.
Specified value: 150 °C {302 °F}
25) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at
DPD Ac- or below the standard value.
cumula- Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
tion Sta- psi}
tus 26) If it is at or above the standard value, perform
ash removal.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Inspection".
2. DTC P1471 Confirm Resolution
1) Turn ON the starter switch.
2) Use the trouble diagnosis scan tool to confirm
DPD Time Status that a DTC has not been detected.
DTC P1621 (Flash Code 54) DTC P1655 (Flash Code 57)
Control Module Long Term Sensor Reference Voltage Circuit
Memory Performance 1. DTC P1655 Diagnostics
1. DTC P1621 Diagnostics 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the
1) Confirm that the connecting sections of all boost sensor.
tools are securely connected. 3) Turn ON the starter switch.
2) Confirm that the programming device is oper- 4) Measure the voltage between the boost sen-
ating normally. sor 5 V power supply terminal and GND of the
3) Turn the starter switch OFF, and wait for 30 boost sensor harness connector.
seconds. Voltage: 5.5 V
4) Turn ON the starter switch. 5) If it is at or above the standard value, inspect
5) Use the trouble diagnosis scan tool to check to see if there is a short circuit to the battery or
if a DTC has been detected. ignition power supply with the boost sensor 5
6) If a DTC has been detected, replace the ECM. V power supply circuit between the ECM and
Refer to "1.Engine 1J.Electrical(4HK1X) ECM the boost sensor.
Removal". 6) If a problem is discovered, repair the boost
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sensor 5 V power supply circuit.
Installation". 7) Inspect to see if there is a short circuit to the
7) Set the injector ID code on the ECM. battery or ignition power supply with the intake
8) Perform the unit difference learning of the fuel throttle position sensor 5 V power supply cir-
supply pump to the ECM. cuit between the ECM and the intake throttle
2. DTC P1621 Confirm Resolution valve.
8) If a problem is discovered, repair the intake
1) Clear the DTC using the trouble diagnosis throttle position sensor 5 V power supply cir-
scan tool. cuit.
2) Turn the starter switch OFF for 30 seconds or 9) Inspect to see if there is a short circuit to the
longer. battery or ignition power supply with the EGR
3) Start the engine. valve position sensor 5 V power supply circuit
4) Use the trouble diagnosis scan tool to confirm between the ECM and EGR valve.
that a DTC has not been detected. 10) If a problem is discovered, repair the EGR
valve position sensor 5 V power supply circuit.
11) If it is at or below the standard value, mea-
sure the voltage between the boost sensor 5
V power supply terminal and GND of the boost
sensor harness connector.
Voltage: 4.5 V
12) If it is at or above the standard value, replace
the boost sensor.
Refer to "1.Engine 1F.Induction(4HK1X)
Boost sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1X)
Boost sensor Installation".
13) If it is at or below the standard value, turn the
starter switch OFF.
14) Remove the harness connector from the in-
take throttle valve.
15) Turn ON the starter switch.
16) Measure the voltage between the boost sen-
sor 5 V power supply terminal and GND of the
boost sensor harness connector.
Voltage: 4.5 V
17) If it is at or above the standard value, replace
the intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Installation".
18) If it is at or below the standard value, turn the
starter switch OFF.
19) Disconnect the harness connector from the
EGR valve.
20) Turn ON the starter switch.
84402826 - May 2011
4023G-60
Engine-side Trouble
21) Measure the voltage between the boost sen- DTC P1669 (Flash Code 75) DPD
sor 5 V power supply terminal and GND of the
boost sensor harness connector. Lamp Control Circuit
Voltage: 4.5 V
1. DTC P1669 Diagnostics
22) If it is at or above the standard value, replace
the EGR valve. 1) Confirm that the monitor panel operates prop-
Refer to "1.Engine 1H.Aux. Emission Control erly.
Devices(4HK1X) EGR valve Removal". 2) Turn OFF the starter switch.
Refer to "1.Engine 1H.Aux. Emission Control 3) Inspect the fuse.
Devices(4HK1X) EGR valve Installation". 4) If a problem is discovered, replace the fuse.
23) If it is at or below the standard value, inspect
to see if there is a short circuit to the GND ANNOTATION:
with the boost sensor 5 V power supply circuit • When the fuse is blown again, repair the
between the ECM and the boost sensor. cause of fuse meltdown.
24) If a problem is discovered, repair the boost
5) Turn OFF the starter switch.
sensor 5 V power supply circuit.
6) Disconnect the harness connector from the
25) Inspect to see if there is a short circuit to the
ECM.
GND with the intake throttle position sensor 5
7) Turn ON the starter switch.
V power supply circuit between the ECM and
8) Check to see if the DPD light is off.
the intake throttle valve.
9) If the DPD light is not turned off, repair the
26) If a problem is discovered, repair the intake
short circuit to GND in the DPD light con-
throttle position sensor 5 V power supply cir-
trol circuit between the ECM and the monitor
cuit.
panel.
27) Inspect to see if there is a short circuit to the
10) Turn OFF the starter switch.
GND with the EGR valve position sensor 5
11) Remove the fuse.
V power supply circuit between the ECM and
12) Turn ON the starter switch.
EGR valve.
13) Measure the voltage between the DPD light
28) If a problem is discovered, repair the EGR
control circuit and GND of the ECM harness
valve position sensor 5 V power supply circuit.
connector.
29) Replace the ECM.
Voltage: 1.0 V
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
14) If it is at or above the standard value, repair
Removal".
the short circuit to the battery or ignition power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply circuit in the DPD light control circuit
Installation".
between the ECM and the monitor panel.
30) Set the injector ID code on the ECM.
15) Turn OFF the starter switch.
31) Perform the unit difference learning of the fuel
16) Install the fuse.
supply pump to the ECM.
17) Connect the test cable with fuse between the
2. DTC P1655 Confirm Resolution DPD light control circuit and GND of the ECM
harness connector.
1) Clear the DTC using the trouble diagnosis 18) Turn ON the starter switch.
scan tool. 19) If the DPD light turns on, inspect the ECM
2) Turn the starter switch OFF for 30 seconds or harness connector for a contact failure.
longer. 20) If a problem is discovered, repair the harness
3) Start the engine. connector.
4) Perform a test-run. 21) If the harness connector is normal, replace the
5) Use the trouble diagnosis scan tool to confirm ECM.
that a DTC has not been detected. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
22) Set the injector ID code on the ECM.
23) Perform the unit difference learning of the fuel
supply pump to the ECM.
24) If the DPD light does not turn on, remove the
DPD light bulb from the monitor panel.
25) Inspect the DPD light bulb.
26) Replace the valve if a problem is discovered.
27) Inspect to see if there is an open circuit or high
resistance in the ignition power supply circuit
between the fuse and the monitor panel.
28) If a problem is discovered, repair the ignition
power supply circuit.
29) Inspect to see if there is an open circuit or DTC P2146 (Flash Code 158) Fuel
high resistance in the DPD light control circuit
between the ECM and the monitor panel. Injector Group 1 Supply Voltage
30) If a problem is discovered, repair the control
circuit.
Circuit
31) Inspect the monitor panel harness connector 1. DTC P2146 Diagnostics
for a contact failure.
32) If a problem is discovered, repair the harness 1) Turn the starter switch OFF.
connector. 2) Disconnect the harness connector from the
33) When the harness connector is normal, re- cylinder head injector harness intermediate
place the monitor panel. connector.
3) Turn the starter switch ON.
2. DTC P1669 Confirm Resolution 4) Measure the voltage between the solenoid
control circuit and GND.
1) Clear the DTC using the trouble diagnosis
scan tool. ANNOTATION:
2) Turn the starter switch OFF for 30 seconds or
longer. • Solenoid control circuit and GND of the first
3) Turn the starter switch ON, and wait for 40 cylinder injector
seconds. • Solenoid control circuit and GND of the
4) Start the engine. fourth cylinder injector
5) Use the trouble diagnosis scan tool to confirm Voltage: 12.0 V
that a DTC has not been detected. 5) If it is at or below the standard value, inspect
to see if there is a short circuit to the GND
with the control circuit between the ECM and
injector harness intermediate connector.
6) If a problem is discovered, repair the control
circuit.
7) Inspect the charge voltage circuit between the
ECM and the injector harness intermediate
connector.
ANNOTATION:
• No short circuit to the battery or ignition
power is present.
• No short circuit to GND is present.
8) If a problem is discovered, repair the charge
voltage circuit.
9) If the charge voltage circuit between the ECM
and the injector harness intermediate connec-
tor is normal, replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
12) Inspect the injector harness intermediate con-
nector for a contact failure.
13) If a problem is discovered, repair the injector
harness intermediate connector.
14) Disconnect the harness connector from the
ECM.
15) Inspect the ECM harness connector for a con-
tact failure.
16) If a problem is discovered, repair the harness
connector.
17) Inspect to see if there is an open circuit or
high resistance with the charge voltage circuit
between the ECM and the injector harness
intermediate connector.
18) If a problem is discovered, repair the charge
voltage circuit.
19) Remove the cylinder head cover. DTC P2149 (Flash Code 159) Fuel
Refer to "1.Engine 1B.Mechanical(4HK1X)
Cylinder head cover Removal". Injector Group 2 Supply Voltage
20) Inspect the injector harness tightening nut for
looseness.
Circuit
21) If the injector harness tightening nut is loose, 1. DTC P2149 Diagnostics
tighten it.
22) Inspect to see if any foreign matter is attached 1) Turn the starter switch OFF.
to the injector terminal. 2) Disconnect the harness connector from the
23) If any foreign matter is attached to the injector cylinder head injector harness intermediate
terminal, remove it. connector.
24) Inspect the injector harness intermediate har- 3) Turn the starter switch ON.
ness connector for a contact failure. 4) Measure the voltage between the solenoid
25) If a problem is discovered, repair the interme- control circuit and GND.
diate harness connector. ANNOTATION:
26) Check if insulation resistance of the first cylin-
der and fourth cylinder injector is at or above • Solenoid control circuit and GND of the sec-
the standard value. ond cylinder injector
Resistance: 1.0 Ω • Solenoid control circuit and GND of the third
27) If it is at or below the standard value, replace cylinder injector
the relevant injector. Voltage: 12.0 V
Refer to "1.Engine 1C.Fuel System(4HK1X) 5) If it is at or below the standard value, inspect
Injector Removal". to see if there is a short circuit to the GND
Refer to "1.Engine 1C.Fuel System(4HK1X) with the control circuit between the ECM and
Injector Installation". injector harness intermediate connector.
28) Set the injector ID code on the ECM. 6) If a problem is discovered, repair the control
29) If it is at or above the standard value, repair or circuit.
replace the injector harness. 7) Inspect the charge voltage circuit between the
2. DTC P2146 Confirm Resolution ECM
and the injector harness intermediate connec-
1) Clear the DTC using the trouble diagnosis tor.
scan tool.
2) Turn the starter switch OFF for 30 seconds or ANNOTATION:
longer. • No short circuit to the battery or ignition
3) Start the engine. power is present.
4) Use the trouble diagnosis scan tool to confirm • No short circuit to GND is present.
that a DTC has not been detected.
8) If a problem is discovered, repair the charge
voltage circuit.
9) If the charge voltage circuit between the ECM
and the injector harness intermediate connec-
tor is normal, replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
12) Inspect the injector harness intermediate con-
nector for a contact failure.
13) If a problem is discovered, repair the injector
harness intermediate connector.
14) Disconnect the harness connector from the
ECM.
15) Inspect the ECM harness connector for a con-
tact failure.
16) If a problem is discovered, repair the harness
connector.
17) Inspect to see if there is an open circuit or
high resistance with the charge voltage circuit
between the ECM and the injector harness
intermediate connector.
18) If a problem is discovered, repair the charge
voltage circuit.
19) Remove the cylinder head cover. DTC P2228 (Flash Code 71)
Refer to "1.Engine 1B.Mechanical(4HK1X)
Cylinder head cover Removal". Barometric Pressure Circuit Low
20) Inspect the injector harness tightening nut for
1. DTC P2228 Priority DTC
looseness.
DTC P0651
21) If the injector harness tightening nut is loose,
2. DTC P2228 Diagnostics
tighten it.
22) Inspect to see if any foreign matter is attached 1) Turn OFF the starter switch.
to the injector terminal. 2) Disconnect the harness connector from the
23) If any foreign matter is attached to the injector atmospheric pressure sensor.
terminal, remove it. 3) Turn ON the starter switch.
24) Inspect the injector harness intermediate har- 4) Measure the voltage between the atmo-
ness connector for a contact failure. spheric pressure sensor 5 V power supply
25) If a problem is discovered, repair the interme- circuit and GND.
diate harness connector. Voltage: 4.5 V
26) Check if insulation resistance of the first cylin- 5) If it is at or below the standard value, inspect
der and fourth cylinder injector is at or above to see if there is an open circuit or high re-
the standard value. sistance with the 5 V power supply circuit be-
Resistance: 1.0 MΩ tween the ECM and the atmospheric pressure
27) If it is at or below the standard value, replace sensor.
the relevant injector. 6) If a problem is discovered, repair the 5 V
Refer to "1.Engine 1C.Fuel System(4HK1X) power supply circuit.
Injector Removal". 7) Connect the test cable with fuse between the
Refer to "1.Engine 1C.Fuel System(4HK1X) atmospheric pressure sensor 5 V power sup-
Injector Installation". ply circuit and the signal circuit.
28) Set the injector ID code on the ECM. 8) Check the atmospheric pressure sensor dis-
29) If it is at or above the standard value, repair or play with the trouble diagnosis scan tool.
replace the injector harness. Voltage: 4.5 V
9) If it is at or above the standard value, inspect
2. DTC P2149 Confirm Resolution
to see if there is a contact failure with the at-
1) Clear the DTC using the trouble diagnosis mospheric pressure sensor harness connec-
scan tool. tor.
2) Turn the starter switch OFF for 30 seconds or 10) If a problem is discovered, repair the harness
longer. connector.
3) Start the engine. 11) If the harness connector is normal, replace the
4) Use the trouble diagnosis scan tool to confirm atmospheric pressure sensor.
that a DTC has not been detected. 12) If it is at or below the standard value, inspect
the signal circuit between the ECM and the
atmospheric pressure sensor.
• There should be no open circuit or high re-
sistance.
• There should be no short to GND.
13) If a problem is discovered, repair the signal
circuit.
14) Inspect the ECM harness connector for a con-
tact failure.
15) If a problem is discovered, repair the harness
connector.
16) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
17) Set the injector ID code on the ECM.
18) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P2228 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
84402826 - May 2011
4023G-64
Engine-side Trouble
DTC P2452 (Flash Code 142) 17) If a problem is discovered, repair the harness
connector.
DPD Differential Pressure Sensor 18) Inspect the signal circuit between the ECM
Circuit and the DPD differential pressure sensor for
a high resistance.
1. DTC P2452 Priority DTC 19) If a problem is discovered, repair the signal
DTC P2456 circuit.
2. DTC P2452 Diagnostics 20) If the harness connector and circuit are nor-
mal, replace the DPD differential pressure
1) Inspect the DPD differential pressure sensor sensor.
hose. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
• There should be no incorrect piping or dis- haust differential pressure sensor Removal".
connection. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
2) If a problem is discovered, repair the hose. tion".
3) Inspect the DPD differential pressure sensor. 21) When the DPD differential pressure sensor
• DPD differential pressure sensor unit should has been replaced, perform the 0-point cor-
not be damaged. rection.
• There should be no dirt or foreign matter Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
blocking the DPD differential pressure sen- haust differential pressure sensor Inspection".
sor entrance. 22) Restore the actual unit.
• There should be no detection error or slow 23) Turn the starter switch ON for 30 seconds.
response from the DPD differential pressure ANNOTATION:
sensor.
• Do not start the engine.
4) If a problem is discovered, replace the DPD • This is for the DPD differential pressure sen-
differential pressure sensor. sor to relearn.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Removal". 24) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- scan tool.
haust differential pressure sensor Installa- 25) Perform the DPD regeneration data reset with
tion". the trouble diagnosis scan tool.
5) When the DPD differential pressure sensor 26) Turn the starter switch OFF for 30 seconds or
has been replaced, perform the 0-point cor- longer.
rection. 27) Perform the DPD forced regeneration with the
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- trouble diagnosis scan tool.
haust differential pressure sensor Inspection". ANNOTATION:
6) Inspect the exhaust system.
• When the DPD filter is replaced by a new
• There should be no absence or damage of one, do not perform the DPD forced regen-
the exhaust pipe gasket. eration.
• There should be no exhaust gas leak from
the exhaust system. 28) Use the trouble diagnosis scan tool to confirm
• The exhaust system should not be modified. that the exhaust temperature (before the filter)
display is at or below the standard value.
7) If a problem is discovered, repair or replace Specified value: 130 °C {266 °F}
the exhaust system. 29) If it is at or above the standard value, idle the
8) Inspect the DPD assembly. engine until it falls to or below the standard
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD value.
assembly Inspection". 30) Check the exhaust differential pressure dis-
9) If a problem is discovered, replace the DPD play when the exhaust temperature (in front
assembly. of the filter) display has reached the standard
10) If the DPD assembly has been replaced, use value with the engine revolution increased to
the trouble diagnosis scan tool to perform the maximum Revolution speed without load.
DPD regeneration data reset. Specified value: 150 °C {302 °F}
11) Turn OFF the starter switch. 31) Use the trouble diagnosis scan tool to check if
12) Disconnect the harness connector from the the exhaust differential pressure display is at
DPD differential pressure sensor. or above the standard value.
13) Inspect the DPD differential pressure sensor Specified value: 0.5 kPa {0.01 kgf/cm2 / 0.1
harness connector for a contact failure. psi}
14) If a problem is discovered, repair the harness
connector. 3. DTC P2452 Confirm Resolution
15) Disconnect the harness connector from the
1) Turn ON the starter switch.
ECM.
2) Use the trouble diagnosis scan tool to confirm
16) Inspect the ECM harness connector for a con-
that a DTC has not been detected.
tact failure.
DTC P2453 (Flash Code 141) 13) Inspect the ECM harness connector for a con-
tact failure.
DPD Differential Pressure Sensor 14) If a problem is discovered, repair the harness
Circuit Range/Performance 15)
connector.
Inspect the signal circuit between the ECM
1. DTC P2453 Priority DTC and the DPD differential pressure sensor for
DTC P2456 a high resistance.
2. DTC P2453 Diagnostics 16) If a problem is discovered, repair the signal
circuit.
1) Inspect the DPD differential pressure sensor 17) If the harness connector and signal circuit are
hose. normal, replace the DPD assembly.
• There should be no incorrect piping or dis- 18) If the DPD assembly has been replaced, use
connection. the trouble diagnosis scan tool to perform
DPD regeneration data reset.
2) If a problem is discovered, repair the hose. 19) Restore the actual unit.
3) Inspect the DPD differential pressure sensor. 20) Turn the starter switch ON for 30 seconds.
• DPD differential pressure sensor unit should ANNOTATION:
not be damaged.
• There should be no dirt or foreign matter • Do not start the engine.
blocking the DPD differential pressure sen- • This is for the DPD differential pressure sen-
sor entrance. sor to relearn.
• There should be no detection error or slow 21) Clear the DTC using the trouble diagnosis
response from the DPD differential pressure scan tool.
sensor. 22) Perform the DPD regeneration data reset with
4) If a problem is discovered, replace the DPD the trouble diagnosis scan tool.
differential pressure sensor. 23) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- longer.
haust differential pressure sensor Removal". 24) Perform the DPD forced regeneration with the
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- trouble diagnosis scan tool.
haust differential pressure sensor Installa- 25) Use the trouble diagnosis scan tool to confirm
tion". that the exhaust temperature (before the filter)
5) When the DPD differential pressure sensor display is at or below the standard value.
has been replaced, perform the 0-point cor- Specified value: 130 °C {266 °F}
rection. 26) If it is at or above the standard value, idle the
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- engine until it falls to or below the standard
haust differential pressure sensor Inspection". value.
6) Inspect the exhaust system. 27) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
• There should be no missing or damage with of the filter) display has reached the standard
the gasket of the exhaust pipe. value with the engine revolution increased to
• There should be no exhaust gas leak from the maximum revolution speed without load.
the exhaust system. Specified value: 150 °C {302 °F}
• The exhaust system should not be modified. 28) Use the trouble diagnosis scan tool to check if
• There should be no flow limitation or crush the exhaust differential pressure display is at
of the exhaust system. or below the standard value.
7) If a problem is discovered, repair or replace Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
the exhaust system. psi}
8) Turn OFF the starter switch. 29) If it is at or above the standard value, perform
9) Disconnect the harness connector from the ash removal.
DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
10) Inspect the DPD differential pressure sensor haust differential pressure sensor Inspection".
harness connector for a contact failure. 3. DTC P2453 Confirm Resolution
11) If a problem is discovered, repair the harness
connector. 1) Turn ON the starter switch.
12) Disconnect the harness connector from the 2) Use the trouble diagnosis scan tool to confirm
ECM. that a DTC has not been detected.
DTC P2454 (Flash Code 47) 11) If the harness connector is normal, replace the
DPD differential pressure sensor.
DPD Differential Pressure Sensor Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
Circuit Low haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
1. DTC P2454 Priority DTC haust differential pressure sensor Installa-
DTC P0697 tion".
2. DTC P2454 Diagnostics 12) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
1) Turn OFF the starter switch. rection.
2) Disconnect the harness connector from the Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
DPD differential pressure sensor. haust differential pressure sensor Inspection".
3) Turn ON the starter switch. 13) If it is at or below the standard value, inspect
4) Measure the voltage between the DPD differ- the signal circuit between the ECM and the
ential pressure sensor 5 V power supply cir- DPD differential pressure sensor.
cuit and GND.
Voltage: 4.5 V • There should be no open circuit or high re-
5) If it is at or below the standard value, inspect sistance.
to see if there is an open circuit or high re- • There should be no short to GND.
sistance with the 5 V power supply circuit be-
14) If a problem is discovered, repair the signal
tween the ECM and the DPD differential pres-
circuit.
sure sensor.
15) Inspect the ECM harness connector for a con-
ANNOTATION: tact failure.
16) If a problem is discovered, repair the harness
• The DPD differential pressure sensor connector.
shares the 5 V power supply circuit with 17) If the harness connector is normal, replace the
other sensors. ECM.
• The DTC set on a sensor which shares this Refer to "1.Engine 1J.Electrical(4HK1X) ECM
circuit may be detected. Removal".
6) If a problem is discovered, repair the 5 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
power supply circuit. Installation".
7) Connect the test cable with fuse between the 18) Set the injector ID code on the ECM.
5 V power supply circuit and signal circuit of 19) Perform the unit difference learning of the fuel
the DPD differential pressure sensor. supply pump to the ECM.
8) Check the exhaust differential pressure dis- 3. DTC P2454 Confirm Resolution
play with the trouble diagnosis scan tool.
Voltage: 4.5 V 1) Clear the DTC using the trouble diagnosis
9) If it is at or above the standard value, inspect scan tool.
to see if there is a contact failure with the DPD 2) Turn the starter switch OFF for 30 seconds or
differential pressure sensor harness connec- longer.
tor. 3) Start the engine.
10) If a problem is discovered, repair the harness 4) Perform a test-run.
connector. 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P2455 (Flash Code 47) 10) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
DPD Differential Pressure Sensor rection.
Circuit High Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
1. DTC P2455 Priority DTC 11) If the test light does not come on, inspect to
DTC P0697 see if there is an open circuit or high resis-
2. DTC P2455 Diagnostics tance with the GND circuit between the ECM
and the DPD differential pressure sensor.
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the ANNOTATION:
DPD differential pressure sensor.
• The DPD differential pressure sensor
3) Check the exhaust differential pressure dis-
shares the GND circuit with other sensors.
play with the trouble diagnosis scan tool.
• The DTC may be detected on a sensor
Voltage: 0.1 V
which shares this circuit.
4) If it is at or above the standard value, inspect
the signal circuit between the ECM and the 12) If a problem is discovered, repair the GND
DPD differential pressure sensor. circuit.
13) Inspect the ECM harness connector for a con-
• There should be no short to the battery or tact failure.
ignition power supply.
14) If a problem is discovered, repair the harness
• There should be no short to the 5 V power connector.
supply.
15) If the harness connector is normal, replace the
5) If a problem is discovered, repair the signal ECM.
circuit. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
6) Connect the test light between the GND circuit Removal".
and battery power supply of the DPD differen- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
tial pressure sensor. Installation".
7) If the test light comes on, inspect DPD differ- 16) Set the injector ID code on the ECM.
ential pressure sensor harness connector for 17) Perform the unit difference learning of the fuel
a contact failure. supply pump to the ECM.
8) If a problem is discovered, repair the harness
3. DTC P2455 Confirm Resolution
connector.
9) If the harness connector is normal, replace the 1) Clear the DTC using the trouble diagnosis
DPD differential pressure sensor. scan tool.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 2) Turn the starter switch OFF for 30 seconds or
haust differential pressure sensor Removal". longer.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 3) Start the engine.
haust differential pressure sensor Installa- 4) Perform a test-run.
tion". 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P2458 (Flash Code 139) DTC P042B (Flash Code 145)
DPD Regeneration Duration Catalyst Temperature Sensor
1. DTC P2458 Description of DTC Circuit Range/Performance
The ECM detects PM accumulation failures from the
DPD differential pressure sensor installed near the
Sensor 2
DPD itself. 1. DTC P042B Description of DTC
When it is reached to a certain amount of PM accu- The exhaust temperature sensor 2 is installed on
mulations or a certain length of operating time, the the DPD housing.
automatic regeneration of the DPD starts. The exhaust temperature sensor 2 is a variable re-
If the automatic regeneration cannot be completed sistor, and measures the temperature of the ex-
by some reason, the manual regeneration is re- haust gas before entering the oxidation catalyst.
quested to the operator by blinking the orange DPD The DTC is set when the ECM detects an abnor-
indicator light on the display. mally high exhaust temperature.
Once the DPD filter regeneration starts, it must be 2. DTC P042B Condition for setting the DTC
finished within a certain time. DTC P042C and P042D are not set
When DPD regeneration continues for longer than The starter switch is ON
the specified period of time, it sets DTC. When the ECM has detected that the exhaust tem-
2. DTC P2458 Condition for setting the DTC perature
The starter switch is ON 2 has been 870 °C (1600 °F) or higher for 5 seconds
The DPD filter regeneration has been completed 3. DTC P042B Action taken when the DTC sets
When the ECM detected that the DPD filter regener- Failure is indicated in the monitor on the actual unit,
ation process took time longer than a certain period or the monitor is turned on.
of time for 3 consecutive times
3. DTC P2458 Action taken when the DTC sets ANNOTATION:
Failure is indicated in the monitor on the actual unit, • Depending on the manufacturer of the actual unit,
or the monitor is turned on. the failure indication may not be shown.
ANNOTATION: Restricts the fuel injection amount.
• Depending on the manufacturer of the actual unit,
the failure indication may not be shown.
Restricts the fuel injection amount.
DTC P042C (Flash Code 49) DTC P042D (Flash Code 49)
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Low Sensor 2 Circuit High Sensor 2
1. DTC P042C Priority DTC 1. DTC P042D Description of DTC
DTC P0697 The exhaust temperature sensor 2 is installed on
2. DTC P042C Diagnostics the DPD housing.
The exhaust temperature sensor 2 is a variable re-
1) Turn OFF the starter switch.
sistor, and measures the temperature of the ex-
2) Disconnect the harness connector from the haust gas before entering the oxidation catalyst.
exhaust gas temperature sensor 2.
This sensor has a signal circuit and GND circuit.
3) Check the exhaust temperature sensor (be- The ECM supplies 5 V to the signal circuit, and the
fore the oxidation catalyst) display with the
GND circuit connects to GND.
trouble diagnosis scan tool. When the exhaust temperature sensor 2 is cold, the
Voltage: 4.5 V
resistance of the sensor is high.
4) If it is at or above the standard value, replace When the exhaust temperature rises, the resistance
the exhaust gas temperature sensor 2.
of the sensor decreases.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- The ECM detects a high voltage when the sensor
haust gas temperature sensor Removal".
resistance is high.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- The ECM detects a low voltage when the sensor
haust gas temperature sensor Installation".
resistance is low.
5) Inspect to see if there is a short circuit to the The DTC is set when the ECM detects an abnor-
GND with the signal circuit between the ECM
mally low signal voltage.
and the exhaust gas temperature sensor 2.
2. DTC P042D Condition for setting the DTC
6) If a problem is discovered, repair the signal
DTC P0112, P0113, P0117, P0118, P060B, P2228,
circuit.
and P2229 are not set
7) Inspect the ECM harness connector for a con-
The battery voltage is between 18 and 32 V The
tact failure.
starter switch is ON
8) If a problem is discovered, repair the harness
The engine coolant temperature is 70 °C (158 °F)
connector.
or higher.
9) If the harness connector is normal, replace the
The fuel injection amount is a certain value or more
ECM.
The engine operating time is 0.5 - 10 minutes or
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
longer
Removal".
When the ECM has detected that the signal voltage
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
of the exhaust temperature sensor 2 has been 4.85
Installation".
V or higher for 5 seconds.
10) Set the injector ID code on the ECM.
3. DTC P042D Action taken when the DTC sets
11) Perform the unit difference learning of the fuel
Failure is indicated in the monitor on the actual unit,
supply pump to the ECM.
or the monitor is turned on.
3. DTC P042C Confirm Resolution
ANNOTATION:
1) Clear the DTC using the trouble diagnosis
• Depending on the manufacturer of the actual unit,
scan tool.
the failure indication may not be shown.
2) Turn the starter switch OFF for 30 seconds or
longer. Restrict the fuel injection amount.
3) Start the engine. Stop the EGR control.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
DTC P060B (Flash Code 36) DTC P242F (Flash Code 131)
Internal Control Module A/D DPD Restriction
Processing Performance 1. DTC P242F Description of DTC
The ECM detects PM accumulation failures from the
1. DTC P060B Diagnostics DPD differential pressure sensor installed near the
1) Replace the ECM. DPD it self.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM When it is reached to a certain amount of PM accu-
Removal". mulations or a certain length of operating time, the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM automatic regeneration of the DPD starts.
Installation". If the automatic regeneration cannot be completed
2) Set the injector ID code on the ECM. by some reason, the manual regeneration is re-
3) Perform the unit difference learning of the fuel quested to the operator by blinking the orange DPD
supply pump to the ECM. indicator light on the display.
If the ECM detects that learned exhaust differential
2. DTC P060B Confirm Resolution pressure is not within a predetermined range, it sets
1) Clear the DTC using the trouble diagnosis DTC.
scan tool. 2. DTC P242F Condition for setting the DTC
2) Turn the starter switch OFF for 30 seconds or The starter switch is ON
longer. The DPD differential pressure has been above the
3) Start the engine. calculated range for 30 seconds or longer.
4) Perform a test-run. 3. DTC P242F Action taken when the DTC sets
5) Use the trouble diagnosis scan tool to confirm Failure is indicated in the monitor on the actual unit,
that a DTC has not been detected. or the monitor is turned on.
ANNOTATION:
• Depending on the manufacturer of the actual unit,
the failure indication may not be shown.
Restrict the fuel injection amount.
Stop the EGR control.
Stop the DPD regeneration.
4023H
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W401 har-
ground and terminal 1 of the CN. D45 About 5 V ness defect (discon-
11 Go to Step 12
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D45 0.25 V or Computer A defect. Y410 harness defect
12 harness side. (disconnection). Re-
higher Replace
place
Is it 0.25 V or higher?
1 COMPUTER A
2 PRESS. SENSOR (P1)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W401 har-
ground and terminal 1 of the CN. D46 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D46 0.25 V or Computer A defect. L411 harness defect
11 harness side. (disconnection). Re-
higher Replace
place
Is it 0.25 V or higher?
1 COMPUTER A
2 PRESS. SENSOR (P1)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W402 har-
ground and terminal 1 of the CN. D47 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D47 0.25 V or Computer A defect. Lg412 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?
1 COMPUTER A
2 PRESS. SENSOR (N1)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W403 har-
ground and terminal 1 of the CN. D48 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D48 0.25 V or Computer A defect. G413 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?
1 COMPUTER A
2 PRESS. SENSOR (N2)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W409 har-
ground and terminal 1 of the CN. D52-1 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D52-1 0.25 V or Computer A defect. Gr419 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?
1 COMPUTER A
2 PRESS. SENSOR (HBCV)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W414 harness defect
10 ground and terminal 1 of the CN. CR9 About 5 V Go to Step 11 (disconnection). Re-
harness side. pair or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR9 0.25 V or Computer B defect. Y434 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W414 or W415 har-
ground and terminal 1 of the CN. CR10 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR10 0.25 V or Computer B defect. L435 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W405 har-
ground and terminal 1 of the CN. D50 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D50 0.25 V or Computer A defect. V415 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?
1 COMPUTER A
PRESS. SENSOR (PILOT UP-
2
PER)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W404 har-
ground and terminal 1 of the CN. D49 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D49 0.25 V or Computer A defect. GR414 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?
1 COMPUTER A
PRESS. SENSOR (PILOT
2
SWING)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W406 har-
ground and terminal 1 of the CN. D51 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D51 0.25 V or Computer A defect. YG416 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?
1 COMPUTER A
PRESS. SENSOR (PILOT
2
TRAVEL)
-
Is it about 5 V?
1. 1. Measure the voltage between the
ground and terminal 2 of the CN. D54
harness side. 4.75 V or YG445 harness de-
5 Go to Step 6
lower fect (short). Replace
-
Is it 4.75 V or lower?
1. 1. Measure the voltage between the
ground and terminal 3 of the CN. D54
harness side. 0.25 V or Computer B defect. BL450 harness de-
6
lower Replace fect (short). Replace
-
Is it 0.25 V or lower?
1. Inspect the arm-in pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D54.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Arm-in pressure sen-
nals 1 and 3 of the CN. D54 arm-in pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. D54 WL430 or YG445
8 harness side. harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. D54
harness side.
Is there continuity?
1. Inspect for continuity between the
ground and terminal 3 of the CN. D54 BL450 harness de-
9 harness side. Go to Step 10 fect (disconnection).
Repair or replace
Is there continuity?
84402826 - May 2011
4023H-23
Main Unit-side Trouble
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the WL430 harness de-
10 ground and terminal 1 of the CN. D54 About 5 V Go to Step 11 fect (disconnection).
harness side. Repair or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D54 0.25 V or Computer B defect. YG445 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?
1 COMPUTER A
2 FUEL LEVEL SENSOR
1 COMPUTER A
2 HYD. OIL TEMP SENSOR
CAUTION
Contrast correction is
performed when the
1. Turn the key switch ON. monitor thermistor is
2. On the service support DIAG at an extremely high
screen, or low temperature.
check whether diagnostic trouble Even if the monitor
1
code: 7045 (●) is displayed. thermistor has a de-
fect, there is a correc-
Is diagnostic trouble code: 7045 (●) dis- tion function inside
played? the monitor, so the
monitor thermistor
does not need to be
replaced if the moni-
tor contrast is not sig-
nificantly affected.
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W414 or W416 har-
ground and terminal 3 of the CN. CR11 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR11 0.2 V Lg436 harness de-
or Computer B defect.
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.2 V or higher?
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the BW457 or W414 har-
ground and terminal 1 of the CN. CR12 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR12 0.2 V Br437 harness defect
or Computer B defect.
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.2 V or higher?
1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)
1 COMPUTER A
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the WL432 or WL430
ground and terminal 1 of the CN. D53 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. 120 0.25 V or Computer B defect. GW444 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the WL431 or WL430
ground and terminal 1 of the CN. D55 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D55 0.25 V or Computer B defect. LR446 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?
a CAN COMMUNICATION
a CAN COMMUNICATION
a CAN COMMUNICATION
a CAN COMMUNICATION
Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock
Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7211 is displayed. Go to Step 2
Is diagnostic trouble code: 7211 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
2 and fuse box F21 (10 A) fuse to see if Go to Step 3
either is blown.
Are 1 and 2 above both OK?
Inspect the rotating light relay.
1. Turn the key switch OFF and disconnect
CN. 19.
Rotating light relay
3 2. Inspect for continuity between terminals Go to Step 4
defect. Replace
1 and 2 of the CN. 19 rotating light relay
side.
Is there continuity?
Inspect for shorts.
1. Install CN. 19. VW858, GW226,
2. Inspect for continuity between the GW227, R106, or
4 Go to Step 5
ground and terminal 1 of the CN. 19 R105 harness defect
harness side. (short). Replace
Is there continuity?
Inspect for disconnection.
VW816, VW817,
1. Turn the key switch ON. GW227, GW226,
2. Inspect for continuity between the Computer B defect. GW225, R106, or
5
ground and terminal 1 of the CN. 19 Replace R105 harness defect
harness side. (disconnection). Re-
pair or replace
Is there continuity?
a CAN COMMUNICATION
a CAN COMMUNICATION
1 CONTROLLER A
2 BOOM DOWN
1 CONTROLLER B
2 ARM CLOSE
1 CONTROLLER B
2 PROPORTIONAL S/V
3 OPT PRESS
1 COMPUTER A
2 HYD. OIL TEMP SENSOR
1 COMPUTER A
LEVEL SWITCH (RESERVE
2
TANK)
1 COMPUTER A
2 ENGINE COMPUTER
3 OIL PRESS SENSOR
1 COMPUTER A
PRESS. SWITCH (AIR
2
CLEANER)
1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)
1 COMPUTER A
2 MONITOR
a CAN COMMUNICATION
1 COMPUTER A
2 ENGINE COMPUTER
a CAN COMMUNICATION
4023K
Non-operational P rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Two pump relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The purpose of data list is for checking the status of the whether the vehicle data is temporarily or always differ-
machine and each equipment. ent from the reference values.
This data is used in trouble diagnosis by comparing the This display menu is subject to change without notice.
each machine data with standard values, and checking
Non-operational P rotation
Non operation P rotation reference value
Data display items Units It varies depending on the actual machine condi-
tion
Battery voltage V 28.3 - 28.5
Target engine rpm min-1 500
Engine speed min-1 1797 - 1801
Accelerator pedal position sensor 1 (APP1) V 0.0
Accelerator pedal position sensor 2 (APP2) V 0.0
Accelerator pedal position (APP) % 0
Fuel rail pressure sensor V 2.0 - 2.1
Fuel rail pressure feedback - Feedback mode
Coolant temperature sensor V 0.4 - 0.5
Coolant temperature °C 80 - 83
Intake temperature sensor V 2.4
Intake air temperature °C 27
Fuel temperature sensor V 1.3
Fuel temperature °C 44
Atmospheric pressure sensor V 1.9
Atmospheric pressure kPa 100
Boost temperature sensor voltage V 4.4
Boost pressure sensor kPa 118 - 119
First cylinder fuel correction amount mm3/st -
Second cylinder fuel correction amount mm3/st -
Third cylinder fuel correction amount mm3/st -
Fourth cylinder fuel correction amount mm3/st -
Engine mode - Fuel mode
EGR valve 1 drive duty % EGR valve 1 drive duty
ON/OF- Reverse the polarity of either 1, 2, or 3
EGR position 1
F (Example:1=ON, 2=ON, 3=OFF, etc)
ON/OF- Reverse the polarity of either 1, 2, or 3
EGR position 2
F (Example:1=ON, 2=ON, 3=OFF, etc)
ON/OF- Reverse the polarity of either 1, 2, or 3
EGR position 3
F (Example:1=ON, 2=ON, 3=OFF, etc)
ON/OF-
Ignition switch ON
F
ON/OF-
Starter switch ON
F
ON/OF- OFF
Glow relay
F ON immediately after the starter switch ON
Q adjustment compensation data 1 - -
Q adjustment compensation data 2 - -
Q adjustment compensation data 3 - -
4040
Main Frame
Engine Harness
Frame
CN.A50 Cab main harness: A (2-pin) CN.D51 Pressure sensor: Travel (3-pin)
HBCV harness (3-pin) (secured to harness with red
CN.A51 Cab main harness: B (8-pin) CN.D52
tape)
CN.A52 Cab main harness: C (8-pin) CN.D53 Pressure sensor: BOOM (3-pin)
CN.A53 Cab main harness: D (14-pin) CN.D54 Pressure sensor: Arm (3-pin) ID tape: Red
CN.A54 Cab main harness: E (22-pin) CN.D55 Pressure sensor: Bucket (3-pin)
CN.A55 Cab main harness: F (20-pin) CN.D57 Fuel level sensor (2-pin)
CN.A56 Cab main harness: G (18-pin) CN.D6 Register (2-pin)
CN.D1 ECM: 1 (60-pin) CN.D64 SV; Free swing (2-pin)
CN.D16 Alternator ground CN.D65 Lamp: Housing (2-pin)
CN.D2 ECM: 2 (94-pin) CN.D66 Boom lamp harness (2-pin)
CN.D3 Turbo computer (16-pin) CN.D67 Washer motor (2-pin)
Travel alarm (2-pin) (secured to harness with red
CN.D35 Suction air sensor (5-pin) CN.D69
tape)
CN.D70
CN.D41 Proportional valve: BOOM (2-pin) ID tape: None Horn (left)
CN.D71
CN.D72
CN.D42 Proportional valve: Arm (2-pin) ID tape: Red Horn (right)
CN.D73
Feed pump harness (3-pin) (secured to harness
CN.D43 Proportional valve: Bucket (2-pin) ID tape: Blue CN.D76
with red tape)
Option proportional valve harness (2-pin) (secured
CN.D44 CN.D77 Receiver dryer (2-pin)
to harness with red tape)
CN.D47 Pressure sensor: N1 (3-pin) CN.D79 LLC tank (2-pin)
CN.D49 Pressure sensor: Swing (3-pin) CN.D80 Ground G1
CN.D5 Barometric pressure sensor (3-pin) CN.D81 Filter indicator (2-pin) ID tape: Red
CN.D50 Pressure sensor: Upper (3-pin) CN.D85 Ground G2
Attachments
Battery
5001A
CAUTION
• Make sure to stop the engine for loosening
shoes and when removing master pins.
Items to prepare
• Wrenches (17 mm, 19 mm)
• Box wrench (19 mm)
• Hammer
• Wood planks, etc.
• Striking jig
• Crowbar
• Rag
• Lifting equipment (with the required breaking load)
• Liftcrane (with the required lifting capacity)
WARNING
• If the check valve (1) is too loose, it may
fly off.
• Do not place your body in front.
4. Put wood planks (1) underneath the track shoe. 6. Remove the track shoe (1).
Straighten out the S-pin (3) attached to the master At this time, support with a wood plank (2) so the
pin (2) by striking one side of it with a hammer, and bottom track shoe (1) does not fall.
use a crowbar, etc. to remove it.
Installation of Shoe Assembly 3. Wrap the edge of the track shoe (1) onto the take-up
roller (2).
1. Raise the lower side frame about 20 cm. Place a wood plank (3) on the ground and lift the
Lift the track shoe (1) and align it with the sprocket bottom-side link to align the position where the mas-
(2). ter pin is inserted.
Pay attention to the backwards and forward direc-
tion of the track shoe.
2. Slowly set the travel lever to forward and feed the 5. Tighten the check valve (1).
track shoe to the take-up roller side as shown in the While monitoring the track shoe tension, inject
diagram. grease into the grease cylinder.
In the middle of this procedure when the track shoe
passes the upper roller, use a crowbar, etc. to lift
the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.
6. To adjust the track shoe tension, raise the lower 7. Adjust the tension so that the distance indicated
side frame with a wood plank (1) as shown in the with A between the frame bottom (1) of the center
diagram. area of the lower side frame and the lowest hanging
part of the top of the shoe plate (2) is 290 - 310 mm.
5001B
Items to prepare
• Box wrench (30 mm)
• Grease
• Rag
• Cleaning fluid
5003A
Items to prepare
• Box wrenches (19 mm, 30 mm)
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
• Wood planks, etc.
2. Use a jack (3) to lift the top of the shoe, and then
insert wood planks (4) to separate the shoe (2) and
upper roller (1) by about 10 mm.
3. Use a box wrench (30 mm) to remove the 2 bolts Installation of Upper Roller
(2), and then remove the upper roller (1).
1. Use a jack (2) to lift the top of the shoe (1), and then
insert wood planks (3).
4. To adjust the track shoe tension, raise the lower side 5. Adjust the tension so that the distance indicated
frame as shown in the diagram. with A between the frame bottom (1) of the center
Place a wood plank (1) under the lower frame to area of the lower side frame and the lowest hanging
prevent falling. part of the top of the shoe plate (2) is 290 - 310 mm.
5003B
Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Face down the part of the roller from which the 5. Use a box wrench (17 mm) to remove the 2 bolts (2)
plug was removed and empty the oil from within the inside the roller, and then remove the thrust plate
roller. (1).
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) under the roller to catch the
oil.
7. Remove the floating seal (2) on the roller (1). 8. Remove the floating seal (2) on the shaft (1).
Check whether the sliding surface has rusted or is
damaged. Also make sure the O-ring (3) on the seal • The shaft and bracket (5) cannot be removed.
Check whether the sliding surface has rusted or
ring (4) is not twisted.
is damaged. Also make sure the O-ring (4) on the
seal ring (3) is not twisted.
10. Use a micrometer caliper (4), caliper (5), cylinder Assembly Procedures
gauge (6), to measure the roller (with bushing) (1),
bracket (2), and shaft (3) for wear and deformation. 1. Clean all parts.
Replace with new parts as necessary.
• Find a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.
4. Invert the roller (1) and insert the bushing (2). 7. Apply hydraulic oil to the floating seal (1).
Restraining from above using jig B1 (3), push in with
the pressing machine (4).
Push in all the way to the position where jig B1
stops.
5. Insert the floating seal (3) into the roller (1) and
bracket (2).
Use jig C (4) to press it into position.
10. Install the thrust plate (1) with 2 bolts (2). 13. Inject compressed air (0.2 MPa) from the oil fill port
Degrease the bolts well, apply Loctite (3) to the bolt and immerse in water to check that there are no
openings, and tighten the bolts. leaks.
After tightening the bolts, mark them (4).
Bolt (2) tightening torque: 62.8 - 72.6 N・m
14. Inject engine oil (50 - 55 cc) into the roller. After
filling the engine oil, use a hexagon wrench (1) to
11. Install the cover (1) with 3 bolts (2). tighten the plug (2) (coated with seal nylon).
Degrease the bolts, apply Loctite (3) to the bolt After tightening the bolts, mark them (3).
openings, and tighten the bolts. • To reuse a plug, wrap it with seal tape.
After tightening the bolts, mark them (4). Plug (2) tightening torque: 24.5 N・m
Bolt (2) tightening torque: 31.4 - 37.2 N・m
12. Rotate the roller in the direction of the arrow and This completes the assembly.
check that it rotates smoothly.
5003C
CAUTION
• Be sure to stop the engine before beginning
work.
Items to prepare
• Box wrenches (19 mm, 27 mm)
• Rag
• Cleaning fluid
• Wood planks, etc.
5003D
Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Items to prepare
• Hexagon wrench (6 mm)
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge
Disassembly Procedures
1. Stand the roller vertically and use a hexagon
wrench (6 mm) (1) to remove the plug (2).
• The plug is coated with seal nylon, which comes
off when the plug is removed.
To reuse the plug, using seal tape is necessary.
4. Use pliers (2) to remove the pushed out wire clip (1).
6. Check whether the surface of the floating seal (2) 9. Remove the shaft (1).
sliding against the removed collar (1) has rusted or
is damaged.
Also make sure the O-ring (3) on the seal ring (4) is
not twisted.
• The O-ring cannot be reused.
Replace it with new part.
12. Use a caliper (6), micrometer caliper (5), and cylin- Assembly Procedures
der gauge (7) to measure the roller (with bushing)
(1), collars (2) (3), and shaft (4) for wear and defor- 1. Clean all parts by immersing them in cleaning fluid
mation. (1).
Replace with new parts as necessary.
• Select a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
4. Use jig C (5) to push the floating seal (4) into the 7. Attach O-rings (3) to the shaft (2) and mount into the
collars (2) (3) and roller (1) by hand. roller (1).
5. Use a special fiber cloth to wipe the surfaces of the 8. Install the collars (1) (2) on both sides.
floating seals so as to increase adhesion and pre-
vent dust from entering.
6. Apply gear oil to the floating seals (3) on the collars • When attaching the wire clip, secure the roller
(1) (2). main unit so that it does not roll.
10. Turn the main unit and check that the roller rotates 12. Fill gear oil (125 cc) into the roller.
properly. Use a hexagon wrench (6 mm) (2) to tighten the
plug (1) with the nylon seal applied.
• Mobile Gear Oil SHC320 is recommended for
use.
• To reuse a plug, wrap it with seal tape.
Plug (1) tightening torque: 24.5 N·m
11. Inject compressed air (0.2 MPa) from the oil fill port
and immerse in water to check that there are no
leaks.
5004
Removal of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
2. Slowly rotate the shoe so that the shoe joint section
• Box wrenches (19 mm) (1) is aligned as in the diagram on the right.
• Wrenches(19 mm、24 mm) Place wood plank (2) under the shoe and return the
• Hammer (to remove the master pin) bucket to its original position.
• Striking jig (to remove the master pin) Perform air bleeding for the hydraulic line.
• Liftcrane (with the required lifting capacity) For details, see Air Bleed Procedures.
• Wire rope (with the required breaking load)
• Loctite #262
• Wood plank
• Rag
• Cleaning fluid
3. Use a box wrench (19 mm) to rotate the grease 5. Place a striking jig (2) against the master pin (1) and
cylinder check valve (1) and loosen the shoe ten- hit it with a hammer (3) to push the master pin out.
sion.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off.
Be careful not to work in front of the check valve.
4. Pull out the S-pin (1) from the rear of the joint sec-
tion.
8. Use a wire rope (1) to lift the drive sprocket (2) and
remove it from the travel motor (3).
5005A
Items to prepare
• Wrench (24 mm)
• Hammer
• Lifting equipment
• Loctite #262 3. Install the lifting equipment (4) on the take-up roller
• Striking jig (1) and recoil spring assembly (3) and hang them
• Liftcrane from the side frame (2) with the liftcrane.
• Crowbar
• Wood planks, etc.
• Rag
Installation of Take-up Roller 2. Install the lifting equipment (4) on the take-up roller
(1) and recoil spring assembly (3) as in the diagram,
1. Place the take-up roller (1) and recoil spring assem- lift them up with the liftcrane, and insert them into
bly (2) onto wood planks (4) as in the diagram. Use the side frame (2).
a wrench (24 mm) to fasten the take-up roller (1) Push in with the crowbar until the recoil spring as-
and recoil spring assembly (2) with the bolt (3). sembly contacts the grease cylinder.
At this time, be sure to coat the bolt with Loctite
#262.
Installation bolt tightening torque: 267 - 312 N·m
5005B
Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Items to prepare
• Hexagon wrench (6 mm)
• Hammer
• Pliers
• Gear puller
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge
3. Remove the hub pin (2) from the hub (1), and re- 5. Remove the floating seal (1) on the roller. As de-
move the hub (1) from the shaft (3). scribed in step 4, check whether the sliding sur-
face has rusted or is damaged. Also make sure the
• Only remove on one side. O-ring is not twisted.
4. Check whether the surface of the floating seal (1) 6. Remove the O-ring (2) on the shaft (1) and then pull
sliding against the removed hub has rusted or is the shaft (1) out.
damaged. Also make sure the O-ring (2) on the seal
ring (3) is not twisted. • The O-ring cannot be reused. Replace it with new
part.
• The O-ring cannot be reused. Replace it with new
part.
8. As described in step 5, remove the floating seal (1) 9. Use a micrometer caliper (4), cylinder gauge (5),
on the opposite side. and caliper (6) to measure the roller (with bushing)
(1), hub (2), and shaft (3) for wear and deformation.
Replace with new parts as necessary.
Assembly Procedures
1. Clean all parts.
• Find a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.
4. Use the jigs (2) (3) attached to the pressing machine 6. Use jig C (3) to attach the floating seal (2) to the
to attach the bushing (1). Use the pressing machine roller (1) side.
to press from the opposite side. Next, use a special
fiber cloth to remove all dust and debris.
9. After attaching the O-ring (4) to the shaft (1), attach 12. Inject compressed air (0.2 MPa) from the oil fill port
the shaft to the hub (2) and fasten it with the hub pin and immerse in water to check that there are no
(3). leaks.
10. Attach the shaft (2) to the roller (1). 13. Fill engine oil (120 cc) into the roller main unit.
• The roller main unit can be very unstable, so be
careful in securing it.
11. Install the opposite side hub (1) on the roller (2) and
fasten with the hub pin (3).
14. After filling the oil, use a hexagon wrench (6 mm) (2)
to tighten the plug (1) with the nylon seal applied.
• To reuse a plug, wrap it with seal tape.
5005C
Items to prepare
• Wrench (24 mm, 27 mm)
• Hammer
• Lifting equipment
• Loctite #262
• Striking jig
• Striking jig
• Crowbar
• Wood planks, etc. 3. Jack up the side frame on the side where the grease
• Rag cylinder is being removed as shown in the diagram.
Jack up so that the shoe is floating about 5 cm,
and insert wood plank (1) under the lower frame to
prevent falling.
5. Install the wire (2) on the grease cylinder assem- Installation of grease cylinder
bly (1), and then lift it with the liftcrane so that it is
slightly tensed. To install, perform the reverse of the removal procedure.
Grease cylinder installation bolt tightening torque: 267 -
312 N・m
When installing bolts, coat the threaded sections with
Loctite #262.
5005D
Configuration diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Items to prepare
• Hammer
• Wrenches (19 mm)
• Box wrench (19 mm)
• Screwdriver
• Specialty jigs
• Special fiber cloth (Kimwipe)
• Marking pen
Disassembly procedures 3. Use the removal jig (B) to remove the dust seal (2)
from the grease cylinder (1).
1. Clean the grease cylinder with kerosene, remove
the bolt (1) and washer (2), and remove the bracket
(3).
Remove the check valve (5) from the grease cylin-
der (4).
2. Pull out the piston rod (2) from the grease cylinder
(1).
Assembly procedures 4. Use the jig (A) and hammer (C) to install the dust
seal (2) on the grease cylinder (1).
1. Place parts in a rough cleaning container filled with Apply grease to the lip section of the dust seal (2).
kerosene to clean off any adhered matter that can
form sharp points and cause scratches. • Use a new dust seal (2).
6001
CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
2. Slowly rotate the shoe so that the shoe joint section
• Box wrenches (19 mm, 24 mm) (3) is aligned as in the diagram on the right.
• Wrenches (19 mm, 27 mm, 41 mm) 3. Place wood planks (4) under the shoe and return
• Hammer (to remove the master pin) the bucket to its original position.
• Striking jig (to remove the master pin) 4. Perform air bleeding for the hydraulic line.
• Liftcrane (with the required lifting capacity) For details, see Air Bleed Procedures.
• Wire rope (with the required breaking load)
• Loctite #262
• Wood planks, etc.
• Rag
• Cleaning fluid
5. Use a box wrench (19 mm) to rotate the grease 8. Open the shoe (2) to the rear.
cylinder check valve (5) and loosen the shoe ten-
sion.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off. Be careful not to work in front
of the check valve.
6. Pull out the S-pin (6) from the rear of the joint sec-
tion.
7. Place a striking jig (9) against the master pin (7) and
hit it with a hammer (8) to push the master pin out.
11. Use a wrench (19 mm) to remove the pilot hoses 13. Use a box wrench (24 mm) to remove all 28 bolts
(15) (14) shown in the diagram. (18).
12. Attach the wire rope (17) to the travel motor (16) as
in the diagram.
Adjust the wire rope so that it is located at the center
of mass and lift it with the liftcrane so that it is slightly
tensed.
Installation of Travel Motor 3. Use a wrench (19 mm) to remove the elbow joint (3)
and pilot hose (4) shown in the diagram.
1. Attach the travel motor to the lower frame as in the
diagram.
• Be careful of the installation angles.
5. Use a wrench (19 mm) to install the cover (8) with 8. Tighten the check valve (12).
the 4 bolts (7). While monitoring the track shoe tension, inject
grease into the grease cylinder.
6002
Standardized
No. Type and dimen-
No. Tool name Part used with
Manufacturer sions
name
1 Nominal size 60 1-2-19
2 Nominal size 120 1-2-8
3 Nominal size 230
4 Nominal size 450 1-2-20
5 Nominal size 900 24, 28
Nominal size
6 Preset-type torque wrench JIS B4650 1-2-2-4, 1-2-11, 1-2-14, 29
1800
Nominal size
7 11
2800
Nominal size
8 1-2-7
4200
Nominal size
9 8, 14
5600
10 Rachet handle for socket wrench JIS B4641
11 Bolt width 2.5 mm 1-2-19
12 Bolt width 4 mm 1-2-8
13 Bolt width 6 mm 1-2-20
14 Hexagon bit for socket wrench Bolt width 8 mm 28
15 Bolt width 10 mm 1-2-11
16 Bolt width 12 mm 11、29
17 Bolt width 14 mm 1-2-2-4
18 Size T50 24
Torx T-shaped bit JASO F116-89
19 Size T90 8, 14
20 Bolt width 10 mm 1-2-14
Socket for socket wrench JIS B4636
21 Bolt width 27 mm 1-2-7
22 Bolt width 2.5 mm 1-2-19
23 Bolt width 4 mm 1-2-8
24 Bolt width 6 mm 1-2-20
25 Hexagon wrench JIS B4648 Bolt width 8 mm 28
26 Bolt width 10 mm 1-2-11
27 Bolt width 12 mm 11, 29
28 Bolt width 14 mm 1-2-2-4
29 Bolt width 10 mm 1-2-14
Wrench JIS B4630
30 Bolt width 27 mm 1-2-7
31 Longnose pliers JIS B4631 1-2-7
32 Snap ring pliers S-2 type 1-4-5
33 Flathead screwdriver JIS B4609 6 x 100 2, 1-27, 1-2, 1-21
34 Plastic hammer OF-05 Nominal size #3
Length of about
35 Punch
10 mm
36 Press 200 kgf or higher
37 Liftcrane For 400 kg
38 For M20
Eyebolt
39 For M12 1-2
40 Chain string (wire)
Secondary Materials
The secondary materials required for the assembly and disassembly of this motor are indicated in Table 2.
Standardized
No. Type and dimen-
No. Secondary materials name Part used with
Manufacturer sions
name
1 Seal tape 1-2-8
2 Adhesive Loctite 271 8, 14
1-1, 1-7, 1-6, 1-2-1, 1-2-2, 1-2-9,
GL-4#90
3 Gear oil 1-4-1, 1-4-2, 1-21, 1-4-4, 1-4-3, 1-5,
equivalent
1-4-2, 1-6
ISO VG46
4 Hydraulic oil
equivalent
1-2-2-5, 1-2-6-2, 1-2-6-4, 1-2-12, 1-2-
5 Grease Lithium-series
21, 1-16, 1-17, 1-23, 1-12, 1-15, 1-21
No.2 equiva-
6 White kerosene
lent oil
7 Liquid packing ThreeBond 1211 4, 27
For sliding sur-
8 Lapping plate 1-4-1, 1-4-2, 1-5、1-21
face repair
For sliding sur-
9 Lapping agent #1000
face repair
10 Copper plate
11 Tube brush For cleaning 1-2-1, 1-4-1
12 Bamboo brush For cleaning
13 Oil pan Oil pan
14 Plastic container For filling grease
15 Rag
Standard-
Type and
ized No. Part used
No. Tool name dimen-
Manufac- with
sions
turer name
1 Pulley remover 1-8, 1-9
2 Bearing press-fit jig 1-8
3 Bearing press-fit jig 1-9
4 Floating seal mounting jig 2
5 Rod 3
6 Angular bearing press-fit jig 3
7 Shim thickness adjustment jig 5
8 Rod 1-2-2
10 Thrust plate selection jig 26
11 Oil seal press-fit jig 1-12
12 Brake piston positioning jig 1-15
13 Snap ring removal jig 1-4-5
14 Poppet seat removal jig 1-2-7-3
Measurement Device
The measurement devices required for assembly of this motor are indicated in Table 4.
Standard-
Type and
ized No. Part used
No. Tool name dimen-
Manufac- with
sions
turer name
1 Dial gauge JIS B7503 5, 26
Micrometer
2 JIS B7502 5, 26
caliper
Tightening Torque
Table 5 indicates tightening torque for each fastening section.
Reference
Part name Screw size Bolt width Tightening torque
number
1-2-2-4 Plug M24 x 1.5 14 127 - 147 N・m
1-2-6-4 Hexagon socket head bolt M12 x 1.75 x 40 L 10 98 - 118 N・m
1-2-7 Relief valve assembly 1-5/16 12UNF 27 353 - 393 N・m
1-2-8 Plug NPTF1/16 4 8.8 - 10.8 N・m
1-2-11 Plug G1/2 10 112 - 124 N・m
1-2-14 Plug G1/2 10 112 - 124 N・m
1-2-17 Orifice M5 x 0.8 x 5 L 2.5 1.96 - 2.94 N・m
1-2-18 Orifice M5 x 0.8 x 5 L 2.5 1.96 - 2.94 N・m
1-2-19 Orifice M5 x 0.8 x 5 L 2.5 1.96 - 2.94 N・m
1-2-20 Plug G1/4 6 34.3 - 39.3 N・m
1-11 Hexagon socket head bolt M14 x 2.0 x 35 L 12 195 - 215 N・m
8 Bolt M20 x 2.0 x 70 L Torx T90 512 - 566 N・m
14 Bolt M20 x 2.0 x 130 L Torx T90 512 - 566 N・m
24 Screw M10 x 1.5 Torx T50 53.9 - 63.7 N・m
28 Hexagon socket head bolt M10 x 1.5 x 16 L 8 69.77 - 77.03 N・m
29 Plug G3/4 12 149 - 165 N・m
CAUTION
Do not perform disassembly if it is not nec-
essary.
CAUTION
When removing the cylinder block assem-
bly, observe the following precautions.
1) Hold the cylinder block assembly
with both hands and lightly rotate it
left and right to slowly remove it.
2) Be careful not to scratch the sur-
face of the cylinder block (1-4-1) that
slides against the valve plate (1-21).
If this surface is scratched, the ma-
chine will no longer display pre-
scribed capabilities.
3) Be careful not to scratch the piston
assembly (1-4-2) shoe sliding sur-
CAUTION
faces.
When removing the brake piston, observe If this surface is scratched, the ma-
the following precautions. chine will no longer display pre-
scribed capabilities.
1) When injecting compressed air from
the flange oil path for the parking
brake, do not let any compressed air
leak out.
2) When injecting compressed air from
the flange oil path for the parking
brake, the brake piston may fly off if
the pressure of the compressed air is
high, and this may cause injury.
For this reason, set the air pressure at
0.29 MPa or below, and hold down the
brake piston while performing work
so that it does not fly off.
2) Mark the piston assemblies (1-4-2) and re- 4) Secure the cylinder block (1-4-1) on the man-
tainer plate (1-4-3) with permanent ink so that ual press platform with the sliding surface fac-
parts can be reassembled in the exact same ing up, remove the snap ring (1-4-5), press the
configuration, and remove the piston assem- collar (1-4-8) with the jig to make the spring
blies from the retainer plate. (1-4-7) bend, and use snap ring pliers to re-
move the snap ring.
CAUTION
When removing the snap ring, ob-
serve the following precaution to pre-
vent injuries.
1) The snap ring is stiff and may
come off from the snap ring pli-
ers when the snap ring is being
removed, which could cause in-
jury.
When removing the snap ring,
make sure to use a disassembly
jig and check that the nails of
3) Remove the retainer holder (1-4-4) from the the snap ring pliers are in the
cylinder block (1-4-1) and remove the pins snap ring hole before removal.
(1-4-9) from the cylinder block.
CAUTION CAUTION
When removing the swash plate, observe When removing the shaft, observe the fol-
the following precautions. lowing precautions.
1) Be careful not to scratch the swash 1) Be careful not to scratch the splines
plate sliding surface. on the shaft.
If this surface is scratched, the ma- 2) Be careful not to scratch the sliding
chine will no longer display pre- section of the shaft oil seal (1-12).
scribed capabilities. Scratching this surface may cause oil
2) Piston assemblies (1-7) and steel leaking.
balls (1-6) may be attached to the
swash plate.
When these are attached, be careful
not to let them fall.
CAUTION
When removing the 1st stage holder as-
sembly, observe the following precaution.
When removing the assembly, be careful of
fingers getting caught.
CAUTION
When loosening bolts, observe the follow-
ing precautions.
1) Loctite has been applied to the bolts
to prevent loosening.
For this reason, securely fix the
flanges.
2) When loosening bolts, use a tool
such as a steel pipe to reach the
bolts.
Straining excessively may cause
back pain or injury.
23. Removal of planetary gear C
Secure the flange (1-1) and loosen the bolts (14) to
remove them.
Next, remove the thrust plates (13), planetary gears
C (12), needle bearings (11), inner races (10), and
thrust plates (9), in that order.
Maintenance Standards
Motor Parts Maintenance Standards
Table 6 indicates maintenance standards for motor parts.
Check each part according to the motor parts maintenance standards in Table 6. When a permissible limit has been
exceeded or is near being exceeded, perform part repair or replacement according to repair and solution procedures.
1) Check that there is no dirt adhered to 1) Use the shim thickness adjustment jig to
the floating seal mounting surface on press the inner ring end sections of the
the housing. angular bearings (3) with a load of 2.94
2) Thoroughly degrease the floating seal kN.
mounting surface on the housing 2) Measure the H level dimensions at this
3) Check that there is no dirt adhered time for the angular bearings inner ring
to the O-ring surfaces on the floating end surfaces and flange (1-1) end sur-
seals. face.
4) Thoroughly degrease the O-ring sur- 3) Measure the h level dimensions of
faces on the floating seals. holder C (6).
4) Select a shim and install it so that the
shim thickness is appropriate to the di-
mensions (H-h).
CAUTION
1) Do not reuse shims.
2) Be sure to perform this
procedure properly.
If precompression adjust-
ment is not done properly,
reduction gear damage
could occur during opera-
tion.
3) Clean the measurement
4) Attachment of the housing to the flange surfaces.
After confirming the items below, use a
liftcrane to attach the housing to the flange so
that the floating seal (2) section of the flange
(1-1) is aligned with the floating seal section
of the housing (4).
Confirmation items:
1) Check that there is no dirt adhered to
the seal ring sliding surfaces of the
floating seals.
2) Apply reduction gear lubricating oil or
hydraulic oil all around the seal ring
sliding surfaces of the floating seals.
3) When attaching the flange and hous-
ing, attach them after checking that
the axis center is aligned.
*1 Press load of 2.94 kN
*2 H dimensions
*3 h dimensions
6) Holder attachment
Secure the flange (1-1) and stand the pins
(31) straight up on the flange in 4 locations.
Use grease to attach the shim selected in 5)
to holder C (6), and press fit the shim while it
5) Shim thickness selection is aligned with the pin holes on the holder.
Select the precompression adjustment shim Mount the washers (7) on the holder, apply
(5) thickness according to the following pro- Loctite to the threaded sections, and tighten
cedure. the bolts (8) to the specified torque.
Make the shear droop side face Mount so that the C2 chamfer
*1
the holder C (6) side. side is the seating surface side
*1
Thrust plate (9) attachment di- for the hexagon socket head
*2 bolts.
rection
CAUTION
1) Press fit the oil seal after ap-
plying grease to the internal di-
ameter surface of flange oil seal
press-fit section and the oil seal
outside diameter section.
2) Press fit the oil seal after apply-
ing grease to the lip section of
the oil seal inner diameter.
3) When press fitting the oil seal,
push it vertically with the press.
Slanting will cause damage to
the oil seal outer diameter sur-
face. 3) Steel ball attachment
4) When press fitting the oil seal, Attach steel balls (1-6) to the spherical hole
be careful not to scratch the lip sections of the flange (1-1).
section of the oil seal internal
diameter. CAUTION
Scratching may cause oil leak-
ing and reduction gear internal Before attaching the steel balls, ap-
damage could occur during mo- ply hydraulic oil to the inner diameter
tor operation. surface of the spherical holes of the
flange.
CAUTION CAUTION
CAUTION
1) Attach by matching the rear
surface spherical holes of the
swash plate with the steel balls
(1-6).
2) Attach the swash plate after ap-
plying hydraulic oil to the sur- Cylinder block attachment di-
*1
face of the steel balls. rection
3) After attaching the swash plate,
check that it moves smoothly. 2) Use the jig to press the top surface of
the collar (1-4-8) to attach the snap ring
(1-4-5).
CAUTION
1) The snap ring is stiff and
may come off from the
snap ring pliers when
the snap ring is being at-
tached, which could cause
injury.
Make sure to use a jig
when attaching the snap
ring, and check that the
nails of the snap ring pli-
ers are in the snap ring
hole before attachment.
2) When retracting the snap 4) Attach the retainer holder (1-4-4) to the
ring is difficult, use the cylinder block (1-4-1).
snap ring pliers that are
one size bigger.
3) When pressing in the col-
lar (1-4-8), make the cen-
ters of the cylinder block
and press align with each
other.
CAUTION
1) When placing the cylinder
block on the work plat-
form, check that there is
no foreign matter on the 6) Attach the piston assemblies (1-4-2) to
work platform. the cylinder block (1-4-1).
2) Be careful not to scratch
the surface of the cylinder CAUTION
block that slides against 1) Apply hydraulic oil to the
the valve plate. 9 cylinder block piston at-
Scratching may cause a tachment holes before at-
reduction in motor perfor- taching the piston assem-
mance and early damage blies.
to the motor. 2) Apply hydraulic oil to the
3) Apply grease to the pin spherical surface of the re-
holes before attaching the tainer holder (1-4-4) before
pins. attaching it.
CAUTION
The disk plates are wet type disk.
7) Cylinder block assembly attachment Before attachment, immerse the fric-
Place the valve plate (1-21) sliding surface tion material parts in hydraulic oil and
side of the cylinder block assembly (1-4) up- have the friction materials thoroughly
wards, engage the internal teeth splines of absorb the hydraulic oil.
the retainer holder (1-4-4) and cylinder block
(1-4-1) with the external teeth splines of the
shaft (1-3), and attach the cylinder block as-
sembly to the inside of the flange (1-1).
CAUTION
1) When performing attachment,
check that the piston assem-
blies (1-4-2), retainer plate
(1-4-3) and retainer holder do
not come off from the cylinder
block assembly.
2) Before performing attachment,
apply hydraulic oil to the swash
plate (1-5) surface and sliding 9) Brake piston attachment
surfaces of the piston assem- Attach the D-rings (1-16) (1-17) to the brake
blies. piston (1-15).
Next, place the large bore side of the brake
piston upwards and attach it to the flange
(1-1).
CAUTION
1) Thoroughly apply grease when
attaching the D-rings.
2) Attach the brake piston after
using a positioning jig to align
the flange base plate (1-2-1)
knock pin hole and brake piston
knock pin hole so that they are
arranged in a straight line.
3) When attaching the brake pis-
ton, apply grease to the outer
circumference of the brake pis-
ton and inner diameter section
of the flange.
4) Push and attach the brake pis-
ton evenly all around so that it
does not become slanted.
If the brake piston is attached at
a slant, this could cause opera-
tional problems or the D-rings to
break.
CAUTION
1) Place the copper alloy side of
the valve plate up to attach it.
2) Thoroughly apply grease to the
matching surface between the
base plate and valve plate to
prevent the valve plate from
falling.
3) Be careful not to scratch the
copper alloy surface of the valve
plate.
CAUTION
1) Replace the O-ring (1-2-7-7) with
new one before attaching the re-
lief valve assemblies.
2) Check that the O-ring (1-2-7-17)
13) Spool assembly attachment
and backup rings (1-2-7-18) are
Attach the spring (1-2-10) to the spool as-
mounted on the each poppet
sembly (1-2-9) and attach the assembly to the
seat (1-2-7-3).
base plate (1-2-1).
3) Apply grease to the O-rings and
After attaching the spool assembly, check that
backup rings before attaching
the O-rings (1-2-12) are mounted to the plug
the relief valve assemblies.
(1-2-11), attach the plug to the base plate, and
tighten it to the specified torque.
CAUTION
1) Apply grease to the O-ring.
15) Plunger assembly attachment 2) The cap assemblies are pushed
Attach the base plate (1-2-1) to the plunger by the springs.
assembly (1-2-2). Push the cap assemblies down
by hand when tightening the
CAUTION socket head bolts.
1) Apply hydraulic oil to the 3) When tightening the hexagon
plunger assembly outer circum- socket head bolts, evenly
ference before attachment. tighten the 4 bolts.
2) Attach the plunger assembly If the cap assemblies are tight-
slowly and in a straight line ened at a slant, this could cause
while rotating it. damage O-rings and cause oil
3) If the plunger assembly be- leaking.
comes stuck, do not force it too
much and lightly strike it with a
hammer.
Motor Installation
Inspection
Before placing the motor in the hydraulic shovel, perform inspection for the following items. If there is a problem,
perform the given procedure.
CAUTION
When motors are shipped from the plant they are filled with Nippon Oil Hypoid Gear Oil 90 lubricating
oil to the stipulated volume (5.0 L).
Diagram 8. Oil fill, oil drain and oil check ports for reduction gear lubricating oil and stipulated oil volume
Troubleshooting
See the troubleshooting section below to perform checking, countermeasures and to solve problems when any kind
of problem occurs in the motor during operation.
1. Piston motor troubleshooting
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pressure is reaching
There is an operation problem in a piece of
the motor inlet side, investigate the causes of
equipment other than the piston motor or reduc-
problems and countermeasures for each piece
tion gear.
of equipment and perform inspection and repair.
Perform disassembly and clean and remove dirt
If the cause is in the motor itself, there is dirt
from parts before reassembling the motor.
clogging an operation section or there is an op-
If parts are damaged due to dirt, replace the
eration problem.
parts.
Operate the main relief valve of the circuit and
Motor inlet side pressure is low.
raise the set pressure.
The motor does
not rotate Perform disassembly and replace abnormally
There is abnormal wear on the sliding sections worn parts.
of the piston motor and pressure oil is escaping. After completely removing surface scratching,
burrs, etc. and cleaning, perform reassembly.
Damage is occurring with the main parts of the
Perform disassembly and replace damaged
piston motor.
parts.
In this instance, abnormal noise is coming from
Perform reassembly after cleaning parts.
the piston motor.
Investigate the load conditions and adjust the
The load on the piston motor is too large and
load to an amount appropriate to the set pres-
the relief valve is operating.
sure of the relief valve.
After investigating whether the required flow is
The cause resides in the hydraulic pump, pres-
being supplied to the piston motor inlet side, in-
sure control valve, flow control valve, etc. Re-
vestigate the causes of problems and counter-
quired oil flow is not being supplied to the piston
measures for each piece of equipment and per-
motor and rotation is insufficient.
form inspection and repair.
Motor rotation
Pressure oil is moving from the high-pressure Perform disassembly, investigate the status of
speed is insuffi-
side to the low-pressure side due to wear on wear on the sliding sections of the piston motor,
cient
the sliding sections of the piston motor (volume and perform repair or replacement according to
efficiency reduction) and speed is insufficient. the maintenance standards.
There is looseness in the piston motor base
Retighten the base plate fastening bolts to the
plate fastening bolts. Internal leaking is in-
specified torque.
creased and speed is insufficient.
There is wear on the sliding sections of the pis-
Perform disassembly, check the status of wear
ton motor and high-pressure oil is leaking and
on the sliding sections, and perform repair or re-
flowing out from the drain port, which is causing
placement according to the maintenance stan-
speed to greatly decrease and causing rotation
Motor rotation dards.
variation.
variation is high
Perform disassembly, check the status of wear
When going down an incline, the double counter
on the double counter balance valve, and per-
balance valve is causing hunting and rotation
form repair or replacement according to the
variation.
maintenance standards.
The shaft is touching driven parts due to prob-
lems with shaft core alignment, and this is pro- Make the shaft core alignment accurate.
ducing noise.
Noise is high
There is wear or damage on the piston motor Perform disassembly and replace damaged
bearings or damage has occurred on springs, parts such as bearings or springs.
etc. and noise is being produced. Perform reassembly after cleaning parts.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
There is looseness in bolts on matching sur- Retighten the fastening bolts to the specified
faces, etc. and oil leaking is occurring. torque.
Perform disassembly and replace seals.
Check the hydraulic oil temperature.
Oil leaking is occurring due to damage to oil When the temperature of the hydraulic oil is
seals, O-rings, packings, etc. 80 °C or higher during operation, recheck the
cooler and reduce the temperature of the hy-
draulic oil to below 80 °C.
Perform disassembly, check the status of wear
Oil leak The amount of drain oil is high due to wear on on the sliding sections, and perform repair or re-
the sliding sections of the piston motor and oil placement according to the maintenance stan-
leaking is occurring due to damage to the oil dards.
seals. Replace oil seals.
Perform reassembly after cleaning parts.
Perform disassembly and replace oil seals.
Drain pressure has increased due to clogging
Perform drain line cleaning and remove foreign
in the drain line or because the drain line is long
matter.
and thin, and this has damaged the oil seals and
Recheck lines and minimize resistance in line
oil leaking is occurring.
paths.
The amount of hydraulic oil in the hydraulic tank Check the amount of hydraulic oil in the hy-
has decreased and aeration is occurring due to draulic tank and fill with hydraulic oil according
tank taking in air. to the instructions on the machine main unit.
Hydraulic oil within the motor lines and motor Check the motor installation direction and cor-
Cavitation is circuit is flowing out while hydraulic devices are rect it.
causing abnor- turned off because the motor installation direc- Check that the oil surface within the hydraulic
mal noise, rota- tion is inappropriate or the hydraulic tank posi- tank is above the motor, and either modify it so
tion variation and tion is inappropriate, and this is causing aeration that it is above the motor or set up a self-supply
pressure varia- to occur within the motor just after the motor is circuit so that the insides of the motor circuit and
tion. started. lines are fully supplied with oil before driving.
When the motor is pumping, pressure on the
Perform disassembly and perform repair or re-
motor inlet side becomes negative due to dou-
placement of the double counter balance valve
ble counter balance valve operation problem,
according to the maintenance standards.
and cavitation occurs.
The load is too large and this caused the engine Check the load conditions and change the load
to stall. to an appropriate amount.
Motor rotation Investigate specifications values (especially
stopped during flow amount and motor speed).
operation Seizing occurred in the sliding sections of the If the motor speed has exceeded the upper limit,
piston motor and the motor stopped rotating. lower the flow amount.
It is not possible to reuse the inside of the motor,
so the motor should be replaced.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
Perform disassembly and replace the parking
Parking brake torque has decreased due to disk
brake disk.
wear.
Perform reassembly after cleaning parts.
The motor rotates The disk surface has been altered due to con- Perform disassembly and replace the disk.
if it is stopped with tact errors, etc., and the parking brake torque Also, repair the surface of the disk companion
external load act- has decreased. parts and perform reassembly.
ing on the motor. The springs are worn or damaged and the park- Perform disassembly and replace the spring.
ing brake torque is reduced. Perform reassembly after cleaning parts.
The external load is too large and the parking Check the external load and change the load to
brake capabilities are insufficient. an appropriate amount.
O-rings are damaged and pressure oil is escap- Perform disassembly and replace the O-rings.
ing, so the parking brake cannot be released. Perform reassembly after cleaning parts.
Foreign matter is clogging the orifice inside the
Motor drive force Perform disassembly and remove foreign mat-
parking brake release oil path and pressure oil
is not being pro- ter from the orifice.
is not reaching the parking brake cylinder cham-
duced. Perform reassembly after cleaning parts.
ber, which prevents the parking brake from be-
Motor is heating Also, flush the inside of the line.
ing released.
up to an abnormal
degree. Drain pressure has increased due to clogging
Clean the drain line.
in the drain line or because the drain line is long
Also, recheck the line system and minimize re-
and thin, and the parking brake cannot be re-
sistance in the line path.
leased.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
There is foreign matter caught between the pop-
Perform disassembly and remove foreign mat-
pet seat and poppet on the relief valve, which
ter.
is causing seating problems, and high-pressure
Perform reassembly after cleaning parts.
oil is leaking to the low-pressure side.
Replace the relief valve.
The relief valve spring is damaged and high-
Disassemble the motor and reassemble it after
pressure oil is leaking to the low-pressure side.
cleaning each part.
The motor does
The relief valve spring is worn and the set pres-
not rotate or motor
sure is decreased, which causes the relief to op- Replace the relief valve.
rotation is slow.
erate at low pressure.
There is foreign matter caught in the seat sec-
Remove the relief valve and remove foreign
tion of the free piston and base plate of the relief
matter.
valve and the set pressure has decreased.
There is foreign matter clogging the orifice set
Remove the relief valve and remove foreign
in the poppet of the relief valve, and the set
matter.
pressure has decreased.
There is foreign matter caught between the pop-
Perform disassembly and remove foreign mat-
pet seat and poppet on the relief valve, which is
ter.
causing seating problems, and the relief valve
Perform reassembly after cleaning parts.
does not close.
Replace the relief valve.
The relief valve spring is damaged and the relief
Disassemble the motor and reassemble it after
does not close.
cleaning each part.
The motor does The relief valve spring is worn and the set
not stop or stop- pressure has decreased, which has caused the Replace the relief valve.
ping is slow. brake force to decrease.
There is foreign matter caught in the seat sec-
tion of the free piston and base plate of the re- Remove the relief valve and remove foreign
lief valve, and the set pressure and brake force matter.
have decreased.
There is foreign matter clogging the orifice set
Remove the relief valve and remove foreign
in the poppet of the relief valve, and the set
matter.
pressure and brake force have decreased.
There is foreign matter caught in the sliding sec-
Replace the relief valve.
tion of the poppet and the poppet is not moving.
Shock at stopping
There is foreign matter caught in the free piston Remove the relief valve and reassemble after
is high
and the piston is not moving. removing foreign matter.
The relief set pressure is too high. Replace the relief valve.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pressure oil is
reaching the motor inlet side, investigate the
Pressure oil is not reaching the motor inlet and
causes of problems and countermeasures for
the plunger is not switching.
each piece of equipment and perform inspec-
tion and repair.
Measure the pressure of the return side inside
the motor circuit, and check that the pressure
Pressure is reaching the motor inlet, but foreign
has increased.
The motor does matter is clogging the orifice in the pilot oil path
After this, perform disassembly and remove for-
not rotate or motor and the plunger is not switching.
eign matter.
rotation is slow.
Next, perform reassembly.
Perform disassembly and remove foreign mat-
ter.
Investigate the degree of damage according to
There is foreign matter caught in the plunger
the maintenance standards and reassemble the
and it is not switching.
plunger if reusing is possible.
If scratching makes the plunger unusable, re-
place it using the base plate kit.
Perform disassembly and remove foreign mat-
ter.
There is foreign matter caught in the plunger, so Investigate the degree of damage according to
the plunger does not return and brake force has the maintenance standards and reassemble the
decreased. plunger if reusing is possible.
If it is unusable, replace it using the base plate
kit.
There is damage to the plunger spring, so the
The motor does plunger does not return and brake force has Perform disassembly and replace the spring af-
not stop or stop- decreased. ter removing foreign matter.
ping is slow. Foreign matter is clogging the orifice in the pilot Perform disassembly and remove foreign mat-
oil path, and the plunger does not return or re- ter.
turn is slow. Next, perform reassembly.
The plunger spring is not fit in place. Fit the spring correctly in place.
The check valve is not fit in place. Fit the check valve correctly in place.
Perform disassembly and replace the spring af-
The check valve spring is damaged.
ter removing foreign matter.
The check valve spring is not fit in place. Fit the spring correctly in place.
When an exter- Perform disassembly and remove foreign mat-
There is foreign matter caught in the plunger
nal load acts on ter. After this, clean the plunger and perform
and plunger movement is not smooth.
the motor and reassembly.
pumping opera- The diameter of the pilot oil path orifice is wrong. Attach the correct orifice.
tion is done, rota-
tion variation oc- The pilot oil path orifice is not fit in place. Attach the orifice in the correct position.
curs.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
Perform disassembly and remove foreign mat-
ter.
There is foreign matter caught in the plunger, Investigate the degree of damage according to
plunger movement is poor, and counter balance the maintenance standards and reassemble the
functions are not fulfilled. plunger if reusing is possible.
If reusing is impossible, perform replacement
When an external with the base plate kit.
load acts on the Perform disassembly and replace the spring
motor and pump- There is damage to the plunger spring and
and perform reassembly after removing foreign
ing operation is counter balance functions are not fulfilled.
matter.
done, cavitation The plunger spring is not fit correctly in place
occurs and abnor- Fit the spring correctly in place.
and counter balance functions are not fulfilled.
mal noise is cre-
ated. There is damage to the check valve spring and Perform disassembly and replace the spring af-
counter balance functions are not fulfilled. ter removing foreign matter.
The check valve spring is not fit in place and
Fit the spring correctly in place.
counter balance functions are not fulfilled.
Foreign matter is clogging the orifice in the pilot
Perform disassembly and reassemble after re-
oil path, and counter balance functions are not
moving foreign matter.
fulfilled.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pilot pressure oil is
reaching the Ps port, investigate the causes of
Pilot pressure oil is not reaching the Ps port.
problems and countermeasures for each piece
of equipment and perform inspection and repair.
After performing disassembly and removing for-
eign matter, investigate the degree of damage
There is foreign matter caught between the
according to the maintenance standards and
spool and base plate, and the spool does not
Will not switch to switch. perform reassembly if reusing is possible.
high-speed rota- If reusing is impossible, perform replacement
tion with the base plate kit.
There is abnormal wear in the 2-speed control
Perform disassembly and replace using the
piston section, and pressure oil is leaking into
flange holder kit.
the case.
The 2-speed control piston is not fit in place. Attach the 2-speed piston in the correct position.
Foreign matter is clogging the orifice in the
Perform disassembly and reassemble after re-
2-speed oil path, and pressure oil is not reach-
moving foreign matter.
ing the 2-speed control piston.
Switching to high-
speed rotation oc-
curs, but switch-
There is abnormal wear in the 2-speed control
ing to low-speed Perform disassembly and replace using the
piston section, and pressure oil is leaking into
rotation occurs if flange holder kit.
the case.
the hydraulic oil
temperature in-
creases.
Even if the speed control switch is set to low Investigate whether the Ps port pressure is 0.5
speed, the Ps port pressure does not decrease. MPa or lower and recheck the line system.
Perform disassembly and replace the spring af-
The 2-speed control valve spring is damaged.
ter removing foreign matter.
The 2-speed control valve spring is not fit in
Attach the spring in the correct position.
place.
After performing disassembly and removing for-
Not switching to eign matter, investigate the degree of damage
low-speed rota- There is foreign matter caught between the according to the maintenance standards.
tion spool and base plate, and the spool does not
Perform reassembly if reusing is possible.
return.
If reusing is impossible, perform replacement
with the base plate kit.
Foreign matter is clogging the orifice in the
Perform disassembly and reassemble after re-
2-speed oil path, and pressure cannot escape
moving foreign matter.
from inside the 2-speed control piston chamber.
The 2-speed control valve spring is worn and
Perform disassembly and replace the spring.
the switching pressure is reduced.
Switching to low-
speed rotation oc- Foreign matter is clogging the pilot line, and the
Clean the inside of the line and remove foreign
curs, but switch- pilot pressure increases up to switchover pres-
matter.
ing to high-speed sure due to leaking from the 2-speed control
Also, recheck the line system.
rotation occurs valve.
during operation.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pressure is reaching
There is an operation problem in a piece of
the motor inlet side, investigate the causes of
equipment other than the piston motor or reduc-
problems and countermeasures for each piece
tion gear.
of equipment and perform inspection and repair.
There is an operation problem in the motor
See [1] - [5] in troubleshooting.
aside from the reduction gear.
A load exceeding the motor output torque is op- After investigating the load, remove the load
erating. acting on the motor.
Replace the reduction gear.
No rotation Investigate whether an excessive external load
The reduction gear angular bearing is damaged
is acting on the motor.
and will not rotate.
If the external load is excessive, remove this
load.
The gear inside the reduction gear is damaged
and it does not rotate.
The bearing inside the reduction gear is dam-
Replace the reduction gear.
aged and it does not rotate.
The spline inside the reduction gear is damaged
and it does not rotate.
The gear inside the reduction gear is damaged.
The bearing inside the reduction gear is dam- Replace the reduction gear.
aged.
Abnormal noise Perform disassembly and check the status of
is coming from damage.
the reduction gear There is wear on the sliding section of the re- If damage is discovered, replace the reduction
during driving. duction gear and interference between parts is gear.
occurring. In there are no parts that are especially dam-
aged, replace worn parts and reassemble after
cleaning.
Check that there are no locations from which oil
is leaking.
Perform disassembly and check the status of
Reduction gear lubricating oil is insufficient. damage within the reduction gear.
If damage is discovered, replace the reduction
gear. Fill with lubricating oil to the specified
volume.
The reduction Adjust the lubricating oil amount to the specified
There is too much reduction gear lubricating oil.
gear section is volume.
heating up to an The bearing inside the reduction gear is dam-
abnormal degree. Replace the reduction gear.
aged.
Perform disassembly and check the status of
internal damage.
An abnormal thrust load is occurring in the re- If damage is discovered, replace the reduction
duction gear due to inappropriate thrust plate gear.
selection. If no especially notable amount of damage is
discovered, replace the thrust plate with another
one of the correct thickness.
Trouble phe-
Suggested cause Countermeasure and solution
nomenon
Remove the cover, reapply liquid packing, and
There is looseness in fastening bolts on the re-
tighten the cover to the specified torque.
duction gear cover, and oil leaking is occurring.
Fill with lubricating oil to the specified volume.
Plugs for the oil fill, oil drain and oil check ports Retighten the plugs to the specified torque.
on the reduction gear cover are loose, and oil After tightening, fill with lubricating oil to the stip-
leaking is occurring. ulated volume.
Replace the O-rings for the plugs.
O-rings for oil fill, oil drain and oil check ports on
After replacement, tighten the plugs to the spec-
the reduction gear cover are deteriorating, and
ified torque and fill with lubricating oil to the stip-
oil leaking is occurring.
ulated volume.
Oil leaking is oc- There is cracking in the housing and oil leaking
curring Replace the reduction gear.
is occurring.
There is foreign matter caught on the sliding Disassemble the reduction gear, remove for-
surface of the floating seal and oil leaking is eign matter from the floating seal and perform
occurring. reassembly.
Oil leaking is occurring due to corrosion on the
sliding surface of the floating seal.
The O-ring of the floating seal is deteriorated or Disassemble the reduction gear and replace the
damaged and oil leaking is occurring. floating seal.
The seal collar of the floating seal is split and oil
leaking is occurring.
Structural Diagram
Part Table
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
1 Piston motor 1 1-2-19 Orifice 2 1-28 Plug 1
1-1 Flange 1 1-2-20 Plug 5 2 Floating seal 2
1-2 Base plate assembly 1 1-2-21 O-ring 5 3 Angular bearing 2
1-2-1 Base plate 1 1-2-22 Orifice 3 4 Housing 1
1-2-2 Plunger assembly 1 1-2-23 Orifice 1 5* Shim t = 0.05 1
Hexagon socket
1-2-2-1 Spool 1 1-2-24 8 5* Shim t = 0.1 1
head bolt
1-2-2-2 Check valve 2 1-3 Shaft 1 5* Shim t = 0.3 1
Cylinder block as-
1-2-2-3 Spring 2 1-4 1 5* Shim t = 0.5 1
sembly
1-2-2-4 Plug 2 1-4-1 Cylinder block 1 5* Shim t = 1.0 1
1-2-2-5 O-ring 2 1-4-2 Piston Assembly 9 6 Holder C 1
1-2-3 Spring seat 2 1-4-3 Retainer plate 1 7 Washer 8
1-2-4 Spring 2 1-4-4 Retainer holder 1 8 Bolt 8
1-2-5 Cap 2 1-4-5 Snap ring 1 9 Thrust plate 4
1-2-6 O-ring 2 1-4-6 Spring seat 1 10 Inner race 4
Relief valve assem-
1-2-7 2 1-4-7 Spring 1 11 Needle bearing 4
bly
1-2-7-1 Relief housing 1 1-4-8 Collar 1 12 Planetary gear C 4
1-2-7-2 Poppet 1 1-4-9 Pin 3 13 Thrust plate 4
1-2-7-3 Poppet seat 1 1-5 Swash plate 1 14 Bolt 4
1-2-7-4 Spring seat 1 1-6 Steel ball 2 15 Sun gear C 1
1-2-7-5 Spring 1 1-7 Piston Assembly 2 16 Snap ring 1
1-2-7-6 Plug 1 1-8 Ball bearing 1 17 Holder B 1
1-2-7-7 O-ring 1 1-9 Ball bearing 1 18 Thrust plate 3
1-2-7-9 Free piston 1 1-10 Pin 1 19 Inner race 3
1-2- Hexagon socket
O-ring 1 1-11 10 20 Needle bearing 3
7-10 head bolt
1-2-7-11 Backup ring 2 1-12 Oil seal 1 21 Planetary gear B 3
1-2-
Spring guide 1 1-13 Disk plate 3 22 Thrust plate 3
7-13
1-2-
O-ring 1 1-14 Friction plate 2 23 Thrust plate 1
7-14
1-2-
Locking screw 1 1-15 Brake piston 1 24 Screw 3
7-15
1-2-
Nut 1 1-16 D-ring 1 25 Drive gear 1
7-16
1-2-
O-ring 1 1-17 D-ring 1 26 * Thrust plate t = 3.6 1
7-17
1-2-
Backup ring 2 1-18 Spring 8 26 * Thrust plate t = 2.3 1
7-18
1-2-8 Plug 8 1-19 Pin 4 26 * Thrust plate t = 2.8 1
1-2-9 Spool assembly 1 1-20 Spring 2 26 * Thrust plate t = 3.0 1
1-2-9-1 Spool A 1 1-21 Valve plate 1 26 * Thrust plate t = 3.2 1
1-2-9-2 Spool C 1 1-22 O-ring 4 27 Cover 1
Hexagon socket
1-2-10 Spring 1 1-23 O-ring 1 28 16
head bolt
1-2-11 Plug 1 1-24 Nameplate 1 29 Plug 3
1-2-12 O-ring 2 1-25 Rivet 2 30 O-ring 3
1-2-13 Spring guide 1 1-26 Plug 2 31 Pin 4
1-2-14 Plug 1 1-27 Plug 1
6003
• Attach caps or plugs to the swing motor and hoses 6. Use a wrench (13 mm) to remove the bolt (15) on
to prevent any entry of water, dust or dirt. the clamp (16) for the hose.
• Clean the swing motor and hoses by spraying
them with a parts cleaner to prevent scratching
and prevent dirt from accumulating on the con-
nectors.
8. Wrap the wire rope (20) around the swing motor and
5. Use a wrench (19 mm) to remove the 3 bolts (13), lift it with a liftcrane.
and then remove the under cover (14).
• A knock pin (19) is driven into the installation sec-
tion of the swing unit. Apply lubricating oil to the
knock pin and pull it out together with the main unit
of the swing motor while hitting with a hammer.
6004
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Reduction Gear Breakdown Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Reduction Gear Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Motor installation
Lift the motor and gently fit it to the reduction gear,
then tighten the hexagon socket head bolts (2) (10
mm hexagon diameter) to the tightening torque of
90 N·m.
Install pipes (4) (3).
• Align the casing K1 (5) and ring gear (1) according
to the reference mark (*1) made before disassem-
bly.
1 Hexagon socket head bolt (12) 12 Thrust plate (3) 23 Roller bearing
2 Swing motor 13 Needle bearing (6) 24 Hose
3 Retaining ring 14 2nd stage planetary gear (3) 25 Drain plug
4 1st stage sun gear 15 Nut 26 Shaft
5 Pin (3) 16 Lock plate 27 O-ring
6 Spring pin (3) 17 Bolt (2) 28 Oil seal
7 Thrust plate (3) 18 Thrust plate (2) 29 Sleeve
8 Needle bearing (3) 19 2nd stage carrier 30 Roller bearing
9 1st stage planetary gear (3) 20 2nd stage sun gear 31 Housing
10 Pin (3) 21 1st stage carrier 32 Hexagon socket head bolt (12)
11 Spring pin (3) 22 Ring gear
8001A
Overall view
Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overall view
1 Swing motor
2 Center joint
3 Control valve
8001B
Port Diagram
Control Valve
Relief Valve
Port Port size Port name Port Port size Port name
P1 SAE6000psi 1 Pressure line pb3 G1/4 Left swing pilot line
SAE5000psi
A1 Left travel (forward) line pb4 G1/4 Boom 2-down drain line
3/4
SAE5000psi
B1 Left travel (backward) line pb5 G1/4 Arm 1-in pilot line
3/4
A2 SAE5000psi 1 Option line pb7 G1/4 Bucket-close pilot line
B2 SAE5000psi 1 Option line pb8 G1/4 Boom 1-down pilot line
SAE5000psi
A3 Swing right line pb9 G1/4 Arm 2-in pilot line
3/4
SAE5000psi Negative control power save
B3 Swing left line Pn1 G1/4
3/4 signal
Negative control power save
A5 SAE5000psi 1 Arm-out line Pn2 G1/4
signal
B5 SAE5000psi 1 Arm-in line PH G1/4 Pressure boost signal port
T1 Return line Ps1 G1/4 Negative control line
pb1 G1/4 Left travel backward pilot line T8 G1/4 Heat circuit line
pb6 G1/4 Right travel backward pilot line Pb2 G1/4 Option line
Port Port size Port name Port Port size Port name
P2 SAE6000psi 1 Pressure line pa7 G1/4 Bucket-open pilot line
SAE5000psi
A6 Right travel (forward) line pa3 G1/4 Right swing pilot line
3/4
SAE5000psi
B6 Right travel (backward) line pa8 G1/4 Boom 1-up pilot line
3/4
A7 SAE5000psi 1 Bucket-open line pa4 G1/4 Boom 2-up pilot line
B7 SAE5000psi 1 Bucket-close line pa9 G1/4 Arm 2-out pilot line
A8 SAE5000psi 1 Boom-up line pa5 G1/4 Arm 1-out pilot line
SAE5000psi
B8 Boom-down line PA G1/4 Upper signal
3/4
T2 Return line PT G1/4 Travel signal
pa1 G1/4 Left travel forward pilot line Ps2 G1/4 Negative control line
Swing priority variable orifice
pa6 G1/4 Right travel forward pilot line Pbu G1/4
switch signal
DR3 G1/4 Straight travel drain line Pa2 G1/4 Option line
Right
Port name Left side Port name Port size
side
1 Bucket close 1 Swing right G3/8
2 Boom down 2 Arm in G3/8
3 Bucket open 3 Swing left G3/8
4 Boom up 4 Arm out G3/8
P Pressure P Pressure G1/4
T Return T Return G3/8
Cushion Valve
Port Port name Port size Port Port name Port size
E, F Boom up G3/8 I, J Swing right G3/8
G, H Boom down G3/8 Q Swing pressure sensor signal G1/4
O, P Bucket open G3/8 U - G1/4
M, N Bucket close G3/8 S Swing priority orifice switch G1/4
C, D Arm out G3/8 V - G1/4
A, B Arm in G3/8 T Return (drain line) G1/4
K, L Swing left G3/8 R Heat circuit G1/4
Port Port name *ISO type Port size Port Port name *ISO type Port size
Remote control valve side/swing-
A G3/8 1 Cushion valve side port G3/8
left port
Remote control valve side/arm-in
B G3/8 2 Cushion valve side port G3/8
port
Remote control valve side/swing-
C G3/8 3 Cushion valve side port G3/8
right port
Remote control valve side/arm-out
D G3/8 4 Cushion valve side port G3/8
port
Shut-off Valve
HBCV
Swing Motor
Travel Motor
Center Joint
8001C
Discharge flow
Q[L/min]
8001D
a Normal screen
b Service support screen
Items to Prepare
Vacuum pump and power supply Wrenches (17, 19, 24, 27 x 2, 32,
1 5 9 Recording sheet
(for vacuum pump) 36 x 2)
2 Pressure gauge (10 MPa-1) 6 Rag 10 Pen
3 Pressure gauge (60 MPa-2) 7 Extension cable 11 Cleaning fluid
Hydraulic oil tank lid
4 Hexagon wrench (8 mm, 6 mm) 8
(for vacuum pump)
4. Ignition key
Switch OFF the ignition key (1), check that the en-
gine has stopped, then switch the ignition key ON
again. (Do not start the engine.)
2. Monitor check
Use the service check to check the no-load engine
maximum speed and the SP mode pump input milli-
amp.
Oil temperature 45 - 55 °C
Flip the gate lock lever (1) forward, then turn the 7. Bleeding pressure from inside the hydraulic oil tank
upper operation lever (2) about 10 times to bleed Press the air breather button (1) on top of the hy-
out the pressure. draulic oil tank to release the pressure inside the
tank.
Pressure Measurement
Main Pressure Measurement
1. Pressure gauge installation
Remove the pressure sensor (a1) (a2) installed
on the hydraulic pump (1) and install the pressure
gauge.
Pressure gauge
for 60 MPa G1/4
Port size
a Arm-out relief
When the attachment operates, since the pressure boost operates automatically, the pressure resulting from the pres-
sure boost setting can be checked for about 8 sec.
After 8 sec.or more, the standard set pressure can be checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.
a Boom-down relief
Pilot Pressure Measurement Install the pressure gauge (1) and measure the pres-
sure.
Pressure gauge installation
Engine speed 2000 min-1
Remove the plug with the wrench (1) to install a pressure
gauge at the pump pressure measuring port (P3). Work mode SP mode
Oil temperature 45 - 55℃
Measuring port P3 port
Set pressure 3.92 MPa
Pressure gauge
for 10 MPa G1/4
Port size
Pressure gauge
for 10 MPa G1/4
Port size
2. Cover removal
Remove the 5 bolts (1), then remove the cover (2).
7. After locking, check the pressure on the boosted For standard pressure
pressure side.
1. Loosen the standard lock nut (27 mm) (1).
Repeat [1] - [7] until the set pressure is correctly ad-
justed.
4 Control valve
5 Wrench (19 mm)
Pressure adjustment
Example: Arm-out (1) overload relief adjustment
1. Loosen the lock nut (1) with the wrench (2) and
adjust by turning the adjusting screw (3) with the
hexagon wrench (4).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first loosen 3. After adjusting the overload relief pressure, adjust
to a pressure lower than the set pressure, then the boosted pressure and standard pressure to
adjust on the tightening side. their normal values referencing the main pressure
adjustment procedure.
* For the position of each overload relief, see the
"Control Valve Relief Locations".
Swing relief pressure adjustment 3. After adjustment, lock the lock nut (1).
Swing relief pressure adjustment — CX250C 3. After adjustment, lock the lock nut (1).
LR only
Engine speed 2000 min-1
Work mode SP mode
Oil temperature 45 - 55℃
Measuring port P1 port
Measurement pressure 27.0 MPa
Pressure per rotation of
11.6 MPa/rotation
adjusting screw
8001E
Items to Prepare
Work Preparations 5. Install the vacuum pump (1) on the hydraulic oil tank
lid.
1. Check that the main unit is in its work posture (arm-
vertical).
2. Bleed out the pressure. (See the details on Bleed-
ing Pressure in the Pressure Measurement and Ad-
justment Procedures.)
* Perform a swing prevention check.
4 Bolt
8. Use the split flange (2) to install the adaptor (flange * When connecting, always check the connection
type (3)) on the tip of the hydraulic hose (1) removed positions.
in 7.. * Always have the metering valve (7) fully open.
Remove the vavuum pump and re-install the hy-
draulic oil tank the same way it was.
Install pressure gauges on P1 and P2.(See "Main
Pressure Measurement".)
Open the engine hood.(See "Main Pressure Adjust-
ment".)
4 Hydraulic hose
10. Install the hydraulic hose (3) on the flow meter (1) 11. Remove the cover.
IN side(2), then fasten with the spanner. 12. Remove the pilot hose for the boosted pressure sig-
Install the (prepared) hydraulic hose (5) on the flow nal, then plug the hose side. (See "Main Relief
meter (1) OUT side (4), then fasten with the span- Pressure Adjustment".)
ner.
Installs the adapter (6) to have instralled in opposite This completes the preparation for flow measurement.
in 8..
1 Lock nut 17 mm
2 Hexagon wrench 6 mm
1 Ignition key
8001F
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
* Be careful.
The drain volume varies greatly with the oil tempera-
ture.
6. Catch the stopper (1) between the sprocket section Forward Backward
and the frame and lock the travel motor. 1st 2nd 1st 2nd
speed speed speed speed
Right
Left
Swing Motor Drain Volume at the same time the motor starts.(At starting, start
measurement with a stop watch (2).)
Measurement After 60 sec., move the extension hose (3) to the
waste oil can (4).
1. Remove the 2 drain hoses (1) and put plugs in the
Measure the volume of oil in the measuring con-
hose side of each. (wrench size: 27 mm, clamp 22
tainer (1) as the drain volume for 60 sec.
mm (hose side))
Measure at least 3 times each for left and right.
Right Left
8001G
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Arm Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CAUTION
Always bleed off any air in the hydraulic cir-
cuits after replacing the hydraulic oil, repairing
or replacing hydraulic equipment, or removing
hydraulic pipes.
Air bleed procedure mode (when bleeding, follow the procedure be-
low.)
Hydraulic
Cylinder air Swing motor Travel motor
pump air Check
bleeding air bleeding air bleeding
bleeding
Hydraulic oil or hydraulic pump re-
placement
Cylinder replacement
1 Drain hose
2. If oil does not ooze out, stop the engine for now, and
fill hydraulic oil (2) from the air bleed port (1) into the
motor case.
Temporarily tighten the air bleed plug.
Run the engine at low idle, slightly loosen the air
bleed port (1) , and run until oil oozes from the air
bleed port (1) section.
Check
2 HBCV
After the air bleeding is complete, stop the engine for at
least 5 minutes to allow any air bubbles in the hydraulic 3. Execute steps 2. for the opposite side boom cylin-
oil tank to dissipate. der too.
4. Check boom operations.
If there is a delay in the operation response, bleed
the air again with the same procedure.
2 Hose mouthpiece
8002
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (7 mm, 19 mm, 22 mm, 24 mm, 27 mm, 36
mm) 3. Prepare a waste oil can (1) under the hydraulic oil
• Eyebolts (M12 x 2) tank.
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank
8. Cut the hose bands on the tank side, and tie the 10. Use a wrench (19 mm) to remove the 3 bolts (1) for
hoses together. the L-shaped frame (2) between the control valve
and the hydraulic oil tank, and then remove the
L-shaped frame.
11. Use a wrench (24 mm) to remove the 4 bolts (1) 13. Use a wrench (19 mm) to remove the 5 bolts (1)
and 4 collars (2) from the bottom of the hydraulic oil from the fuel tank side cover (2), and then remove
tank. the side cover.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame.
Do not lose them.
Also, mark or write down the location where they
are and how many.
Tightening torque for bolt installation: 232.4 - 276.0
N・m
Installation of Hydraulic Oil Tank For bolts for which the torque is not specified, check
of the "About This Shop Manual Section • Tightening
To install, perform the reverse of the removal procedure. Torque • Retightening Torque Table" in the explanation
Tighten bolts being installed to the specified torque. in the materials.
8003
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm, 22 mm, 27 mm,
36 mm) • Remove the engine hood.
• Hexagon wrenches (8 mm, 10 mm) For details, see "Removal and Installation of En-
• Nylon sling (with the required breaking load) gine Hood".
• Liftcrane (with the required lifting capacity) • Remove the side door (right). (For details, see
• Marking pen "Removal and Installation of Side Door".)
• Cap
• Plug 2. Close the drain cock (1).
• Rag
• Cleaning fluid
• Wood planks, etc.
4. Use a wrench (27 mm) to remove the hose (1), 7. Use a wrench (19 mm) to remove the 7 bolts (1),
use a wrench (19 mm) to remove the hose (2), use and then remove the cover (2) (3).
a wrench (22 mm) to remove the hose (3), use a
wrench (17 mm) to remove the 2 bolts (4) and 2
washers, and then remove the pilot filter (5).
• Remove the 5 stack solenoid. (For details, see
"Removal and Installation of 5 Stack Solenoid".)
10. Use a wrench (19 mm) to remove the 4 bolts (1), • Clean the pump and hoses by spraying with a
and then remove the center duct cover (2). parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
14. Use a liftcrane and the nylon sling (1) to pull the Installation of Hydraulic Pump
pump out from the shaft and lift the pump.
• When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for a bolt, see the "Bolt
Size and Torque Table".
• Fill the pump case with hydraulic oil from the drain port
so that no air remains in the pump case.
Additionally, when there is a 2nd option gear pump,
bleed off air from the air bleed port on the top surface
of the power take-off case.
1. Use a liftcrane and nylon sling (1) to secure the
pump.
• Use a hexagon wrench (10 mm) to install the suc- 6. Use a wrench (19 mm) to instal the 2 bolts (1), and
tion line bolts (1), and install the suction line (2). then instal the rear duct cover (2).
• Use a wrench (19 mm) to install the hydraulic pilot
hoses (3).
9. Use a wrench (19 mm) to instal the 8 bolts (1), and 11. Use pliers to tighten the hose bands (1) and install
then instal the duct cover (2). the 2 hoses (2).
Use a wrench (13 mm) to install the 2 bolts (3) and
2 washers, and then install the pre-filter (4).
10. Use a wrench (27 mm) to install the hose (1), use a
wrench (19 mm) to install the hose (2), use a wrench
(22 mm) to install the hose (3), use a wrench (17 12. Open the drain cock (1).
mm) to install the 2 bolts (4) and 2 washers, and
install the pilot filter (5).
• Install the 5 stack solenoid. (For details, see "Re-
moval and Installation of 5 Stack Solenoid".)
8004
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (7 mm, 19 mm, 22 mm, 24 mm)
• Hexagon wrenches (8 mm, 10 mm)
• Wire cutters 2. After opening the engine hood, use a wrench (19
• Eyebolts (M10 x 2) mm) to remove the 5 bolts (1), then remove the top
• Shackle (with the required lifting capacity) x 2 cover (2).
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood planks, etc.
4. Remove the connectors (1) (2) from the pressure 6. Use a wrench (7 mm) to remove the hose band (2),
sensor. then remove the low-pressure hose (1).
5. Use a wrench (7 mm) to remove the hose band (2), 7. Use a wrench (17 mm) to remove the 2 bolts (1),
and then remove the low-pressure hose (1). then remove the bracket (2).
11. Install the shackles (2) on the eyebolts, then use the
liftcrane and wire ropes (3) to lift the control valve
(1).
Installation of Control Valve 4. Use wrenches (19 mm, 22 mm) and hexagon
wrenches (8 mm, 10 mm) to install the control valve
1. Install the 2 eyebolts (1) (M10) on the control valve. lines and hoses.
5. Use a wrench (17 mm) to install the 2 bolts (1), then 8. Install the connectors (1) (2) on the pressure sensor.
install the bracket (2).
7. Use a wrench (7 mm) to install the hose band (2), 10. Use a wrench (19 mm) to install the top cover (2)
then install the low-pressure hose (1). with the bolt (1).
8005A
Items to prepare
• Wrenches (19 mm, 36 mm)
• Hammer
• Striking rod
• Liftcrane (with the required lifting capacity)
• Nylon sling (with the required lifting capacity)
2. Tie the cylinder rod with wire (1) so that it cannot
• Grease
come out.
• Rag
• Cleaning fluid
• Crosstie
• Wire
3. Turn the key switch (1) OFF and stop the engine.
4. Switch the key switch ON again, and then turn the • Use caps or plugs to cover the hoses and lines to
control lever (1) about 10 times to bleed out any prevent any entry of water, dust or dirt.
pressure. • Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
Note:
dirt from accumulating on the connectors.
Do not operate the bucket at this time.
10. Use a hammer (2) and striking rod (3) to push the Installation of Bucket Cylinder
pin (1) out.
• Tighten lines and bolts being installed to the specified
• When removing the pin, be careful not to damage torque.
the installed O-rings or dust seals. • When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.
11. Lift the bucket cylinder (1) and then place it on the
crosstie.
2. Tie the cylinder rod with wire (1) so that it cannot
come out.
4. Align the bucket cylinder (1) with the arm and use a
hammer (3) to push in the pin (2).
• If a pin is hard to insert, the cylinder is tilted.
• When inserting the pin, be careful not to damage
the installed O-rings or dust seals.
8005B
Items to prepare
• Wrenches (19 mm, 36 mm, 41 mm) 2. Use a wrench (19 mm) to remove the bolt (1) and
• Nylon sling (with the required lifting capacity) washer (2).
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire
4. Start the engine, move the arm out at idle, and re- 7. Switch the key switch ON again, and then turn the
tract the arm cylinder (1) rod. control lever (1) about 10 times to bleed out any
pressure.
Do not operate the arm at this time.
6. Turn the key switch (1) OFF and stop the engine.
10. Use a wrench (41 mm) to remove the hose (1) and
use a wrench (36 mm) to remove the hose (2).
• Use caps or plugs to cover the hoses and lines to
prevent any entry of water, dust or dirt.
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
12. Use a wrench (19 mm) to remove the bolt (1) and
washer (2).
13. Use a hammer (2) and striking rod (3) to push the
pin (1) out.
4. Align the arm cylinder with the boom and use a ham-
mer (2) to push in the pin (1).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed dust seals.
8. Start the engine, move the arm in at idle, and extend 10. Use a wrench (19 mm) to tighten the bolt (1) and
the arm cylinder (1) rod. washer (2).
• Grease up.
9. Align the arm cylinder (1) with the arm pin hole and
use a hammer (3) to insert the pin (2).
Be careful. The arm and arm cylinder rod may come
out of place at this time.
8005C
Items to prepare
• Wrenches (19 mm, 30 mm, 36 mm)
• Crowbar
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Nylon sling
• Marking pen
• Cap
• Plug
2. Use a wrench (19 mm) to remove the grease hoses
• Hammer
on the left and right sides (1).
• Striking rod
• Grease • Use caps or plugs to prevent any entry of water,
• Rag dust or dirt.
• Cleaning fluid
• Crosstie
• Wire
4. Use a hammer (2) and striking rod (3) to push the 7. Switch the key switch ON again, and then turn the
pin (1) out. control lever (1) about 10 times to bleed out any
Start the engine, lower the boom at idle, and retract pressure.
the boom cylinder (right) (left) rods.
6. Turn the key switch (1) OFF and stop the engine.
9. Press the air breather button (1) on top of the hy-
draulic oil tank to release the pressure inside the
tank.
11. Use a wrench (19 mm) to remove the bolt (1) and
washer (2).
Also, remove the cab side in the same way. 13. Use a liftcrane and nylon slings (1) to lift the boom
cylinders (right) (left) (2) (3) and remove.
• Place the boom cylinders (right) (left) (2) (3) on
crossties.
Installation of Boom Cylinder 4. Align the boom cylinders (right) (left) with the swing
frame pin holes and use a hammer (2) to push in
• Tighten bolts being installed to the specified torque. the pin (1).
• When the torque is not specified, check the "Bolt Size
and Torque Table". • When inserting the pin, be careful not to damage
the installed dust seals.
1. Clean each pin and pin hole.
3. Use a liftcrane and nylon slings (1) to lift the boom 6. Use wrench (36 mm) to install the hose (1).
cylinders (right) (left) (2) (3). Also, install the cab side hose in the same way.
7. Start the engine, raise the boom at idle, and extend 9. Use a wrench (19 mm) to attach the grease hoses
the boom cylinder (right) (left) (1) (2) rods. on the right and left sides (1).
Align the boom cylinder (right) (left) (1) (2) with the
boom pin holes and use a hammer (4) to push in • Grease up.
the pin (3). • When installing as far as the boom, first install
the bucket, bucket link, bucket cylinder, arm, arm
• If the insertion of a shim is possible according to cylinder according to their respective removal and
the tolerance adjust the shim. installation procedures.
8006
Items to prepare
• Wrenches (17 mm, 19 mm, 27 mm, 36 mm)
• Hexagon wrenches (5 mm, 6 mm)
• Box wrench (19 mm)
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
Cap 2. Attach the specialty adapter (1) to the area where
•
Plug the air breather is removed, and set the vacuum
•
Wire rope (with the required breaking load) pump (2).
•
Liftcrane (with the required lifting capacity) Create negative pressure in the hydraulic oil tank
•
Wood planks, etc. using the vacuum pump.
•
• Rag
• Cleaning fluid
• Waste oil can
4. Prepare a waste oil can (1) to receive the oil that 7. Use a wrench (19 mm) to remove the 2 bolts (2),
spills out under the center joint. and then remove the center joint lock bar (1).
5. Use a wrench (36 mm) to remove the travel hoses 8. Use a wrench (36 mm) to remove the 4 travel hoses
(1) and a wrench (27 mm) to remove the drain hoses (1).
(2).
• Mark the hoses so that the connectors can be
• Mark the center joint and hoses so that the con- matched during assembly.
nectors match at the time of assembly. • Attach caps or plugs to the hoses to prevent any
• Attach caps or plugs to the center joint and hoses entry of water, dust or dirt.
to prevent any entry of water, dust or dirt. • Clean the hoses by spraying them with a parts
• Clean the center joint and hoses by spraying them cleaner to prevent scratches and prevent dirt from
with a parts cleaner to prevent scratches and pre- accumulating on the connectors.
vent dirt from accumulating on the connectors.
9. Wrap wire ropes (1) around the center joint and sus-
6. Use a wrench (19 mm) to remove the pilot hoses (1) pend it with a liftcrane so that the center joint does
and a wrench (27 mm) to remove the drain hose (2). not fall during removal and installation operations.
• Attach caps or plugs to the center joint and hoses
to prevent any entry of water, dust or dirt.
• Clean the center joint and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
10. Use a wrench (19 mm) to remove the 4 bolts (1) Installation of Center Joint
from the center joint.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check the
"Bolt Size and Torque Table".
1. Wrap the wire rope (2) around the center joint (1)
and lift it with a liftcrane.
11. Use the wire ropes (2) and liftcrane to lift the center
joint (1).
Thoroughly check that the location is safe before
lowering the center joint on wood planks.
4. Use a wrench (19 mm) to install the 2 bolts (2), then 7. Use a box wrench (19 mm) to install the 8 bolts (2)
install the center joint lock bar (1). and install the lower under cover (1).
Bolt (2) tightening torque: 88.3 - 107 N·m
• Bolt (2) tightening torque: 63.9 - 73.5 N·m
• Apply Loctite #262 to the bolts.
8007A
CAUTION
• Be sure to stop the engine before beginning
work.
Items to prepare
• Wrench (19 mm)
• Hexagon wrench (8 mm)
• Phillips screwdriver
• Marking pen
• Cap
• Plug 2. Use a hexagon wrench (8 mm) to remove the 2 bolts
• Rag (2) on both the left and right sides, and then remove
• Cleaning fluid the left and right travel pedals (1).
4. Use a wrench (19 mm) to remove the 6 bolts (2), 6. Use a wrench (19 mm) to remove the 2 hose
and then remove the under cover (1). adapters (1).
5. Use a wrench (19 mm) to remove the 6 hoses (1). 7. Use a hexagon wrench (8 mm) to remove the 2 bolts
(1) on both the left and right sides of the travel lever.
• Mark the valve and hoses so that the connectors
match at the time of assembly.
• Install caps or plugs to the valve and hoses to
prevent any entry of water, dust or dirt.
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
Installation of Travel Remote 4. Use a wrench (19 mm) to install the 6 hoses (1).
Tightening torque: 25.4 - 31.4 N・m/44.0 - 54.0 N・
Control Valve m
Be careful not to connect the hydraulic hoses in incorrect
locations.
Before installing the hoses, check that the hose adapters
are not loose and retighten them to the specified torque.
When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Pull down the travel remote control valve (1) into the
cab, then install the travel remote control valve.
7. Use a hexagon wrench (8 mm) to install the 2 bolts 8. Install the floor mat (1).
(2) on both the left and right sides, then install the
left and right travel pedals (1).
8007B
CAUTION
• Be sure to stop the engine before beginning
work.
Items to prepare
• Wrenches (19 mm, 22 mm)
• Box wrench (10 mm)
• Hexagon wrench (5 mm)
• Phillips screwdriver
• Marking pen
• Cap
• Plug
• Rag 2. Use the Phillips screwdriver to remove the 2 screws
• Cleaning fluid (2), and then remove the handle of the tilt lever (1).
4. Use the Phillips screwdriver to remove the 2 screws 7. Roll up the boot (1) of the control lever, remove the
(1) of the console top cover. connector (2) of the horn switch, and cut the wire
band (3).
11. Use a hexagon wrench (5 mm) to install the 2 bolts Removal of Operation Remote
(2), and install the grip (1) of the gate lock lever.
Control Valve (right side)
1. Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm) to
remove the 2 bolts (2) of the console top cover.
4. Remove the 3 connectors (2) and remove the con- 7. While securing the nut (2) with a wrench (22 mm),
sole top cover (1). use a wrench (19 mm) to remove the lock nut (3)
and remove the control lever (1).
6. Roll up the boot (1) of the control lever, remove the 9. Use a wrench (22 mm) to remove the 6 hoses (1).
connector (2) of the horn switch, and cut the wire
band (3). • Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
10. Use the hexagon wrench (5 mm) to remove the 3 Installation of Operation Remote
bolts (1) and 3 washers (2).
Control Valve (right side)
1. Clean all the parts with a rag.
11. Use the Phillips screwdriver to install the 2 screws 12. Use the Phillips screwdriver or box wrench (10 mm)
(2), then install the handle of the tilt lever (1). to install the 2 bolts (2) for the console top cover and
cover the control lever boot (1).
8007C
CAUTION
• Be sure to stop the engine before beginning
work.
Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm, 22 mm)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
3. Remove the 5 connectors (1). • Clean the solenoid valve and hose by spraying
them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the con-
nector.
1 Solenoid valve
5. Install the 5 connectors (1).
*1 Hose assembly
*2 Code
Solenoid valve (left side) de-
*3
tails
Solenoid valve (right side) de-
*4
tails
• The electrical connector connection colors are in- 6. Use a wrench (13 mm) to install the 2 cover bolts
dicated below. (1), then install the cover (2).
8007D
CAUTION
• Be sure to stop the engine before beginning
work.
Items to prepare
• Wrenches (17 mm, 19 mm, 22 mm)
• Hexagon wrench (5 mm)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
2. Use a wrench (19 mm) to remove the 5 bolts (2),
and then remove the under cover (1).
scratches and prevent dirt from accumulating on 5. Use a wrench (17 mm) to remove the 4 bolts (1)
the connectors. on the cushion valve bottom, and then remove the
cushion valve.
*2 Use 22 mm wrench
*3 Use 19 mm wrench
2 Use 22 mm wrench
3 Use 19 mm wrench
3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
Swing priority switching pilot
11
line
12 Drain line
1 Arm in
2 Boom up
8008
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Install the pilot piston (643) into the flow control hole
on the casing.
10. Assemble the set spring (655) into the spool hole,
• Check that the pilot piston slides smoothly without assemble the compensation piston (621) and piston
catching. case (622) into the compensation hole, install the
6. Insert the pin press fit in lever 2 (613) into the groove pilot cover (641), and tighten the hexagon socket
on the pilot piston, and assemble lever 2. head bolts (436, 438).
7. Assemble the fulcrum plug (614) and install the 11. Install the spring seating (644), pilot spring (646),
locking ring (858) so that the pins press fit in the and adjusting ring (645) into the pilot hole, and in-
fulcrum plug are inserted into the pin holes on lever stall the spring seating (624), inner spring (626), and
2. outer spring (625) into the compensation hole.
• Be careful to install the spring seating in the cor-
rect direction.
8010
Recom-
Reference mended
Part name and inspection item dimen- replace- Solution
sions ment
value
Piston and cylinder bore clearance (D - d) 0.038 mm 0.065 mm Replace piston or cylinder.
Piston and shoe caulking section backlash (δ) 0 - 0.1 mm 0.3 mm Replace piston and shoe assembly.
Shoe thickness (t) 5.4 mm 5.0 mm Replace piston and shoe assembly.
Free height of cylinder spring (L) 40.9 mm 40.1 mm Replace cylinder spring.
Assembled height of holder plate and spherical Replace holder plate or spherical
23.8 mm 22.8 mm
bushing (H - h) bushing.
Cylinder opening diameter(spline in cylinder) Replace cylinder and spherical bush-
35.17 mm 35.57 mm
Spherical bushing spline ing.
Clearance between the piston and cylinder bore : D-d Free height of cylinder spring : L
Loseness of piston, shoe, and caulking : δ Combined height of pressure plate and spherical bush :
Thickness of shoe : t H-h
Standards for repairing cylinders, valve plates, and swash plates (shoe
plates)
Valve plate (sliding section)
Surface roughness re-
Swash plate (shoe plate 3-Z
quiring repair
section)
Cylinder Standard surface rough-
0.4 Z or lower (lapping)
Surface roughness ness (repair value)
Tightening torque
Tighten-
Part name Size ing torque Tool name (mm)
(N•m)
M5 6.9 B=4
M6 11.8 5
M8 29.4 6
M10 56.9 8
Hexagon socket head bolt M12 98.1 10
M14 156.9 12
M16 235.4 14
M18 333.4 14
M20 431.5 17
R 1/16 6.9 4
Rc plug R 1/8 10.3 5
NOTE: R 1/4 17.2 6
Wrap seal tape around the plug 1.5 - 2 times R 3/8 34.3 8
R 1/2 49.0 10 Hexagon
G1/4 29.4 6 wrench
G1/2 98.1 10
G3/4 147.1 14
PO plug
G1 186.3 17
G1 1/4 264.8 17
G1 1/2 274.6 17
Overall View
Attached diagram 1. pump assembly cross-section diagram
Part Table
Code Part name Q'ty Component part No. (Q'ty) or type
04 Gear pump 1 set ZX10LBRZ1-07A-V
011 Piston subassembly 2 sets 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC)
041 Check valve 1 subassembly 2 sets 541 (1PC), 543 (1PC), 545 (1PC)
042 Check valve 2 subassembly 2 sets 541 (1PC), 544 (1PC), 545 (1PC)
Electromagnetic proportional pressure
079 1 set KDRDE5KR-V3-V
reducing valve, casing subassembly
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC)
Operation explanation
1. Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi.(See the Pilot pressure Pi)
Discharge
volume Q
Pilot pressure Pi
1) When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the location
where the pilot spring (646) force and hydraulic pressure force balance each other.
The pin (875) fixed to lever 2 (613) fits into the crimped groove section [A section] of the pilot piston, so
lever 2 rotates through the movement of the pilot piston with point B [fastened by the fulcrum plug (614)
and pins (876)] as the fulcrum.
The pin (897) fixed to the feedback lever (611) projects into the large opening [C section] of lever 2, so as
lever 2 rotates, the pin (897) moves to the right.
The pin (548) fixed to the tilting pin (531) that shakes the swash plate is bonded to the 2-side width section
[D section] of the feedback lever.
Therefore, as the pin (897) moves, the feedback lever rotates with section D as the fulcrum.
Since the spool (652) is linked to the feedback lever via the pin (874), the spool moves to the right.
When the spool moves, the discharge pressure P1 is led to the servo piston large-bore chamber via the
spool and Cl port.
The discharge pressure P1 is always led to the servo piston small-bore chamber, but the servo piston is
moved to the right due to the surface area difference and the tilting angle is reduced.
When the servo piston moves to the right, point D also moves to the right.
The return spring (654) is mounted on the spool.
Since force pulling the spool to the left is always acting, the pin (897) is pressed into the large opening (C
section) of lever 2.
Because of this, accompanying the point D movement, the feedback lever rotates around the point C as
the fulcrum and the spool moves to the left.
This movement causes the open section between the sleeve (651) and the spool (652) to begin to close,
and the servo piston stops at the point the open section fully closes.
Flow reduction operation
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot spring (646)
force and lever 2 (613) rotates with point B as the fulcrum.
The pin (897) is pressed in the large opening [C section] of lever 2 by the return spring (654) via the spool
(652), pin (874), and feedback lever (611), so accompanying rotation of lever 2, the feedback lever rotates
with point D as the fulcrum and the spool moves to the left.When the spool moves, the Cl port opens to the
tank port, so the pressure in the large-diameter section of the servo piston drains out, the servo piston is
moved to the left by the discharge pressure P1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston, point D moves to the left, the feedback lever rotates with
point C as the fulcrum, and the spool moves to the right.
This operation continues until the open section between the spool and sleeve closes, and then the servo
piston stops at the point the open section fully closes.
2. Horsepower control
Discharge
volume Q
Discharge pressure
(1.33P1 + 0.67P2)
The pump tilting angle decreases when the load pressure increases and overload of the power source is pre-
vented and overload of the self pump is prevented.
The regulator utilizes a method to control horsepower in which a hydraulic force that is the sum of the self pump
pressure multiplied by 1.33 and the counterpart pump pressure multiplied by 0.67 is transmitted as a signal.
Discharge
volume Q
Discharge pressure
(1.33P1 + 0.67P2)
The flow control and the horsepower control tilting command is transmitted to the feedback lever and spool via
the large openings [C and F sections] of lever 1 and lever 2, but since the C and F sections have a structure in
which a pin (D4) projects into a large hole (D8), the pin (897) only contacts the lever that makes the tilting smaller
and the D8 hole for the lever on the side that has the larger tilting command state is free rather than being in
contact with the pin (897).
This type of mechanical selection method gives priority to flow control and horsepower control commands with
low tilting.
4. Power shift control (decreased horsepower control)
Discharge
volume Q
Discharge pressure
(P1 + P2)
Use the power shift pressure Pf to arbitrarily control the pump set horsepower.(See the Discharge pressure (P1
+ P2))
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right via the pin (898)
and the compensation piston (621), so the pump tilting angle and the horsepower setting are reduced in the same
way as was explained with the overload prevention operation of horsepower control.
By contrast, as the power shift pressure Pf decreases, the horsepower setting increases.
Regulator adjustment
The adjusting screws on this regulator can be used to adjust the maximum flow, minimum flow, horsepower control
properties, and flow control properties. (Each of the adjustment amounts is shown in "6. (1) Regulator adjustment
amount list".)
1. Maximum flow adjustment
Discharge
volume Q
Pilot pressure Pi
Loosen the hexagon nut (808) and tighten (or loosen) the locking screw (954) to adjust the maximum flow.
This only changes the maximum flow.
It does not change the other control properties.
2. Minimum flow adjustment
Discharge
volume Q
Pilot pressure Pi
Loosen the hexagon nut (808) and tighten (or loosen) the hexagon socket head locking screw (953) to adjust (or
tighten) the minimum flow.
Similar to the maximum flow adjustment, this does not change other control properties.
However, if the hexagon socket head locking screw is tightened too much, the required power may increase at
the time of maximum discharge pressure (during relief), so adjust this carefully.
Discharge
volume Q
Discharge pressure
(P1 + P2)
Loosen the hexagon nut (630) and tighten (or loosen) the adjusting screw (C) (628) to adjust the outer
spring.
As the adjusting screw is tightened, the control diagram shifts to the right as in the diagram on the right and
the input horsepower increases.
When the adjusting screw (C) is rotated N times, the inner spring setting also changes.
Therefore, return the adjusting ring (C) (627) by rotating it N x A times in the opposite direction.
2) Inner spring adjustment
Discharge
volume Q
Discharge pressure
(P1 + P2)
Loosen the hexagon nut (802) and tighten (or loosen) the adjusting ring (C) (627).
As the adjusting screw is tightened, the flow increases as in the diagram on the right and the input horse-
power increases.
Discharge
volume Q
Pilot pressure Pi
Loosen the hexagon nut (801) and tighten (or loosen) the hexagon socket head locking screw (924) to adjust the
flow control properties.
As the hexagon socket head locking screw is tightened, the control diagram shifts to the right as in the diagram
on the right.
(KR3K-9Y04-HV) (KR3K-9X04-HV)
Front side regulator Rear side regulator
Disassembly preparations
1. These regulators comprise small precision parts, so assembly and disassembly operations are somewhat com-
plex.
2. The pressure-flow settings of the front side regulator and the rear side regulator differ, so mark the regulators
when disassembling to differentiate between the drive side and the driven side.
3. When disassembling the regulators, read this disassembly procedure thoroughly before following the sequence
below.
The numbers in parentheses after the part names are the codes indicated in "Diagram 1.
Front-side regulator assembly cross-section diagram" "Diagram 2.
Rear-side regulator assembly cross-section diagram".
8. Remove the locking rings (858), and remove the 10. Pull out the pin (874), and remove the feedback
fulcrum plug (614) and adjusting plug (615). lever (611).
• The fulcrum plug (614) and adjusting plug (615) • Use a fine steel rod to push out the pin (874) (pin
can be easily removed by pulling them out with diameter D4) from above without touching lever 1
an M6 bolt. (612).
Assembly procedures
The assembly procedure is the reverse of the disas-
sembly procedure. However, follow the precautions
below.
1. Be sure to repair any parts damaged during dis-
assembly, and prepare replacement parts in ad-
vance.
2. Any foreign matter entering the equipment can
create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow
the equipment, and perform assembly in a clean
location.
3. Make sure to tighten bolts and plugs of each sec-
tion to the specified torque.
4. Be sure to apply clean hydraulic oil to sliding sec-
a Lever (1) side
tions before assembly.
5. As a rule, replace all seals such as O-rings with Lever (2) side (Fulcrum plug,
b
new parts. adjusting plug side)
*1 Spool
*2 Feedback lever
• At this time, check that the backlash from the 11. Install the spring seating (644), pilot spring (646),
movement of the feedback lever is not too great and adjusting ring (645) into the pilot hole, and in-
and that the feedback lever does not catch on stall the spring seating (624), inner spring (626), and
anything. outer spring (625) into the compensation hole.
9. Install the return spring (654) and spring seating • Be careful to install the spring seating in the cor-
(653) into the spool hole, and install the stop ring rect direction.
(814).
12. Assemble the cover (C) (629) set with the adjusting
10. Assemble the set spring (655) into the spool hole, screw (628), adjusting ring (C) (627), lock nut (630),
assemble the compensation piston (621) and piston hexagon nuts (801, 802), and the hexagon socket
case (622) into the compensation hole, install the head locking screw (924), and tighten the hexagon
pilot cover (641), and tighten the hexagon socket socket head bolts (438).
head bolts (436, 438).
Tightening torque
Tightening torque
Part No. Screw size
N•m
412, 413 M8 29
418 M5 6.9
436, 438 M6 12
466 G1/4 36
467 G3/8 74
496 NPTF 1/16 8.8
630 M30 x 1.5 160
801 M8 16
802 M10 19
Tightening torque
Part No. Screw size Tightening torque N•m
412, 413 M8 29
436, 438 M6 12
466 G1/4 36
467 G3/8 74
496 NPTF 1/16 8.8
630 M30×1.5 160
801 M8 16
802 M10 19
8011
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cautions for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of long cap and pull out of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of arm regeneration release valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of load check valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly of antidrift valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of valve housing union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for O-Ring handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for spool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adhesive application method (for male thread section and female thread section of parts requiring adhe-
sion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Procedure for assembly of sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of spool assembly (main spool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of arm 1 parallel-tandem spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of neutral cut spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of antidrift valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Procedure for assembly of control valve main unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of load check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of antidrift valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of arm regeneration release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of arm 1 parallel-tandem spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of neutral cut spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Procedures for assembly and disassembly of main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Procedures for assembly and disassembly of overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Procedures for assembly and disassembly of low-pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Procedures for assembly and disassembly of add-on main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Relief valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8011-1 PRINTED IN FRANCE
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly
Cautions for disassembly
1. On level ground, bring all the operating machines into contact with the ground.
When doing this, have the main machine in a horizontal position.
Check that the machine is in such a state that it will not travel or swing on its own.
Then stop the engine and bleed out the pressure from each actuator.
CAUTION
Do not replace a valve assembly or disassemble a valve with pressure remaining in the system.
This would be dangerous.
High-pressure oil might spray out or parts might suddenly come out.
For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the cir-
cuits.
Disassembly procedure
Removal of long cap and pull out of main spool
1. Loosen the hexagon socket head bolts (74) (8 mm hexagon socket diameter) for the 9 caps (8) and the 1 cap
(9), and remove them.
When pulling out the spool only, do not loosen the M6 screws on the plate except for the 4 hexagon socket head
bolts (75) and the 1 hexagon socket head bolt (94) fastening the plate assemblies.
2. Loosen and remove the plugs (91) (19 mm hexagon diameter) attached to the ports as necessary.
3. Remove the O-rings (7) (1 in each section) from the plate assemblies (10) and (11).
4. Pull out each spool from the valve housing still in the sub-assembly state.
CAUTION
1) When pulling out the spool, be careful not to cause any dents or scratches.
2) 2Identify each spool with a shipping tag so that there will be no mistake about their positions
when they are re-assembled.
5. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) and hexagon socket
head bolts (94) (5 mm hexagon socket diameter) those fastens the plate assemblies (10), (11), (28) and (29) to
the housing.
Remove the plate assemblies still in the assembly state.
Do not disassemble them.
6. Loosen and remove the plugs (91) (19 mm hexagon socket diameter) as necessary.
7. Remove the O-rings (7) and (41) from the valve housings (1) and (13).
8. Disassembly of spool assembly
CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
(as in the diagram on the right) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250℃ ℃.
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one. (Wooden blocks for spool assembly/
disassembly)
1) Loosen the spool assembly (2) - (6) and (14) - (17) spool ends (8 mm hexagon socket diameter) and dis-
assemble the spring seat and spring.
2) The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and filters in the spools,
but do not disassemble them unless necessary.
When disassembly is required, heat up the outer edge of the spool to break down the adhesive on the
thread section, then remove the plug.
When assembling, always replace O-rings and backup rings with new ones.
CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
for assemble (as in the diagram) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250℃ ℃.
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one.
1) Loosen the spool (19) spool end (22) (5 mm hexagon socket diameter) and disassemble the spring seat
(20) and spring (21).
CAUTION
1. When removing the plug, pressure left within can make parts fly out dangerously.
2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassem-
ble.
1. Loosen and remove the plug (24) (32 mm hexagon diameter) and remove the O-ring (25).
2. Remove the spring (26) and spool (27-1) from the sleeve (27-2).
3. Pull out the sleeve (27-2) from the valve housing.
4. Remove the piston (27-3), O-ring (30), and backup ring (31) from the sleeve (27-2).
1. Loosen and remove the hexagon socket head bolts (75) (4 in each section, 8 mm hexagon socket diameter) for
the flanges (37) (6 locations) and (61) (1 location).
Only (61) has a different shape from the others, so keep it separate from (37).
2. Remove the spring (35), poppets (34) and (51) and O-ring (36) from the valve housing.
Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58).
3. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) for the flanges (52) (2
locations) .
4. Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup ring (55) from the spacer
(53).
5. Remove the spring (35) and poppet (34) from the valve housing.
6. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
7. Remove the spring (33) and poppet (32) from the valve housing.
8. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
9. Remove the spacer (57), spring (33), and poppet (32) from the valve housing.
10. Loosen and remove the plug assembly (92) (36 mm hexagon diameter). (P4 section, cross section H-H )
11. Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm hexagon socket diameter) for the
flange (43) .
12. Remove the spring (45), poppet (44), and O-ring (36) from the valve housing.
13. Loosen and remove the plug (46) (27 mm hexagon diameter) and remove the O-ring (47). (H-H cross section)
14. Remove the spring (48) and poppet (49) from the valve housing.
CAUTION
1. When removing the antidrift valve assembly, pressure left within can make seals and other parts fly
out dangerously.
2. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to residual
pressure, then disassemble.
1. Loosen and remove the hexagon socket head bolts (74) (4 in each section, 8 mm hexagon socket diameter) for
the 2 antidrift valve assemblies (67).
2. Remove the O-rings (36) and (41) from the valve housing.
3. Remove the spring (39) and poppet (38) from the valve housing.
4. Disassembly of antidrift valve assembly
CAUTION
1) If parts inside the antidrift valve are disassembled with the antidrift valve installed in the valve
housing, pressure left within can make parts fly out dangerously.
2) Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual
pressure, then disassemble.
1) Loosen and remove the plug assembly (67-14) (38 mm hexagon diameter) and remove the O-ring.
2) Remove the piston (67-3), spool (67-4), and spring (67-6).
3) Loosen and remove the plug (67-14) (12 mm hexagon diameter).
4) Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings (67-8) and (67-9),
backup rings (67-10) and (67-11) from the outer edge of the sleeve.
5) Remove the spring seat (67-13) and spring (67-7) from deep in the hole.
1. Loosen and remove the overload relief valve (69) (32 mm hexagon diameter).
2. Loosen and remove the main relief valve (68) (32 mm hexagon diameter).
3. Loosen and remove the 2 relief valve assemblies (70) (32 mm hexagon diameter).
Remove the O-rings (70-5) and (70-8).
CAUTION
When removing the add-on section, be careful not to cause any dents, scratches, or the like on
matching surfaces.
Any dents, scratches, or the like on matching surfaces have a danger of allowing oil to leak from
those surfaces and causing malfunction.
Also, be careful not to let any foreign matter enter the oil path.
Such foreign matter has a danger of the spool sticking due to biting of the spool sliding section or
a load check seat defect making the actuator run wild or stop disabled.
1. Loosen and remove the 8 hexagon socket head bolts (77) (14 mm hexagon socket diameter).
Tightening torque: 166 - 177 N•m
2. Remove the valve housing matching surface O-rings (65) and (66).
Cleaning
Completely clean all the disassembled parts with clean mineral oil.
Dry with compressed air and place each part on clean paper or vinyl for inspection.
Inspection
Inspect all surfaces of each part for burrs, scratches, gouges, and other defects.
1. Inspect the valve housing load check seat surface for scratches, gouges, and also for debris, dents, rust.
Repair any minor scratches with an oilstone.
2. Check that there are no scratches, dents, etc. on the outer edge of the spool.
Repair any small scratches with an oilstone.
3. Sliding parts must all move easily.
Also, all grooves and paths must be free of foreign matter.
4. If a spring is broken or extremely deformed or worn, replace it.
5. If relief valve operation is poor, inspect according to "Troubles and countermeasures Relief valve".
6. Replace all O-rings and backup rings from disassembled parts.
7. After removing caps or plugs, check for any paint fragments around the body opening or plug seating surface. (If
paint fragments were to get inside the valve, they could jam up or clog up the valve, resulting in operation defects
and oil leaks.)
Adhesive application method (for male thread section and female thread section of parts
requiring adhesion)
1. Cleaning (degreasing)
Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent.
2. Drying
Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally.
Inadequate drying reduces the effectiveness of the adhesive.
3. Applying the adhesive
Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at the entrance of the spool
female threads.
At this time, install being careful that the application section does not touch the spring seat.
CAUTION
Do not use "Loctite Primer T" hardening accelerator.
It causes insufficient adhesion strength.
CAUTION
If the parts are not left out in the air for the above period, adequate adhesive strength may not be
achieved.
CAUTION
1) Be careful not to apply so much adhesive that it drips into the spool.
2) Be careful not to tighten any spool end with excessive torque.
Excessive torque there would deteriorate spool operation.
3) There are 2 types of spring.
Be careful to assemble each in its correct location. (only boom 2 different)
CAUTION
1) Be careful not to apply so much adhesive that it drips into the spool.
2) Be careful not to tighten any spool end with excessive torque.
Excessive torque there would deteriorate spool operation.
CAUTION
1) Be careful not to apply so much adhesive that it drips into the spool.
2) Be careful not to tighten any spool end with excessive torque.
CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and the drop
of the actuator from its own weight increasing.
2. Insert the poppet (67-2) and spool (67-4) in the sleeve hole.
Be careful to assemble the spool in the correct direction.
3. Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount on the spring (67-7),
and insert into the body (67-1) together with the sleeve.
CAUTION
Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on the
poppet seat.
4. Screw the plug (67-14) into the body (67-1) and tighten it.
Tightening torque: 78 - 88 N•m
5. Assemble the spring (67-6) and piston (67-3) on the plug (67-14).
6. Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1).
Tightening torque: 147 - 157 N•m
CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and causing
external leaks.
4. Mount the O-ring (36) in the option section (H-H cross section) and assemble the poppet (44) and spring (45).
Mount the flange (43) and tighten with the hexagon socket head bolts (74).
Tightening torque: 58 - 64 N•m
5. Assemble the poppet (49) and spring (48) in the travel section (H-H cross section).
Screw in and tighten the plug (46) with O-ring (47) mounted.
Tightening torque: 107 - 117 N•m
6. Assemble the poppet (32) and spring (33) in the arm 1 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
Tightening torque: 73 - 79 N•m
7. Assemble the poppet (32), spring (33), and spacer (57) in the arm 2 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
Tightening torque: 73 - 79 N•m
CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.
2. Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m
CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.
2. Mount the O-ring (65) into the housing and tighten the cap (86) with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m
CAUTION
1) Line up the spool straight with the opening and insert it slowly.
2) After inserting the spool, slide it to check for any sticky or rough feeling.
3) If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation defect.
3. Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in the order (75), (94).
Be careful not to apply excessive tightening torque to (94).
Tightening torque:
(75) 39 - 44 N•m
(94) 8.8 - 10.8 N•m
4. Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75).
Tightening torque: 39 - 44 N•m
5. Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74).
Tightening torque: 39 - 44 N•m
6. Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross section) short cap and
tighten it.
Tightening torque: 19 - 22 N•m
7. Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross section) and straight travel
section (I-I cross section) long caps and tighten them.
Tightening torque: 19 - 22 N•m
CAUTION
1) Be careful not to apply excessive torque when tightening a plug to a cap.
2) Applying excessive torque could crush the cap threads.
Part list
Code Part name Q'ty Code Part name Q'ty
1 Valve housing 1 48 Spring 1
2 Spool assembly 1 49 Poppet 1
3 Spool assembly 1 51 Poppet 1
4 Spool assembly 1 52 Flange 2
5 Spool assembly 2 53 Spacer 2
6 Spool assembly 1 54 O-ring 2
7 O-ring 20 55 Backup ring 2
8 Cap 9 56 O-ring 1
9 Cap 1 57 Spacer 1
10 Plate assembly 1 58 Sleeve 1
11 Plate assembly 1 59 Poppet 1
13 Valve housing 1 60 Spring 1
14 Spool assembly 1 61 Flange 1
15 Spool assembly 1 64 O-ring 3
16 Spool assembly 1 65 O-ring 14
17 Spool assembly 1 66 O-ring 12
18 Cap 1 67 Antidrift valve assembly 2
19 Spool 1 68 Relief valve kit 1
20 Spring seat 2 69-1 Relief valve kit 5
21 Spring 1 69-2 Relief valve kit 1
22 Spool end 1 70 Relief valve assembly 2
23 O-ring 1 71 Plug assembly 3
24 Plug 1 72 Plug assembly 10
25 O-ring 1 73 Plug assembly 3
26 Spring 1 74 Socket head bolt 32
27 Spool assembly 1 75 Socket head bolt 66
28 Plate assembly 1 77 Socket head bolt 8
29 Plate assembly 1 78 Socket head bolt 4
30 O-ring 1 79 Name plate 1
31 Backup ring 2 80 Drive screw 2
32 Poppet 2 82 Metal plug 5
33 Spring 2 83 Socket head bolt 4
34 Poppet 7 84 Spool assembly 1
35 Spring 8 86 Cap 1
36 O-ring 10 88 Cap 2
37 Flange 6 89 O-ring 2
38 Poppet 2 90 O-ring 2
39 Spring 2 91 Plug 2
40 Orifice plug 1 92 Plug assembly 2
41 O-ring 27 93 Plug assembly 2
42 Body assembly 1 94 Socket head bolt 2
43 Flange 1 95 Outlet housing 1
44 Poppet 1 96 Tie rod 4
45 Spring 1 97 Nut 4
46 Plug 1 110 Plug assembly 1
47 O-ring 1
Relief valve
Procedures for assembly and disassembly of main relief valve
1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) (32 mm diameter) with a wrench and remove the O-ring (2).
If oil leaks from the nut (4) (36 mm hexagon diameter), loosen the nut (4) (36 mm hexagon diameter) and the
plug (1) (32 mm hexagon diameter), and replace the O-ring (3).
If oil leaks from the nut (7) (30 mm hexagon diameter), loosen the nut (7) (30 mm hexagon diameter) and the
plug (8) (27 mm hexagon diameter), and replace the O-ring (5).
2. Assembly
Carefully check to make sure there is no debris, paint fragments around the thread sections of the plugs (1) (32
mm hexagon diameter), (6) (27 mm hexagon diameter), (8) (27 mm hexagon diameter) and nuts (4) (36 mm
hexagon diameter), (7) (30 mm hexagon diameter) and assemble the new O-rings.
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the plug (1)
(32 mm hexagon diameter).
Tightening torque: 78 - 88 N・m
When the plug has been disassembled, adjust the pressure according to the Main relief valve item in 5).
1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the cap (1) (31.75 mm hexagon diameter) with a wrench and remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).
CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the cap and assemble a new
O-ring (2).
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the cap (1)
(31.75 mm hexagon diameter).
Tightening torque: 78 - 88 N・m
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Overload relief valve item in 5).
1. Disassembly
Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and poppet (2).
Then loosen the plug and take out the O-rings (5) and (8) from each part.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring.
Install new O-rings (5) and (8) on the plug and install the plug.
Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug.
Tightening torque: 103 - 113 N・m
Also clean the valve housing relief valve installation section well and tighten the relief assembly plug (1) (36 mm
hexagon diameter).
Tightening torque: 103 - 113 N・m
1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) (32 mm hexagon diameter) with a wrench and remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).
CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring (2).
Also clean the valve housing relief installation section well, install the relief valve, and tighten the plug.
Tightening torque: 59 - 69 N•m
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Add-on main relief valve item in 5).
Installation
1. Be careful that the line does not apply excessive force to the valve.
2. Tighten all the bolts the same.
3. Be careful.
Welding close to a valve can damage its seal due to excess heat and sputter.
4. In order to keep out debris, do not remove the cap for a port until it is time to work on the line.
Operation
1. Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pressure (inch the operating
machine in low idle) and check that no oil leaks to the outside.
2. For the oil, use hydraulic oil with an aniline point of 82 - 113°C.
3. Do not raise the relief valve above the specified set pressure.
4. Set a difference of at least 2.0 MPa between the set pressure for the main relief valve and for the overload relief
valve.
5. Warm up the machine adequately before starting the actual work.
Pay attention to the following points in order to avoid sticking due to spool heat shock particularly when starting
up with the hydraulic oil temperature or valve temperature low.
• Do not operate the main relief valve and overload relief valve right too suddenly after each other.
Raise the temperature of each section uniformly and operate in such a way that the hydraulic oil circulates
within each actuator.
• Fine operations and compound operations generate heat locally due to throttling of individual sections, so do
not suddenly perform these operations with the machine still at low temperature.
Relief valve
8012
Specifications and Structure Diagram (including the assembly diagram and parts table) . . . . . . . . . . . . . . . . . . . . . . 3
Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function of Each Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Precautions for Installing the Cylinder on the Machine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Usage Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance and Inspection Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trouble Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Storing Parts Individually (In principle, store indoors.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
When Mounted on Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recommended Anti-rust Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly and Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection after Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Required Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drain the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Secure the Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pull out the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fasten the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remove the Piston Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal of Piston etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly of the Retraction Side Cushion Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove the Piston Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of the Buffer Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of U-ring and Wiper Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal of O-ring and Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal of Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation of Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replacement of Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembly of Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembly of Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Insertion of Piston Rod into the Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston rod (2). Together with
the slide rings (18) (19) on the outer circumference of the piston, the bushing divides the lateral load applied to the
cylinder and moves linearly relative to the piston rod. Furthermore, it supports one end of the piston rod and has
the function of minimizing eccentricity which has a negative impact on the sealing.
• Buffer ring
The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7) by the hydraulic oil
to improve durability.
• U-ring and backup ring
The U-ring (7) seals the pressure oil within the cylinder. The U-ring also has the function of forming an appropriate
oil film on the surface of the piston rod in order to prevent rust of the piston rod (2). The backup ring (8) has the
function of suppressing extrusion of the U-ring into the gap between the piston rod and the cylinder head (3) when
the pressure operates and of improving durability.
• Wiper ring
The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder.
This wiper ring (9) prevents dust and water from getting into the cylinder from the outside. It also has the function
of wiping off any mud sticking to the surface of the piston rod as the piston rod moves.
For some cylinder sizes, the piston (15) and nut (21) are separate.
28 Pipe assembly
29 Pipe assembly
CAUTION
Never suspend the cylinder from the line section. This would not only pose the danger of falling but
could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state.
If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the
need for repair or make the piston rod unusable.
Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly.
• Do not weld after the cylinder has been mounted on the machine body.
CAUTION
Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark
within the cylinder and damage parts.
This could cause extensive damage, making it necessary to replace parts or replace the cylinder.
• When painting the machine body, mask the piston rod and wiper ring.
CAUTION
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper
ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and
paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak.
• For stopping the machine temporarily or storing it, always have the machine in a safely secure posture.
CAUTION
When extended, the cylinder cannot hold a load for a long time in a fixed position.
This is because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil temperature
variation.
This results in the danger of machine moving unexpectedly, which can lead to serious accidents.
For stopping the machine temporarily or storing it, always have the machine in a safely secure posi-
tion.
CAUTION
For periodic inspection and service, first work to prevent any hazard to operators. Strive to prevent
hazards by working with an attitude based on good sense.
Item Symptom
Piston rod sliding section oil leak
1
(For the judgment values, see "Inspection after Assembly".)
2 Cylinder head matching section oil leak
3 Pipe and cylinder tube welding section oil leak
4 Operation defect
HINT
The cylinder may extend or retract
somewhat when the cylinder stops
suddenly.
This phenomenon occurs due to the
4 compressibility of the hydraulic oil.
This occurs particularly easily for
cylinders with long strokes.
The impact is high
when switching The gap between the installa- Measure the pin and pin bushing di-
Pin bushing
over between ex- tion section and the pin bushing mensions and replace any part that
Pin
tension and re- is enlarged. exceeds its specified dimension.
traction.
The oil or grease feed is inade-
Cylinder sliding Apply oil or grease.
Pin bushing quate.
operations make
Pin There is seizing at matching Replace with a new part and apply oil
sounds.
section. or grease.
CAUTION
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.
Maintenance Standards
Replace sliding parts and seal parts as follows.
1. Bushing
When 1/4 of the circumference is worn brown over the entire length.
2. Seals and slide rings
Replace with new parts when the cylinder is disassembled.
3. Pin bushing
When there is severe seizing.
4. Piston rod
When the piston rod is bent 0.5 mm/1 m or more.
1 Oil ring
a Acceptable
b Not acceptable
3 Vise 1
5 Punch 1
8 Monkey wrench 1
9 Scoop 1 set
CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
KHV0512 Cylinder head assembly and disassembly jig (70)
KHV0513 Cylinder head assembly and disassembly jig (75)
KHV0514 Cylinder head assembly and disassembly jig (80)
KHV0515 Cylinder head assembly and disassembly jig (85)
KHV0516 Cylinder head assembly and disassembly jig (90)
KHV0517 Cylinder head assembly and disassembly jig (95)
KHV0518 Cylinder head assembly and disassembly jig (100)
KHV0519 Cylinder head assembly and disassembly jig (105)
KHV0520 Cylinder head assembly and disassembly jig (110)
KHV0521 Cylinder head assembly and disassembly jig (115)
KHV0522 Cylinder head assembly and disassembly jig (120)
CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
KHV0527 Seal ring insertion and calibration jig (105)
KHV0528 Seal ring insertion and calibration jig (110)
KHV0529 Seal ring insertion and calibration jig (115)
KHV0530 Seal ring insertion and calibration jig (120)
KHV0531 Seal ring insertion and calibration jig (125)
KHV0532 Seal ring insertion and calibration jig (130)
KHV0533 Seal ring insertion and calibration jig (135)
KHV0534 Seal ring insertion and calibration jig (140)
KHV0535 Seal ring insertion and calibration jig (145)
KHV0536 Seal ring insertion and calibration jig (150)
KHV0537 Seal ring insertion and calibration jig (160)
KHV0539 Seal ring insertion and calibration jig (170)
1 About 1.5 m
2 Cylinder secured
Line band (Removal is unnec-
3 essary when replacement is
unnecessary.)
a Beware of falling
31 Bushing 34 Press
36 Jig
a Press with the press.
Cleaning and Storage
Clean the removed parts with white kerosene, and then
apply hydraulic oil, cover the parts, and store them.
If they are left disassembled, there is a danger of their
collecting rust and dust and not being able to function
adequately after they are assembled again.
1 Press
2 Installation jig
3 Pin bushing
9 Cylinder head
12 Cylinder head
13 Pressing base
14 Press
28 Metal block
29 Press
*1 Flat surface processing
*3 Face the slit to the screw side.
3. If there is a cushion on the extension side, assemble
the cushion ring (33) and cushion seal (34) with the
following procedure. 35 Piston
36 Screw
1) Insert into the groove with the side of the cush-
ion seal with the slit (*2) facing the piston side.
2) Assemble with the part of the cushion ring pro- CAUTION
cessed to be flat facing as in the diagram. Make sure that the cushion seal and cush-
ion ring face the correct direction.
If they are installed backwards, the cush-
ion will not be effective.
After installing the cushions, check that
the extension and retraction cushion rings
move up and down and left and right.
Nominal diameter (mm) Standard thickness (mm) Minimum thickness (mm) Solution
95 - 160 t2.42 - 2.48 t2.37 Replace the slide ring.
165 - 250 t2.92 - 2.98 t2.87 Replace the slide ring.
8013
CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after
thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean
location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or com-
promise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts,
take precautions to prevent the parts from rusting or collecting dust.
Items to prepare
Maintenance Procedures
Required Tools and Tightening Torque
Tightening
Dimension
Tools Part No. Part name Screw size torque
(mm)
(N·m)
Adjusting
22 312 M14 63.7 - 73.5
Wrench nut
32 302 Disk M14
Special jig 24 301 Joint M14 44.2 - 50.0
Other
• Vapor corrosion inhibitor
• White kerosene
• Heat-resistant grease
• Sandpaper (#1000, #2000)
• Whetstone
• Vise
• Screwdriver
• Torque wrench
Push rod
NOTE:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse
these after it is confirmed that they are not damaged.
6. If the return springs are weak, the plugs (1) will re-
main in the casing due to the sliding resistance of
the O-rings, so use a flathead screwdriver to re-
move it.
3. Use a jig (1) to remove the joint. • Use the groove in the outer circumference of the
plugs and remove them while making sure they
are not damaged by an unbalanced load.
• Use caution as plugs may fly off when they are
being removed due to the return springs.
3 Push rod
10. Use a jig, and tighten the joint (1) to the casing (2)
to the specified torque.
7. Install the plug assembly (1) in the casing (2). Tightening torque: 44.2 - 50.0 N·m
If the return spring is weak, it will be stopped by the
sliding resistance of the O-ring.
• Be careful not to scratch the casing hole by forcing
in the spool.
Tightening torque
Tightening
Code Screw size
torque
301 M14 44.2 - 50.0 N·m
302
M14 63.7 - 73.5 N·m
312
Detailed diagram of jig main unit (1) and (2) are inserted by tightening. Attached diagram 2. Jig main unit
c Bushing
8014
CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• When removing devices or positioning devices at the time of installation, use a removal jig and a ham-
mer or steel rod.
• Follow the precautions below when suspending the load.
• The liftcrane must be operated by a qualified operator.
• Do not stand or pass under the suspended load.
• Check the weight of the load to determine whether it can be carried by hand or whether a liftcrane
must be used.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction.
Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and as-
semble in a clean location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or
compromise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust.
Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting
or collecting dust.
Items to prepare
• Wrench
• Screwdriver
• Specialty jigs
• Vise
• Loctite 262
• Special fiber cloth (Kimwipe)
• White kerosene
2. Use a hexagon wrench (1) on the hexagon socket 5. Use a hexagon wrench (1) on the hexagon socket
head locking screws to loosen them. head bolts to loosen and remove them.
Be careful, as application of Loctite #241 makes the
loosening torque high.
3. Place a round rod (D8 mm or less) against one end • Record the positions of the covers in relation to
the casings (4).
of the cam shafts (1) and lightly strike it with a ham-
Be careful when removing, as the push rods (2) or
mer to remove the shafts.
plugs (3) may fly off due to the damping springs.
(The plugs are only kept in the casing by the slid-
ing resistance of the O-rings.)
11. Remove the spring seating (2) from the casings (1).
8. Remove the plugs (1) with the grease caps and • Record the positions of the spring seating in rela-
NHU packings left attached. tion to the casing holes.
Record the positions of the plugs in relation to the
casing holes.
Be careful when removing parts, as the pistons (3)
may fly off due to the damping springs (2).
25. Tilt the cams (1) and fill the grease cups of the plugs
with grease while coating the top of the push rods
with grease.
• For grease application and filling, use a flat object
made of soft material so as to not scratch the push
rod or plug surfaces.
23. Tighten the hexagon socket head locking screws to
the specified torque.
• Hexagon socket head locking screw tightening
torque: 5.9 - 7.9 N·m
26. After mounting the top end of the bellows (1) on the
cams, mount the bottom end into the grooves on the
covers (2).
• Before mounting the bottom end of the bellows
into the grooves of the covers, spray anti-rust oil
on the parts within the bellows.
• Be careful that the bellows are properly mounted
in the grooves and not twisted, as this may reduce
anti-rust and anti-moisture protection.
8016
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Written Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly Procedures
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit
together, so do not disassemble it as much as possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only disassemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
• Check the internal structure before starting work, and carefully study the disassembly objective and scope.
Diagram 1
2. Fasten the spool (3) assemblies taken out in 1. in a
vise.
CAUTION
Diagram 3
Use a piece of wood (jig) (4) to prevent
scratches.
Diagram 2
Diagram 4
Assembly Procedures
This valve has a structure that forms small gaps.
It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as
possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only assemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Clean the disassembled parts and prepared parts.
• Study the internal structure before starting the work and prepare the parts required by the disassembly objective
and scope.
Diagram 6
Diagram 5
2. Insert the spool assemblies (1) assembled in 1. into
the body.
CAUTION • Assemble the plugs (2) with the O-rings (3) (4)
attached.
The check plungers have similar shapes, • Tightening torque: 39.2 - 49.0 N·m
so be careful to insert each one in its cor-
rect position.
Diagram 8
Diagram 7
Written Materials
1. Check plunger table
Cross section V -
Cross-section diagram
8017A
Items to prepare
• Wrench (22 mm)
• Hexagon wrench (10 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
8017B
Items to prepare
• Wrench (19 mm, 22 mm, 27 mm)
• Hexagon wrench (8 mm)
• Marking pen
• Caps
• Plugs 3. Use a hexagon wrench (8 mm) to remove the 4
• Rag hexagon socket head bolts (1), and then remove the
• Cleaning fluid boom HBCV (2).
• Crossties
1 Pilot hose (use 22 mm wrench) 6. Use a hexagon wrench (8 mm) to remove the 4
Drain hose (use 19 mm hexagon socket head bolts (1), and then remove the
2 boom HBCV (2).
wrench)
3 Pilot hose (use 22 mm wrench)
4 Pilot hose (use 22 mm wrench)
8018
Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAUTION CAUTION
• The following cautions for hydraulic equip- General cautions
ment should be observed with these parts.
• To ensure safe operations, wear protective • Be careful not to drop precision parts or let
devices for the work and follow all precau- bump them with other parts during work.
tions. • Do not forcefully open or hit parts in an effort
• When removing devices or positioning de- to speed up operations.
vices at the time of installation, use a removal Pay careful attention and proceed slowly so
jig and a hammer or steel rod. as not to damage any parts, create any oil
• Make sure that the jig is used for disassembly leaks, or compromise the efficiency of the
of the axle and rotor. equipment, etc.
• Follow the precautions below when suspend- • Disassembled parts can easily rust or collect
ing the load. dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
• The liftcrane must be operated by a quali- parts from rusting or collecting dust.
fied operator. • Make sure that foreign matter such as debris
• Do not stand or pass under the suspended and moisture does not enter.
load. • The work platform used should be solid, sta-
• Check the weight of the load to deter- ble, and sufficiently spacious.
mine whether it can be carried by hand or Also, items should be clean and free of debris
whether a liftcrane must be used. and moisture.
Remove debris and moisture before perform-
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts ing work.
in advance. • Inspect, remove debris and moisture, and
clean tools and jigs before work.
• If any parts are significantly rusted or dirty,
clean them before disassembling. • Jigs and tools that are appropriate to the con-
tents of work should be used.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the Items to prepare
equipment with cleaning oil, air blow the • Hexagon wrenches (6 mm, 14 mm, or 17 mm)
equipment, and assemble in a clean location. • Torque wrench
• When assembling V-rings, O-rings, and other • Socket wrenches (6 mm, 14 mm, or 17 mm)
sliding parts, be sure to coat them with new • Lights
grease. • Mirror
• As a rule, replace all O-rings and other seal • Specialty jigs
parts with new parts.
Configuration Diagram
Dimension Diagram
Do not coat any processed surfaces marked with a symbol or port processed surfaces.
Disassembly Procedures 4. Use axle removal jig 1 to push out the axle (2) from
the rotor (1).
1. Use a hexagon wrench (6 mm) to remove the 4
hexagon socket head bolts (3) from the rotor (1), • Do not strike it with the hammer at this time.
then remove the cover (2).
3. Use a hexagon wrench (6 mm) to remove the 4 6. Use removal jig 1 or the like to remove the O-ring
hexagon socket head bolts (2), then remove the (2) and packing ring (3) from the rotor (1).
thrust plate (1).
5. After installing the O-ring and packing rings on the 8. Using a hexagon wrench (6 mm), coat the hexagon
rotor (1), use the mirror to check for any parts that socket head bolts (3) with Loctite, install the thrust
are sticking out or are twisted. plate (2) on the axle (1), and tighten to the specified
Also, check for installation mistakes. tightening torque.
After checking, coat with grease. After coating with
grease, check again for any parts sticking out, etc. • Bolt (3) tightening torque: 31.4 - 37.3 N·m
6. Install the V-ring (2) on the axle (1) and coat suffi- 9. Install the O-ring (2) on the rotor (1).
ciently with grease. • Use new O-ring (2).
Be careful that no water or dirt gets into the grease.
• Use a new V-ring (2).
8019
CAUTION
1. Read and understand the contents of this
maintenance manual before performing
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C or below before removing it.
Working on this product while it is still hot
can cause burns.
Additionally, always bleed out the pressure
before removing any line from this prod-
uct.
Removing a pressurized line can result in
oil spraying out and causing injury or oil
leak.
4. Use the specialty tools and measurement
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury.
7. Check performance after reassembly.
Do not resume use unless performance is
fully recovered.
Using this product at a sub-par perfor-
mance level may result in product damage.
8. The cautions (mark !) listed in this main-
tenance manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.
6) Oil leak
1) Oil leak from oil seal
Recom-
Standard mended
dimen- replace-
Item Solution
sions ment
(mm) value
(mm)
Clearances between piston and cylinder
bore 0.028 0.058 Replace the piston or cylinder.
(D-d)
Piston and shoe caulking section back-
0 0.3 Replace the piston and shoe assembly.
lash (δ)
Shoe thickness (t) 5.5 5.3 Replace the piston and shoe assembly.
Friction plate thickness 2.0 1.6 Replace.
Surface roughness
Part name Standard surface roughness
requiring repair
Shoe 0.8 - Z (Ra = 0.2) (lapping) 3 - Z (Ra = 0.8)
Shoe plate 0.4 - Z (Ra = 0.1) (lapping) 3 - Z (Ra = 0.8)
Cylinder 1.6 - Z (Ra = 0.4) (lapping) 12.5 - Z (Ra = 3.2)
Valve plate 0.8 - Z (Ra = 0.2) (lapping) 6.3 - Z (Ra = 1.6)
Note:
1) Using lapping, make the degree of surface roughness of each sliding surface equal to or lower than the
standard value.
2) If the plate spring and cylinder spherical surface sliding section are rough, these should be replaced as
a set.
Required Tools
1. Bolt tightening torque
Tightening torque values for bolts used in the motor are indicated in Table 3. When assembling, securely tighten
bolts to the values in Table 3.
If there is a variance with the part codes listed above, see the assembly cross-section diagram.
2. Tools for assembly and disassembly
The necessary tools for assembly and disassembly are indicated in Tables 4 and 5. The bolts and plugs used
vary for each type, so prepare tools based on examination beforehand.
Applicable
Name Size Bolt width Tools
part code
Hexagon socket
M20 17 401 Hexagon wrench
head bolt
Hexagon wrench, socket
Relief valve M33 x P1.5 41 051
wrench
ROMH plug M36 x P1.5 17 469 Hexagon wrench
ROH plug PF1/4 6 467 Hexagon wrench
If there are variances with the plugs and bolts listed above, see the assembly cross-section diagram.
Tools Dimensions
Screwdriver Flathead Medium-sized x 2
Steel rod About size 10 x 8 x 200 1
Plastic hammer
Hammer 1 each
Hammer
Torque adjustment range
• For 5 - 10 N·m
Torque wrench • For 10 - 45 N·m
• For 40 - 275 N·m
• For 75 - 550 N·m
Slide hammer bearing puller
Brake piston removal jig See the next page
8. Take out the brake springs (712) from the brake pis-
ton (702).
12. Take out the drive shaft (101) and shoe plate (124).
• The spline will damage the oil seal (491) when the
drive shaft is removed, so wrap the spline section
of the drive shaft with vinyl tape, etc. (*2).
Assembly
1) Check each part for scratches from use or from
disassembly. If there are any scratches, remove them
with a whetstone or sandpaper of the necessary grain,
clean with pure cleaning oil, then dry off with an air
blower.
2) Replace seal parts with new ones.
3) Thoroughly clean all parts with cleaning fluid and
dry with compressed air.
4 ) When assembling sliding sections, apply clean
hydraulic oil before assembling.
1. Place the housing on an appropriate platform with
the cover on top.
2. If the roller bearing (443) was removed, shrink fit
This completes the disassembly.
the inner race of the roller bearing to the drive shaft
(101).
• Be careful with the direction of the flange of the
roller bearing.
3. Use a jig to insert the oil seal (491) into casing JA1
(301).
• Be careful with the direction of the oil seal.
• Apply a thin layer of grease to the oil seal lip sec-
tion.
• Be careful to evenly hit it without scratching the
outer circumference.
4. Use a steel rod to install the outer race of the roller 7. Set the plate spring (114) on the holder plate (123),
bearing (443) into casing JA1 (301). and then set the pistons (121).
5. Mount the drive shaft (101) in casing JA1 (301). 8. Install the piston subassembly (10) on the cylinder
(111).
• Carefully insert it so as not to scratch the lip sec-
tion of the oil seal (491).
• Wrap vinyl tape, etc. around the shaft spline sec-
tion to protect it.
10. Set the housing down with the oil seal side facing
downwards, and alternately install separator plates
(743) and friction plates (744) in that order to the
housing. Install the 4 separator plates and 3 friction
plates.
13. Install the brake springs (712) into the brake piston
(702).
16. Mount the O-ring (472) to the cover. 19. Mount the relief valve (051) in valve casing H0
(303).
• Apply grease to the O-ring. Tightening torque: 177 N·m
17. Install valve casing H0 (303) on casing JA1 (301) 20. Assembly confirmation
and tighten with the bolt (401). Open the input/output ports, apply 3.2 - 4.9 MPa of
• Be careful with the installation direction of the pilot pressure to the brake release port to check if
valve. the output shaft rotates smoothly for at least 1 ro-
• Make sure that valve plate B (131) does not fall tation with about 30 - 40 N·m of torque. There is
over. an assembly problem if it does not rotate, so disas-
• Make sure that the brake springs (712) do not fall semble again and adjust it.
over. • At this time, have the drain port open.
Tightening torque: 430 N·m
1 Seat 7 Piston
2 Poppet 8 Cap
3 Spring 9 Backup ring
4 Spring seat 10 O-ring
5 Shim 11 Holder
6 Liner
8020A
Travel Circuit
Travel low-speed circuit
As an example, this section explains simultaneous forward travel and boom-up operations.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight
travel signal (right).
On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left)
via the straight travel signal (right).
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4
port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to
the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to
prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right
travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel
is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize
the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.
As an example, this section explains simultaneous forward travel and boom-up operations.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight
travel signal (right).
On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left)
via the straight travel signal (right).
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4
port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to
the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to
prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right
travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel
is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize
the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.
Swing Circuit
Swing speed limit control circuit
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode)
For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal, the
computer A outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 280 L/min by the signal output from the computer A to the P1 flow
control proportional valve.
This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil drained from
the swing motor relief valve for the starting pressure boost for a independent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals, com-
puter A outputs a signal to the hydraulic pump P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pressure to reduce the hydraulic
pump A1 side discharge flow.
Also, the input signal from hydraulic pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge
flow.
1 Swing motor 10 Remote control valve (arm, swing) 19 Arm load holding valve check valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 5 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 15 Arm cylinder 23 Arm (2)
6 Cushion valve 16 Arm (1) 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 17 Swing 25 Hydraulic pump
8 Shuttle valve 18 Arm load holding valve spool 26 Check valve
9 Computer A 15 Arm cylinder 27 Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing
spool.
Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
1 Swing motor 10 Remote control valve (arm, swing) 19 Arm load holding valve check valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 5 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 15 Arm cylinder 23 Arm (2)
6 Cushion valve 16 Arm (1) 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 17 Swing 25 Hydraulic pump
8 Shuttle valve 18 Arm load holding valve spool 26 Check valve
9 Computer A 15 Arm cylinder 27 Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing
spool.
Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and the control
valve swing spool returns to neutral.
The pressurized oil fed to the swing motor A port from the control valve A3 port is cut.
At the same time, the destination location is eliminated for the pressurized oil flowing from the swing motor B port to the control
valve B3 port, so the pressure rises to the swing motor relief valve set pressure.
The pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In order to make up the shortfall
in the oil volume, oil is supplied from the make-up line connected to the swing motor Mu port from the control valve T3 port to
open the make-up check valve and oil is suctioned in to prevent cavitation.
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from computer A.
The swing motor P port oil goes from the 5 stack solenoid valve C2 port through the swing brake solenoid, and returns to the
hydraulic oil tank to hold the swing parking brake.
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input), the
pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 0.5 MPa or higher at the pressure sensor in the swing pilot line, the output from
computer A to the swing brake solenoid valve goes OFF, the swing motor PR port pressure rises, the swing parking brake is
released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve pa3 port
via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the
electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.The pilot pressure oil is
fed to the swing motor PR port from the swing brake solenoid valve C2 port to release the swing parking brake.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing
spool.
Switching the spool lets the oil flow into the swing motor A port and the right swing operation is carried out.
The pressurized oil from the swing motor B port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure sensor
and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake solenoid valve output from
computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when about
1 sec. passes after the end of the upper operation, the swing parking brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the end of
the upper operation, the swing parking brake works again.
Swing pilot pressure Upper pilot pressure Swing brake solenoid Swing motor mechani-
Key switch
sensor sensor valve cal brake
OFF 0 MPa 0 MPa OFF ON
ON 0 MPa 0 MPa ON ON
ON 0.5 MPa min. 0 MPa OFF OFF
ON 0 MPa 0.5 MPa min. OFF OFF
ON 0.5 MPa min. 0.5 MPa min. OFF OFF
When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the swing brake solenoid C2
port through the lever lock solenoid and returns to the hydraulic oil tank, holding the swing parking brake hold status.
Boom Circuit
Boom-up circuit (independent operation)
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve pa4 port and the boom (2) spool is switched.
At the same time, the pilot pressure oil from the pa4 port separated in the internal path is fed to the boom (1) pilot port and
switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool.
The discharge oil from hydraulic pump A2 is fed to the boom (1) spool via the parallel oil path, merges with the discharge
oil from boom (2), flows through the boom load holding valve check valve and into the boom cylinder bottom side and the
boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve Pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the Pa4 port separated in the
internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom (1) spool
via the parallel oil path, merges with the discharge oil from boom (2), pushes open the boom load hold valve check valve,
flows through the boom cylinder HBCV check valve and into the bottom side, and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2)
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2)
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom (1) spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches
the spool.
This opens the HBCV check valve.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom (1) spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches
the spool.
This opens the HBCV check valve.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.
1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 12 Control valve 19 Console lever lock switch
4 Bleed-off 13 P2 pressure sensor 20 Monitor display
5 Cushion valve 14 Hydraulic pump 21 Computer A
6 Boom (up) 15 Boom cylinder 22 P1 pressure sensor
7 Boom (down) 16 Boom (1)
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 12 Control valve 19 Console lever lock switch
4 Bleed-off 13 P2 pressure sensor 20 Monitor display
5 Cushion valve 14 Hydraulic pump 21 Computer A
6 Boom (up) 15 Boom cylinder 22 P1 pressure sensor
7 Boom (down) 16 Boom (1) 23 Boom HBCV check valve
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and
returns to the hydraulic oil tank.
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and
returns to the hydraulic oil tank.
Arm Circuit
Arm-out circuit
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
1 Load holding valve spool 10 Cushion valve 19 Travel pilot pressure sensor
2 Load holding valve check valve 11 Remote control valve (arm, swing) 20 Upper pilot pressure sensor
3 Oil cooler 12 Lever lock 21 Console lever lock switch
4 Regeneration check valve 13 Boost pressure relief 22 Monitor display
5 Metering large 14 5 stack solenoid valve 23 Computer A
6 Metering small 15 Control valve 24 P1 pressure sensor
7 Forced regeneration release valve 16 Arm cylinder 25 P2 pressure sensor
8 Arm (in) 17 Arm (1) 26 Hydraulic pump
9 Arm (out) 18 Arm (2) 27 Check valve
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the right.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.
1 Load holding valve spool 11 Remote control valve (arm, swing) 21 Console lever lock switch
2 Load holding valve check valve 12 Lever lock 22 Monitor display
3 Oil cooler 13 Boost pressure relief 23 Computer A
4 Regeneration check valve 14 5 stack solenoid valve 24 P1 pressure sensor
5 Metering large 15 Control valve 25 P2 pressure sensor
6 Metering small 16 Arm cylinder 26 Hydraulic pump
7 Forced regeneration release valve 17 Arm (1) 27 Check valve
8 Arm (in) 18 Arm (2) 28 Arm HBCV check valve
9 Arm (out) 19 Travel pilot pressure sensor 29 Arm HBCV
10 Cushion valve 20 Upper pilot pressure sensor
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the right.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.
1 Load holding valve spool 9 Boost pressure relief 17 Console lever lock switch
2 Load holding valve check valve 10 5 stack solenoid valve 18 Monitor display
3 Oil cooler 11 Control valve 19 Computer A
4 Arm (in) 12 Arm cylinder 20 P1 pressure sensor
5 Arm (out) 13 Arm (1) 21 P2 pressure sensor
6 Cushion valve 14 Arm (2) 22 Hydraulic pump
7 Remote control valve (arm, swing) 15 Travel pilot pressure sensor 23 Check valve
8 Lever lock 16 Upper pilot pressure sensor
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load
holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the right.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and returns
to the hydraulic oil tank.
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load hold
valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil
path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
The pilot pressure oil from the Pb5 port separated in the internal path flows into the HBCV PL port and switches the spool.
This opens the HBCV check valve.
The pilot pressure oil from the Pb5 port separated in the internal path is fed to the load hold valve spool and moves the spool
to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line through the load hold
valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the HBCV check valve, load hold valve check valve and the arm (1)
spool and returns to the hydraulic oil tank.
Bucket Circuit
Bucket-open circuit
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the control
valve pa7 port and switches the bucket spool to the open side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket
spool.
Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve pb7 port and switches the bucket spool to the close side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket
spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.Through this, the return oil
pushes open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cylinder rod side load
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve P1 and P2 ports through the center bypass oil path, and through the downstream negative control variable
relief, and returns to the hydraulic oil tank.
The discharged oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve,
is fed to the control valve Pn1 and Pn2 ports, and holds the P1 and P2 negative control relief at the set pressure of 2.55 MPa.
The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and Ps2 ports to the hydraulic
pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is reduced.
The purpose of this control is to reduce fuel consumption during standby by reducing the back pressure for the negative control
signal.
When the remote control valve operation lever is set to neutral, the non-operation state signal enters the computer A from the
travel pilot pressure sensor and the upper pilot pressure sensor installed on the control valve PT port and PA port.
After about 1 sec., the power save solenoid valve is excited and switched ON by the signal output from computer A, and the
oil path is switched.
The pressurized oil from the control valve negative control relief Pn1 and Pn2 ports goes through the power save solenoid
valve and returns to the hydraulic oil tank.
Therefore, the negative control relief set pressure is switched to low pressure to further reduce the A1 and A2 pump discharge
pressure.
With the system running this way, the negative control signal is cut off and the P1 and P2 pump discharge volume increases.
The discharge oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve, is
fed to the hydraulic pump P2 port from the C5 port, moves the A2 side pump tilting to the minimum flow side, and this reduces
the discharge flow.
At the same time, the discharge oil from the pilot pump A3 is fed to the hydraulic pump P1 port by the signal from computer
A to the P1 flow restriction proportional valve, moves the A1 side pump tilting to the minimum flow side, and this reduces the
discharge flow.
For the arm-in operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the arm pilot pressure sensor input signal and P1 pressure sensor and P2 pressure sensor input signals.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional
valve from computer A.
Condition under which the arm-in horsepower boost control is entered
Arm-in pilot pressure 0.5 MPa {72.5 psi} or higher (arm-in operation)
P1+P2 45 MPa {6527 psi}
Conditions under which the arm-in horsepower boost control is ended
Arm-in pilot pressure 0.3 MPa {43.5 psi} or lower (arm-in operation end)
P1+P2 45 MPa {6527 psi}
When either occurs
Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is stopped,
and when an arm-out operation is followed by an arm-in operation.
Cushion circuit (arm-out operation)
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control valve 2 port
into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9 ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through the
cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the cushion
valve R port and returns to the hydraulic oil tank, so heat performance is improved.
When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5 and pa9
ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve to the hydraulic
oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is improved.
When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the pilot
pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check valve, and
reaches the control valve pb5 port and pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes through the
cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is improved.s
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion spool to
the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat perfor-
mance.
When an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 MPa to 36.8 MPa
according to the engine load ratio and hydraulic load pressure, then ends the pressure boost after 8 sec.
As an example, this section explains bucket-close operations.
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve pb7 port and switches the bucket spool to the close side.
At the same time, the output signal from the upper pilot pressure sensor that detected the pressurized oil separated from the
pilot internal path is input to computer A, which judges that there is upper operation.
Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to
the pressure boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH
port to hold the pressure boost relief set pressure for 8 sec.
There is no boost for the option circuit and during travel operation.
8020B
Option Circuits
Breaker circuit (independent operation)
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the relief valve A port through the B port and into the breaker.
The breaker set pressure is set by this relief valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display with the ON
signal from the breaker switch in the cab, the optimum operating flow can be selected.
As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool to the close side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the option spool,
flows into the hydraulic fork because of the option spool switching and operates to the close side.
At this time, the option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil tank.
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the computer A to the option
switchover solenoid valve to switch the valve.
The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is fed to the 3-direction valve
PP port and shut-off valve PP port and each valve is switched.
Always switch the 2 pumps flow select switch to the 1 pump side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.
When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal (24 V) is output from the
computer A to the 2 pumps flow solenoid valve to switch the valve.
When the multi-purpose circuit switch is flipped to the crusher side, the crusher circuit is formed without outputting a signal
from the computer A to the option switchover solenoid valve and without switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms the A
⇔ B circuit.
By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool.
At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the A2 port and is fed to the
control valve pcc port and the control valve neutral cut valve is switched.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and goes through the center bypass oil path and
since the neutral cut valve has closed the port to the tank, the oil goes from the P3 port via the P4 port and merges on the
upstream side of the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the crusher.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the crusher returns from the 3-direction valve A port through the B port and the option spool and returns
to the hydraulic oil tank.
Because the crusher operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.
1 Control valve 6 Console lever lock switch 11 2nd option pilot pressure switch
2 Travel pilot pressure sensor 7 2nd option remote control valve 12 Monitor display
3 Upper pilot pressure sensor 8 Check valve 13 Computer A
4 Lever lock 9 Oil cooler 14 4th pump
5 5 stack solenoid valve 10 Hydraulic rotation fork 15 Hydraulic pump
As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve par2
port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and flows to
the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
8030A
Part Table
Regulator
Regulator Operation Explanation
1. Flow control
• Operation explanation (See the Regulator Operation Explanation Diagram.)
1) Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the diagram below.
Pilot pressure Pi
2. Horsepower control
1) Horsepower control
As the load pressure increases, the pump tilting angle decreases and the overload of the engine is pre-
vented as in the diagram below. Since this regulator uses the simultaneous full-horsepower control method,
the tilting angles (displacement volumes) of the 2 pumps are controlled to be the same value as in the fol-
lowing equation.
Tin = Pd1 x q/2π + Pd2 x q/2π = (Pd1 + Pd2) x q/2π
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(See the pages on Flow control for the detailed movement of each part.)
KR3K-9Y04-HV KR3K-9X04-HV
Front side Rear side
Hydraulic circuit
84402826 - May 2011
8030A-13
Structure and Operation Explanation of Hydraulic Pump
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
- Regulator subassem-
1 626 Inner spring 1 728 O-ring 1
bly
Hexagon socket head
412 2 627 Adjusting ring (C) 1 730 O-ring 1
bolt
Hexagon socket head
413 2 628 Adjusting screw (C) 1 732 O-ring 1
bolt
Hexagon socket head
436 4 629 Cover (C) 1 733 O-ring 1
bolt
Hexagon socket head
438 8 630 Lock nut 1 734 O-ring 1
bolt
466 VP plug 1 631 Pf sleeve 1 735 O-ring 1
467 VP plug 1 641 Pilot cover 1 753 O-ring 1
496 Insert plug 12 643 Pilot piston 1 755 O-ring 3
545 Steel ball 1 644 Spring seating (Q) 1 756 O-ring 1
546 Seat 1 1 645 Adjusting ring (Q) 1 763 O-ring 1
547 Seat 2 1 646 Pilot spring 1 801 Hexagon nut 1
601 Casing 1 651 Sleeve 1 802 Hexagon nut 1
611 Feedback lever 1 652 Spool 1 814 Stop ring 1
612 Lever 1 1 653 Spring seating 1 836 Stop ring 1
613 Lever 2 1 654 Return spring 1 858 Locking ring 2
614 Fulcrum plug 1 655 Set spring 1 874 Pin 1
615 Adjusting plug 1 656 Blind cover 1 875 Pin 2
621 Compensation piston 1 708 O-ring 1 876 Pin 2
622 Piston case 1 722 O-ring 3 887 Pin 1
623 Compensation rod 1 724 O-ring 9 897 Pin 1
624 Spring seating (C) 1 725 O-ring 1 898 Pin 1
Hexagon socket head
625 Outer spring 1 727 O-ring 1 924 1
stop screw
Hydraulic circuit
84402826 - May 2011
8030A-15
Structure and Operation Explanation of Hydraulic Pump
KSJ12240-D00S3
Gear Pump
Gear Pump Internal Structure Diagram
Hydraulic circuit
*1 To main pump
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
307 Poppet 1 353 Drive gear 1 466 VP plug 1
308 Seat 1 354 Driven gear 1 700 Angle ring 1
309 Ring 1 355 Filter 1 710 O-ring 1
310 Spring 1 361 Front case 1 725 O-ring 1
311 Adjusting screw 1 433 Flange socket 2 732 O-ring 1
312 Lock nut 1 434 Flange socket 2 850 Locking ring 1
351 Gear case 1 435 Flange socket 4
8030B
g Oil path C2
i Damper chamber A2
k Spring chamber 2
Diagram 5 Double counter balance valve and relief valve during piston motor braking
Pressure Pressure
Time Time
Conventional type Shockless type
Diagram 10 Shockless function and pressure wave comparison
q Area S2
r Area S1
s Spring chamber D
Operating the relief valve in 2 stages in this way reduces the shock that occurs when the piston motor is started or
braked and provides good operability.
Diagram 10 compares the pressure waveforms of the conventional type and the shockless type.
t Pilot pressure
u Pressure in motor
v Motor load pressure
t Pilot pressure
u Pressure in motor
v Motor load pressure
Diagram 15 Parking brake released state Diagram 16 Parking brake engaged state
Piston Motor
The "piston motor" is a swash plate-type piston motor that converts the fluid energy of the pressure oil sent from the
hydraulic pump into mechanical energy and outputs high-speed, low-torque power.
A swash plate-type piston motor is used as the piston motor.
Diagram 17 shows a structural diagram of the piston motor.
9 pistons (4-2) are incorporated in the cylinder block (4-1) and the end of the cylinder block (4-1) touches a valve plate
(22) that has 2 sausage-shaped ports, B and C. The pressure oil discharged from the hydraulic pump flow in from the
P1 port or the P2 port and while the piston motor rotates, flows out from the P2 port or P1 port.
Also, the drain oil in the case that has leaked from the sliding sections and the gap returns to the hydraulic tank from
the base plate (2-1) T1 or T2 port.
1. The high-pressure oil from the P1 port enters the valve plate (22) sausage-shaped B port, the piston (4-2) is
pressurized, and the top of the swash plate (5) rotates and moves from top dead center to bottom dead center.
2. The P2 port becomes the low-pressure side and while the piston (4-2) rotates and moves from bottom dead
center to top dead center, the oil is discharged to the P2 port via the valve plate (22) sausage-shaped C port.
3. Accompanying the reciprocal movement of the piston (4-2), the cylinder block (4-1) and the shaft (3) spline cou-
pled to it rotate in the counter-clockwise direction of the arrow in the diagram.
4. When the piston motor rotates clockwise, the P1 port side becomes the low-pressure side and the P2 port side
becomes the high-pressure side.
In this way, the piston motor converts the fluid energy of the pressure oil sent from the hydraulic pump into mechanical
energy and outputs high-speed, low-torque rotation power. Also, the piston motor torque and speed are determined
by the pressure and flow. Therefore, the larger the pressure and flow, the higher the piston motor torque and speed.
a C port
b B port
Reduction Gear
Diagram 18 shows a structural diagram of the reduction gear.
The reduction gear structure combines in two stages the simple planetary reduction gear system made up of the drive
gear, sun gear, holder, planetary gear, and ring gear (with teeth cut in the inner diameter of the housing).
When pressure oil flows into the piston motor, the piston motor shaft rotates at high speed and power is input to the
reduction gear section.In the reduction gear section, this high-speed rotation has its speed reduced in 2 stages by
the simple planetary 2-stage reduction system. Low-speed, high-torque output is obtained from the rotation of the
housing with ring gears (1-3) (2-3).
1. 1st stage reduction section operation
The 1st stage reduction section comprises the drive gear (1-1), planetary gear A (1-2), ring gear (1-3), holder
(1-4), needle bearing (1-5), and inner race (1-6).
The planetary gear A (1-2) meshes with the drive gear (1-1). When the drive gear (1-1) rotates clockwise, the
planetary gear A (1-2) rotates counter-clockwise. On the other hand, since it meshes with the ring gear, it kicks
the tooth of the ring gear and tries to revolve clockwise around the circumference of the drive gear (1-1).
Because the planetary gear (1-2) is fixed in a state in which it rotates freely on the holder (1-4) via the needle
bearing (1-5), this clockwise revolution movement is transmitted to the holder (1-4) and the holder (1-4) starts to
rotate in the clockwise direction.
Also, since the holder (1-4) is spline coupled with the 2nd stage sun gear (2-1), this holder (1-4) rotation is trans-
mitted to the 2nd stage sun gear (2-1).
2. 2nd stage reduction section operation
The 2nd stage reduction section comprises the sun gear (2-1), planetary gear B (2-2), ring gear (2-3), holder
(2-4), needle bearing (2-5), and inner race (2-5).
The planetary gear B (2-2) meshes with the sun gear (2-1). When the sun gear (2-1) rotates clockwise, the
planetary gear B (2-2) rotates counter-clockwise.
The planetary gear B (2-2) is fixed in a state in which it rotates freely on the holder (2-4) via the needle bearing
(2-5). Furthermore, the holder (2-4) is coupled to the flange (5) by the bolts (3) (4) and the flange (5) is fastened
to the frame of the machine main unit, so it cannot rotate.
Therefore, the planetary gear B (2-2) cannot revolve as in the 1st stage reduction section and rotates counter-
clockwise at the position at which it was incorporated. Also, because the planetary gear B (2-2) is meshed with
the ring gear, the counter-clockwise revolution of the planetary gear B (2-2) is transmitted to the ring gear and
the ring gear is rotated counter-clockwise.
Through the above action, the housings (1-3) (2-3) with the ring gear cut into their inner diameters receive the
force of the planetary gears (2-2) (1-2) and rotate. This transmits power to the driven section of the machine main
unit which is coupled with the housings (1-3) (2-3).
8030C
1 M port
2 Control valve
Brake Section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate (743) is constrained for
circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is pressed to the casing
(301) by the brake spring (712) via the separator plate (743) and the brake piston (702), friction force is generated
between the friction plate and casing and between the separator plate and the brake piston. The drive shaft is con-
strained and braked by this friction force.
On the other hand, when brake release pressure is applied to the oil chamber (1) formed between the brake piston
and the casing and the hydraulic pressure (3) wins out over the spring force (2), the brake piston moves, the force
pressing the friction plate against the casing disappears, and the brake is released.
8030D
a RCV Remote control valve c RCV Remote control valve e RCV Remote control valve
b MCV d MCV f MCV
2. Independent operation
1) Travel spool switchover [Fig. 4 and Fig. 5]
When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1 (Pa1), the oil fed
from the P1 port flows from the neutral path (L1) through the spool neck section and into the B1 (A1) port.
The return oil returns to the tank path (Ta) from the A1 (B1) port through the spool neck section.
When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6 (Pa6), the oil fed
from the P2 port flows from the neutral path (R1) through the spool neck section or path (S6-1) and into the
B6 (A6) port.
For independent travel operation, the parallel path (R3) and the path (S6-1) have the same pressure, so
the poppet (S6-2) does not open. The return oil returns to the tank path (Ta) from the A6 (B6) port through
the spool neck section.
a (Section 2)
b (Section 6)
a (Section 1)
b (Section ST)
a (Section 2)
b (Section 6)
a (Section 1)
b (Section ST)
a (Section 3)
b (Section 7)
a (Section 3)
b (Section 7)
2) Open [Fig. 8]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pa7, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3),
the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7 port.
The return oil returns to the tank path (Ta) from the B7 port through the spool neck section.
Bucket open
a (Section 3)
b (Section 7)
Neutral
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
Up (2 pumps flow)
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
Down (regeneration)
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
Neutral
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
a (Section 5)
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
8) Relief valve
1) Main relief valve [Fig. 17]
The oil fed from the P1 port passes through the poppet (LP) and the oil fed from the P2 port passes
through the poppet (RP) and path (3) and is led to the main relief valve. The maximum pressure of
the P1 and P2 side pumps is controlled by the operation of the main relief valve.
3. Compound operation
1) Travel compound operation [Fig. 19, Fig. 20]
Under the conditions below when the travel left/right and the front system are operated at the same time,
the straight travel spool is switched, and the straight travel characteristic is maintained.
1 When the front is operated during travel left/right simultaneous operation (forward, backward, or pivot
turn)
2 When the left/right are operated simultaneously during front system operation
Front system operation is not affected by the switchover section or quantity of switchovers.
1) Signal circuit [Fig. 19]
(A) When the [Travel 1] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then switches the switchover valve [V1].
(B) When the [Travel 2] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then if the switchover valve [V1] is switched, it
switches the switchover valve [V2] through the path. On the other hand, if the switchover valve [V1]
is in the neutral state, the path is cut off by the switchover valve [V1]. Therefore, if both (A) and (B)
are established at the same time, the straight travel spool internal path (Pst) is connected to PA.
Also, if either (A) or (B) are established, the travel signal (PT) pressure rises.
(C) If at least one of the front systems is switched, the highest pressure of all the pilot pressures
in the front system is selected and is connected to the front signal port (PA). Therefore, if (A), (B),
and (C) are established at the same time, the straight travel spool switchover quantity is determined
proportional to the front signal (PA) pressure through the internal straight travel signal path (Pst).
[Fig. 19] shows the example of a case of travel left/right forward + boom up.
a (Section 1)
b (Section 6)
c (Section ST)
4. Anti-drift valve
The anti-drift valve is mounted on the arm rod (boom head) side cylinder port to prevent the arm (boom) cylinder
from dropping naturally.
Also, the release signal operates led by the internal path from the pilot signal.
(The arm side (A5) is shown as a typical example.)
1) Neutral (A5 port hold)
1) The A5 port hold pressure passes from path (a) through path (b), through path (c), and is connected
to the poppet (1) spring chamber (d).
2) Therefore, the A5 port pressurized oil is cut off by the seat section (S1) and the seat section (S2).
1 Main spool
1 Main spool
1 Main spool
5. Relief valve
1) Main relief valve operation
1) This relief valve is incorporated between the neutral path "HP" and the low-pressure path "LP". The
oil passes through the metering hole of the main poppet (C) and charges the interior space (D). Also,
the sleeve (E) and the main poppet (C) seat securely operating on the different surface areas [A] and
[B].
2) When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (F)
opens. The oil flows around the poppet, passes through the notch hole (G), and is led to the low-
pressure path "LP".
3) Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C) opens, so the
oil flows directly into the path "LP".
2) When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (E)
opens. The oil flows around the poppet, passes through the notch hole (H), and is led to the low-
pressure path "LP".
3) Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of the piston (C),
a pressure difference is generated between the path "HP" and the rear side of the piston (C), and the
piston (C) moves and seats with the poppet (E).
4) The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the ring-shaped
gap between the poppet (D) and the piston (C) and through the orifice (F), so the pressure difference
increases.
Because of this, the poppet (D) opens and the oil flows directly into the path "LP".
1 Subassembly screw
a Travel 2
b Travel 1
2) Spool section
When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and switched, the neutral
path [Pg] is closed. The oil fed from the Pg port flows from the parallel path [Rg] through the load check
valve [S10-1], the path [S10-2], and the spool neck section, and into the AR1 (BR1) port.
The return oil returns to the tank path [Ta] from the BR1 (AR1) through the spool neck section.
2) Relief operation
When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure generated in path (L2
(R2)) by the orifice (Lc1 (Rc1)).
Through this poppet operation, the oil flows from the path, through the notch hole path, and out to the
tank path [Ta]. This prevents the generation of excess pressure at the low-pressure relief signal port.
2) When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet [3] opens.
The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the ring-shaped
gap [D] and is led to the tank path "LP".
3) Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the main poppet
[1] opens, so the "HP" oil flows directly into the path "LP".
8030E
Normal closed type solenoid; SP, S1, S3 Normal open type solenoid; S2 4-port type solenoid; S4
Operation Explanation
Electromagnetic switchover valves S1, S3 → Oil passing through when valve excited
Electromagnetic switchover valve S2 → Oil passing through when valve not excited
→ Oil passing to C5 when valve excited Oil passing to
Electromagnetic switchover valve S4
C4 when valve not excited
8030F
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 T port
2 P port
4. Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top end section touches
the push rod bore bottom section and the output pressure goes into the state of still being connected with the P
port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside the push rod, when
the handle is flipped down beyond a certain angle, the push rod bore bottom section and the spring touch. That
spring force changes the 2nd pressure gradient and after that the push rod bore bottom section and the spring
seating top end section touch, and the output pressure remains connected to the P port.
8030G
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Reduction Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Section Damping Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8030H
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structure
This valve is made up of a shuttle valve section and cushion valve section with heat circuit.
The cushion valve with a heat circuit is connected between the hydraulic shovel car control valve and the pilot oper-
ation valve to reduce body shaking (cushion function) caused by emergency stop operations by the operator.
This valve is also equipped with a circuit with which the operator can deliberately disable the cushion function for
reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems.
This valve has 2 circuits.
*1 Arm
*2 Boom
Operation Explanation
1. Normal operation
The pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) pushes up the check plunger
and is sent to the B port (or D, F, or H port).
The pressure oil that has passed through the B port operates on the control valve spool and operates the actuator.
The oil pushed out from the control valve spool passes through the D port (or B, F, or H port) and flows out to the
T port.
2. Cushion operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is closed by the pilot
operation valve, the pressure oil that has operated on the control valve spool is pushed back to the B port (or the
D, F, or H port) by the return spring on the spool.
The returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E, or G port),
and is drained from the pilot operation valve.
At this time, by passing through the metering orifice, the pressurized oil holds down the control valve spool speed,
which prevents the sudden stopping of the actuator and reduces shaking of the body. (Cushion function)
3. Reverse operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is switched to the C port
(or A, E, or G port), the pressure oil that has operated on the control valve spool is pushed back to the B port.
Because the pushed back oil flows out to the T port without passing through the check plunger metering orifice,
it does not hold down the control valve spool speed, so the cushion function does not work.
4. Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through the inside of the
reverse operation spool and flows out to the T port, which heats up the inside of the valve.
When pressure oil is being fed from the pilot operation valve to the A port (or C, E, or G port), the oil fed to the
R port flows out to the C port (or A, E, or G port) and heats up the circuit to the pilot operation valve and inside
the valve.
5. Shuttle valve
The steel ball is pressed from the higher of the pressures between the I and J ports and the K and L ports to the
lower of these pressures. Through this process, high-pressure oil is fed to the S port or the Q port.
In the same way, oil of the higher pressure between the M and N ports and the O and P ports is fed to the U port.
9002
Removal of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Items to prepare
• Box wrench (50 mm)
• Eyebolt (M42)
• Balance lifting device
• Shackles (with the required lifting capacity) x 4
• Wire rope (with the required breaking load x 4)
• Liftcrane (with the required lifting capacity)
• Wood planks, etc.
• Rag
• Cleaning fluid
3. Install the 2 eyebolts (M42) (1) in place of the re-
moved caps.
• Apply lubricating oil to the eyebolts.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
5. Use a box wrench (50 mm) to remove the 4 bolts (1) 7. Thoroughly check that the location is safe before
and spacers (2) on the lower section of the counter- lowering the counterweight on wood planks (1).
weight.
• Thoroughly secure the counterweight with the
wire ropes and liftcrane so that it does not fall
over.
Installation of Counterweight 3. Use a box wrench (50 mm) to attach the 4 bolts (1)
and spacers (2) on the lower section of the counter-
1. Connect the shackles (1) to the eyebolts, and thor- weight.
oughly secure the counterweight with the wire ropes
(2) and liftcrane so that it does not fall over. • Bolt (1) tightening torque: 1862 - 2058 N·m
2. Use the wire ropes and liftcrane to lift and install the 4. Remove 2 eyebolts (M42) (1).
counterweight.
• Suspend the counterweight so that it does not in-
terfere with the housing, engine parts and pipes.
9003A
Removal of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Items to prepare
• Hammer
• Striking rod
• Screwdriver
• Grease
• Rag
• Cleaning fluid
2. Use a hammer (4) and striking rod (5) to push the
bucket side pin (3) and arm side pin (2) out, and
then remove the bucket (1).
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.
Installation of Bucket
1. Clean each pin and pin hole.
9003B
Items to prepare
• 2 wrenches (30 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
2. Use 2 wrenches (30 mm) to remove the double nuts
(1), and then pull out the bolts (2) (3).
4. Use a hammer (4) and striking rod (5) to push out Installation of Bucket Link
the pin (3) and remove the arm links (1) (2).
1. Clean each pin and pin hole.
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.
9003C
Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Items to prepare
• Wrench (19 mm)
• Hammer
• Striking rod
• Nylon sling (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
• Crosstie 2. Use a wrench (19 mm) to remove the bolt (1) and
washer (2).
Installation of Arm
• Tighten bolts being installed to the specified torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.
2. Bring the arm (1) top in contact with the ground and
use a liftcrane and nylon sling (2) to secure it.
At this time, insert the arm cylinder pin (3) and se-
cure with the nylon sling.
3. Align the arm (1) with the boom and use a hammer
(3) to push in the pin (2) and then install the arm (1).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed dust seals.
9003D
Removal of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Use a wrench (30 mm) to remove the double nuts 6. Tie the cylinder rods on the left and right sides with
(1) and bolt (2), and then remove the fastening ring wire (1) so that they cannot come out.
(3).
Also, remove the cab side in the same way.
9. Install the pin (1) removed in Step 4. 11. Use a wrench (19 mm) to remove the bolt (1) and
Use a wrench (30 mm) to tighten the bolt (3) with washer (2).
the 2 double nuts (2), and then install the fastening
ring (4).
Also, install the cab side in the same way.
12. Use a slide hammer (1) (24 mm) to remove the pin
(2).
10. Wrap nylon slings (1) around the pins on the left and
right sides installed in Step 9 and secure with the
liftcrane.
Installation of Boom 4. Tie the cylinder rods on the left and right sides with
wire (10) so that they cannot come out.
• This section explains the procedure for when not in-
stalling the boom cylinder.
• Tighten bolts being installed to the specified torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.
5. Align the boom with the swing frame pin hole and
use a slide hammer (1) (24 mm) to tighten the pin
(2).
• When inserting pins, be careful not to damage the
dust seals.
• If the insertion of a shim is possible according to
2. Install the pin (1). the tolerance adjust the shim.
Use a wrench (30 mm) to tighten the bolt (3) with
the 2 double nuts (2), and then install the fastening
ring (4).
Also, install the cab side in the same way.
7. Start the engine, raise the boom at idle, and extend 10. Use a wrench (19 mm) to attach the grease hoses
the boom cylinder (1) (2) rod. on the right and left sides (1).
8. Use a hammer (2) to push in the pin (1). 11. Bring the boom (1) top in contact with the ground.
Use a liftcrane and nylon slings (3) to hold the boom
cylinders (right) (left) so that they does not fall. • When installing the boom cylinder too, see "Re-
moval and Installation of Boom Cylinder".
• Install the arm. (For details, see "Removal and
Installation of Arm".)
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)
9004
Job code 90120AD17 3. Use a wrench (13 mm) to remove the 2 bolts (1)
from the rear of the seat.
Tightening torque for bolt (1) installation: 19.6 N·m
Items to prepare
• Wrench (13 mm)
2. Pull the slide lever (1) to slide the seat forward, and
then pull the reclining lever (2) to fold the seatback
forward.
9005A
Items to prepare
• Wrenches (10 mm, 12 mm, 13 mm, 19 mm, 41 mm)
• Box wrenches (10 mm, 13 mm, 19 mm)
• Longnose pliers
• Flathead screwdriver
• Eyebolt (M24 x 4)
• Chains (wire ropes) (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Lubricating oil
• Rag
• Cleaning fluid
• Wood planks, etc. 2. Use a box wrench (10 mm) to remove the 3 bolts
(1), and then remove the air conditioner ducts on
both sides (2) (3).
Tightening torque for bolt (1) installation: 2.9 - 3.9
N·m
4. Use a flathead screwdriver or longnose pliers to re- 7. Use a wrench (13 mm) to remove the bolts (2) for
move the clip pins (1), and then remove the air con- the ground wire (1) connecting the cab and frame.
ditioner ducts (2) by pulling them forward.
10. Use a wrench (13 mm) to remove the 4 bolts (1), use 13. Use a wrench (10 mm) to remove the 2 bolts (1),
a wrench (12 mm) to remove the 3 bolts (4) and 2 and then remove the bracket (2).
nuts (2), and then remove the rear brackets (3) (5).
16. Remove the 4 caps (1) from the top of the cab.
17. Install the 4 eyebolts (M24) (1) in place of the re- 19. Use a wrench (19 mm) to remove the 8 cab bolts
moved caps. (1) and 4 nuts (2).
• Fully tighten the eyebolts, and then loosen them
by a half turn.
21. Use chains (1) and liftcrane to remove the cab (2). 22. Thoroughly check that the location is safe before
lowering the cab on wood planks (1).
• Thoroughly secure the cab with the chains and
liftcrane so that it does not fall down.
Installation of Cab Assembly Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Tightening Torque"
To install, perform the reverse of the removal procedure. section.
9005B
Removal of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of Wiper
1. Use a wrench (17 mm) to remove the 1 nut (1), and
then remove the wiper arm (2).
Tightening torque for nut (1) installation: 12 - 16 N·m
Installation of Wiper
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
9005C
Job code 55518BH01 2. Remove the connector (2) from the wiper controller
(1).
Items to prepare
• Wrench (10 mm)
• Box wrench (10 mm)
• Phillips screwdriver
• Flathead screwdriver
9005D
Job code 55518AZ46 3. Use a Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (1), use a hexagon wrench (5
mm) to remove the 3 bolts (2) and 3 washers (3),
Items to prepare
and then remove the front upper trim assembly (4).
• Hexagon wrench (5 mm) Tightening torque for bolt (1) installation: 5.9 - 7.8
• Wrenches (10 mm, 17 mm) N·m
• Box wrench (10 mm)
• Flathead screwdriver (longnose pliers)
• Phillips screwdriver
6. Use a box wrench (10 mm) to remove the 4 bolts Installation of Wiper Motor
(1), and then remove the wiper motor assembly (2).
To install, perform the reverse of the removal procedure.
• Be careful about the wiper link and wiper arm installa-
tion location.
• Check the wiper arm wipe location and stop location.
• When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for an installation bolt, see
the "Tightening Torque" section.
9005E
Removal of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Items to prepare
• Wrench (10 mm)
Removal of Monitor
1. Use a Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (1), and then remove the side
front lower trim (2).
• Bolt (1) tightening torque: 5.9 - 7.8 N·m
9005F
Job code 90156AL10 3. Use a wrench (10 mm) to remove the 3 bolts (1)
each, and then remove the brackets (2) (3).
Tightening torque for bolt (1) installation: 880 - 1270
CAUTION N·cm
Reinforced glass is used for the front win-
dow.
Be extremely careful not to damage it when
touching it during removal or installation.
Items to prepare
• Wrench (10 mm)
• Phillips screwdriver
• Rag
• Cleaning fluid
6. Use a wrench (10 mm) to remove the 3 bolts (1), Installation of Cab Front Glass
and then remove the front glass right lower bracket
(2). To install, perform the reverse of the removal procedure.
Tightening torque for bolt (1) installation: 880 - 1270 Tighten bolts being installed to the specified torque.
N·cm If the torque is not specified, see the "Tightening Torque"
section.
9005G
Window Lock (rear side) 3. Set the cab front glass (1) in place.
9005H
Tightening torque
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tightening torque
When installing cab inner and outer parts, for bolts and screws for which the torque is not specified, tighten according
to the following.
9006
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
Compressor; Air con-
1 Cooler hose (Liquid 2) 1 5 1 9 Dryer receiver (D60.5) 1
ditioner
2 Cooler hose (Suction) 1 6 Slide shaft 1 10 Cooler hose (Liquid 1) 1
Rubber hose 16 x Tension pulley (With Bracket receiver
3 2 7 1 11 1
5600 cover) (D60.5)
Cooler hose (Dis-
4 1 8 Air condenser 1 12 V belt B-45.5 1
charge)
White marking
a Air conditioner unit e Heater (Engine output) i Must be connected with the air
conditioner unit.
b Engine f Heater (Unit outlet) j Clamp
c Heater (Engine return) g Heater (Unit inlet)
Must be connected with the air
d White marking h
conditioner unit.
84402826 - May 2011
9006-4
Air Conditioner Overall Diagram
Cab
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
1 Solar radiation sensor 1 8 Duct; H and C box 1 15 Duct; Intake-B (Fresh) 1
2 Duct; Face-A 1 9 Bracket; Box 1 16 Unit; Air conditioner 1
3 Duct; Def-A 1 10 Box; Hot and cool 1 17 Duct; Foot 1
4 Grille; Air vent 7 11 Duct; Vent (Left) 1 18 Duct; Def-B
5 Duct; Face-B 1 12 Duct; Vent (Right) 1 19 Control panel (AC) 1
6 Duct; Def-C 1 13 Air filter (Fresh) 1 20 Drain hose 2
7 Duct; Face-C 1 14 Duct; Intake-A (Fresh) 1 21 Flange plate 1
Circuit Diagram
Air Conditioner Circuit Diagram
5 V system
5 V are always applied.
Analog Signal:0 - 5 V are applied
GND
P W B R Y G L Br Lg O Sb V
Light Sky
Pink White Black Red Yellow Green Blue Brown Orange Violet
green blue
NOTE:
• Wire diameters that are not indicated are 0.5.
• Broken lines indicate wiring on the vehicle side.
• Codes displayed on the connectors indicate the code colors seen from the connection ports of the connectors.
Explanation of Functions
Explanation of Control
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the vehicle main key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next time air
conditioner operation starts, it goes into the same state as before it was stopped.
When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 sec. of switch input, that switch input is not stored into
memory.
Also, the data read out from EEPROM when the power is switched ON is judged to see if it is within the valid range.
If data outside the valid range was written into memory, for example due to noise, then operation starts from the default
setting values to avoid abnormal operation.
Fahrenheit temperature display
To switch, hold down both the temperature setting UP and DOWN switches for 5 sec.
The display toggles between Celsius and Fahrenheit display each time the switches are both held down for 5 sec.
The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained.
Internal calculations are all done in Celsius.
Only the operation panel display is in Fahrenheit.
Therefore, the display may differ slightly from the exact Fahrenheit temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal processing.
CAUTION
These specifications are written with Celsius as the standard.
Therefore, if the temperature is displayed in Fahrenheit, convert the temperature to centigrade by using
the table below.
3. Manual control
1) When operation of the blow mode select switch is recognized, the blow mode motor actuator is driven to
attain the output shaft angle below and the display is switched too.
Each time operation of the switch is recognized, the display switches MODE 1 → MODE 2 → MODE 3 →
MODE 4 → MODE 1 →...
However, if this switch is pressed during auto control, auto control is ended and the diffuser is fixed at its
current position.
2) MODE 5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode becomes the one
that was in effect just before operation of the DEF select switch was recognized.
Also, even if the DEF switch is pressed again during this mode, the mode is not canceled.
Panel display
Panel display
Display
Priority or-
Control
der
Blower air flow control when mode motor actuator angle
1
switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
* is a value between 0 - 9, and each time the DOWN switch is closed, this value decreases by 1; each
time the UP switch is closed, this value increases by 1.
Monitor Mode
1. Summary explanation
Monitor mode is a mode for understanding abnormalities in the operation panel itself or in other control.
The system goes into monitor mode when there is the special switch input below on the operation panel.
2. Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON/OFF switch closed path con-
tinues for 1 sec. while the refresh/recirculate select switch closed path is ongoing, monitor mode is started.
3. Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 sec.
An LCD with trouble does not light up.
2) Sensor diagnosis
The detection value (AD value or °C) for each sensor is displayed.
3) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4. Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is dis-
played in the 3-digit of the 7-segment display for the temperature setting.
The data displayed is selected with the blower UP/DOWN switches and AUTO switch.
The blower UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through 16
displays, 0 - F, and the corresponding data is displayed.(Table A)
Hexadecimal data display and decimal data display can be selected with the AUTO switch. Only for the coolant
temperature signal recognition value, the value detected immediately before entry into monitor mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3rd-digit of the 7-segment display
for the temperature setting. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 - 9)
are displayed there.
1) Hexadecimal display
AD values 00H - FFH are displayed.
When the AD value corresponds to that in Table B (or Table C for the solar radiation sensor), this indicates
a disconnection or short.
In the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadecimal display
changes with it.
If the display before entering monitor mode was , the error judgment value is displayed. (In
other words, the detected value before the abnormality was detected) In the same way, if the display be-
fore entering monitor mode was , the display becomes **.E and the error judgment value is
displayed.
2) Decimal display
Decimal display is used from -99.9 °C to 99.9 °C.
Also, the "-" minus display is displayed on the left side of the 3 digit segment.
5. Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until monitor mode
is ended, operations and settings of basic control through all the switches are not possible.
6. Ending monitor mode
In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 sec. while the refresh/recir-
culate select switch closed path is ongoing, monitor mode is ended and the system returns to the basic control
state.
The same also occurs if the vehicle main key power supply is switched OFF.
Sensor Discon-
Short
name nection
Inside air
F6H 0CH
sensor
Evaporator
F6H 0CH
sensor
Sensor
5 V short Ground short
name
Solar radia-
D5H 0CH
tion sensor
Actuator Inspection
Air Mix Motor Actuator Inspection
• Structural diagram
• Chart
Standard
Step Action Yes No
value
Press the temperature setting
switches and set to COOLMAX
1 (18.0 °C). Go to Step 2 Go to Step 3
Does the actuator operate at
all?
2 Is an error displayed? Go to Step 6 Damper lock or link defect
Press the temperature setting
switches and set to HOTMAX
3 (32.0 °C). Go to Step 2 Go to Step 4
Does the actuator operate at
all?
4 Is an error displayed? Go to Step 5 Control panel defect
Is there continuity in harness
Actuator defect or damper
5 between the actuator and con- Harness defect
lock or link defect
trol panel?
Remove the actuator connec-
tor (9).
About 4.7
6 Is the resistance between L/Y Go to Step 7 Actuator defect
KΩ
and B/L of the actuator about
4.7 KΩ?
Is there continuity between the
7 G/L and L/Y and between G/L Control panel defect Actuator defect
and B/L of the actuator?
• Chart
Standard
Step Action Yes No
value
Press the refresh/recirculate
1 switch. Does the actuator operate Go to Step 2 Go to Step 3
at all?
2 Is an error displayed? Go to Step 5 Damper lock or link defect
3 Is an error displayed? Go to Step 4 Control panel defect
Is there continuity in harness be-
Actuator defect or damper
4 tween the actuator and control Harness defect
lock or link defect
panel?
Remove the actuator connector
(11). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the L/G
6 and L/Y and between L/G and B/L Control panel defect Actuator defect
of the actuator?
• Chart
Standard
Step Action Yes No
value
Press the mode select switch.
1 Go to Step 4 Go to Step 2
Does the actuator operate at all?
2 Is an error displayed? Go to Step 3 Control panel defect
Is there continuity in harness be-
Actuator defect or damper
3 tween the actuator and control Harness defect
lock or link defect
panel?
4 Is an error displayed? Go to Step 5 Damper lock or link defect
Remove the actuator connector
(10). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the Y/L
6 and L/Y and between Y/L and B/L Control panel defect Actuator defect
of the actuator?
Panel display
1 Main power switch 4 Air flow select switch 7 Diffuser select switch
Refresh/recirculate select
2 Auto control switch 5 Air conditioner ON/OFF switch 8
switch
3 Temperature control switch 6 Defrost switch
Through the operation of its internal microcomputer, the control panel compares, operates on, and processes the
sensor input signals and control panel switch input signals, switches the output side actuators (refresh/recirculate
switching, mode switching, air mix) and comprehensively controls the fan motor and compressor.
Also, it is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the air conditioner
troubleshooting.)
Blower Amp
The power transistor receives the base current from the control unit and changes the speed of the fan motor.
Blower amp inspection
The blower amp can be easily judged by removing the blower amp connector and checking for continuity across
the blower amp terminals.
Terminal No.
Continuity
1 2 3
+ --- - Yes (4.7 kΩ)
Tester - + --- No
+ - --- Yes (diode parallel forward direction)
Relay
4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay
This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp
and the blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp compressor control.
Relay inspection contents
1. Relay
2. Coil resistor: 320Ω
3. Specification voltage: DC 20 - 30 V
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect for continuity between 3 and 4 under the conditions below.
The air mix actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and
closes the air mix damper via the link.
Built into the air mix actuator is the potentio-meter which switches linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit reads in the
potentio-meter position in the actuator and determines whether the motor turns forward or reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
Terminal
Direction of rotation 1 2
Clockwise (forward) + -
Counter-clockwise (reverse) - +
Refresh/Recirculate Actuator
CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.
The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
door via the link.
Built into the refresh/recirculate switch actuator is the potentio-meter that switches linked with the actuator shaft.
When the refresh/recirculate door position is determined by the refresh/recirculate switch on the control panel, the
control unit reads in the signal of the potentio-meter in the actuator and determines whether the motor turns forward
or reverse.
The position detection switch also rotates linked with the motor and stops the refresh/recirculate door at the set po-
sition.
CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.
The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens
and closes the mode door via the link.
Built into the blow mode actuator is the potentio-meter which switches linked with the actuator shaft.
When blow mode is determined by the temperature control switch, the control unit reads in the potentio-meter position
in the actuator and determines whether the motor turns forward or in reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
Evaporator Sensor
In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor
ON/OFF is controlled.
1 (Low-pressure side)
2 (High-pressure side)
CAUTION
Always measure with the tester in voltage measurement mode (V mode).
Measuring in resistance mode (Ω mode) would destroy the sensor.
The inside air sensor is installed in the inside air side intake port of the air conditioner unit and switches the tempera-
ture inside the cab to the resistance.
This resistance value is converted into a voltage value in the control panel and processed.
Inside air sensor inspection method
Remove the inside air sensor connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Inside air sensor inspection details (specifications)
Resistance between terminals
For 0 °C: 7.2 kΩ ± 3 %
For 25 °C: 2.2 kΩ ± 3 %
9007
2. Remove the filter cover (1) and inside air filter (2).
• Remove the 4 Phillips screws (3) and remove the
intake case (4).
Screw size
Phillips screws (3): M5 x 16 (T1)
• The installation procedure is the reverse of the • The installation procedure is the reverse of the
removal procedure. removal procedure.
Screw size
Phillips screws (3): M4 x 16 (T1)
2. Replacement of air mix motor actuator
a Thermistor holder position Remove the link cover.
b 20 mm Remove the connector (2) from the motor actuator
c 73 mm (1).
d 9th row Remove the 3 Phillips screws (3) securing the mo-
tor actuator (1), remove the rod (4) attached to the
e 27th row
motor actuator (1) from the rod hole on the damper
lever, and then install the new motor actuator (1).
The installation procedure is the reverse of the re-
moval procedure.
Screw size
Phillips screws (3): M4 x 16 (T1)
9009
Removal of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAUTION
• Be sure to stop the engine before beginning
work.
• When removing and installing the compres-
sor, check the compressor oil quantity.
Items to prepare
Wrench (13 mm) 2. Use a box wrench (13 mm) to loosen the bolts (1)
•
Box wrench (13 mm) on the lines in the 2 locations, and then remove the
•
Rag 2 lines (2) (3).
•
• Cleaning fluid • Always remove the low-pressure side line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.
Tightening torque for bolt (1) installation: 19.6 -
24.5 N·m
9010
Removal of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm, 22 mm)
• Cap
• Plug
• Rag
• Cleaning fluid
3. Use a wrench (13 mm) to remove the 4 bolts (1), Installation of Condenser
and then remove the condenser (2).
• To install, perform the reverse of the removal proce-
• Bolt (1) tightening torque: 17.7 - 21.6 N·m dure.
Tighten the lines and bolts to the specified torque.
If the torque is not specified for a bolt, see the "Bolt
Size and Torque Table".
• Make sure to resupply and check the compressor oil
quantity.
The compressor contains 135 cc of oil.
The oil quantity being low will cause compressor seiz-
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if
needed.
Resupply quantity: 40 cc
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
• Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".
9011
CAUTION
• Be sure to stop the engine before beginning
work.
CAUTION
• When replacing the receiver dryer, resupply
and check the compressor oil quantity. 2. Use a wrench (10 mm) to remove the 2 bolts (2)
from the line (1).
Items to prepare
• Attach caps or plugs to the receiver dryer and line
• Wrench (10 mm) to prevent any entry of water, dust or dirt.
• Cap • Clean the receiver dryer and line by spraying them
• Plug with a parts cleaner to prevent scratches and pre-
• Rag vent dirt from accumulating on the connectors.
• Cleaning fluid • Bolt (2) tightening torque: 7.8 - 11.8 N·m
3. Use a wrench (10 mm) to remove the 1 bolt (1), and Installation of Receiver Dryer
then remove the receiver dryer (2).
• To install, perform the reverse of the removal proce-
dure.
When installing the lines and bolts, tighten them to the
specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
• Check the compressor oil quantity.
The compressor contains 135 cc of oil.
The oil quantity being low will cause compressor seiz-
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if
needed.
Resupply quantity: 20 cc
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
• Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".
9015
Work Precautions
Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation". . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging Hose Connection Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gauge Manifold Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vacuuming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas Filling Operation, High-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Filling Operation, Low-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Work Precautions
WARNING
• Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a experi-
enced and qualified worker with the procedure performs this operation.
• Always wear protective eyewear.
• Gas entering the eyes may cause blindness.
• Refrigerant in the liquid state is very cold (about -26 °C), so be very careful during handling.
• Refrigerant coming in contact with skin may cause frostbite.
Work Procedures
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation".
1. The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during operation such
as freezing in the small hole of the expansion valve causing the circuit to clog and rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation consists of eliminating
moisture inside the circuit through boiling and evaporation.
2. The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life of the parts
which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and this will cause
reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor will be poor and
this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the operation using an
incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrigerant filling.
Operation Chart
Vacuuming start 30 min. or longer (750 mmHg or less)
↓
Vacuuming stop Let sit for 5 min.
Vacuuming
↓
operation
Gauge display abnormality (connectors check and
Airtightness check
repair)
↓
Fill with refrigerant gas up to a gauge pressure of
Refrigerant filling
0.098 MPa.
Refrigerant fill- ↓
ing operation Gas leak check
↓
Refrigerant filling
Tools
No. Part name Q'ty Shape Application
1 Gauge manifold 1
Red: high-pressure
side
Blue: low-pressure
2 Charging hose 3
side
Yellow: vacuum
pump side
3 Quick joint 1
Vacuum pump
7 1 For vacuum pump
adapter
Filling Procedures
CAUTION
• Because gauge manifold specifications such as hose color are different depending on the manufac-
turer, read the operator's manual for the gauge manifold to be used for details.
9 Low-pressure gauge
10 High-pressure gauge
Vacuuming
1. Open the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13).
2. Turn the vacuum pump (8) switch on and vacuum for at least 30 min.
3. After the prescribed vacuuming time has elapsed (degree of vacuuming achieved: -750 mmHg or less), close
the gauge manifold (13) high-pressure valve (12) and low-pressure valve (11).
4. Next, turn the vacuum pump (8) switch off.
5. Perform a check of air-tightness.
Let the gauge manifold (13) sit for at least 5 min. with the high-pressure valve (12) and low-pressure valve (11)
closed, and check that the gauge indicator does not go back to 0.
If the gauge indicator starts to swing back to 0, this indicates there is a leak. Tighten the line connections, perform
vacuuming again, and check to see if there is still a leak.
After finishing the high-pressure side filling operation, perform the operation for the low-pressure side.
1. Check that the high-pressure valve (12) and low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17) are closed.
2. Start the engine, increase speed to 1400 - 1600 min-1, and completely open the cab door and window.
3. Turn the air conditioner switch on, move the fan switch to the maximum position, and move the temperature
adjustment switch to the maximum cooling position.
4. During filling, set the degree of discharge for the compressor at 1.37 - 1.57 MPa.
5. Open the low-pressure valve (11) of the gauge manifold (13) and valve for the service can (17), and fill with the
regulation amount of refrigerant until the air bubbles in the receiver sight glass (19) are gone.
• Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air
When the amount bubbles are visible. The glass then be-
is correct comes transparent and turns to a pale,
milky-white color.
When filling was After the AC is turned ON, air bubbles are
insufficient seen continuously.
6. After refrigerant filling is complete, close the low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17), and stop the engine.
84402826 - May 2011
9015-10
Work Precautions
• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging effect on the
compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insufficient cooling
and there is the danger of pressure in the circuit becoming abnormally high.
Be sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (12).
• Never invert the service can.
(Gas is suctioned in liquid form, so this may cause damage to the compressor valve.)
7. After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (15) from the low-pressure side (SUC) service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98 MPa or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure side charge hose
(red) (14) from the high-pressure side (DIS) service valve.
3R 105d
3R 105b
3R 105e
3R 105c
3R 105a
180,215,242,250,260,267
400,410,411,412,413,414,415,416,419,420,430,444,445,446,450,490,492,532,534,535,538,559,660,800,801,802,803,805,0806,807,812,813,900,901,902,903,904,905,906,907,908,909,910,911
5RW 020
DIESEL ENGINE
(CN.A50
YAZAKI
1
2
(F20)
(F19)
(F18)
(F17)
(F16)
(F15)
(F14)
(F13)
(F12)
(F10)
FUSIBLE LINK FUSE FUSIBLE LINK FUSIBLE LINK
(F11)
58L
(F9)
(F8)
(F7)
(F6)
(F5)
(F4)
(F3)
(F2)
(F1)
10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 BACK UP CONT FUSE BOX SAFETY RL
20 19 18 17 16 15 14 13 12 11 20 19 18 17 16 15 14 13 12 11 ALTERNATOR
15A
15A
10A
10A
10A
10A
10A
20A
15A
50A 15A 65A 50A
10A
15A
10A
15A
10A
10A
10A
15A
15A
1 1 1 1 8B 797 E 24V 50A
5A
5A
SUMITOMO SUMITOMO 2
(CN.A41) (CN.A42) 2 2 2 M6
YAZAKI
WIPER / WASHER
YAZAKI YAZAKI YAZAKI
BLOWER MOTOR
YAZAKI
CIGAR LIGHTER
M8
TRAVEL ARALM
(CN.D15)
(BOOM,HOUSE)
1 2 3 1 2 3 1 2 3
COMPRESSOR
REFUEL PUMP
2
1
2
1
1
2
58L 58L 58L
CONTROLLER
CONTROLLER
1.25BG 600 8 2BG 600 CN-A
2
1
AIRCON UNIT
LEVER LOCK
CONVERTOR
KEY SWITCH
4 5 6 4 5 6 4 5 6 (CN.D23) (CN.D26) (CN.D25) (CN.D24) IC
SOLENOID
1.25B 700 2B 700 YAZAKI
SEAT SUS
7
BACK UP
REGULATOR
BEACON
10
12
13
14
15
16
17
18
19
20
10
12
13
14
15
16
17
18
19
20
11
11
AIRCON
AIRCON
OPTION
ENGINE
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
6
5
4
3
2
1
1
2
3
4
5
6
DC / DC
YAZAKI YAZAKI YAZAKI (CN.D16)
SPARE
SPARE
(GATE)
HORN
6
LAMP
LAMP
(CAB)
5RW 103
5RW 102
8R 105
8R 104
5R 002
5R 003
M M M
GPS
1.25W 107
1.25W 106
(CN.A38) (CN.A39) (CN.A40) 5
PG 41b
PG 41d
PG 41g
PG 41h
BG 630
BG 637
BG 640
PG 41a
PG 41c
PG 41e
P 40b
P 40d
P 40g
P 40h
P 40a
P 40c
P 40e
RL 160
RL 161
RL 162
RL 163
RL 164
PG 41f
PG 41i
PG 41j
P 40f
G2
P 40i
P 40j
1.25W 109
1.25W 108
1.25W 107
1.25WR 141
1.25WR 142
1.25WR 145
1.25WR 146
1.25WR 147
1.25WR 148
1.25Y 870 1.25Y 870
1.25W 112
1.25W 110
1.25W 111
1.25G 510 0.75R R
0.85G 502
0.85G 503
0.85G 504
0.85G 505
0.85G 506
1.25BG 600
1.25BG 601
1.25BG 602
0.85BG 603
1.25BG 609
1.25BG 610
0.85BG 620
1.25B 700
0.85B 701
0.85B 702
1.25B 703
0.85B 704
0.85B 720
4 1
WB 245
WL 260
2W 250
GR 180
LgW 190
VR 230
RL 160
0.85GW 215
1.25WR 235
WL 267
1.25RW 140
1.25W 205
0.85VW 170
1.25Br 515 0.75L L
0.85OR 225
1.25LW 200
0.85R 130
1.25RB 150
3 2
0.85YR 220
0.85LR 240
1.25GrR 195
0.85BrR 210
WL 266
WL 267
0.85GW 216
0.85GW 215 2 0.85GW 215
0.85YR 221
0.85LR 242
(CN.D14)
SWP
YAZAKI
B 749 2W 250 1 2W 250
1 2
0.85B 708
K7
(CN.D19)
RL 166 0.85G 507
YAZAKI
(CN.D17)
(CN.D18)
1 2 3 4
5 6 7 8
YAZAKI
YAZAKI
0.5μF
(CN.A51)
8R 030 B
YAZAKI
108,109,110 YAZAKI M6
58M
RELAY BATTERY
601,602,603,701,702,703 G1 (CN.D13)
STARTER MOTOR
CONTROLLER A 503,504,505,515,520,521,530,536,537,539,558,804,808,809
K63 (CN.A09) K64 (CN.A13) K65 (CN.A11) K66 (CN.A12) K67 (CN.A10) (CN.A14) K68 (CN.A15) K34 60R 100 60R 101
M8 M8 YAZAKI
60R 001 B
M10
M
RELAY RELAY RELAY RELAY DPF RELAY RELAY
10 11 12 13 14 15 16 17 18 19 20
6 7 8 9
POWER 24V 1.25W 108 V 097 (CN.D21) 5Y 004 S
M1
0.85BG 660
1 1
A1 ECM KEY ON BATTERY RL IDLE STOP RELAY NEUTRAL START STARTER CUT M10 M10 M10 M10
7 8 9 10 11 12 13 14
4 5 6
(CN.D11)
58Y
YAZAKI
12 1.25W 108a VG 098 2 M4 YAZAKI YAZAKI M5
- + - +
(CN.D12)
(CN.C21)
SDL
YAZAKI
POWER 24V 11 G 099 (CN.D20)
6 5 4 3
2
3
1
24V 5.0kw
(CN.A44)
VR 595 M4
(CN.C3)
YAZAKI
22 4
YAZAKI
P1
60B 799
2
1
SDL
GND_2 1.25BG 601 Br 596 5BW
SDL
2 5 5L 021 1
1.25WR 511
1.25G 501
1 2 3 4 5
1
GLOW PLUG
1 2 3
B
1.25BG 601a BG 612
13 6
X37
YR 882a
LR 881a
1 4 2 1
GND_3 0.85B 701 MONITOR DISPLAY 12V 12V
14 13 12 11
(CN.D9)
SWP
YAZAKI
5 5
7 6 5 4
YAZAKI
10 9 8
R1
3 2 1
1
16 0.85B 701a 3 M8 CN-A
GND BZ. BATT. 0.85RL 161 0.85RL 161 0.85RL 161 RL 161 SUMITOMO (CN.D22)
9 1 1 1
VGS TURBO
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
20 IGN 2 1.25W 111 2 1.25W 111 1.25W 111 2 1.25W 111 1.25W 107 1 1.25W 107 0.85B 751
GND_A 10 D-IN8 ALTERNATOR 4 0.85BrW 519 4 0.85BrW 519 0.85BrW 519 3 0.85BrW 519 0.85G 501 2 1.25G 501 0.75GR 389 1 0.75GR 5
U
P4 M
0.85GW 303
P 040b P 040b 0.85LR 881 LR 881
1.25WR 141
1.25WR 146
1.25WR 147
1.25WR 145
0.85WR 511 1.25WR 511 0.75Y 390 0.75YR
1.25RW 140
0.85W 112
0.85W 113
0.85W 114
0.85W 115
0.85WR 511
CAN H
0.85G 501
0.85O 804
0.85GR 845
0.85B 704
0.85B 705
0.85B 706
21 5 5 4 3 2 6
0.85YR 370
0.85LR 890
0.85LR 891
0.85LR 890
0.85Y 011
0.85Y 011
0.85LR 373
0.85YL 808
0.85LgR 500
0.85LY 824
0.85GrR 012
0.85BrR 010
V
NPN_OUT1 SOL SWING BRAKE 6 W 800 H1 CAN L 6 PG 041b 6 PG 041b 0.85YR 882 5 YR 882 0.85Br 515 4 1.25Br 515 0.75WR 391 3 0.75LR 7
W
NPN_OUT2 SOL 2 STAGE TRAVEL 4 L 801 CAN GND 18 18 V 809 6 V 809 0.85GrR 012 5 0.85GrR 012 0.75R 357 8 0.75R 4 VCC
LCD DISPLAY
RELAY STARTER
NPN_OUT3 SOL 2 STAGE RELIEF 7 Y 802 TxD(RS232C) 8 WL 061b 8 WL 061b P 040b 7 P 040b 373 0.85RY 840 6 0.75RY 840
K69
0.75W 358 5 LW 1 U
M23
(CN.E1)
DL090
SUMITOMO
(CN.D30)
CN-A
YAZAKI
5 6 7 8
1 2 3 4
CPU RELAY GLOW
NPN_OUT4 FREE SWING 3 Br 803 RxD(RS232C) 9 W 060b 9 W 060b PG 041b 8 PG 041b 303 7
K2 0.75G 359 6 Br 2 V
508
509
TFT FULL COLOR
118
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
1
NPN_OUT5 RL BATTERY 8 0.85O 804 GND(RS232C) 19 BL 064b 19 BL 064b WL 061b 9 WL 061b 142 8 0.85B 779 1 5R 003 0.75L 360 7 L 3 W
517
519
I/O
NPN_OUT6 SOL OPT 2SPEED 14 YR 805 5V-OUT PGM_WRITE 3 V 097 3 V 097 W 060b 10 W 060b 140 370 2 5Y 004 0.75B 361 9 0.75B 8 GND
(CN.D28)
SWP
YAZAKI
NPN_OUT7 SOL OPT SELECT 15 LY 806 PGM_WRITE SW 12 VG 098 12 VG 098 BL 064b 11 BL 064b 804,808 301 5RW 020 1 1 5L 021 0.75BW 693b 4 0.75BW
070MIULTI
1 2
NPN_OUT8 TRAVEL ALARM 18 WL 807 RESET 7 G 099 7 G 099 WB 949 12 WB 949 500 501 10
(CN.C1)
2 3
4 5 6 7 8
INTAKE THROTTLE
AMP
NPN_OUT9 RL DPF 0.85YL 808 8V-OUT CAMERA+ R 960 R 960 BW 950 BW 950 112 511 0.75BR 392 BL
(CN.A52)
17 10 10 13 12
(CN.D27)
1 2
YAZAKI
DC-MOTOR
YAZAKI
1 2 3 4
SDL
(CN.D31)
58
YAZAKI
A/D-IN THERMO SN 010 012 0.85L 372 0.85B 750 0.75P 326 VW BL
1
13 13 2 2 11 2
M
1
040/070HYBRID I/O
CN-A
AGND 14 14 840 840 14 G 1
SWITCH PANEL
1 2 3 4 5
(CN.E2)
AMP
PWM_OUT1 PUMP POWER(OUT) 0.85Y 900 SCL(12C) 845
9 10 11 12 13 14 15 16 17 18
3 16 16 6
5 6 7 8
S11 M24
(CN.D29)
CN-A
YAZAKI
PWM_RTN1 PUMP POWER(RTN) 6 0.85BY 901 SDA(12C) 17 17 824 L 5 Vcc
WIPER
AMP
PWM_OUT2 BOOM DOWN(OUT) 0.85O 902 GND 1.25BG 611 1.25BG 611 VW OUT
2
1
1 15 15 3
S12
(CN.A45)
PWM_RTN2 BOOM DOWN(RTN) 4 0.85BO 903 GND 20 1.25BG 610 20 1.25BG 610 704 508,372 LW 4 GND
YAZAKI
16 15 14 13
12 11 10 9
(CN.D8)
SWP
YAZAKI
8 7 6 5
4 3 2 1
WASHER
K36 K35 K5 K3 K11
22 21 20 19 18 17 16 15 14 13 12
11 10 9 8 7 6 5 4 3 2 1
0.85L 904
SDL
PWM_OUT3 P1 FLOW(OUT) 2
S10
1 2 3 4
(CN.D38)
MT090
SUMITOMO
PWM_RTN3 P1 FLOW(RTN) 5 0.85BL 905 1.25W 119 1
520
521
RELAY RELAY RELAY RELAY RELAY RELAY RELAY EGR VALVE
BG 613
BG 614
W.LAMP
1 2
SHLD GND CAMERA1 SIG Y 962 Y 962 1.25G 754
8
S2
1 1
K37 SPEAKER:R SPEAKER:L ROOM LAMP BEACON HORN LAMP:CAB LAMP:UPPER K10 2
0.85WR 512
0.85Br 516
7 CAMERA1 GND 11 W 963 11 W 963 0.75WR 386 5 0.75WR 5
M20
(CN.A4)
(CN.D37)
58W
YAZAKI
M25
1
2
O 542 WR 973 WR 973 0.85WY 829 0.85WV 829 1.25W 118 2BY 0.75GB 353 0.75GB U
M
SW_IN13 LM MODE 10 CAMERA3 GND 13 13 4 (CN.D81) SOLENOID VALVE 1 1 1
(CN.E3)
DL090
SUMITOMO
1 2
DPF CLEAN
5 6 7 8
1 2 3 4
D-IN1 F-WINDOW SW 4 O 590 4 O 590 1.25GR 875 5 1.25GR 875 1.25G 753 2 2B 0.75GW 354 2 0.75GW 2 V
S87 1 4 2
6 5 4 3 2 1
12 11 10 9 8 7
LEVER 24V
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
(CN.D59)
SWP
YAZAKI
D-IN2 MUTE SW 5 YL 591 5 YL 591 VG 822 6 VG 822 5 0.75RY 840 1 0.75R 0.75GR 355 3 0.75GY 3 W
ATT SELECT (SP)
1 2
TXD 4 PW 055 D-IN3 CAMERA SW 6 V 592 6 V 592 WG 823 7 WG 823 3 0.75B 752 2 0.75B 0.75RW 352 4 0.75L 4 VCC
(CN.A3)
RXD 12 PL 056 S88 D-IN4 DOOR SW 7 OL 593 7 OL 593 LY 824 8 0.85LY 824 SUMITOMO SUMITOMO
LOCK
9
(BLUE TAPE)
Y2
040MIULTI
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
MENU MT090
RS232C_TXD 3 W 060a D-IN5 ONE TIME WIPER 8 YG 594 8 YG 594 LG 825 9 LG 825 10
(CN.C2)
(CN.D60)
SWP
YAZAKI
AMP
RS232C_RXD 10 WL 061a D-IN6 SPARE1 9 VR 595 9 VR 595 OR 826 10 OR 826 0.75R 181 1 0.75R 1.25Y 871 1 1.25Y 871 1 0.85R 11
24V
WG 831
WG 823
SENSOR
G 888
OR 826
LW 841
LgW 190
LgW 191
LG 825
LG 832
LG 842
2 1 (S2)
LR 880
RL 164
RL 165
DISPLAY SEL
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
1 2
0.85GW 216
0.85GW 217
BL 064a D-IN7 SPARE2 Br 596 Br 596 G 888 G 888 0.75W 800 0.75B 1.25B 758 1.25B 758 0.85B
1.25GR 875
1.25LW 200
1.25LW 201
RS232C_GND
0.85R 885
0.85RB 292
0.85RB 293
0.85RB 290
2 10 10 11 2 2 2 12
0.85Y 980
0.85YB 984
1.25Y 870
0.85L 981
0.85LB 985
S90 BRAKE
1.25GrR 195
1.25GrR 196
D-OUT1 WIPER-INT GR 820 GR 820 YL 591 YL 591
70W Vcc
GND 5 14 14 12 (WHITE TAPE)
Y3 13 1
(CN.E4)
YAZAKI
TRIP / CAMERA
(CN.A2)
B49
1 2 3
GND 13 D-OUT2 WIPER-CNT 15 Lg 821 15 Lg 821 V 592 13 14 3 OUT(PULSE)
(CN.D66)
SWP
YAZAKI
(CN.G2)
CN-A
YAZAKI
LR 881
2STAGE LAMP
(CN.D61)
SWP
YAZAKI
CAN_H 6 P 040c D-OUT3 RL FUEL PUMP 16 VG 822 16 VG 822 YG 594 14 YG 594 GR 180 1 0.75GR 180 0.75R 182 1 0.75R
E2 15 2 GND
1 2
(S1)
2
1
(BOOM)
1 2
CAN_L 14 PG 041c D-OUT4 RL LAMP 17 WG 823 17 WG 823 0.85YB 984 15 0.85YB 984 833 W 800 2 0.75W 800 0.75L 801 2 0.75B TRAVEL 16
+5V_OUT 11 D-OUT5 RL IDLE STOP 18 LY 824 18 LY 824 0.85LB 985 16 0.85LB 985 164,190,195,200,216 L 801 3 0.75L 801 (RED TAPE)
FREQUENCY_IN 1 D-OUT6 RL MUTE 19 LG 825 19 LG 825 0.85BY 982 17 0.85BY 982 Y 802 4 0.75Y 802 Y4 COMMON RAIL PRESS
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
(CN.D62)
SWP
YAZAKI
FREQUENCY_GND 9 D-OUT7 RL ROOM LAMP 20 OR 826 20 OR 826 0.85BL 983 18 0.85BL 983 829,834850,851,852,853,880,882,885,943 Br 803 5 0.85Br 803 0.75R 183 1 0.75R 1.25Y 870 1 0.85R
(S3) 24V (HOUSE)
1 2
AVcc 7 0.85Y 408 11 WB 949 G 812 6 0.75G 812 0.75Y 802 2 0.75B RELIEFE 1.25B 757 2 0.85B 1
70W
(CN.E5)
AMP
1 2 3
L 530 BW 950 Lg 813 0.75W 310 VW
SW_1 IDLE SW 15 22 7
Y5 1 2
B52
(CN.D65)
CN-A
YAZAKI
(YELLOW TAPE)
SW_2 ANTI-THEFT 16 VG 531
S1
WL 807 8 0.85WL 807
E1 0.75R 311 6 GrB 3
(CN.A1)
2
1
R3 S51 POWER
(CN.D63)
SWP
YAZAKI
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11
SW_3 COOLANT 8 GrR 532 SUNLOAD SENSOR VG 822 9 0.85VG 822 0.75R 184 1 0.75R 0.75G 312 15 WB
CAMERA (S4)
7 8 9 10 11 12 13
1 2
4 5 6
(See page 2/2) 0.85R 130 1 0.85R 130 KEY SWITCH LR 880 10 0.85LR 880 0.75G 812 2 0.75B SAVE 0.75B 690b 11 0.75B
TRAVEL
WB 949 0.85RB 290 0.85RB 290 YR 882 0.85YR 882
Y6 0.85WL 807 B
(CN.C4)
1 2 11 1 12
THROTTLE VOL. LIMIT SWITCH CONNECTION (GREEN TAPE)
H2
YAZAKI
SN_IN1 SN HYD.TEMP 2 0.85YB 490 2 BW 950 0.85VW 170 3 0.85VW 170 0.85WV 829 12 0.85WV 829 0.85GW 215 2 R 0.75W 313 5 L
1.0Ⅲ
B G1 G2 ACC M ST
AMP
0.85GL 492 0.85LgR 500 0.85LgR 500 0.85R 885 0.85R 885 0.75L 314 LW
ON
(CN.D69)
SWP
YAZAKI
SN_IN2 SN FUEL LEVEL 15 4 13 10
0.85Y 410 A4 0.85BrR 010 0.85BrR 010 HEAT 0.85GW 943 0.85GW 943 0.75G 315 Br 0.75RW
1 2
POT_IN1 SN_P P1 21 WIPER 5 14 SOLENOID VALVE 17 1
(CN.E6)
SUMITOMO
ST
1 2 3
0.85L 411 0.85RY 840 0.85RY 840 OFF 0.85LR 242 0.75BW 691b 0.75BW 0.75L
POT_IN2 SN_P P2 9 CONTROLER R 970 1 TO CAMERA 3 6 15 14 2
B47
(CN.C5)
1 2
C
FREE
(CN.D64)
SWP
YAZAKI
POT_IN3 SN_P N1 22 0.85Lg 412 0.85GR 845 7 0.85GR 845 16 0.75R 187 1 0.75R 2W 250 1 16 0.75RL 3
(BLUE TAPE) ACC
AMP
B 971 2
Y18
040
1 2
POT_IN4 SN_P N2 10 0.85G 413 WIPER SW.IN(INT) 11 GR 820 0.85G 507 8 0.85G 507 17 0.85Br 803 2 0.75B SWING 0.85VG 822 3 0.75RW 319 29 0.75RW
YR 972 3 ON
Br 834
0.85GR 414 WIPER SW.IN(CNT) Lg 821 0.85B 720 0.85B 720 2B 764 REFUEL PUMP 0.75GW 320 0.75L
(CN.C20)
POT_IN5 SN_P SWING 23 12 9 18 2 24
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
(NO TAPE)
1 2
3 4
YAZAKI
WR 973 4 OIL PRESS
0.85B
A/D
0.85Y
ST
0.85L
0.85V 415 WASHER SW. IN V 809 0.85BG 620 0.85BG 620 (See page 2/2) 0.75RG 321 0.75RL
(CN.D76)
58W
YAZAKI
SWP
POT_IN6 SN_P UPPER 12 13 10 19 19
0.85YG 416 POWER (24V) IN 0.85BrR 210
SENSOR
1 2
POT_IN7 SN_P TRAVEL 24 1 20 18
3
ROOM LAMP 3 2 1 1 2
5 6 7 8 9 10
1 2
WASHER CONT.(+) 0.85WY 829 0.75GR 180 0.75WB 322 0.75WB
(CN.B6)
MT090
SUMITOMO
0.75WB
POT_IN8 13 2
E4 1 30 1
(CN.A46)
SDL
YAZAKI
TO CAMERA 2
(CN.E7)
SUMITOMO
YAZAKI
(CN.A55)
(CN.C8)
1
2
3
YAZAKI
R 965
1 2
1
2
YAZAKI
YAZAKI
(CN.D68)
MT090
SUMITOMO
1 2 3
0.85LY 418 WASHER CONT.(-) 0.75R 181 0.85WV 830 0.75YB 323 0.75LY 0.75LY
1 2
B21
POT_IN9 SN_ANG THROTTLE 25 3 24V,10W (RED TAPE) SDL 1 2 3 2 1 25 2
090
B 966 SWP
SDL
2
4
2
5
3
6
1
1 2
POT_IN10 SN_POWER LOAD 26 0.85Gr 419 WINDOW CONTROL 9 (CN.B2) 4 5 6 0.75R 182 3 0.85B 756 2 0.75BY 324 20 0.75BY 0.75BY 3
(CN.B3)
1 2 3 4
YB 967 3
3 4
(CN.D58)
SWP
YAZAKI
OFF
(CN.C22)
0.85G 503 REV. SIG. 0.85G 485 G 888 G 888 0.75R 183
0.85VW 170
0.85BO 428
COMP_IN1 KEY ON
5 6 7 8
1 2 3 4
7 7 2 1 4 21
0.85Y 408
(CN.C19)
0.85RY 840
YAZAKI
0.85LY 418
YAZAKI
1 2
3 4
YAZAKI
WB 968
1
2
4
CN-A
COMP_IN2 SW GATE LEVER 0.85RY 520 STOP SIG. 0.85L 486 Y 843 Y 843 0.85RY 844 CN-A 0.75R 184 0.75YG 342 0.75YG
0.85R 130
0.85RB 290
20 DOOR 1 2 2 5 31
0.85LgR 500
SWP
0.85BrR 010
0.85Br 515 WINDOW LIMIT SW. L 530 0.85L 530 0.85GR 845 (CN.B1) 0.75R 185 WASHER
COMP_IN3 BATTERY CHARGE 8 4 ON 1 1 6 22
SW_IN1 AVcc 11 0.85W 400 WIPER MOTOR(CW) 8
5 0.85LR 827 YG 594 2 0.85YG 594 7 0.75BR 344 9 0.75BR FUEL TEMP.SENSOR
0.85BO 428 WIPER MOTOR(CCW) 0.85LB 828 X29 G 850 0.85G 850 0.75R 187 0.85WV 829 0.75G 345 0.75RL 0.75YG t C
M
(CN.E8)
ECO-J
AMP
SW_IN2 AGND 1 6 LIMIT SW 3 8 1 13 1
(CN.C9)
YAZAKI
1 2
3 4
M4 B3
1 2
SW_IN3 AGND 14 0.85BW 420 GND 10 1.25B 710 (DOOR) O 851 4 0.85O 851 0.85B 755 2 23 0.75LW 2
24V
(CN.D67)
CN-A
YAZAKI
SW_IN4 SW AIR CLEANER 16 LW 533 LW 841 5 0.85LW 841 0.75WR 365 7 0.75WR
SW_IN5 P-SW OPT1 3 VY 534
M3 S53 1 OL 593 2 OL 593
R 960 1 TO CAMERA 1 YL 591 6 0.85YL 591 RADIO AM / FM STEREO 0.75GW 366 2 0.75GY
P15
2
1
KNOB (RIGHT)
B 961 2 (NO TAPE) P3 24V,2A <NA>
4 5 6
1 2 3
SW_IN6 P-SW OPT2 17 GY 535 2 Y 843 4 Y 843 GL 852 7 0.85GL 852 0.85Y 900 1 0.75Y 900 26
(CN.C7)
YAZAKI
SW_IN7 SW FREE SWING GW 536 WIPER MOTOR BG 613 BG 613 3 OL 853 0.85OL 853
S16 0.85O 902 0.85O 902 0.75R 340 0.75RB
(CN.C23)
4 3 1 8 2 3
I/O
(CN.C18) SENSOR
YAZAKI
BUCK UP
1 2
3 4
HORN LOW
YAZAKI
1
2
3
W 963 4
B2
CN-A
WG 537 0.85L 530 L 0.85L 904 0.75L 904 0.85LR 880 0.75R 0.75BR t C
(CN.E9)
PACKARD
SW_IN8 SW HBCV / TRVL ALM 18 3 6 3 8 1
IDLE SW
SWP
(LEFT)
B92 B51
GND
4 5 6 7 8
1
ACC
(CN.A47)
SDL
YAZAKI
R(+)
1 2
L(+)
t C
R(-)
YL 538 0.85LR 0.85LR 827 0.85BG 625 L 0.85G 906 0.85G 906 0.75YB 490 0.75RL
L(-)
SW_IN9 SW FILTER IND 5 1 7 4 2 YAZAKI(CN.D70) 27 2
24V,370Hz
SW_IN10 SW ENG STOP 19 LB 539 M 0.85LB 3 0.85LB 828 DOOR OPEN:CLOSE 0.85YG 594 4 Y S11 0.85W 908 5 0.75BW 491 1 0.85B 760
111dB
4 0.75G
U1 X28
4 5 6 7 8
1
DOOR CLOSE:OPEN
2 3
0.85BG 626 Y WIPER 0.85V 910 0.85VR 910
(CN.B4)
62C
YAZAKI
(CN.D56)
SWP
YAZAKI
SW_IN11
GrR
6 2 5 6 YAZAKI(CN.D71) 28
OW
(CN.C10)
GR
1 2
3 4
Gr
YAZAKI
S31
G
H4
B
0.85G 0.85G 485 0.85G 850 G
X8
1 2
SW_IN12 4 3 7 32
SPEAKER(R) FUEL LEVEL EGR INTAKE TEMP.SENSOR
2 3
0.85L 0.85L 486 RL 167 0.85B 723 G 1ST.ACT
SW_IN13 6
DC/DC(24V/12V) 8 8
SENSOR R5 HORN HIGH
1
2
3
4
5
6
7
8
9
S/V(R)
(CN.E10)
YAZAKI
0.85B 5 1.25B 711 1 0.85BY 982 3 0.85BY 982 RL 162 1 RL 162 0.85O 851 1 O 0.85BY 901 9 0.75BY 901 0.85YR 882 0.75WR 1 t C
CONVERTER
S32 (RIGHT)
B86
(CN.C24)
B93
1 2
R
YAZAKI
2 0.85YB 984 1 0.85YB 984 0.85YR 221 2 0.85YR 221 0.85B 724 2 O 0.85BO 903 10 0.85BO 903 0.85GL 492 2 0.75Y YAZAKI(CN.D72) 0.75GY 2
1
2
(CN.D7)
NMW
MITSUBISHI
32
27
22
17
14
10
24V,370Hz
5
CN-A
RL 162
24V 1 2 3 4
0.85BL 983 24V IN (MAIN) 0.85OR 225 GW 536 0.85GW 536 1ST.ACT 0.85BL 905 0.75BL 905 0.85BG 660 0.75B 0.85B 761
1.25B 728
0.85RB 291
4 6 3 11 1
0.85Y 980
0.85BY 982
31 30 29 28
26 25 24 23
21 20 19 18
13
0.85L 981
0.85BL 983
9 8 7 6
4 3 2 1
S/V(L)
5 6 7 8 9 111dB
0.85LB 985 24V IN (BACKUP) RL 163 WG 537 0.85WG 537 0.85GB 907 0.85GB 907
(CN.D57)
SWP
YAZAKI
2 2 4 12 YAZAKI(CN.D73)
YAZAKI
16 15
12 11
GND 0.85B 708 YL 558 0.85YL 558 0.85YL 818 0.85YL 818
1 2
5 5 13
ACC PA PRESS. SENSOR WATER TEMP.SENSOR
X15 H5 SPEAKER(L)
12V OUT(BACKUP) 3 0.85RY 280 YB 570 6 0.85YB 570 (CN.B13) 14 B42
(CN.E11)
SUMITOMO
SOCKET KNOB (LEFT) (P1)
CONTROLLER B
P2
(CN.D74)
SWP
YAZAKI
t C
B1
12V OUT(MAIN) 1 0.85WR 281 V 571 7 0.85V 571 0.85WB 909 15 0.85R 885 1 0.75RB 1
BEACON
1 2
X2
3
S15
1 2
0.85B 712 0.85WR 282 1 0.85BL 983 GND 4 0.85BW 709 Br 834 8 0.85Br 834 0.85VG 911 16 0.85VG 911 0.75W 400 1 0.85B 762 2 0.75BY 2
12V
(CN.D45)
ECO-J
AMP
M8 YAZAKI
(CN.C25)
L
YAZAKI
1 2 3
1 POWER 24V 1.25W 109 YAZAKI YAZAKI 2 0.85LB 985 SHUT OFF 7 LG 842 9 0.85LG 842 0.85LW 841 6 L 17 0.75Y 410 2 0.75R 3
A13
1
2
HORN (CN.B22)
CN-A
1.25W 109a (CN.C16) (CN.C15) 0.85Y 980 0.85Y 980 0.85B 725 L 0.85RY 280 0.75BW 420
9 10 11 12 13 14 15 16 17 18
5 6 7 8
12 10 7
S69 YAZAKI(CN.B14)
18 3
(CN.D75)
SWP
YAZAKI
0.85L 981 0.85L 981 0.85YL 591 Y 0.85WR 281 0.75R 886
X36
POWER 24V 11 11 4 1
RADIO (NOT USED)
E51 CIGAR LIGHTER YAZAKI(CN.B15)
4 5 6 7 8
1
1 2
0.85BY 982 0.85BY 982 0.85BG 627 Y 0.85BW 709 0.75B 763
(CN.B5)
62C
YAZAKI
22 12 5 MUTE 2 OVER HEAT SW.
YAZAKI(CN.B16) PRESS. SENSOR
24V,5A
B44
2 3
4 5 6 7
(CN.A56)
GND_2 2 1.25BG 602 0.85BL 983 13 0.85BL 983 0.85GL 852 3 G
S33 M4
X35
YAZAKI
(CN.A28)
(P2) ISUZU(CN.A24)
YAZAKI
2 3
1.25BG 602a 0.85B 713 0.85YR 220 0.85RY 280 0.85RY 280 0.85B 726 G
SDL
13 14 8 2ND.ACT
S52
1 2 3 4
(WINDOW) (FOR RADIO) DUAL SWITCH
PA
P-G S/V(R)
1
GND_3 5 0.85B 702 YAZAKI YAZAKI YAZAKI(CN.A30F) 0.85WR 281 15 0.85WR 281 0.85OL 853 1 O 0.75W 401 1
(CN.D46)
ECO-J
AMP
(RECIVER DRYER) CAM ANG (MRE)
(CN.C14) (CN.C13)
S34
1 2 3
0.85B 702a O 590 O 590 0.85BW 709 0.85BW 709 0.85B 727 O 0.75L 411
S70
16 6 16 2 2
SENSOR
(CN.B17)
SWP
YAZAKI
S54
(CN.D77)
090
SUMITOMO
N-G GND 9 BG 614 3 BG 614 17 2ND.ACT 0.75BW 421 3 0.85GW 943 2
HORN VOL.SW
1 2
S/V(L)
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 2
20 YAZAKI(CN.A31F) 2 18 AIR SUSPENSION 1.25W 944 1 1 Vcc
(CN.E12)
SUMITOMO
9 10
L-G
B87
1 2 3
GND_A 10 6 3 5 3 OUT(PULSE)
PRESS. SENSOR
B43
(CN.A49)
SDL
YAZAKI
5 2 WINDOW OPEN:CLOSE 1.25GR 875 0.85YR 221 1.25R 0.85W 400 0.75W 400 GND
21 1 1
M 1
(N1)
2
(CN.D78)
SWP
YAZAKI
A-G 4 1 WINDOW CLOSE:OPEN 1.25B 714 0.85B 720 1.25B 0.85BW 420 0.75BW 420 0.75R 316 Y
NPN_OUT1 6 4 2 2 MAGNET CLUTCH 17
7 8
0.85Y 410 0.75Y 410 0.85W 402 0.75L 317 T
Y8
1
NPN_OUT2 4 3 1 (COMPRESSOR) 18
5 6 7 8
(CN.D47)
ECO-J
AMP
10
1
2
3
4
5
6
7
8
9
CARLING
(CN.B18)
MT090
SUMITOMO
1 2 3
NPN_OUT3 SOL POWER SAVE 7 G 812 YAZAKI(CN.A26F) 0.85YR 222 1 0.85L 411 4 0.75L 411 0.85Lg 412 2 0.75G 318 19 OB
VC2 24V SUCTION CONT.VALVE
1 2
NPN_OUT4 SOL FAN REVERSE Lg 813 0.85R 1.25GR 875 0.85B 721 0.85Lg 412 0.85Lg 412 0.85BW 422 1.25W 944 1.25G 0.75BL 692b 0.75BW
X6
3 (CN.C12) 2 5 3 1 15
24V
1 2 3
4 5 6
(CN.C11)
YAZAKI
(CN.E13)
MT090
SUMITOMO
NPN_OUT5 8 0.85LR 881 0.85W 1.25B 714 0.85G 413 6 0.75G 413 3 2
70W
CN-A
LAMP
Y35
I/O
1 2
NPN_OUT6 14 0.85YR 882 VR 230 1 VR 230 0.85GR 414 7 0.85GR 414 7 1
(CAB) YAZAKI(CN.A27F) PRESS. SENSOR
NPN_OUT7 15
E3
1.25WR 235
0.85LR 240
2 1.25WR 235
0.85LR 240
0.85V 415
0.85YG 416
8 0.85V 415
0.85YG 416
(N2) B40 0.75RG 394
0.75RW 396
20 0.75RB
0.75RW
NPN_OUT8 18 3 ENG STOP BEACON<EU> 9 16
PUMP
NPN_OUT9 BUCKET CLOSE (PWM) 17 0.85YL 818
MEMORY CLEAR 1.25WR 148 4 0.85WR 148 S9 S85 0.85Gr 419 10 0.85Gr 419 0.75W 403 1 10
(CN.D48)
ECO-J
AMP
PUMP INJ1 (#1)
(CN.D39)
SWP
YAZAKI
X23
1 2 3
NPN_OUT10 19 YAZAKI(CN.A28F) BG 635 0.85LG 302 5 0.85LG 302 0.85WL 430 11 0.85WL 430 0.75G 413 2 0.75Y 900 1 11
YAZAKI(CN.A37M)
Y7
1 2
(CN.E14)
MT090
SUMITOMO
0.85R 1.25GR 876 BrY 084 LB 539 6 0.85LB 539 0.85BL 450 12 0.85BL 450 0.75BW 423 3 0.75BY 901 2 1.25R 374 5 1.25W 4 1
IMMOBILIZER 24V POWER
040/070HYBRID I/O
YAZAKI(CN.A37F)
Y63
1 2
VG 531 0.85W 1.25B 715 0.85Y 408 0.85Y 408 0.85GW 444 0.85GW 444 1.25G 375 1.25L
PWM_OUT1 ARM CLOSE (OUT) 3 0.85G 906 BG 637
YAZAKI(CN.A33F) X9 LAMP 70W 0.85LY 418
7
8 0.85LY 418
9
6
10
3
9
6
10
3 0.85VG 445
13
14 0.85VG 445 1.25R 378
1
6 1.25WR
8
1
2
10
10
YAZAKI(CN.A33M) YAZAKI(CN.A29F)
B22
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
PWM_RTN1 ARM CLOSE (RTN) 6 0.85GB 907 BG 634 0.85BO 428 9 0.85BO 428 5 2 5 2 0.85LR 446 15 0.85LR 446 1.25Br 379 2 1.25LW 5
M8 M8
E3 X24 YAZAKI(CN.A36M) 4 1 4 1 (PILOT SWING) P1 INJ3 (#4)
(CN.D40)
ECO-J
AMP
AMP
PWM_OUT2 FAN SPEED (OUT) 1 0.85W 908 PB 083 P 040g 10 P 040g 7 8 7 8 0.85YB 490 16 0.75YB 490 0.75L 904 1 1.25R 376 8 1.25R 2
TO CONTROLLER C YAZAKI(CN.A36F)
Y11
1 2
(CN.E15)
MT090
SUMITOMO
0.85WR 148
0.85WB 909 YAZAKI YAZAKI PG 041g PG 041g 0.85GL 492 0.85GL 492 0.85W 404 0.75BL 905 1.25RW 377 1.25LY
0.85BG 620
0.85LG 302
PWM_RTN2 FAN SPEED (RTN)
0.85LB 539
0.85B 722
4 11 17 1 2 4 6 1
0.85LG 842
FLOW
(CN.D49)
ECO-J
AMP
(CN.C17) (CN.C32) CARLING CARLING
Y65
1 2
22 21 20 19 18 17 16 15 14 13 12
1 2 3
11 10 9 8 7 6 5 4 3 2 1
PWM_OUT3 OPT PRESS (OUT) 2 0.85V 910 1.25W 110 1 WB 949 12 WB 949 VC2 VC2 0.85BG 660 18 0.85BG 660 0.85GR 414 2 1.25R 380 13 1.25RB 3 2
0.85VG 911 WL 266 A BG 631 1 BG 631 BW 950 BW 950 (CN.B7) (CN.B10) GrR 532 0.85GrR 532 0.85BW 424 1.25RG 381 1.25LR
PWM_RTN3 OPT PRESS (RTN) 5 2
X25 RL 166 RL 166
13 19 3 9 7
SHLD GND 8 0.85G 505
0.85RY 521
3 X5 B
C P 040
2
3 P 040h
0.85GW 943 14 0.85GW 943 LW 533
YL 538
20 0.85LW 533
0.85YL 538
12
INJ2 (#3)
7 4 21 14
EST CONNECTOR A
(CN.A8)
D 4
(CN.A19)
YAZAKI
(CN.D10)
D
SUMITOMO
S-G
(CN.E16)
MT090
SUMITOMO
YR 067 YB 570 LB 559
20 19 18 17
16 15 14 13
12 11 10 9
BOOT_CNT
5 6 7 8
1 2 3 4
11 5 22 1
8 7 6 5
4 3 2 1
(PILOT UPPER)
Y64
3 2 1
14 13 12 11 10 9 8 7
PL 081 PL 081
F A B
BOOM
(CN.52)
HD10
DEUTSCH
E 5
(CN.D41)
SWP
YAZAKI
1 2
YR 068 V 571 0.85O 902
G
(CN.A48)
SDL
YAZAKI
E
FWE
Y59
12 6 1 2
F 6 SOL3
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2
H
(CN.D50)
ECO-J
AMP
C
(CN.A23)
G
YAZAKI
1 2 3
PG 041e 0.85V 415
SW_IN13 10 8 CAN
S13 OVER LOAD WARNING<EU> FREE SWING<NA> S22 2 (NO TAPE)
INJ4 (#2)
4 5 6
SDL
LED
X31 YAZAKI(CN.A34F)
(CN.A26)
SDL
YAZAKI
6 5 4 3 2 1
12 11 10 9 8 7
J ARM
(CN.D42)
SWP
YAZAKI
3 4 5 6
1
(CN.E17)
MT090
SUMITOMO
O 542 10 PG 041j 0.85G 906 1 1
(CN.A54)
Y60
SOL2
Y66
YAZAKI(CN.A35F)
YAZAKI
1 2
1 2
TXD 4 PL 056 LG 833 11 0.85GB 907 2 2
(CN.A7)
SDL
B27
A
PW 055
1 2 3 4 5
2
7 8 9 10 11 12
6 5 4 3 2 1
10
6 3
DEUTSCH
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
5 2 BUCKET
(CN.D43)
SWP
YAZAKI
A/C PANEL & A/C UNIT
(CN.A25)
(CN.D51)
ECO-J
AMP
SOL1 FUEL FILTER
YAZAKI(CN.A32M) 4 1
Y61
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
60B 798
1 2
(See page 2/2)
S28
1 2 3
RS232C_GND 2 BY 069 1.25W 205 2 4 1 0.85YG 416 2 0.85YL 818 2
TRAVEL ALARM<NA> 7 8 CLOSE
SENSOR
DT
YAZAKI(CN.A32F)
X4 7 8
0.85WG 537
0.85GW 536
P 040i 0.85BW 426
0.85BG 623
0.85BG 622
GND 5 3 3
0.85YR 223
(BLUE TAPE)
0.85Br 834
CARLING
M10
(CN.A6)
(CN.D36)
PACKARD
VC2
CAN_H 6 P 040d W 060a 7 Y 065b 2 5 BG 632 (CN.B9) LY 806 2 0.75GW 335 3
B88
1 2
(CN.B11)
0.85BW 429
3
X27
0.85Gr 419
PG 041d WL 061a YL 066b 1.25RB 150 V 050 YR 805 0.75BW 336
0.85W 409
CAN_L 14 12 3 1 6 3 1
PROPORTIONAL S/V
Y62
X32
8 7 6 5 4 3 2 1
BL 064a 0.85Br 517 0.85G 507 GY 535 0.85VR 910 0.85VR 910 OPT
(CN.A27)
DIAG
AMP
FREQUENCY_IN 1 11 3 8 5 5 1 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1 EXSHAUST PRESS
8 7 6 5 4
3
4 3 2 1
(CN.A24)
SDL
YAZAKI
FREQUENCY_GND 9 Y 065a 1 W 060b 4 9 2 P 040k G 850 6 YAZAKI 0.85VG 911 2 0.85VG 911 2 PRESS
(CN.A29)
TO DRM
2
3
1
YL 066a WL 061b PG 041k O 851 SDL
AVcc 7 3 5 10 8
X34 7
(HBCV)
SDL
(CN.D44-1)
ECO-J
AMP
(CN.D52)
X33
2 1
(CN.D44)
SWP
YAZAKI
SW_1 15 6 6 11 3 10 9 10 9 8 1
(CN.D32)
SUMITOMO
7 8 9 10 11 12 13
1 2 3
1 2 3
BY 069 PG 041f PB 082 0.85BG 629 3 6 3 6 OL 853 1.25W 405 0.75P 332
B89
1 2
1 2
SW_2 16 8 7 12 1 9 1 2
(CN.A5)
(CN.B23)
PA
YAZAKI
YAZAKI(CN.B25)
(CN.G6)
ECO-J
AMP
(NOT USED) 2 5 (FOR FAN REVERSE) 2 5
1 2 3
SW_3 8 9 8 1.25B 740 13 4 BG 640 10 1.25Gr 425 2 0.75BW 333 3
1 4 1 4
5 14 VG 051 6 8 7 8 7 1.25BW 445 3
LEVEL SWITCH S55
10
10
4 5 6
4
5
6
1
2